Home

stellar™ sr44 soft starter user manual

1. HERR RR ERR 5 4 4 Basic Menu The Basic menu holds the parameters which control the primary functions of the unit Changing the values of these parameters will vary the starting and stopping duties the trip protection set for the unit and the source of the start signal Keypad or Remote Basic Menu Explanation Diagram LOAD Current Notes Limit Level 1 Thisis the Start Pedestal voltage P 11 P30 2 This is the Stop Pedestal voltage P 16 3 This is the supply voltage minus the voltage thatis dropped across the SR44 LOAD Veto 4 Stop Time P12 P17 Start Time Basic Menu Settings P52 8182 Disable Starter Range P52 B1 amp B2 Default Off Scaling n a Type R W Disable Starter disables the starter by setting P52 B1 amp B2 1 While the unit is disabled it will not comply with a start signal Disabling the starter also allows the user to change certain parameters which cannot be changed while the unit is enabled such as Password and Station 7 P52 8182 Enable Starter Range P52 B1 amp B2 Default On Scaling n a Type R W Enable Starter enables the starter by setting P52 B1 amp B2 0 While the unit is enabled it will comply with a start signal Some parameters cannot be changed while the unit is enabled 5 30 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 5 K
2. 1st Ed RevA 09 2011 SR44 Series Soft Starter User Manual 5 19 Chapter 5 Keypad Menu Items and Parameters ll M M R RR 5 3 Parameter Basic Information continued Parameter Basic Information continued Name Function Protection 2 Start Ped 2 Start Time 2 Kick Ped 2 Kick Time 2 Dwell Time 2 Stop ped 2 Stop Time 2 AutoConfig 2 Auto Ramp Auto 3MC Auto Bypass Auto Jog Auto Endstop Auto Stop Auto Endstart Auto Pedestal X le 0 03125 Low 2 cycles 1 Low time 2 X le 0 03125 C L 2 seconds 1 C L Time 2 X le 0 03125 Shearpin 2 cycles 1 Shear time 2 X le 0 03125 Ovid Level 2 none 1 Ovid Delay 2 PR o N Un e 96 seconds 96 cycles seconds 96 seconds Un N ul N Un Un n o Default Hin ele ee ee e e 5 Scaling flags o Oo o CO H H oO a o o flags 1 User Flags12 Kickstart 2 Current Limit Timeout Sel d 2 Overload Selected 2 Shearpin Selected 2 Under Current Selected 2 5 32 Thermistor Selected 2 not available 6 64 U nused 7 128 1 Terminal Starting 2 Type R Read Only R W Read Write Scaling applies O NLY when using serial commuication details in Serial Communications chapter T
3. 0 01 02 03 04 05 06 07 08 09 1 0 11 12 13 14 1 5 Time s P18 87 Auto Pedestal Range P18 B7 Default Off Scaling n a Type R W Auto Pedestal turns On and Off the automatic overriding of the start pedestal When On the unit approximately detects the start of motor rotation and tries to adjust the pedestal to suit P18 86 Auto end start Range P18 B6 Default Off Scaling n a Type R W Auto End Start turns On and Off the automatic detection of motor full speed during the start up Having detected motor full speed achieved before the end of the programmed ramp this menu item brings forward the end of the ramp cutting short an overlong programmed start P18 B5 Auto stop Range P18 B5 Default Off Scaling n a Type R W Auto Stop turns On and Off the automatic adjustment of the Soft Stop When On the unit attempts to automatically adjust the soft stop profile to suit the load P18 84 Auto end stop Range P18 B4 Default Off Scaling n a Type R W Auto End Stop turns On and Off the automatic detection of a stalled motor during Soft Stop When On and the motor has stopped before the end of the unit s programmed Soft Stop the unit will attempt to detect the stall and turn off the thyristors thus truncating the soft stop time 5 28 SR44 Series Soft Sta
4. I AMA nsn This rung takes the Status Word that was read from the Soft Start and converts the word to control bits The bits C100 thru C115 could be used in your program to turn on outputs and or they could just be monitored by an Operator Interface to generate messages Copy Unpack Always ON Status Word from Strtr sci ere DH1 420 ma Stopped LevelReached Des B C100 B C115 When Start PB is pressed activated a value of 7 is copied to DS30 and C21 is set This will activate the Send instruction which will write the contents of DS30 to P124 When the Starting or Top of Ramp bits read from the unit turn on the Start sequence is reset Start PB C20 f 1 DS30 Start SoftStart B C21 SET Starting Start SoftStart B C101 B C21 RST TopOfRamp B C103 Stop PB C22 1st Ed Rev A 09 2011 SR44 Series Soft Starter User Manual 6 21 Chapter 6 Serial Communications rr EE EE EEE H B BRI M U 6 7 1 CLICK PLC Example Program continued When Stop PB C22 is pressed activated a value of 8 Stop is copied to DS30 and C23 is set This will activate the Send instruction which will write the contents of DS30 to P124 Stop PB B C22 f Stop SoftStart C23 SET When the Stopping or Stopped bits read
5. Oo CO O O O CO O O O 5 22 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 5 Keypad Menu Items and Parameters 5 4 Menu Settings and Parameter Descriptions This section gives a description of the individual menus and the functions that their parameters perform Menu Settings and Parameters are presented in the same groups and sequence as they appear in the Keypad Menu Structure We highly recommend that you configure the SR44 by first selecting and setting an application from the Applications menu that is similar to your application If necessary you can then fine tune your LJ configuration by changing the settings of other parameters and menu items j To keep Menu Item and Parameter setting changes they must be permanently saved using the c Permanent Store menu See section A 1 5 for more information 5 4 0 Restoring Defaults There are two methods of restoring the SR44 parameters and settings to their default values 1 Through the Applications menu choose Default keypad or Default Auto 2 Through the Permanent Store menu choose D efault Param Refer to the applicable menu descriptions for further details 5 4 1 Example of Menu Settings and Parameters Descriptions Parameter Number if applicable Parameter Setting Name Scaling if applicable J Default Setting p 12
6. J7 Ribbon cable connector output output input to optional J8 J9 J10 SR44 RS485 Comm Card DOD ODO 22 24 21 12 14 11 S0 S1 J t Connection for current transformer CT i J3 is factory prewired to SR44 internal CT User supplied external CT may be reqired for Bypass operation depending upon other settings amp parameters i If user supplied external CT is required remove the two i Connection polarity is irrelevant Programmable output Relay K2 i Change over contacts that can be mapped from a selected parameter i Default Top of Ramp i Programmable output Relay K1 i Change over contacts that can be mapped from a selected parameter i Default Run Relay i Programmable Input Control Input 1 S1 SO A voltage applied to these terminals will either SET or CLEAR the parameter bit mapped by P65 i Default Start Stop SR44 Electronic Control Card D5 ribbon cable O O Input connector J7 J8 J9 J10 Bo ojoo I 22 24 21 12 14 11 S091 000000000000 000000000000 S S S 1st Ed Rev A 09 2011 SR44 Series Soft Starter User Manual 2 11 Chapter 2 Electrical Installation lli m e Hat 2 6 Power Supply Connections 2 6 1 Power
7. Control Comm Error B C212 Error O DS103 ErrCode When both comm instructions have successfully operated this rung will reset the communication bits and allow the comms to restart Time Control Time Comm Control Comm Comm Comm Success Success Success 2 B C207 B C211 B C207 B C211 13 E M E ns DS31 is assumed to come from an HMI C more for example and when a new value is entered it will not be equal to the old value and this difference will set C11 That will start the Receive Send sequence Then the new value is copied to DS32 which will turn off the rung SoftStart Old SoftStart Enable Time Time Entry Time Entry Comm 1 DS31 I DS32 B C11 14 SET Copy Single SoftStart Time Entry Src 1 DS31 Old SoftStart Time Entry Des I DS32 This rung will be activated until DS31 is equal to DS41 which is the Received value from the unit When equal the sequence is reset SoftStart P12 Decimal Enable Time Enable Time Comm Tima Entry aoe n BI C11 IJDS31 UIDS41 BI C11 Jt sr 15 lstEd RevA 09 2011 SR44 Series Soft Starter User M anual 6 23 Chapter 6 Serial Communications ll A nop 6 7 1 CLICK PLC Example Program continued This rung manipulates the data retrieved DH10 from
8. U ser supplied current transformer is required if any of the current and power related monitoring features are needed in bypass mode Refer to Electrical Installation Chapter 2 sections 2 4 1 amp 2 5 2 for details Power Range 0 to 20 000 000W Default OW Three phase power as calculated by the Soft Starter keypad Protection P 26 P 27 P 40 P 39 Range 0 to 192 Default 192 Scaling n a Type R W Protection M ode controls which trips are available 64 FULL full protection with full volts after top of ramp optimizing function turned off 192 FULL 0 PTIMIZE full protection optimize 128 START BYPASS protection during start then bypass 0 PHASE LOSS ONLY p phase loss detection only Start and O ptimize mode is forced to FULL Protection Mode when Delta Firing Mode is selected P 6 1 In PHASE LOSS ONLY Protection Mode P 7 0 the bottom 12 5 of starter current is ignored after TOR Top Of Ramp P 78 Protection Mode 2 is the second parameter set counterpart of P 7 Protection Mode Current Range 0 to 3000 Amps Default 0A Scaling n a Type R Running Current displays the current that the motor is taking as monitored in one phase This is the source parameter for the O verload Current Limit Shearpin Under Current Trip etc The divisor is 32 and the multiplier is the rated current of
9. 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual D 7 Appendix D Using AutomationDirect PLCs with SR44 Soft Starters lli ee HERR D 8 SR44 Series Soft Starter User Manual lstEd RevA 09 2011 1st Ed RevA 09 2011 SR44 Series Soft Starter User Manual SR44 Series Soft Starter User Manual lst Ed RevA 09 2011
10. Range 0 to 255 flags Default 0 Scaling 1 Type R Status 5 flags Read this parameter by individual bits Bit 0 OverTemperature inhibits re start if set effectively the heatsink is too hot to start but is OK to run 1 Offline Command Fail the last offline command failed automatically resets when the next command is attempted unused Fan Status used in conjunction with an output relay to control fans unused unused unused unused TI Oo WU BB W N P 121 UserFlags 4 Range 0 to 255 flags Default 0 Scaling 1 Type R W User Flags 4 is a fourth set of individual bits for user control or system status O ther User Flags are parameters 51 52 53 95 amp 96 Bit 0 Impact Load limit max delay adjustment in optimizing for highly volatile loads 1 unused 2 Auto Soft Stop Smoothing Enable P 122 Soft Stop Smoothing for pumps 3 Breaker Present Line Contactor If the starter is to be used with a circuit breaker then set bit 3 to a one 1 Read the description of the Line Contactor Menu Item in section 5 4 5 Advanced Menu fora more detailed explanation of this functionality 0 Line Contactor 1 Breaker Present 4 Optimize gains the maximum amount of energy savings on variable loads Requires an external user supplied bypass contactor and current transformer Associated with P109 Upper Limit and P110 Lowe
11. to SR44 105 4 99 10 SR44 146 35 99 10 to SR44 202 6 99 SR44 242 35 60 to SR44 370 6 60 To calculate times for a lower value of current divide the square of the next highest given current multiplied by its given time by the square of the required current For example To find the time Ty for X 22 5 x le then Tx 32 x 35 2 5 50 seconds Index Rating Example Standard Operation AC 53a Utilization Category per IEC 60947 4 2 9 to 105 AC 53a 35 2210 10 For a 99 on load factor L Duty Cycle Cycle F S i 99 10 99 on load factor 10 cycles nr 2d 10 standard operating cycles per hour Lo Overload Current Profile Profile X Tx the unit can accommodate 3 35 3 times rated current le for 35s 3 x le for 35 seconds Utilization Category AC 53a controller semiconductors provide squirrel cage motor Start Run and Stop control Rated Operational Current le 9 to 105 controllers with Rated Operational Currents from 9A to 105A 1st Ed Rev A 09 2011 SR44 Series Soft Starter User M anual 2 17 Chapter 2 Electrical Installation rr a 3 ta 2 10 4 Overload Current Profile AC 53b IEC 60947 4 2 Motor Utilization Category AC 53b operating in bypass mode SR44 Index Ratings for AC 53b Bypassed Operation UC X T OFF time AC 53b 5 4 120 le A AC 53b 4 6 120 146 to 202 AC 53b 3 35 120 AC 53b 4 6 420 Index ratings AC 53a and AC 53b are spec
12. ReadStarterlnProg COUNTER Cnt Up Preset Value 9999 Current Value CommCountCurr Don t Reset Preset CommCountDone WriteStarterlnProg Always Off Bit Cnt Down CommCountDone Reset This rung monitors our Comm Errors Ordinarily this counter will only be activiated very infrequently unless a slave been lost It has a preset of 999 and will repeat itself ReadStarterErr COUNTER Cnt Up Preset Value 999 Current Value CommErrCurr Don t Reset Preset CommErrorsDone WriteStarterError Always Off Bit Cnt Down A CommErrorsDone Reset 6 30 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 6 Serial Communications T 4 1 51 6 1 6 2 N 44 6 7 3 Productivity3000 PLC Example Program continued This rung is always active and Auto Polls the SoftStarter for Status The tag StarterStatusWord16 is converted into Bool tags via the Unpack Bit instruction located in task StatusBits so we will have a tag dedicated to various status conditions Stopped Starting Current Limit Alarm etc These Bool tags could be used in ladder to verify operation or to set indicator lights for example MODBUS READ CPU 485 In Progress ReadStarterlnProg Slave Node Number 1 Complete ReadStarterCmplt Automatic Polling 300 0 Success ReadStarterSuccess Don t Skip Execution Error ReadStarterErr Word Swap Timeout ReadStarterO No Mapping Excepti
13. 5 4 11 Parameters Menu continued P 78 through P 96 define the 2nd parameter set which can be used to define a different Start Stop profile See appendix A 2 1 Using An Alternative Parameter Group for more information Protection 2 Range 0 to 192 Default 192 Scaling 1 Type R W Protection Mode 2 Use with 2nd parameter set Protection Mode 2 controls which trips are available for use with second parameter set 64 FULL full protection with full volts after top of ramp optimizing function turned off 192 FULL 0 PTIMIZE full protection optimize 128 START BYPASS protection during start then bypass 0 PHASE LOSS ONLY p phase loss detection only Start and O ptimize mode is forced to FULL Protection Mode when Delta Firing Mode is selected P 6 1 In PHASE LOSS ONLY Protection Mode P 78 0 the bottom 12 5 of starter current is ignored after TOR Top Of Ramp P 7 Protection Mode is the 1st parameter set counterpart of P 78 Protection Mode 2 Start Ped 2 Range 10 to 60 percent Default 5096 Scaling 1 Type R W Start Pedestal 2 Use with 2nd parameter set Start Pedestal 2 sets the percentage of the unit s rated supply voltage that is applied to the load before the ramp starts P 11 Start Ped is the 1st parameter set counterpart of P 79 Start Ped 2 Start Time 2 Range 1 to 255 seconds Default 5s Scaling 1 Type R W Sof
14. Chapter 5 Keypad Menu Items and Parameters ee 707 P51 B5 P 126 P 109 P 110 1st Ed RevA 5 4 5 Advanced Menu continued Thermistor Trip reserved Range P51 B5 Default Off Scaling n a Type R W Thermistor Selected Not Available P126 Comms Trip Range Off On Default Off Scaling n a Type R W Bus Action on Fail Action following a bus failure Active only with certain Comms Options 0 No Trip 1 Trip Bypass Upper Limit Range 1 to 50 Default 12 Scaling n a Type R W Bypass U pper Limit e Associated with P121 B4 Optimize Optimise requires an external user supplied bypass contactor and current transformer Refer to Electrical Installation Chapter 2 sections 2 4 1 amp 2 5 2 for details Typically set about 8096 of motor FLC Current required motor FLC SR44 FLC 32 Bypass Lower Limit Range 0 to 150 Default 10 Scaling n a Type R W Bypass Lower Limit Associated with P121 B4 Optimize Optimise requires an external user supplied bypass contactor and current transformer Refer to Electrical Installation Chapter 2 sections 2 4 1 amp 2 5 2 for details Typically set about 40 of motor FLC Current required motor FLC SR44 FLC 32 09 2011 SR44 Series Soft Starter User M anual 5 41 Chapter 5 Keypad Menu Items and Parameters 5 4 6 Monitoring Menu E
15. DO 05AR 8 AC IN 6 RELAY OUT MICRO PLC W AC P S D0 05DD 8 DCIN 6 DC OUT MICRO PLC W AC P S D0 05DD D 8 DC IN 6 DC OUT MICRO PLC DC POWER SUPPLY D0 05DR 8 DC IN 6 RELAY OUT MICRO PLC W AC P S D0 05DR D 8 DC IN 6 RELAY OUT MICRO PLC DC POWER SUPPLY DLO5 DLO6 Discrete I O D0 07CDR COMBO 4 PT 12 24VDC INPUT 3 PT RELAY OUTPUT D0 08CDD1 COMBO 4 PT 12 24VDC INPUT 4 PT 12 24VDC OUTPUT D0 08TR 8PT RELAY OUTPUT 6 27VDC OR 6 240VAC DO 10TD1 10PT 12 24VDC SINK OUTPUT DO 10TD2 10PT 12 24VDC SOURCE OUTPUT DO 16TD1 16PT 6 27 VDC SINK OUTPUT DO 16TD2 10PT 12 24VDC SOURCE OUTPUT F0 04TRS 4PT ISO RELAY OUTPUT 5 30VDC OR 5 125VAC DLO6 PLCs D0 06AA DL06 20 AC IN 16 AC OUT MICRO PLC W AC P S D0 06AR DL06 20 AC IN 16 RELAY MICRO PLC W AC P S DO 06DA DL06 20 DC IN 16 AC OUT MICRO PLC W AC P S D0 06DD1 DL06 20 DC IN 16 DC OUT MICRO PLC W AC P S D0 06DD1 D DL06 20 DC IN 16 DC OUT MICRO PLC W DC P S D0 06DD2 DL06 20 DC IN 16 DC OUT MICRO PLC W AC P S D0 06DD2 D DL06 20 DC IN 16 DC OUT SRC MICRO PLC W DC P S DO 06DR DL06 20 DC IN 16 RELAY MICRO PLC W AC P S D0 06DR D 1st Ed Rev A 09 2011 DL06 20 DC IN 16 RELAY MICRO PLC W DC P S D 3 SR44 Series Soft Starter User M anual Appendix D Using AutomationDirect PLCs with SR44 Soft Starters rrr rrrRr XRXR RR
16. Option This example assumes that the unit has been disabled see section A 1 2 1 With Starter Disabled shown on the display press the ENTER button 2 With Applications shown on the top line of the display press the ENTER button again 3 With Settings on the top line of the display press the W button until Default keypad is shown on the top line of the display 4 Press the ENTER button and the display will flash three times to indicate that the default parameters with keypad starting have been loaded 5 Press the button twice to return to Stopped and ready JE There is no need to save the parameters as they have automatically been saved when the system was reset to default values TG Starter Disabled kag TO POET 1 V To Enable kag Features POET keypad E 9 9 O l 1 Default Edu o Default keypad Edu Pump Small Pump 1l A 8 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Appendix A Setup Examples A 1 7 Loading the Default Parameter Values with Remote Starting Option E This example assumes that the unit has been disabled see section A 1 2 1 With Starter Disabled shown on the display press the ENTER button 2 With Applications shown on the top line of the display press the W button until Permanent Store is on the top line of the display 3 Press the ENTER button 4 Press the V button until Default Param i
17. A 5 Appendix A Setup Examples lk ga wap M sma ana aaa agad A 1 4 Changing from Keypad Starting to Remote Starting With Keypad Starting set the unit is started from the keypad or remote keypad While Remote Starting is set the unit is started with a start signal between SO and S1 Keypad Starting is the factory default value 1 With Stopped and ready shown on the display press the ENTER 2 With Applications shown on the top line of the display press W button until Basic is shown at top of display 3 Press ENTER to select Basic menu 4 With Starting shown at top of display press ENTER to select the Starting option 5 With the display now showing Starting on the top line press ENTER to toggle the bottom line of display from Keypad Starting to Remote Starting 6 At any of the above stages pressing will return the user to the previous menu 7 The SR44 will now start and stop remotely from the customer s switches see section 2 3 1 of Electrical Installation but will return to Keypad Starting if the control supply on terminals X1 and X2 is removed and a Save Param has not been performed Alternatively to return to Keypad Starting repeat the above procedure and select Keypad Starting at step 5 To keep the Remote starting setting after removal of the control supply t
18. Kick Time Dwell Time Stop Ped Stop Time oO Oo oo O O O O O N o seconds cycles seconds seconds Un N ul N Un Un H o Pl e Re ele H HH flags Auto Config Auto Ramp Auto 3MC Auto Bypass Auto Jog Auto end stop Auto stop Auto end start Auto Pedestal 19 5 30 none 1 Opt Rate 20 146 76 146 76 degrees 0 57554 Reference PF 21 146 76 146 76 degrees 0 57554 Internal PF 22 146 76 146 76 degrees 0 57554 Delay Angle 23 57 554 146 76 17 27 degrees 0 57554 Max Angle Type R Read Only R W Read Write Scaling applies ONLY when using serial commuication details in Serial Communications chapter Table continued next page o oO o O O H H o Q O 5 16 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 5 Keypad Menu Items and Parameters ee Jail 5 3 Parameter Basic Information continued Parameter Basic Information continued Name Function amps Reserved Rated Amps 100s amps Reserved Rated Amps amps 0 03125 Current amps 1 Peak Start Xle 0 03125 Low Level cycles 1 Low I Time X le 0 03125 C L Level seconds 1 C L Time X le 0 03125 Shear Level cycles 1 Shear Time X le 0 03125 Ovld Level none 1 Ovld Delay 0 39216 Overload z
19. 10 25 Crusher not rock unloaded 25 75 Can be high inertia Drilling machine unloaded 10 Escalator unloaded 25 50 Optimizing feature can be effective Fan axial flow propeller 20 40 Feeder screw 100 175 Needs high starting torque motor Feeder vibrating motor driven 100 150 Needs high starting torque motor Grinder unloaded 10 25 Usually high inertia Hammer mill 20 125 Eccentric load needs high starting torque motor Mills flour etc 30 50 Mixer dry contents 35 75 Mixer fluid contents 10 40 Mixer plastic contents 75 125 High torque motor offers advantage Mixer powder contents 75 125 High torque motor offers advantage Pelletizers 50 100 Press flywheel 50 150 Needs high starting torque motor Pump centrifugal 10 25 Soft stopping useful Pump positive displacement piston type 100 175 Needs high starting torque motor Pump vane type positive displacement 100 150 Needs high starting torque motor Rolling mill 30 50 Saw band 10 35 Saw circular 25 50 M ay be high inertia Plug brake may be useful Screen vibrating 30 60 Travelators walkways 25 Unloaded starting Transformers voltage regulators Nil Change firing mode Tumblers 30 100 Can be eccentric load may need high torque motor 1st E
20. 2 1 3 ACCESS saga PERS PECK Eos APANG NANGAKONG Peete had BANA KNA 2 2 2 1 4 Fuse Protection MET PM PPP 2 2 2 1 5 Agency Approvals ansaa aaa aaan ded aa 2 2 2 2 Electrical Connections Specifications 2 3 2 2 1 Electrical Supplies a oe oa bald nena ate haw OX sew eeu Seeds 2 3 2 2 2 Control Power and Ground Terminations 2 3 2 3 Standard Wiring Configurations 2 4 2 3 1 Wiring Diagram for In Line Connection of Motors 2 4 2 3 2 Wiring Diagram for In Delta Connection of Motors 2 5 2 4 Motor Control Circuits 4 22 7 aceite a 9 9 9n bax 2 6 2A 1 Bypass COMBO x35 9 93 da EROR ees SEES eae DAS KG DA 2 6 2 4 2 Multiple Motor Starting amp Stopping cerle 2 7 2 4 3 External Motor Protection Relay 2 7 2 4 4 Motor Reversing os52 cs deere NG dex 3e 3 SEER KEEP Yi SE EHE 2 7 2 4 6 Wiring Diagram for Motor Reversing 2 8 2 5 Electrical Connections Terminal Locations 2 9 2 5 1 General Electrical Connections ees 2 9 2 5 2 Electronic Control Card os o oan ie e KGG EARL KG dace x eee 2 11 Table of Contents continued next page 2 la ELECTRICAL INSTALLATION Table of Contents continued from previous page 2 6 Power Supply Connections 0 200 a ee 2 12 2 6 1 Power Circuit Electrical Supply lt lt iciccesed Meleeyc
21. 5 66 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 5 Keypad Menu Items and Parameters eee SSS rr rj 5 4 11 Parameters Menu continued P 88 Low time 2 Range 5 to 255 cycles Default 50 cycles Scaling 1 Type R W Low Current Time 2 Use with 2nd parameter set Low Current Time 2 sets the number of cycles for which an Under Current situation must exist before tripping P 29 Low Current Time is the 1st parameter set counterpart of P 88 Low Current Time 2 P 89 C L2 Range 0 375 to 7 9688 xle Default 4 xle Scaling 0 03125 Type R W Current Limit Level 2 Use with 2nd parameter set Current Limit Level 2 sets the current level at which the the Soft Start ramp will be held The Current Limit only holds the ramp if its level is reached The current naturally falls as motor speed increases allowing the ramp to continue This parameter is not available in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass P 30 Current Limit Level is the 1st parameter set counterpart of P 89 Current Limit Level 2 P 90 C LTime2 Range 5 to 255 seconds Default 15s Scaling 1 Type R W Current Limit Time 2 Use with 2nd parameter set Current Limit Time sets the maximum time allowed for the current limit before it trips or continues the ramp regardless of motor current level P 3
22. Altitude APAPAP PDA PA PEE PE PEEPS 1 3 16 Assisted FOW outta ERA eee et ee KAR DALA KWAN AMA KANG ES 1 4 1 7 Heat Output of Drills Lees PAKA KUALA LALA DR ele vhnea need 1 4 1 8 Clearance cg a ap wa ear a ee be weds Sasa eed a os he 1 5 1 9 Mechanical Outline Chassis Sizel 00 0a 1 6 1 10 Mechanical Outline Chassis Size2 0 000 es 1 7 Chapter 1 Mechanical Installation I M anual Overview Overview of this Publication The SR44 Soft Starter User M anual describes the installation configuration and methods of operation of the SR44 Soft Starter Who Should Read This Manual This manual contains important information for those who will install maintain and or operate any of the SR44 Soft Starters Supplemental Publications The National Electrical Manufacturers Association NEMA publishes many different documents that discuss standards for industrial control equipment Global Engineering Documents handles the sale of NEMA documents For more information you can contact Global Engineering Documents at 15 Inverness Way East Englewood CO 80112 5776 1 800 854 7179 within the U S 303 397 7956 international www global ihs com Technical Support By Telephone 770 844 4200 Mon Fri 9 00 a m 6 00 p m E T On the Web www automationdirect com Our technical support group is glad to work with you in answering your questions If you cannot find the solution to your particular appl
23. Low Amps Time has elapsed then the unit will not trip Low Amps Time Min 2 Low Amps Time Max 3 5 34 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 5 Keypad Menu Items and Parameters eee aaa Current Sub menu of Advanced Menu continued P51 81 C L Time Out Current sub menu of Advanced menu Range P51 B1 Default Off Scaling n a Type R W The C L Time Out menu item turns On and Off the Current Limit Time Out trip A Current Limit Time Out trip will occur if this menu item is set to On and the load is demanding more current than the level specified in the Current Limit parameter for longer than the time specified in the Limit Time Out parameter If the C L Time Out menu item is set to Off then no trip would occur in a similar situation Refer to Current Limit Explanation Diagram e This parameter bit is not available in Bypass Operation unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass P 30 C L Level Current sub menu of Advanced menu Range 0 375 to 7 9688 Xle Default 3 5 Xle Scaling n a Type R W The Current Limit Level parameter sets the level in Amps at which the unit will begin current limiting Refer to Current Limit Explanation Diagram This parameter is not fully functional in Bypass O per
24. Only the 1st address of the Function 03 read instruction matches the parameter number but there is an offset of one address from the parameter If the PLC targets 40074 the PLC will return data starting with P 73 P 73 will be in the high byte and P 74 will be in the low byte The Function 03 mutliple read instruction gets data from an even number of parameters U nwanted data can be discarded by the PLC PLC addresses are any valid user assigned memory addresses Modbus Function 03 Transaction Table Query Response Field Hex Byte Field Hex Byte Slave Address 01 Slave Address 01 Function 03 Function 03 Start Address High 00 Byte Count 04 Start Address Low 4A decimal 274 Data High Byte 00 P 73 No of Registers High 00 Data Low Byte 02 P 74 No of Registers Low 02 Data High Byte OD P 75 CRC Low PLC amp SR44 automatically Data Low Byte OE P 76 CRC High calculate CRC checksum values Data High Byte 10 P 77 Data Low Byte CO P 78 CRC Low Byte PLC amp SR44 automatically CRC High Byte calculate CRC checksum values The SR44 has a Modbus offset of one address for registers amp bits PLC targets one address higher 6 14 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 6 Serial Communications 6 5 2 Writing Single Coil Modbus Function 05 This function i
25. Optional Hardware chapters All parameters that control the operation of the SR44 Soft Starter can be accessed via the interfaces Parameters and their values are shown on the interface display and any changes to parameter values are affected by using the buttons on the interface The interface has three basic modes of operation System Status M ode Menu Navigation Mode Data Entry Mode Explanation of the modes mentioned above can be found in sections 5 2 3 5 2 4 and 5 2 5 Figure 5 1 2a Keypad Figure 5 1 2b Remote Keypad Keypad Remote Keypad Selects or deselects optimizing providing keypad control is Starts motor providing keypad control is selected selected and moves the cursor along one space from left to right meee indata entry mode A user to previous menu o NI Selects or deselects devel orcancels a change a optimizing providing keypad control is selected mac Returns userto previous menu level orcancels a change A Allows userto move up amenu Allows user to move up a group or incrementa value menu u group orincrement oF Allows user to move down a menu Vw N Enter E move down group or decrement a value a menu group or decrementa value CO Takes user to next menu level or updates any changes made Takes userto next menu level or updates any changes made Starts Stops motor providing keypad control is selected Stops motor providing keypad controlis selec
26. Ovld Integrating Energizes when the SR44 s overload is integrating K Stall Energizes when the motor is stalling K Cooling Energizes when the SR44 is cooling start inhibited K Enable Status Energizes when the SR44 is enabled K z I P1 K 60H2 K Shearpin K Undercurrent K C L Timeout K Thermistor not available K z Overload K Thermal Switch K RYB Phase sequence ABC or L1 L2 L3 A worked example showing how to program a relay is given in Appendix A 1 11 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual 5 47 Chapter 5 Keypad Menu Items and Parameters _ _ rpgjrjlhr hr Fr rrrr 7 Kav p pr r ij v vr rk R2 3 3 5 6 63 T6 6 c Z ret6 Z rmF Z rie ZA 5 4 10 Outputs Menu continued K2 Range n a Default Bypass Relay The K2 menu item allows the customer to program the K2 relay section 2 7 2 of Electrical Installation At the bottom of the sub menu is a list of programming shortcuts which will set up the relay for the user Below is a list of the shortcuts with a description of when they energize the relay K2 Map From P 59 K2 Bit Mask P 60 K2 Polarity P 54 B 1 K Run Relay Usually for controlling the main contactor energizes while the unit is running K Bypass Relay Usually for controlling the bypass contactor energizes when the u
27. Q ES NI m om om om om om mom m m m m m m m m m m mom mom S NGI P98 U1 I P Mask P98 U1 I P Mask G P98 U1 I P Mask 2 P98 U1 I P Mask O P98 U1 I P Mask P99 U1 OIP Dest Q 00000001 Mask 00000000 Mask 00000000 Mask 00001000 Mask 23 CL a al lt EE P98 U1 I P Mask P98 U1 I P Mask r P99 U1 O P Dest 00001000 Mask i pes continued next page V lstEd RevA 09 2011 SR44 Series Soft Starter User Manual A 21 Appendix A Setup Examples UK Ffktr a PP ZrrrrwPrrrrRrRirrrr wmrprrmrmrmrm 2 2 M M Z88p EEeE err prrrrpv V prrr gp pp A 2 2 Changing the Parameter Group After the Unit Has Passed Top of Ramp continued continued from previous page 17 Press the W button once so that P99 U1 O P Dest is shown at the top of the display 18 Press ENTER to select P99 U1 O P Dest 19 With O Parameter shown on the display press the A button until 52 Parameter is displayed 20 Press ENTER once to accept the change 21 Press once to return to P99 U1 O P Dest 22 Press W once until P100 U1 O P Mask is shown at the top of the display 23 Press ENTER to select P100 U 1 O P Mask 24 Press the O PTIM ISE button six times so that the cursor is displayed on bit 6 25 Press the A button once to change the bit state of bit 6 to one 1 26 Press ENTER once to accept the change 27 Press four times to retu
28. Reserved 1 UserFlags 5 Reserved Unused Reserved Reserved Unused Unused Unused co o H o Min Value o o W HG Un U nused U nused 39 degree R PF Angle 40 volts R Supply Volts 41 Reserved 42 Reserved 43 Reserved 44 Reserved 45 Reserved 46 Reserved 47 Reserved 48 Reserved 49 Reserved 50 Reserved Type R Read Only R W Read Write Scaling applies O NLY when using serial commuication details in Serial Communications chapter Table continued next page 0 0 0 0 0 0 0 0 0 0 lst Ed RevA 09 2011 SR44 Series Soft Starter User M anual 5 17 Chapter 5 Keypad Menu Items and Parameters ee EEE 5 3 Parameter Basic Information continued Parameter Basic Information continued Name Function User Flags 1 Kickstart Current Limit Timeout Sel d O verload Selected Shearpin Selected Under Current Selected Thermistor Selected not available Unused Terminal Starting User Flags 2 Low Voltage Soft Stop Not Global Enable 1 Not Global Enable 2 Pod Start Stop Board Start Stop Main Contactor Second Parm Set Zero Start Time User Flags 3 o oO o OF
29. RevA 09 2011 SR44 Series Soft Starter User Manual 5 11 Chapter 5 Keypad Menu Items and Parameters Esse ETE 5 2 2 Complete Keypad Menu Structure continued Keypad Menu Structure continued Horizontal Keypad Scrolling Enter key right forward key left back Level Parameter Parameter 1 Level 2 Bit Level 3 Bit Power Protection full optimise P7 Current P26 P27 Peak Start P27 P40 Supply Volts P40 Real PF P39 P22 Delay Angle P22 P23 Max Angle P23 P20 Reference PF P20 P21 Internal PF P21 up down Up Arrow key Save Param j h 8 t Power On Param Default Param Enter Password Change Password n a Down Arrow key Stopped and Ready 1 or Starter Disabled 1 V to Enable Map to P65 52 Parameter Digital l p 1 Bit Number P66 0001 0000 Mask Polarity P54 B4 Positive Logic Inverse Logic Table continued next page 5 12 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 5 Keypad Menu Items and Parameters ee il 5 2 2 Complete Keypad Menu Structure continued Keypad Menu Structure continued Horizontal Keypad Scrolling Enter key right forward key left back Level Parameter Parameter 1 Level 2 Bit Level 3 Bit Map From P57 52 Parameter Bit Number P58 0010 0000 Mask Polarity P54 BO Positive Logic Inverse Logic K Run Relay K Bypass Relay
30. m 6 4 Parameter Memory Addresses continued Parameter M emory Addresses continued Parameter Bit s amp j Name Function n a Reserved Reserved Reserved U ser Flags 1 Kickstart Current Limit Timeout Sel d Overload Selected Shearpin Selected Under Current Selected Thermistor Selected Unused Terminal Starting User Flags 2 Low Voltage Soft Stop 417 Not Global Enable 1 Not Global Enable 2 419 Pod Start Stop Board Start Stop 421 Main Contactor Second Parm Set 423 Zero StartTime User Flags 3 424 pf1 pol pf2 pol 426 User Current Limit User Trip 428 Invert Controller Input 5 32 Cooling Inhibit Restart 6 64 Unused 7 128 Unused Modbus addresses apply only to Function 06 Write Single Register or to only the first parameter of Function 03 Read Holding Registers Parameter Bit s apply only to Function 05 Write Single Coil Type R Read Only R W Read Write Table continued next page 1st Ed RevA 09 2011 SR44 Series Soft Starter User Manual 6 7 Chapter 6 Serial Communications _ _ F3 j7 zrrrrrr mrmrmrmvrrrxrrrnrh nm r rrk pF i ve Q Zr 9 9 9Z Z9 j j j jj lRrrrrrrr FFM M M V M Hrr 6 4 Parameter Memory Addresses co
31. o O O O O e o O O H H H oO UI p pf1 pol pf2 pol User Current Limit User Trip Invert Controller Input Cooling Inhibit Restart Unused 0 Unused Type R Read Only R W Read Write Scaling applies ONLY when using serial commuication details in Serial Communications chapter Table continued next page 5 18 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 5 Keypad Menu Items and Parameters i 5 3 Parameter Basic Information continued Parameter Basic Information continued Name Function I O Polarity K1 Polarity K2 Polarity Unused Unused I p 1 Polarity Unused Unused Unused 55 Reserved 56 Reserved 57 K1 Map 58 K1 Bit Mask 59 K2 Map 60 K2 Bit Mask 61 Reserved 62 Reserved 63 Reserved 64 Reserved 65 i p1 Map 66 i p1 bit M sk 67 Reserved 68 Reserved 69 Reserved 70 Reserved 71 ms Cntactor Dly 72 15 none Trip Snstvty 73 17 trips Last Trip 74 17 trips 2nd Last Trp 75 17 trips 3rd Last Trp 76 17 trips 4thLast Trp 77 17 0 trips 5th Last Trp Type R Read Only R W Read Write Scaling applies O NLY when using serial commuication details in Serial Communications chapter Table continued next page e P Re ele H HH
32. the bottom line of the display will show a brief list of some of the basic parameters and their current values including the firmware version numbers the starting option Remote or Keypad the current protection mode the selected application if none the lower line of the display will remain blank for a moment and whether any derating has been applied to the unit if none the lower line of the display will remain blank for a moment When the arrow icon has disappeared the report showing the basic parameters has finished and the user is the back in Menu Navigation mode see section 5 4 2 4 This menu item is read only 5 Press the button twice to return to Stopped and ready Since this menu item is read only it cannot be saved O Q Stopped and ready Applications Settings e Settings v Auto Features O Default keypad Remote starting 5 A 10 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Appendix A Setup Examples A 1 9 Changing a Password This example assumes that the unit has been disabled see section A 1 2 and if necessary has already been unlocked see section A 1 10 1 With Starter Disabled displayed press the ENTER button 2 With Applications shown on the top line of the display press the W button until Password takes its place on the top line 3 Press the ENTER button to select the Password menu Press the W button and C
33. when communicating with Technical Support regarding this publication Manual Number SR44 M WO Issue First Edition Revision A Issue Date 09 2011 Publication History Issue Date Description of Changes First Edition 01 2011 Original Issue Ch2 Bypass Control amp external CT 2 4 1 amp 2 5 2 Fuse and Current Ratings 2 10 1 amp 2 10 2 1st Ed Rev A 09 2011 Ch5 Modified parameter explanations especially with regard to Auto Jog O ptimise bypass operation and current related features SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 STELLAR SOFT STARTER USER MANUAL TABLE OF CONTENTS Chapter 1 Mechanical Installation 1 1 Manual Overview lise Rh hh 1 2 1 Mechanical Installation XX mada rack ca eR gw RR Ca eee nna 1 3 Chapter 2 Electrical Installation LL 2 1 2 1 Warnings amp Agency Approvals llli 2 2 2 2 Hectrical Connections Specifications 2 3 2 3 Standard Wiring Configurations 2a aaa exes rh Rm RR me 2 4 2 4 Motor Control Circuits 0 es 2 6 2 5 Hectrical Connections Terminal Locations 2 9 2 6 Power Supply Connections eee ees 2 12 2 7 Control Card Connections kaaa owes xm Son ee ene 2 13 2 8 Reserved for Future Use es 2 13 2 9 Typical Motor Power at Rated Voltage 2 14 2 10 Fuse and Current Ra
34. 1 9 lstEd RevA 09 2011 SR44 Series Soft Starter User Manual 5 45 Chapter 5 Keypad Menu Items and Parameters rr VVV 3 rVrQ EZE ana tg 5 4 9 Inputs Menu Digital i p 1 Range n a Default n a Digital Input 1 gives access to the setup parameters for the first programmable input see section 2 7 2 of Electrical Installation An example showing how to set up a digital input is given in Appendix A 2 4 p1 Map To P 65 p1 Bit M ask P 66 p1 Polarity P 54 B 4 5 46 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 5 Keypad Menu Items and Parameters eee SSS as 5 4 10 Outputs Menu K1 Range n a Default Run Relay The K1 menu item allows the customer to program the K1 relay section 2 7 2 of Electrical Installation At the bottom of the sub menu is a list of programming shortcuts which will set up the relay for the user Below isa list of the shortcuts with a description of when they energize the relay Map From P 57 Bit M ask P 58 Polarity P 54 B 0 K Run Relay Usually for controlling the main contactor energizes while the unit is running K Bypass Relay Usually for controlling the bypass contactor energizes when the unit reaches Top of Ramp P8 B3 1 K Alarm Energizes when an Alarm condition is present K Current Limitng Energizes when the unit is current limiting K
35. 2011 SERIAL COMMUNICATIONS Contents of this Chapter 6 1 Overview eser 6 2 6 2 Quick Start PAA 6 2 6 3 Specifications nanan aaaea 6 3 6 4 Parameter Memory Addresses 6 4 6 5 Serial Communication to SR44 6 13 6 5 0 Parameter Scaling eee eee enna 6 13 6 5 1 Reading Holding Registers Modbus Function 03 6 14 6 5 2 Writing Single Coil Modbus Function 05 6 15 6 5 3 Writing Single Register Modbus Function 06 6 16 6 5 4 P 124 Offline Commands 2 3o 244084042064 GABAY 08 6 6 17 6 5 5 Read Exception Status Modbus Function 07 Starter 01 6 18 6 5 6 Returned BITOES 4 ic exa KA AA eee REESE dco dos ass 6 18 6 7 Example PLC Communications Programs 6 19 6 7 1 CUCK PLC Example Program u2gasesaswsmisezesreea KA BG HANGAN 6 19 6 7 2 DiretLOGIC PLC Example Program suisse 6 25 6 7 3 Productivity3000 PLC Example Program 6 30 Chapter 6 Serial Communications WARNING The owner installer and user are responsible for the correct installation and use of the SR44 and must ensure that only qualified personnel install the SR44 The owner installer and user must ensure that the installation operation and maintenance of the SR44 complies with the relevant Codes of Practice Regulations and Statutory Requirements The Manufacturer or his agent do not IN
36. 5 Keypad Menu Items and Parameters rr EEEEEEE E E E EEE E _ _ _ EE _ 5 3 Parameter Basic Information continued Parameter Basic Information continued 2 G 2 Name Function none StopProfile none Last App minutes CoolingTime Reserved Reserved Reserved Status 5 O ver Temperature Offline Command Fail unused Fan Status unused unused unused unused UserFlags 4 Impact Load unused Auto Soft Stop Smoothing Breaker Present 0 Contactor 1 Breaker Optimise Quick Ramp Times Two Stop Bits Auto Stop 2 Stop Smooth Temp Alt D erate Off Line Command Reserved Comms Trip Trip Flags Trip 1 Enabled Phase Loss Trip 8 Enabled Motor Side Thyristor Loss Trip 9 Enabled Thyristor Sensing Trip Type A Trip 10 Enabled Thyristor Sensing Trip Type B Trip 4 Enabled Thyristor Sensing Trip Type C 5 32 Trip 5 Enabled Edge Sensing Trip 6 64 Trip 6 Enabled Sensing Trip Type A 7 128 0 Trip 7 Enabled Sensing Trip Type B Type R Read Only R W Read Write Scaling applies O NLY when using serial commuication details in Serial Communications chapter P116 default value varies depending upon soft starter model size D OO UO OLGO O O O CO OF O OG O D GO O 0 O O O
37. Application Type Start Pedestal 96 Start Time s Current Limit Level x FLC O ptimize Rate Auto End Start Soft Stop Smoothing Notes Application Type Start Pedestal 96 Start Time s Current Limit Level x FLC O ptimize Rate Auto End Start Soft Stop Smoothing N otes High Torque Start Appendix B Applications Data 60 Stop Pedestal 0 3 Soft Stop Time s 0 4 375 Current Limit Time s M Auto 3MC L1 Low Voltage Soft Stop Motor Generator Set Stop Pedestal 96 Soft Stop Time s Current Limit Time s Auto 3MC Low Voltage Soft Stop 12 Auto Pedestal VI Auto Bypass L1 Auto Ramp Auto Pedestal Auto Bypass Auto Ramp Auto Jog Auto Stop Auto End Stop Auto Jog Auto Stop Auto End Stop Application Type Start Pedestal 96 Start Time s Current Limit Level x FLC O ptimize Rate Auto End Start Soft Stop Smoothing N otes Application Type Start Pedestal 96 Start Time s Current Limit Level x FLC O ptimize Rate Auto End Start Soft Stop Smoothing N otes Application Type Start Pedestal 96 Start Time s Current Limit Level x FLC O ptimize Rate Auto End Start Soft Stop Smoothing Notes 1st Ed RevA 09 2011 Aerator 10 Stop Pedestal 96 60 Soft Stop Time s 3 Current Limit Time s 5 o Auto 3MC val Low Voltage Soft Stop Flywheel Press 40 Stop Pedestal Soft Stop Time s Current Limit Time s 3 3 5 o Auto 3MC L1 Low Voltage
38. Auto Jog P18 B3 Auto Pedestal P18 B7 Auto End Start P18 B6 Auto Stop P18 B5 Auto End Stop P18 B4 Auto Bypass P18 B2 Auto Bypass detects the presence of a bypass contactor and should be ON when using one Using a bypass contactor with Auto Bypass in the OFF state can cause thyristor faults Auto 3MC P18 B1 Auto Ramp P18 BO 1st Ed RevA 09 2011 SR44 Series Soft Starter User Manual 5 27 Chapter 5 Keypad Menu Items and Parameters rrr 5 4 3 Auto Features Menu continued P18 B3 Auto Jog Range P18 B3 Default Off Scaling n a Type R W Auto Jog turns On and Off automatic Jog detection When Auto Jog is On and the soft stop time is set greater than zero 0 the stop varies based upon the length of time the start signal is applied If the start signal is applied for less than 0 5 seconds the unit executes a zero 0 second stop when the start signal is removed If the start signal is applied for more than 0 5 seconds the unit executes a timed stop per the stop settings This menu item is intended to be used for short term jogging of light loads Auto Jog Explanation Diagram Run V Status St PAA MAPASA PAA MAGAAN AA MAA MAAN PAA AA AA HA 5222 2 4 AN Start ON pe aa Signal OFF 1 D 1 D 1 I D 1 Sauces qd 4 4 9 peo peme
39. CT1 will normally be counting rapidly while CT2 will be counting very infrequently if at all If both counters are counting up then there are problems which could be in addressing wiring or PLC SR44 setup Status Comm Receiving a Counter omm Transaction Wi Counter Set Point CT1 Control Comm Sending B C210 Current Comm Transaction Counter CT1 Reset Counts errors by both Receive and Send instructions Status Comm Read Error C202 Comm Error Counter CT2 Up Set Point Control Comm Error C212 B Comm Error Counter B CT2 lstEd RevA 09 2011 SR44 Series Soft Starter User Manual 6 19 Chapter 6 Serial Communications _ _ eee EEE EEE w5 6 7 1 CLICK PLC Example Program continued This rung will be performing nearly all the comms with the starter It will continuously read parameters P8 and P9 the soft starter is 8 bit based and the CLICK performs communications by 16 bit words So the single value that is retrieved from the soft starter contains 2 values Since both values are actually bit patterns they are placed directly into a Hex data register DH1 This will be copied to C bits further in the program Receive Port3 MODBUS Status Comm Slave ID 1 Receiving Modbus Function Code 03 C200 Slave Add
40. Default Delay 140 Delay 80 0 1 Delay 30 Delay 10 0 01 1 2 3 4 5 6 7 8 910 Fault current Motor Current x N t Parameter selected through either the primary or secondary group of value parameters Current Limit O verload Level and O verload Delay settings may be adjusted to limit overload currents in accordance with the trip curves shown in the O verload Trip Graph For motors with Full Load Currents lower than the rated current of the SR44 the O verload Level can be adjusted using the following formula Overload Level Motor FLC x 1 1 A TheOverload monitors only one of the phases and the Current Limit level is only active during motor starting We recommend that the control power supply be maintained between starts to ensure the integrity of the Overload which will reset on removal of control power 1st Ed Rev A 09 2011 SR44 Series Soft Starter User Manual 2 19 Chapter 2 Electrical Installation _ _ _ _ rr 1 4U Ua maan aan werp 2 20 SR44 Series Soft Starter User Manual lstEd RevA 09 2011 APPLICATIONS Contents of this Chapter 3 1 Motor Suitability and Associated Considerations 3 2 Deel E Uo MC PCT ere se pcr 3 2 3 1 2 Induction Motor Characteristics assas hod a Ree im aed 3 2 3 1 3 Rating MPPRRREERRTTTETTETTHRPTTREPETTEEEPEEREMPTTTEPEEITT 3 2 3 1 4 Maximum Motor Cable Length asaan aaa 3 3 3 1 5 Power Factor Cor
41. First Starter NONE Last Starter Installed Network Start i i i i i i 1st Ed RevA 09 2011 For SR44 KPD connected to only one SR44 install jumpers 1 2 4 5 SR44 Series Soft Starter User Manual Network End Chapter 7 Optional Hardware lli i 7 6 SR44 Series Soft Starter User Manual lstEd RevA 09 2011 SETUP EXAMPLES Contents of this Appendix A 1 Setup Examples 0 ccc eee A 2 A 1 1 How to Read the Setup Examples 00000 c cece eae A 2 A 1 2 Enabling and Disabling the SR44 cc eee A 4 Note for A 1 Setup Examples 4 aa Ka ERE rx ERE KALA A 5 A 1 3 Loading the Large Pump Application into Memory A 5 A 1 4 Changing from Keypad Starting to Remote Starting A 6 A 1 5 Permanently Saving Parameters Set by the User A 7 A 1 6 Loading the Default Parameter Values with Keypad Starting Option Sade nieule Svar cies thendeyerkesecaes aces chee S pamesed oerees A 8 A 1 7 Loading the Default Parameter Values with Remote Starting Option bash Sek Bak aNG ered ANU GA GA ie a wera BC eek Boerne PAA NA KAPA A 9 A 1 8 Viewing Basic Operating Parameter Values via the Settings Menu Option qe A 10 A 1 9 Changing a Password 2e vede ue EDAX core ra A 11 A 1 10a Unlocking and Locking the Keypad A 12 A 1 10b C
42. Items and Parameters E M 5FF Saas 5 2 2 Complete Keypad Menu Structure continued Keypad Menu Structure continued Horizontal Keypad Scrolling Enter key right forward key left back Parameter Parameter Level 2 Bit Level 3 Bit Level Level 0 1 Rated Current le P24 amp P25 Low Current O n O ff P51 B4 Low Amps Level 0 1xFLC P28 Low Amps Time 50 cycles P29 C L Time O ut On Off P51 B1 Current Limit 3 5Xle P30 Limit Time O ut 30s P31 Shearpin O n O ff P51 B3 Shearpin Level 3 125xle P32 Shearpin Time 100 cycles P33 Overload Level 1 1xlg P34 O verload D elay 140 P35 up Current down Up Arrow key Optimise Rate 5 P19 Optimise O n O ff P121 B4 Kickstart O n O ff P51 BO Kick Pedestal 75 P13 Kick Time 25 cycles P14 Dwell Time 5s P15 Low Volts Stop O n O ff P52 BO Contactor Delay 160ms P71 Trip Sensitivity 1 P72 Station Number 1 P1 Firing Mode 0 P6 P122 Stop Smoothing 5 P122 Cooling On Off P53 B5 Cooling Time P116 Temp Alt D erate 096 P123 Line Contactor O n O ff P121 B3 Thermistor Trip not available 8 P51 B5 P126 Comms Trip O n O ff P126 P109 U pper Limit 12 P109 P110 Lower Limit 10 P110 Table continued next page Stopped and Ready 1 or Starter Disabled 1 V to Enable 3 Ist Ed
43. K Alarm K Current Limiting Note K 2 Ovid Integrating K Stall The K selection in Level 3 loads P57 amp P58 with the appropriate values to K Enable Status configure the K1 output relay K 1 P1 to perform the described K 60Hz function up K Cooling K Shearpin A simpler way to configure K Undercurrent the relay K C L Timeout K Thermistor not available Choose only one function K Overload K Thermal Switch K RYB phase sequence ABC Map From P59 8 Parameter Bit Number P60 0000 1000 Mask Polarity P54 B1 Positive Logic Inverse Logic K Run Relay K Bypass Relay K Alarm K Current Limiting Note K 2 Ovld Integrating K Stall The K selection in Level 3 loads P59 amp P60 with the appropriate values to K Enable Status configure the K2 output relay K P1 to perform the described K 2 60Hz function K RYB phase sequence ABC A simpler way to configure K Shearpin the relay K Undercurrent K C L Timeout Choose only one function down Up Arow key Stopped and Ready 1 or Starter Disabled 1 V to Enable K Cooling E E E K Thermistor not available K Overload K Thermal Switch Table continued next page 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual 5 13 Chapter 5 Keypad Menu I
44. Motor side phase loss during the ramp and after full voltage 06 SCR Signal Sensing Trip Type A Short circuit thyristor during the ramp and after full voltage Motor side phase loss during the ramp and after full voltage Input side phase loss during the ramp and after full voltage 07 Sensing Signal Sensing Trip Type B Short circuit thyristor or external noise during the ramp and after full voltage M otor side phase loss during the ramp and after full voltage 08 SCR Loss Motor M otor Side Thyristor Loss Short circuit thyristor at the start M otor side phase loss at the start 09 Sensing Signal Thyristor Sensing Trip Type A Short circuit thyristor or external noise during the ramp and after full voltage 10 SCR Shorted Thyristor Sensing Trip Type B Short circuit thyristor during the ramp Motor side phase loss during the ramp 11 Low Current Output current falls below a previously set level P28 Low Amps Level for a specified time P29 Low Amps Time Active only during the running stage 12 C L Time Out During start up ramp output current exeeds the Current Limit level P30 for the time specified in Limit Time Out P31 13 Overload O utput current exceeds the previously set O verload Level P34 and O verload Delay time P35 Active in all stages of operation See section 5 4 5 Overload Explanation Diagram 14 Shearpin O utput
45. SR44 Series Soft Starter User M anual 5 7 Chapter 5 Keypad Menu Items and Parameters ll U7 5 2 Keypad Menu Structure 5 2 1 Abbreviated Map of Keypad Structure Level 0 Level 1 Level 2 Level 3 Stopped and ready lt Applications Settings 1 Default Keypad Default Auto 9r etc Starter Disabled V to Enable Auto Features lt 15 Settings Auto Jog Auto Pedestal etc Basic 4 2 5 Disable Starter Enable Starter Starting etc Protection emma aap FU ze Full Optimize Start Bypass Phase Loss Only Advanced Current lt gt Rated Current Optimize Rate Low Current Optimize Low Amps Level etc etc Monitoring Power Protection Current etc Permanent Store gt Save Param Power On Param ie Default Param Password 5 Enter Password Change Password ie Inputs 5 Digital i P 1 Map To Bit Number 1 Polarity kx Outputs KI A Map From K2 Bit Number ie Polarity etc Parameters PILA P1 to P21 P22 to P40 lt A Parameter viewing P41 to P60 and or manipulation P61 to P80 x2 P81 to P100 P101 to P Trips PIL Trips Pa Trip 1 Tri
46. Soft Stop Stop Pedestal 96 Soft Stop Time s Current Limit Time s Auto 3MC Low Voltage Soft Stop 10 60 60 Auto Pedestal lvi Auto Bypass L1 Auto Ramp Auto Pedestal Auto Bypass Auto Ramp Auto Pedestal Auto Bypass Auto Ramp NO Auto Jog Auto Stop Auto End Stop Auto Jog Auto Stop Auto End Stop Auto Jog Auto Stop Auto End Stop SR44 Series Soft Starter User Manual NO B 5 Appendix B Applications Data res B 6 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 TECHNICAL HINTS Contents of this Appendix Technical HINES 2272 99 0 8 97 dcn den eque oh di a oh di ede decedens e C 2 Category General enn nnn C 2 Category Troubleshooting ue euin eh hn xe tt ha C 3 Category WII s queo wERQ RA erini rip QN ES qi RIP E reo ed C 3 Appendix C Technical Hints rrr Technical Hints Category General Subject Motor Configuration If the motor starts O K but stalls as soon as a load is applied then check the configuration of the motor i e it may be that the motor is meant to be connected in delta but is actually connected in star wye No 2 Subject Kick Start Kick start is not always suitable for use with rolling starts or very light loads No 3 Subject Slip Ring Motors 1 When sizing a single stage of resistors for use with a Soft Starter care must be taken to balance the standstill torque requirements against large slips at full
47. W Soft Stop Time sets the time period over which the Soft Stop Ramp is performed P 30 Current Limit Range 0 375 to 7 9688 xle Default 3 5 Xle Scaling n a Type R W Current Limit Level sets the current level at which the the Soft Start ramp will be held The Current Limit only holds the ramp if its level is reached The current naturally falls as motor speed increases allowing the ramp to continue e This parameter is not fully functional in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass we 1 The actual current drawn by the load may exceed the Current Limit Level slightly j as the unit manages the current limit through control of the delay angle 2 Current Limit is active only during starting lstEd RevA 09 2011 SR44 Series Soft Starter User Manual 5 31 Chapter 5 Keypad Menu Items and Parameters EEE rr F ee P 7 5 4 4 Basic Menu continued Protection Range 0 to 192 Default 192 Scaling n a Type R W Protection M ode controls which trips are available e 64 FULL full protection with full volts after top of ramp optimizing function turned off 192 FULL 0 PTIMIZE full protection optimize 128 START BY PASS protection during start then bypass 0 PHASE LOSS ONLY p phase loss detection only Start and O ptimize mode is forced to F
48. WU N HI 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual 5 59 Chapter 5 Keypad Menu Items and Parameters MKV eyrr rrprzpgvpprrrrr RRRr rRr mr rp 1 r w 5 4 11 Parameters Menu continued P 57 KI Map Range 0 to 123 parameter Default 52 parameter Scaling 1 Type R W Map K1 To holds the parameter for the internal starter function assigned to drive the K1 relay output Works in conjunction with P58 Refer to Appendix A 1 12 or A 1 13 in the Programming chapter P 58 KI Bit Mask Range 0 to 255 bit mask Default 32 Scaling 1 Type R W KI Bit Mask holds the parameter bit for the internal starter function assigned to drive the K1 relay output Works in conjunction with P57 P 59 K2 Map Range 0 to 123 parameter Default 8 parameter Scaling 1 Type R W Map K2 To holds the parameter for the internal starter function assigned to drive the K2 relay output Works in conjunction with P60 Refer to Appendix A 1 12 or A 1 13 in the Programming chapter P 60 K2 Bit Mask Range 0 to 128 bit mask Default 8 Scaling 1 Type R W K2 Bit Mask holds the parameter bit for the internal starter function assigned to drive the K2 relay output Works in conjunction with P59 P 61 reserved P 62 reserved P 63 reserved P 64 reserved P 65
49. acceleration and the quicker full speed is reached and the greater the stresses experienced by the supply and drive systems during the acceleration process An ideal start would accelerate the load with just sufficient force to reach full speed smoothly in a reasonable time and with minimum stress to the supply and drive mechanisms Generally speaking the motor speed torque characteristic is controlled by the rotor resistance A motor with high rotor resistance can generate its peak torque pull out torque at standstill giving the high break away torque characteristic which reduces steadily as the speed increases and becomes zero at synchronous speed At the other end of the scale a motor with a very low rotor resistance will produce a low starting torque but will generate its peak torque closer to the synchronous speed Consequently this type of motor runs at full power with higher operating efficiency and low slip speed It is possible to combine the twin requirements of high starting torque and efficient full speed operation within a single motor by techniques such as double cage or deep bar design and this usually is the motor characteristic chosen for lifting and hoisting applications Figure 3 3 2 4 Torque Speed Curve High Starting Torque Pull Out Torque Mx Pull up Torque Figure 3 3 2 4 0 SPEED S Torque Speed Curve High Starting Torque TORQUE Locked Rotor Torque LRT MA Full Load Torque FLT My
50. and illustrates this important characteristic of asynchronous three phase induction motors 3 8 SR44 Series Soft Starter User M anual lstEd RevA 09 2011 Chapter 3 Applications Figure 3 3 2 1 Torque Speed Curve Induction Motor Pull Out Torque M Pull up Torque Figure 3 3 2 1 0 SPEED S Torque Speed Curve Induction Motor TORQUE Locked Rotor Torque LRT MA Full Load Torque FLT Mj Synchronous speed Figure 3 3 2 2 Torque Speed Curve Coupled Load Each load coupled to an induction motor has its own speed torque curve Pull Out Torque M TORQUE Locked Rotor Torque LRT MA Pull up Torque Full Load Torque FLT My Synchronous speed Figure 3 3 2 2 0 SPEED S Torque Speed Curve Coupled Load Figure 3 3 2 3 Torque Speed Curve Accelerating Torque The acceleration of a motor load system is caused by the difference between the developed torque motor and the absorbed torque load and is shown by the shaded area in the next figure Pull Out Torque M TORQUE Locked Rotor Torque LRT Ma Full Load Torque FLT Mp Synchronous speed Pull up Torque Figure 3 3 2 3 E SPEED 2 Torque Speed Curve Accelerating Torque lstEd RevA 09 2011 SR44 Series Soft Starter User Manual 3 9 Chapter 3 Applications ee 3 3 2 The Induction Motor continued Obviously the larger the difference between the developed torque and the absorbed torque the faster the
51. assume any liability expressed or implied for any consequence resulting from inappropriate negligent or incorrect installation application use or adjustment of the product or circuit design or from the mismatch of the SR44 to a motor To prevent an electrical shock hazard the SR44 must be properly connected to a safety ground The SR44 is not designed for use in hazardous areas Use in such an area may invalidate the hazardous area certification 6 1 Overview The SR44 has built in serial communication capability that is a compatible subset of the widely recognized Modbus RTU protocol slave and the SR44 may be connected to a PC or suitable PLC network via an optional SR44 RS485 interface card Serial communication requires an optional interface card SR44 RS485 which includes a Local Remote switch to easily switch starter control from communication to keypad Serial communication is valid only in the Remote position and the local keypad powers down In the Local position the local keypad powers up and controls the soft starter and all serial communication is ignored 6 2 Quick Start Work should only be carried out on the SR44 with all electrical power disconnected 1 Communication settings a 9600 baud 8 data bits 1 stop bit no parity b network station number 1 2 Before Connecting a Comm interface use the standard keypad to make any changes for your bus system a Set Parameter 1 to the
52. autres marques et d signations Copyright 2011 Automationdirect com Incorporated Tous droits r serv s Nulle partie de ce manuel ne doit tre copi e reproduite ou transmise de quelque facon que ce soit sans le consentement pr alable crit de la soci t Automationdirect com Incorporated AutomationDirect conserve les droits exclusifs l gard de tous les renseignements contenus dans le pr sent document W 2 SR44 Series Soft Starter User Manual Ist Ed RevA 09 2011 The owner installer and user are responsible for the correct installation and use of the Stellar SR44 for ensuring that only qualified personnel install the SR44 and for ensuring that the operation and maintenance of the unit complies with the relevant Codes of Practice Regulations and Statutory Requirements The manufacturer or his agent do not assume any expressed or implied liability for any consequences resulting from inappropriate negligent or incorrect installation application use or adjustment of the product or circuit design or from the mismatch of the unit to a motor To prevent an electrical shock hazard the SR44 must be properly grounded The SR44 is not designed for use in hazardous areas Use in such an area may invalidate the hazardous area certification WARNING Read this manual thoroughly before using Stellar SR44 Series Soft Starters WARNING The SR44 uses semiconductor devices in the main power circuit and is not designed to p
53. bits flags are bit positions starting at parameter 0 bit 0 Register numbers are 0 127 Coils flags 0 1024 10 Offline EEROM Registers are 1000 1127 N on volatile registers where the Permanent Store parameters are saved Supports the following Modbus functions O On O UI LL mnm Function 03 read holding registers up to 4 words 8 parameters in number Function 05 write single coil Function 06 write single register byte Function 07 exception status Error 01 illegal function write to read only parameter Error 02 illegal data address bad parameter number Error 03 illegal data trying to read or write too much data Error 06 slave busy Error 07 negative acknowledge lstEd RevA 09 2011 SR44 Series Soft Starter User Manual 6 3 Chapter 6 Serial Communications l P ww 6 4 Parameter Memory Addresses Parameter Memory Addresses Parameter Bit s Number x Name Function pg amp dummy parameter Station No Language Program Type Software Ver Password Firing Mode yO JU BW N HO Protection Status 1 64 40 Stopped 65 41 Starting 66 42 Current Limit 67 43 Top of Ramp 68 44 Dwell 69 45 Full Conduction 70 46 Energy Saving 71 47 Stopping Status 2 72 48 Alarm 73 49 Overload Integrating 74 4A Stall 75 4B Fo
54. cable tie 3 Set Communication Card jumpers J1 5 as shown in Network Connections drawing below 4 Mount the Keypad using the screws provided and plug the other end of the cable with the larger ferrite into the SR44 KPD Remote Keypad SR44 KPD mounting dimensions are shown on the reverse side of this page Use RTV sealant at mounting holes A if NEMA 4X rating is required Remote keypad is NEMA 4X soft starter is not The starter can now be controlled by the Remote Keypad when the Local Remote switch is placed in Remote This setting disables the integral keypad on the cover of the starter Switching to Local disables the Remote Keypad and enables the integral Local Keypad Only one function can control the starter at a time The Remote Keypad and the soft starter s integral Local Keypad are mutually exclusive Switching to Local will always disable remote control of the starter One SR44 KPD Remote Keypad Controlling Multiple SR44 Soft Starters using RJ45 connections SR44 KPD can control only one soft starter at a time Legend aaa SR44 SR44 SR44 for J1 J5 Road Soft Start Soft Start Soft Start Jumpers eypa Station 1 Station 2 Station 3 SR44 KPD SR44 RS485 SR44 RS485 SR44 RS485 LEDULI Comms Card Comms Card Comms Card Jumpers Jumpers J1 J5 Jumpers J1 J5 Jumpers J1 J5 Uninstalled J1 J2 J3 Jumpers installed J4 J5 Jumpers fitted Middle Starters Jumpers installed Jumpers
55. can only be changed via the dedicated parameter numbers Asa default the Soft Starter uses the Primary group of parameters The user can select either group from the keypad or by using one of the programmable control inputs 09 2011 SR44 Series Soft Starter User Manual A 19 Appendix A Setup Examples Jibj59Q2Qj fj9 2 Pp ppr r rprprp m rrrrrr X ERR RR RR pn A 2 2 Changing the Parameter Group After the Unit Has Passed Top of Ramp In this example the user is shown how to change parameter groups while running This could be useful for example if two overload values were required one for starting and the other for running 1 With Stopped and ready shown on the display press the ENTER button once 2 With Applications shown on the top line of the display press the W button until Parameters is shown at the top of the display 3 Press ENTER once to select the Parameters menu 4 With P1 P20 shown on the display press the W button until P81 P100 is shown at the top of the display 5 Press ENTER to select P81 P100 6 With P81 Kick Ped 2 at the top of the display press the V button until P97 U1 I P srce is shown on the top line of the display 7 Press ENTER to select P97 U1 I P srce continued next page Stopped and ready o Applications O Auto Features Pg Q 2 a press button multiple times or hold to
56. control supply GROUND STUD Electrical ground PE An M8 threaded stud for connection to the system ground POWER TERMINALS L1 L2 L3 Input Isolatable 3 phase supply via contactor isolator etc Any phase can connect to any terminal EEE gt mJ c jc am Cover inside view size 1 location size 1 location To remove cover unscrew KEYPAD CIRCUIT 2 positions size 1 only CARD POWER TERMINALS T1 T2 T3 Output ELECTRONIC CONTROL CARD Induction motor Refer to sections 2 5 2 and 2 7 1 For correct motor rotation these connections must correspond with the supply connections at L1 L2 L3 When removing and replacing the front cover take care not to damage the cable that connects the Keypad and the Electronic Control Card The cable from the Keypad to the Electronic Control Card must be connected or disconnected O NLY when the control power is turned OFF to the unit Otherwise the circuitry may be damaged 1st Ed Rev A 09 2011 SR44 Series Soft Starter User Manual 2 9 Chapter 2 Electrical Installation _ EEE Qng ws r 2 5 1 General Electrical Connections continued Figure 2 5 1b SR44 Chassis Size 2 Electrical Connections CONTROL VOLTAGE TERMINALS X1 X2 Input CONTROL VOLTAGE SELECTOR SWITCH Ensure that the selector switch position corresponds to the control supply used either 115V or 2
57. current exceeds the previously set Shearpin Level P32 for a time set in Shearpin Time P33 Active only during the running stage See section 5 4 5 Shearpin Explanation Diagram 15 Unused 16 User A trip which can be triggered by the customer via a variety of means e g through the serial comms or via a programmable input 17 Comms Timeout No communication on the serial connection for more than five seconds 5 76 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 5 Keypad Menu Items and Parameters aS 5 4 12 Trips Menu continued Trips Sub menu of Trips Menu P 73 Last Trip Trips sub menu of Trips menu Last Trip holds the number of the last trip P 74 2nd Last Trp Trips sub menu of Trips menu 2nd Last Trip holds the number of the second to last trip P 75 3rd Last Trp Trips sub menu of Trips menu 3rd Last Trip holds the number of the third to last trip P 76 4th Last Trp Trips sub menu of Trips menu Ath Last Trip holds the number of the fourth to last trip P 77 5th Last Trp Trips sub menu of Trips menu 5th Last Trip holds the number of the fifth to last trip P 72 Trip Sensitivity Range 1 to 15 Default 1 Scaling n a Type R W Trip Sensitivity holds an arbitrary number to adjust the sensi
58. cycles 60 cycles s 1 67s Refer to Shearpin Explanation Diagram Shearpin Explanation Diagram LOAD Notes 4 aas Shearpin Level 2 If l xg EXCeedS lih for a time equal to Shearpin Time and Shearpin is set to on then the unit will trip as indicated 1 SHEARPIN Time gt Shearpin Time 2 5 36 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 5 Keypad Menu Items and Parameters Current Sub menu of Advanced Menu continued P 34 Overload Level Current sub menu of Advanced menu Range 0 5 to 1 25 x le Default 1 0938 x le Scaling n a Type R W The Start of O verload Level parameter holds the level in Amps at which an Overload trip will start integrating Refer to O verload Explanation Diagram This parameter is not available in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass 2 Special case If a load current exceeding 7 2 x FLC occurs for longer than 60 ms a Shearpin Trip is forced whenever the O verload is On see section 5 4 12 P 35 Overload Delay Current sub menu of Advanced menu Range 10 to 140 Default 140 Scaling n a Type R W The Overload Delay parameter holds an arbitrary dimensionless number which slows down the integration of an Overload trip The larger the value of the number store
59. ds ead eae PG 5 33 5 4 6 Monitoring Menu a 5 42 5 4 7 Permanent Store Menu 0 cee ees 5 44 5 4 8 Password Melilla a cese daga Rage Pe reese BAYARAN eats NG 5 45 5 4 9 Inputs MENU is toes See ba RENA TER RO eed oe soe ae Red 5 46 5 4 10 Outputs MENU uou aa esq ds PENAS ee tue Keke HG NG NUNG Bard 5 47 5 4 11 Parameters Menu dcc eR ka KA eg hPEREYVEP KAAL he PATERE SS 5 49 54 12 Tps ME cuori CROIRE TA AA ACC aoe RE OE REA E PR D PY 5 76 5 5 Definitions for Chapter5 5 79 5 1b KEYPAD MENU ITEMS AND PARAMETERS 5 Chapter 5 Keypad Menu Items and Parameters res 5 0 How to Use This Chapter SR44 Soft Starters have two basic types of settings that can be changed and or viewed by users Keypad Menu Items These settings have no numerical address and can be accessed only through a keypad Parameters These settings have numerical parameter numbers and numerical addresses and they can be accessed through a keypad or by serial communications O ptional accessories are required for serial communications refer to the Accessories chapter 5 0 1 How Keypad Menu Items and Parameters are Arranged in this Chapter 1 2 3 4 Keypad Menu Structure Abbreviated Map of Keypad Structure This section contains a one page flow chart that shows an abbreviated map of the keypad layout and how to scroll through the keypad to access the Keypa
60. ensure that the required standards or regulations are not affected by so doing 1st Ed Rev A 09 2011 SR44 Series Soft Starter User Manual 2 15 Chapter 2 Electrical Installation li MH M HQ 2 10 1 Full Load Current Limit and Short Circuit Protection continued SR44 Fuse and Current Ratings for Non UL Applications Short Circuit ma Current Bussman Edison l Model e Arms FWP 700V E70S RMG Model Model SR44 9 9 SR44 16 16 SR44 23 23 SR44 30 30 SR44 44 44 SR44 59 59 SR44 72 72 SR44 85 85 SR44 105 105 SR44 146 146 SR44 174 174 SR44 202 202 SR44 242 242 SR44 300 300 18 kA SR44 370 370 FW P 700A E70S700 U se these fuses with SR44 soft starters only in NON UL applications FW P 50B E70550 FW P 80B E70580 FW P 125A E705125 FW P 200A E705200 FW P 300A E705300 FW P 400A E70S400 FW P 500A E70S500 2 10 2 External Fuse Requirements The rating of HRC High Rupturing Capacity fuses for motor protection needs to be carefully analyzed when using a Soft Starter due to the longer start times which are involved When high inertia loads e g fans are being started special consideration should be given to fuse ratings due to the extended ramping times Most fuse manufacturers have an extended start or dual element range of
61. fuses intended for this type of application The advantage of an HRC fuse becomes evident during a fault current condition Asa result of the high current large amounts of heat are created within the fuse melting the filling of the fuse into glass Being an insulator glass suppresses arc over and breaks the circuit instantly This behavior minimizes the possibility of a continuing dangerous high arc current For semiconductor protection fusing refer to the table in section 2 10 1 2 16 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 2 Electrical Installation l 2 10 3 Overload Current Profile and Duty Cycle AC 53a IEC 60947 4 2 Motor Utilization Category AC 53a not operating in bypass mode SR44 Index Ratings for AC 53a Soft Starter la A Standard Operation Model Number e UC ES AC 53a 99 10 SR44 9 to SR44 105 9t0105 KER3 i 99 10 AC 53a 99 10 AC 53a 60 3 Index ratings AC 53a and AC 53b are specified by IEC standard 60947 4 2 IEC Index Ratings for standard operation are comprised of Rated O perational Current le Utilization Category AC 53a Overload Current Profile X T and Duty Cycle F S AC 53a Overload Current Profiles applicable to specified Soft Starter models aa baal Overload Current Durationof Ratio of On load Number of Overload Period to Total Operating Cycles multiple of le seconds Load per Hour SR44 9 35 99 10
62. has a statutory obligation to provide a guide for compliance with this directive For the SR44 this guidance is given in the EMC guide which is chapter 4 of this manual Itis essential that users and installers understand and comply with the requirements described in these sections 3 1 14 Fuses Circuit protection fuses should be rated to allow for the extended start times associated with the use of a Soft Starter Traditional HRC motor fuses may need to be rated higher than the motor rated current for normal low inertia applications but modern extended start fuses will generally give full motor protection See also section 3 2 2 relating to high inertia loads Semiconductor fuses are available for the short circuit protection of the thyristors in the SR44 See the Fuse and Current Ratings section in chapter 2 Electrical Installation of this manual for semiconductor fuse recommendations and details of the Overload incorporated into the SR44 3 4 SR44 Series Soft Starter User M anual 1stEd RevA 09 2011 Chapter 3 Applications M 3 2 Rules for Specific Applications 3 2 1 In Delta Operation The SR44 control system allows the soft starter to be installed in the delta connections of the motor which can permit the use of a lower current rated unit However in this mode of operation it is important that the soft starter is connected in accordance with the relevant wiring diagram The connection diagram
63. load P 81 Kick Pedestal 2 is the 2nd parameter set counterpart of P 13 Kick Pedestal P 14 Kick Time Range 10 to 40 cycles Default 25 cycles Scaling 1 Type R W Kick Time sets the number of cycles for which Kick Ped P13 is applied if selected P51 B0 P 15 Dwell Time Range 1 to 255 seconds Default 5s Scaling 1 Type R W Dwell Time provides a period of time following soft start allowing the load to settle and to ensure that it is up to speed before optimizing commences if selected P 16 Stop Ped Range 10 to 60 percent Default 10 Scaling 1 Type R W Soft Stop Pedestal sets the percentage of supply voltage at which the Soft Stop will cease The actual value is affected by certain load variations P 17 Stop Time Range 0 to 255 seconds Default Os Scaling 1 Type R W Soft Stop Time sets the time period over which the Soft Stop Ramp is performed 5 52 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 5 Keypad Menu Items and Parameters SSS aa 5 4 11 Parameters Menu continued P 18 Auto Config Range 0 to 255 flags Default 6 Scaling 1 Type R W Auto Configuration Set this parameter by individual bits Bit 0 Auto Ramp gently ramps voltage to starter acts somewhat like an automatic current limit 1 Auto 3MC enable automatic removal of low voltag
64. makes Relay K1 ACTIVE normal logic sense or INACTIVE inverted logic sense Default setting is P52 Bit5 Main Contactor Relay change over contacts Contact rating 230VAC 3A AC1 24VDC 3A 11 Common 12 Normally closed 14 Normally open Programmable O utput Relay K2 A bit 1 on the parameter bit selected by P59 makes Relay K2 ACTIVE normal logic sense or INACTIVE inverted logic sense Default setting is P8 Bit 3 Top of Ramp or Full Volts Relay change over contacts Contact rating 230VAC 3A AC1 24VDC 3A 21 Common 22 Normally closed 24 Normally open 2 8 Reserved for Future Use 1st Ed Rev A 09 2011 SR44 Series Soft Starter User M anual 2 13 Chapter 2 Electrical Installation app 2 2 Ph raging 2 9 Typical Motor Power at Rated Voltage The amperage values for the Soft Starter are the maximum continuous current for the model The motor ratings are the nearest values for the output powers of standard squirrel cage motors below the unit current rating of the SR44 The currents amps quoted are for 3 phase 4 pole motors operating on 50 60Hz power supplies Actual currents of motors may vary by 10 depending on size and manufacturer Motors of lower speeds generally draw higher currents for the same rated output Typically 1096 for 6 pole or 20 for 8 pole as compared to 4 pole motors Motor ratings are in kiloW atts kW as defined by the IEC or Horsepower HP as defined b
65. next page continued from previous page l l l L_a LOW Amps Level gt 2Amps TD press button multiple times or hold to scroll 9 O o icd NA l li Advanced Low Amps Level Low Amps Level Permanent Store Q oe 14 NN 40 press button multiple times or hold to scroll Q NO CC TS kr XN il MI eese ELO From LG a From PENE CC EE rm Parameter 112 Bit Mask q 1 M Y 23 23 Q ana O continued next i 15 6 scroll e 3 From Te i EEN From o Bit HER ees Parameter 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual A 15 Appendix A Setup Examples A 1 12 Setting the Low Amps Level and Using the K2 Relay to Display the Status of Low Current Bit continued continued from previous page 18 19 20 21 With Map From on the top line of the display press the W button Press the ENTER button to select Bit Number Press the Optimise button to move the cursor to bit 3 Press the A button to change the bit state to one 1 This may not be necessary bit 3 may already be a one turn off any other bits simply use the O ptimise button to navigate to the required bit and press the W Only one bit in any relay bit mask may be set to a positive bit state set to one 1 at any one time To button to change its bit state to zero 0 22 Press the Enter button to confirm any changes the display will flash 23 Press the butt
66. of maximum demand charges further energy savings and other benefits deriving from the soft starting process itself reduced total energy demand reduced wear and tear reduced maintenance and replacement costs 3 18 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 3 Applications M 3 4 6 Estimating Energy Savings Basis for estimations 3 phase squirrel cage induction motor standard type Supply 380 to 440V 50Hz Supply voltage minimum working voltage on motor rating plate Operation 3096 rated nameplate full load Table 3 4 6 1 Estimations Energy Savings Estimations Table 3 4 6 1 Motor Size kW HP Estimated Savings Yo rated kW 5 10 6 5 3 5 2 5 More than Table 3 4 6 2 Modifying Factors 1 5 Energy Savings Modifying Factors Table 3 4 6 2 Motor Poles Motor Slip Number of Poles Add Yo kW Slip Add kW 0 5 0 5 0 5 0 2 0 0 5 3 3 0 5 Examples of estimated savings 1 37 5 kW 4 pole motor 1 5 1 From Table 1 use the estimated savings figure for the next higher rating ie 55 kW The savings would be approximately 3 5 x 37 5 kW 1 3125 kW 2 37 5 kW 2 pole motor From Table 1 use the estimated savings figure for the next higher rating ie 55 kW From Table 2 apply the pole number factor of 0 5 96 The savings woul
67. output Figure 3 3 6 1 Motor Efficiency Load Characteristic 100 EFFICIENCY 0 1 2 1 1 Figure 3 3 6 1 LORD Motor Efficiency Load Characteristic In fact very few motors actually experience consistent fully rated operation and the vast majority operate at much lower loads due to either over sizing a very frequent situation or natural load variations For Fan and Pumping applications the affinity laws will allow the inverter drive to show very considerable energy savings over virtually all other methods of control through varying the speed of the motor in response to changes in load W here motor speeds cannot be varied an optimizing version of semiconductor motor controller such as the SR44 will also produce energy savings in lightly loaded motors Less sophisticated systems of soft starters remain at full conduction and the motor then behaves as if it were connected directly to the main supply However at light loads and mains voltages induction motors always have excess magnetic flux and efficiency loss and power factor degradation result By detecting the load at any instant and adjusting the motor terminal voltage accordingly it is possible to save some of the excitation energy and load loss and therefore improve motor power factor when the motor is running inefficiently at light loads Figure 3 3 6 2 Motor Efficiency Loss Characteristic zZ MECHANICAL n 0 1 2 1 1 LOSSES Figure 3 3 6 2 Motor Efficien
68. reset the password 2 Once the display has flashed press and hold the W button until to reset is displayed Do NOT press to reset Press the A button once Press the W button once Press ENTER Display shows Bingo Press ENTER Display will show Comms Failure Cycle power to the SR44 and all parameters will be reset to factory defaults 0 C NAA Y A 12 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Appendix A Setup Examples M A 1 11 Using the Pre programmed Relay Options This example shows the user how to program any relay on the unit via the pre programmed options The option shown in the example below is the Alarm but the instructions apply to all of the pre programmed relay options see section 5 4 10 and for all of the relays since they are all programmable 1 With Stopped and ready shown on the display press the EN TER button 2 With Applications shown on the top line of the display press the W button until O utputs is shown at the top of the display 3 Press ENTER to select the O utputs menu 4 With K1 on the top line of the display press the W button until K2 is shown at the top of the display 5 Press ENTER to select K2 6 With Map From on the top line of the display press the W button until K Alarm is shown on the top line of the display 7 Press ENTER to select K Alarm The display will flash tw
69. scroll O Sm Trips o P21 P40 D Q O o o P101 O D A 20 SR44 Series Soft Starter User Manual press button multiple times or hold to scroll P81 Kick Ped 2 P82 Kick Time 2 6 press button multiple times or hold to scroll O o P97 U1 I P srce g P98 U1 I P Mask Q Y continued next page 1st Ed RevA 09 2011 Appendix A Setup Examples LY A 2 2 Changing the Parameter Group After the Unit Has Passed Top of Ramp continued continued from previous page 8 With 0 Parameter shown on the display press the A button until 8 Parameter is displayed 9 Press ENTER once to accept the change 10 Press once to return to P97 U1 I P srce 11 Press the W button once until P98 U 1 I P Mask is shown at the top of the display 12 Press ENTER to select P98 U 1 I P Mask 13 Press the V button once to change the bit state of bit O to zero 0 14 Press the OPTIMISE button three times so that the cursor is displayed on bit 3 15 Press the A button once to change the bit state of bit 3 to one 1 16 Press ENTER once to confirm the changes 17 Press once to return to P98 U 1 I P Mask continued next page previous page 2 Ali P97 U1 I P srce P97 U1 I P srce P97 U IP srce P98 U1 I P Mask 8 Parameter 8 Parameter NY continued from 8 press button multiple times or hold to scroll O P97 U1 I P srce 0 0 Parameter
70. set Setting for Motor Generator Set application See Appendix B Applications Data for details aerator Setting for Aerator application See Appendix B Applications D ata for details Flywheel Press Setting for Flywheel or Press application See Appendix B Applications Data for details z Moulder Setting for Moulder application injection molding See Appendix B Applications Data for details 5 26 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 5 Keypad Menu Items and Parameters 5 4 3 Auto Features Menu The Auto Features Menu contains commonly used parameters that may be automatically adjusted by the unit Auto Features Menu Explanation Diagram Auto EndStart U oap A Auto Pedestal Auto End Stop N A Start Pedestal Stop Pedestal Y Start Time f Stop Time Time Auto Features Menu Settings P 18 Settings Range P18 Auto settings listed by name Default Auto 3MC Auto Bypass When active the Settings menu item will provide a brief report on which if any Auto options have been switched On A downwards facing arrow will appear on the right hand side of the top line of the user interface display While this icon is present all of the Auto options that appear on the bottom line of the display have been switched On
71. the reconnection to delta is made a large phase differential can exist between the supply and the rotor fluxes This can give rise to very large current surges as much or more than full voltage locked rotor current together with massive transient torque oscillations which can peak at levels in the region of fifteen times full load torque Although the effects described are only present for a very short period of time about one fifth of a second they are sources of great stress and damage to the whole drive system and where frequent starting is necessary invoke high maintenance costs The current surges in the form of very high level short duration spikes are an increasing problem for computer control systems and other sensitive electronic equipment The voltage disturbance on the supply is very difficult to filter out and can cause severe problems especially when larger motors are involved 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual 3 11 Chapter 3 Applications _e_ __ _ _ _ _ _ _ _ _ _ _ _ z amp _ _ _ E_ 86 a a qx There are methods of control for example the Wauchope starter which eliminate or reduce the reconnection transients However such starters are expensive and have reliability implications and they are not widely applied for these reasons The wye delta starter also has disadvantages due to the restricted starting torque available if
72. the O PTIM ISE button five times Then to turn on the Auto Pedestal bit just pressing the A key once will change the bit to the required value To confirm the changes made the user would then press the ENTER button Not pressing ENTER would effectively cancel the changes made by the user 5 1 9 Keypad Boot up Messages When the control supply to the SR44 is switched on the user interface will go through a boot up procedure during which it will display some information relevant to the SR44 s current state The messages are displayed during the boot up procedure in the order that they are listed below A brief explanation of each message is included V1 069LM This message shows the keypad firmware version number and release date 10 12 16 date displayed in European format YY M M DD This message indicates that the keypad is looking for a Soft Starter starting with a station number of 1 If itis unable to find a starter with that station number it will move on to station number 2 etc until 32 the highest valid station number is reached See section 5 3 4 for further details Password is Set This message appears if the password has been set Stopped amp ready Stopped and ready is displayed after the end of a successful boot up procedure The number 1 on the second line is the station number of the unit that the keypad is currently talking to 1 Find Starter 1st Ed RevA 09 2011
73. the soft starter paramters P11 and P12 Since each Modbus word actually has 2 values 1 in each byte the data has to be manipulated to put each relevant value in its own register First DH10 is loaded and the RSH instruction is performed to Shift the value to the right by 8 bits which moves the upper byte to the lower byte and this is output to DH11 P11 Pedestal Next the LSH Left Shift Register instruction is used in the 2nd MATH box to reload the original value in DH10 and move the lower byte to the upper byte shifting left 8 bits and we put the result in DH12 as an intermediate step Finally we load DH12 in the 3rd MATH box and perform a RSH Right Shift Register instruction to move the upper byte back to the lower byte again shifting 8 bits Now the result is the bare lower byte value from the original word and this result is output to DH13 as our final value To summarize the original data is shifted to the right 8 bits which moved our original upper byte to the lower byte and zeroed out the upper byte This was the 1st MATH box Then the original value is reloaded moved to the left 8 bits then moved to the right 8 bits This zeroed out the upper byte and resulted in the lower byte value This took 2 MATH boxes The values now reside in DH11 and DH13 Always ON SC1 Math P11 Pedestal RSH DH10 8h HIDH11 Result 16 Intermediate Math Calc LSH DH10 8h HIDH
74. under these conditions A heavy duty start thermal overload or an electronic overload with dual settings for start and run is recommended Modern HRC motor fuses will allow for some overload during the start but the fuse curve giving time current data will give an indication of suitability for the particular application 3 2 3 Reserved 3 2 4 Resistive Loads AutomationD irect does not support the control of resistive loads with the SR44 Soft Starter 3 2 5 Frequent Starting High starting frequencies require careful consideration of the soft starter thermal capabilities In many cases a standard sized SR44 may be suitable as start times are generally shorter for this type of application If this is not the case then a larger soft starter may be required 3 2 6 Optimizing Drives which operate for long periods of time at less than their rated capacity can benefit from the energy saving function optimizing of the SR44 which adjusts the thyristor triggering to reduce the excitation losses of the motor This feature will lower the running temperature of the machine and help to extend its life See Section 3 4 Principles of the O ptimizing M ode 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual 3 5 Chapter 3 Applications rs 3 2 7 Soft Stopping Soft stopping can reduce positive surge pressures in pipelines on shutdown It is necessary to make sure that the ramp down time is long enough to remove the energy from the f
75. voltage starter is the wye delta or star delta starter Consisting of three contactors and a time switch which can be mechanical pneumatic electrical or electronic the wye delta starter changes the motor winding configuration from an initial wye connection to a delta connection as the motor accelerates The change over or transition point is controlled by the time switch and is usually arranged to be approximately at 80 of full speed The effect of starting in the wye connection is to alter the voltage across each stator winding to 58 of normal This reduces the starting torque to a third of locked rotor torque LRT with a consequent reduction in starting currents and acceleration forces Although an apparent improvement over the direct system significant disadvantages still remain The transfer from wye to delta momentarily removes the motor from the supply During this time the motor is under the mechanical influence of the rotating load and at the instant of disconnection current will still flow in the rotor bars due to the time delay necessary for the magnetic flux to die away Therefore there is a residual flux frozen on the surface of the rotating rotor which cuts the stator windings generating a voltage whose frequency depends on the rotor speed If the load inertia is small such as in a pump or if the friction is high there could be a significant loss of speed during the time the supply is disconnected In this case when
76. will reset TopOfRamp StartUnitCommand RST Starting StopUnitCommand This rung controlled by StopUnit input usually a pushbutton input to the P3 activates the Stop Unit sequence by setting the Bool tag StopUnitCommand Then a value of 8 Bus Stop is written to tag P124 Starter Control Again writing will begin until status bits reflect the desired response Then the sequence resets StopUnit StartUnitCommand SET COPY DATA Source Destination 8 P124 Starter Control Enable Stopping RST StopUnitCommand 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual 6 31 Chapter 6 Serial Communications lli E E E E E E E E EE E _E_ _ _ _ _ _ _ EE Hr r amp P nm 6 7 3 Productivity3000 PLC Example Program continued The following rungs are optional and are included as an example of how to Read and Write to a parameter of the SoftStart The SoftStart is 8 bit based so Reads actually return 2 values which have to be separated shown on the next rung with theShift Rotate instructions so we can use them MODBUS READ CPU 485 In Progress ReadStarterlnProg Slave Node Number 1 Complete ReadStarterCmplt Automatic Polling 300 0 Success ReadStarterSuccess Don t Skip Execution Error ReadStarterErr W
77. you need 40 LRT to break away you can only increase the motor size or revert to direct on line Combined with the severe effects of the re switching surges and the additional costs of bringing six conductors from the motor to the starter instead of only three wye delta only offers an imperfect solution to the problem of starting the induction motor Method C Primary Resistance Starter It has long been recognized that the transition step in the wye delta system was a source of problems such as welded contactors sheared drive shafts etc For many years a method of stepless control has been available in the form of the primary resistance starter This type of controller inserts a resistance in one or more often in each of the phase connections to the stator at start up after which it is progressively reduced and shorted out at the end of the acceleration process Frequently the resistances are movable blades that are gradually inserted into an electrolyte liquid The mechanism is usually large and expensive both to purchase and to maintain and considerable heat is created by the passage of current through the electrolyte resistor This limits the starting frequency because the electrolyte has to condense back to liquid before a new start can proceed and these restrictions prevent this starter from being a popular option when selecting a control system However it has the distinction of being the smoothest and least stressful method of ac
78. 00m 6562 ft lstEd RevA 09 2011 SR44 Series Soft Starter User Manual 1 3 Chapter 1 Mechanical Installation rr 1 6 Assisted Flow An enclosure may need additional fans to maintain the required air temperature immediately surrounding the unit This temperature is referred to as the Ambient Temperature Use the following formula to determine whether or not fan s are required An allowance has been incorporated into the formula so that the figure for Q should be the air delivery quoted in the fan supplier s data Q 4x Wt tmax tamb Q required volume of air in cubic meters per hour m3 h Wt heat produced by the unit and all other heat sources within the enclosure in Watts W tmax maximum permissible temperature within the enclosure C tomb temperature of the air entering the enclosure 9C If you prefer to work in CFM substitute 9F for 2C Refer to the table in section 1 7 for the heat produced by the SR44 and note that the heat figure Wt is the total heat produced by everything within the enclosure 1 7 Heat Output of Units At rated operational current le unit Full Load Current FLC SR44 Approximate Heat Output non bypass Chassis Size 1 Chassis Size 2 Model Heat Output W Model Heat Output W SR44 9 30 SR44 174 520 SR44 16 45 SR44 202 610 SR44 23 60 SR44 242 650 SR44 30 90 SR44 300 850 SR44 44 120 SR44 370 970 SR44 59 155 SR44 72 210 SR44 85 220 S
79. 1 Current Limit Time is the 1st parameter set counterpart of P 90 Current Limit Time 2 P 91 Shearpin 2 external CT required for bypass mode see P 86 Bit 2 for note Range 1 063 to 5 x le Default 3 x le Scaling 0 03125 Type R W Shearpin Level 2 Use with 2nd parameter set Shearpin Level 2 sets the level of current which will cause a quick trip Not active during Start or Stop This parameter is not available in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass P 32 Shearpin Level is the 1st parameter set counterpart of P 91 Shearpin Level 2 p 92 Shear time 2 external CT required for bypass mode see P 86 Bit 2 for note Range 5 to 255 cycles Default 50 cycles Scaling 1 Type R W Shearpin Time 2 Use with 2nd parameter set Shearpin Time 2 sets the number of cycles a Shearpin Current must be present before tripping The shearpin is only active during the running phase not Start or Stop The shearpin flag P 95 Bit 3 is updated even if tripping is not enabled This parameter is not available in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass P 33 Shearpin Time is the 1st parameter set counterpart of P 92 Shearpin Time 2 lstEd RevA 09 2011 SR44 Series Sof
80. 12 Result P12 SoftStart Math Time RSH DH12 8h HIDH13 This rung copies the Hex values in DH11 and DH13 to DS40 and DS41 respectively Always ON P11 Pedestal B SC1 HI DH11 17 P11 Decimal Value Des IJ DS40 Copy Single P12 SoftStart Time Src H DH13 P12 Decimal Value Des IJ DS41 18 END 6 24 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 6 Serial Communications 6 7 2 DiredLOGIC PLC Example Program This information provided by AutomationDirect com Technical Support is provided as is without a guarantee of any kind These documents are provided by our Technical Support D epartment to assist others We do not guarantee that the data is suitable for your application nor do we assume any responsibility for them in your application This DirectLO GIC ladder program example works with the MW X and MRX instructions found in the DLO6 and DL260 PLC platforms The DLO6 and the DL260 can do RS 485 directly out of port 2 This program is for illustrational purposes only and is not intended for a true application The first 2 rungs monitor comm attempts and errors for troubleshooting Counter CTO counts the attempts by both MRX and MWX instructions and CT1 counts errors CTO will normally be counting rapidly while CT1 will be counting very infrequently if at all If both counters are counting up then there are problems whic
81. 30V before you apply the control supply POWER TERMINALS L1 L2 L3 Input Isolatable 3 phase supply via contactor isolator etc Any phase can connect to any terminal GROUND STUD Electrical ground PE An M8 threaded stud for connection to the system ground ar gt gt c gt i Cover inside view KEYPAD CIRCUIT CARD sz 2 location 4 KA Control Card SU size 2 location To remove cover unscrew 4 positions size 2 only 2 10 SR44 Series Soft Starter User Manual ELECTRONIC CONTROL CARD Refer to sections 2 5 2 and 2 7 1 POWER TERMINALS T1 T2 T3 Output Induction motor For correct motor rotation these connections must correspond with the supply connections atL1 L2 L3 When removing and replacing the front cover take care not to damage the cable that connects the Keypad and the Electronic Control Card The cable from the Keypad to the Electronic Control Card must be connected or disconnected O NLY when the control power is turned OFF to the unit Otherwise the circuitry may be damaged 1st Ed RevA 09 2011 Chapter 2 Electrical Installation 2 5 2 Electronic Control Card Figure 2 5 2 Electronic Control Card Electrical Connections SR44 0064 J11 Electronic Control Card PIN Output Output Relay Relay K2 K1
82. 4 Chassis Size 1 Mounting Specifications Mass Weight Unit Mounting Holes Model Number kg Ib Top Bottom SR44 9 to SR44 44 7 3 16 2 holes amp 2 slots 2 holes amp 2 slots SR44 59 to SR44 146 8 3 18 suitable for M6 or 1 4 fittings suitable for M6 or 1 4 fittings 1 6 SR44 Series Soft Starter User M anual 1st Ed RevA 09 2011 520 0 Chapter 1 Mechanical Installation 1 10 Mechanical Outline Chassis Size 2 SR44 174 to SR44 370 250 0 265 0 q EE S 29 Y ig T ka z T 5 fil T Mounting Holes Slots n SR44 size 2 SR44 174 to SR44 370 e Y e dimensions mm in SR44 Chassis Size 2 Mounting Specifications Unit Mounting Holes Model Number De 2 kg Ib Top Bottom SR44 174 to SR44 202 16 35 2 keyholes 2 open slots suitable for M 6 or 1 4 fittings SR44 242 to SR44 370 22 49 suitable for M6 or 1 4 fittings 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual 1 7 Chapter 1 Mechanical Installation tr 1 8 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 ELECTRICAL INSTALLATION Contents of this Chapter 2 1 Warnings amp Agency Approvals 2 2 2 1 1 Isolation APAPAP PER PP PP 2 2 2 1 2 Hectrical Power and Control Supply Requirements 2 2
83. 584 984 Mode Exception Response Buffer V406 10 Ramp Comm Interlock Ramp Comm Intlk C12 SET Updates the Soft Start Time P12 value of the SoftStart Ramp Comm Interlock MWX Port 2 Busy Enable Ramp Comm Ramp Comm Intlk CPU DCM Slot SP116 C11 C12 Port Number m Slave Address Function Code 06 Preset Single Register Start Slave Memory Address K40013 Start Master Memory Address V6014 Number of Elements n a Modbus Data type 584 984 Mode Exception Response Buffer V410 11 Ramp Comm Interlock Ramp Comm Intlk C12 RST 1stEd RevA 09 2011 SR44 Series Soft Starter User Manual 6 27 Chapter 6 Serial Communications NN l ar a Trrr rvrrrrk rRrrkr er rrpr prrrrr r r r jjj krkkrmkr rk r p pp 6 7 2 DirectLOGIC PLC Example Program continued Loads the value in V6020 Soft Start Time Entry and converts it to Binary and places the result in V6014 V6014 is the register that holds the value that is written to P12 Soft Start Time Entry from OIT Last value of for example 8 SS Time SS Time Entry Old SS Time LD V6020 V6021 Entry from OIT for example SS Time Entry V6020 OUT Last value of SS Time Old SS Time V6021 Soft Start Time V6014 Updates the Soft Start Time P12 value of the SoftStart Enable Ramp Comm C11 SET Updates the Soft Start Modbus Exception Time P12 va
84. Bypass in the OFF state can cause thyristor faults 3 Auto Jog enable automatic Jog detection Stop requests within about 0 5 seconds of a Start request are forced to 0 stop time Use this feature for short jogging of light loads For details amp timing chart refer to subsection 5 4 3 Auto Features M enu 4 Auto Endstop enable Detect Stalled Motor during soft stop and turn off thyristors 5 Auto Stop detect variations in PF during stop smooth stall 6 Auto Endstart enable detection of full speed during Start and complete Start ramp 7 Auto Pedestal enable approximate detection of motor rotation at Start and adjust pedestal to suit P 18 Auto Configuration is the 1st parameter set counterpart of P 86 Auto Configuration 2 P 87 Low I 2 Range O to 0 7813 x le Default 0 125 x le Scaling 0 03125 Type R W Low Current Level 2 Use with 2nd parameter set The Low Current Level 2 parameter if enabled sets a level of current under which the unit will trip This low current trip level is not active during the starting or stopping phases The Low Current Level flag is continually updated even if tripping is disabled This parameter is not available in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass P 28 Low Current Level is the 1st parameter set counterpart of P 87 Low Current Level 2
85. C OR 12 220VAC OUTPUT F3 08TRS 5 8PT RELAY 12 30VDC OR 12 220VAC OUTPUT lstEd RevA 09 2011 SR44 Series Soft Starter User Manual D 5 Appendix D Using AutomationDirect PLCs with SR44 Soft Starters eee DL405 PLC I O Compatible with SR44 Soft Starters DL405 PLCs Compatible with SR44 Soft Starters DL405 AC I O D4 08TA 8PT 18 220VAC OUTPUT D4 16TA 16PT 18 220VAC OUTPUT DL405 DC I O D4 08TD1 8PT 12 24VDC SINK OUTPUT D4 16TD1 16PT 5 24VDC SINK OUTPUT D4 16TD2 16PT 12 24VDC SOURCE OUTPUT D4 32TD1 32PT 5 24VDC SINK OUTPUT D4 32TD1 1 32PT 5 15VDC SINK OUTPUT D4 32TD2 32PT 5 15VDC SINK OUTPUT D4 64TD1 64PT 5 24VDC SINK OUTPUT F4 08TD1S 8PT 24 150VDC SINK SOURCE ISOLATED OUTPUT DL405 AC DC I O Relay Outputs D4 08TR 8PT RELAY 5 30VDC OR 5 250VAC OUTPUT D4 16TR 16PT RELAY 5 30VDC OR 5 250VAC OUTPUT F4 08TRS 1 8PT RELAY 12 30VDC OR 12 250VAC OUTPUT F4 08TRS 2 8PT RELAY 12 30VDC OR 12 250VAC OUTPUT P3000 PLC I O Compatible with SR44 Soft Starters P3000 PLCs Compatible with SR44 Soft Starters P3000 DC I O P3 08TD1S 8PT ISO LATED SINKING OUTPUT 6 27VDC PRODUCTIVITY3000 DC OUTPUT MODULE P3 08TD2S 8PT ISO LATED SOURCE OUTPUT 6 27VDC PRO DUCTIVITY3000 DC OUTPUT MODULE P3 16TD1 16PT SINKING OUTPUT 6 27VDC PRODUCTIVITY 3000 DC OUTPUT MODULE P3 16TD2 16PT SOURCING OUTPUT 6 27VDC PRODUCTIVITY3000 DC OUTPUT MODULE P3 32TD1 32PT SINKING OUTPUT 12 24VDC PRODUCTIVI
86. CDR COMBO 4 PT 24VDC INPUT AND 4 PT RELAY OUTPUT D2 08TR 8PT RELAY OUTPUT 5 30VDC OR 5 240VAC D2 12TR 12PT RELAY OUTPUT 5 30VDC OR 5 250VAC F2 08TR 8PT RELAY OUT 10A COMMON 12 28VDC 12 250VAC F2 08TRS 8PT RELAY OUTPUT 12 28VDC OR 12 250VAC D 4 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Appendix D Using AutomationDirect PLCs with SR44 Soft Starters l DL305 PLC I O Compatible with SR44 Soft Starters DL305 AC I O DL305 PLCs Compatible with SR44 Soft Starters D3 04TAS 4PT 110 220VAC ISOLATED OUTPUT D3 08TA 1 8PT 110 220VAC OUTPUT REM OVABLE TERM BLK D3 08TA 2 8PT 110 220VAC OUTPUT NON REM OVABLE BLOCK D3 16TA 2 16PT 15 220VAC OUTPUT F3 08TAS 1 8PT 20 125VAC ISOLATED OUTPUT 1 5A PO INT 8 COMMONS ISOLATED F3 16TA 2 16PT 20 125VAC OUTPUT MODULE 1 1A DL305 DC I O D3 04TD1 4PT 5 24VDC SINK OUTPUT D3 08TD1 8PT 5 24VDC SINK OUTPUT D3 08TD2 8PT 5 24VDC SOURCE OUTPUT D3 16TD1 1 16PT 5 24VDC SINK OUTPUT D3 16TD2 16PT 5 24VDC SOURCE OUTPUT DL305 AC DC I O Relay Outputs D3 08NE3 8PT 24VAC VDC SINK SOURCE IN PUT D3 08TR 8PT 5 30VDC OR 5 220VAC RELAY OUTPUT D3 16NE3 16PT 24VAC VDC SINK SOURCE INPUT D3 16TR 16PT RELAY 5 30VDC OR 5 220VAC OUTPUT F3 08TRS 1 8PT RELAY 12 30VDC OR 12 220VAC OUTPUT F3 08TRS 2 8PT RELAY 12 30VD
87. Circuit Electrical Supply Power terminals 1 L1 3 L2 5 L3 on all units must be connected to a balanced 3 phase 3 wire AC power supply that is within the limits specified below SR44 Power Electrical Tolerances Nominal Supply Voltage Range 230V 15 to 460V 10 Rat tional Voltage Ve 230V 460V PEO Petal oral Vola ge gl usable on 208V systems down to 196V Rated Frequency Hz 50 60 2Hz Phase sequence The SR44 will operate with any 3 phase rotation sequence It is important however to ensure that the correct connections are made when used with a rotation sensitive load 2 6 2 Motor Connections The motor connects to terminals 2 T1 4 T2 6 T3 All SR44 units will control any standard 3 phase squirrel cage induction motor capable of operating satisfactorily when connected to the main supply with its normal load coupled 2 6 3 Control Circuit Electrical Supply All units require a separate 2 wire single phase supply connected to terminals X1 and X2 At the Control Voltage Selector Switch the user can select either 115V or 230V The diagrams in section 2 5 show the location of the terminals X1 and X2 for each model of SR44 Supply voltage must be in the range 115V 15 10 or 230V 15 10 1 The control supply requires external fuse protection 2 Ensure that the control Voltage selector switch is set correctly before applying power SR44 Control Power Consumption Cu
88. Command Failed Modbus Function 07 Transaction Table Showing Error Response Query Response Field Hex Byte Field Hex Byte Slave Address 01 Slave Address 01 Function 07 Function 87 CRC Low 41 Exception Data 01 CRC High E2 CRC Low PLC amp SR44 automatically CRC High calculate CRC checksum values Returned Error Response Number Modbus Meaning 0 Illegal Function Writing Illegal Data Address O ut of allowed parameter range Illegal Data Too many data bytes in query 1 2 3 6 18 SR44 Series Soft Starter User Manual Slave Busy Slave is performing a long command 1st Ed Rev A 09 2011 Chapter 6 Serial Communications 6 7 Example PLC Communications Programs 6 7 1 CLICK PLC Example Program This information provided by AutomationDirect com Technical Support is provided as is without a guarantee of any kind These documents are provided by our Technical Support D epartment to assist others We do not guarantee that the data is suitable for your application nor do we assume any responsibility for them in your application j This program is for illustrational purposes only and is not intended for a true application The first 2 rungs monitor comm attempts and errors for troubleshooting Counter CT1 counts the attempts by both Receive and Send instructions and CT2 counts errors
89. Default Off Scaling n a Type R W This menu item turns On or Off the Low Voltage Stop function When On this allows soft stop pedestals of less than 40 to be set Soft stop pedestals of 40 and less can be set with the Low Volts Stop set to Off but they will be treated by the unit as a 40 soft stop pedestal P 71 Contactor Delay Range 100 to 800 milliseconds Default 160 ms Scaling n a Type R W Contactor Delay Following a start command this is the delay allowed for the main incoming contactor to close After this time a phase loss detection routine checks the incoming supply P 72 Trip Sensitivity Range 1 to 15 Default 1 Scaling n a Type R W Trip Sensitivity holds an arbitrary number to adjust the sensitivity of some of the fault trips The larger the number the slower the trip P 1 Station No Range 1 32 Default 1 Scaling n a Type R W Station Number assigns the Local N etwork ID of this card P6 Firing mode Range 0 to 1 Default 0 Scaling n a Type R W Firing M ode 0 Normal Motor outside delta or star wye 1 Delta inside delta no optimizing An in line isolation contactor controlled by the soft starter MUST be used with the In Delta Firing Mode and motor connections P 122 P122 Stop Smooth Range 1 to 25 Default 5 Scaling n a Type R W Auto Soft Stop Smoo
90. K STELLAR soft starter STELAR SR44 Sorr STARTER USER MANUAL WAUTOMATIONDIRECT SR44 M WO 1st Edition Revision A Automation SR44 Series Soft Starter User Manual 1s Ed RevA 09 2011 Thank you for purchasing automation equipment from Automationdirect com doing business as AutomationDirect We want your new automation equipment to operate safely Anyone who installs or uses this equipment should read this publication and any other relevant publications before installing or operating the equipment To minimize the risk of potential safety problems you should follow all applicable local and national codes that regulate the installation and operation of your equipment These codes vary from area to area and usually change with time It is your responsibility to determine which codes should be followed and to verify that the equipment installation and operation is in compliance with the latest revision of these codes Ata minimum you should follow all applicable sections of the National Fire Code National Electrical Code and the codes of the National Electrical Manufacturer s Association NEMA There may be local regulatory or government offices that can also help determine which codes and standards are necessary for safe installation and operation Equipment damage or serious injury to personnel can result from the failure to follow all applicable codes and standards We do not guarantee the products described in thi
91. R W User Flags 5 reserved Bit 0 unused Reserved Reserved unused unused unused unused unused NOOB WN H 5 56 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 5 Keypad Menu Items and Parameters ee el 5 4 11 Parameters Menu continued P 39 PF Angle Range 0 to 127 5 degrees Default 0 Scaling 0 5 Type R Real Power Factor Angle displays the angle by which the sine curve of the voltage in a curcuit leads the sine curve on the current in that circuit This parameter is not available in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass P 40 Supply Volts Range 108 to 1000 Volts Default 416V Scaling 4 Type R Supply Volts is the manually entered main supply voltage It also works in conjunction with Bit 1 of P 38 User Flags 5 for voltages above 500V P 41 reserved P 42 reserved P 43 reserved P 44 reserved P 45 reserved P 46 reserved P 47 reserved P 48 reserved P 49 reserved P 50 reserved Ist Ed RevA 09 2011 SR44 Series Soft Starter User M anual 5 57 Chapter 5 Keypad Menu Items and Parameters lli us 6 M 6 kx M I cs 5 4 11 Parameters Menu cont
92. R44 105 275 SR44 146 440 1 4 SR44 Series Soft Starter User M anual 1stEd RevA 09 2011 Chapter 1 Mechanical Installation i 1 8 Clearance To maintain adequate ventilation each model of SR44 Soft Starter requires a minimum clearance to adjacent equipment and partitions These clearances are specified in the following diagram and table S Soft Starter Soft Starter B 1 Unit Air Intake F 7 Outline of Mounting Enclosure Surface Minimum Clearance for Heat Dissipation SR44 Mounting Clearances Model Number Unit Cooling Method Minimum Clearance mm in Bottom B Side S Top T Front F SR44 9 to SR44 23 Natural Convection Forced Air SR44 30 to SR44 370 1st Ed RevA 09 2011 internal cooling fan inside each starter with 75 2 95 75 2 95 15 0 59 25 0 98 1 5 SR44 Series Soft Starter User Manual Chapter 1 Mechanical Installation 1 9 Mechanical Outline Chassis Size 1 SR44 9 to SR44 146 362 0 14 25 380 0 14 96 400 0 15 75 415 0 16 34 lt 195 0 7 68 lt 150 0 5 91 gt lt 222 0 8 74 SR44 size 1 SR44 9 to SR44 146 o o dimensions mm in o o SR4
93. RXRXV7 J rplrpr JJ v v p p prjrpvvFvFpv P P P PV p F ri J DL105 PLC I O Compatible with SR44 Soft Starters DL105 PLCs Compatible with SR44 Soft Starters DL105 PLCs F1 130AA 10 AC INPUT 8 AC OUTPUT 85 265VAC 5A 24VDC F1 130AD 10 AC INPUT 8 DC OUTPUT 85 265VAC 5A 24VDC F1 130AR 10 AC INPUT 8 RELAY OUTPUT F1 130DA 10 DC INPUT 8 AC OUTPUT 85 265VAC 5A 24VDC F1 130DD 10 DC INPUT 8 DC OUTPUT 85 265VAC 5A 24VDC F1 130DD D 10 DC INPUT 8 DC OUTPUT 10 30VDC P S F1 130DR 10 DC INPUT 8 RELAY OUTPUT 85 265VAC 5A 24VDC F1 130DR D 10 DC INPUT 8 RELAY OUTPUT 10 30VDC P S DL205 PLC I O Compatible with SR44 Soft Starters DL205 PLCs Compatible with SR44 Soft Starters DL205 AC I O D2 08TA 8PT 18 220VAC OUTPUT D2 12TA 12PT 18 110VAC OUTPUT F2 08TA 8PT 24 140VAC OUTPUT HIGH CURRENT 1 5A PT DL205 DC I O D2 04TD1 4PT 12 24VDC SINK OUTPUT D2 08TD1 8PT 12 24VDC SINK OUTPUT D2 08TD2 8PT 12 24VDC SOURCE OUTPUT D2 16TD1 2 7 116PT 12 24VDC SINK 2TERM 0 1A PT 1 6A MODULE D2 16TD2 2 116PT 12 24VDC SOURCE 2TERM 0 1A PT 1 6A MODULE D2 32TD1 32PT 24V DC OUTPUT MODULE D2 32TD2 32PT 24V DC SOURCING OUTPUT F2 16TD1P 16 PT 12 24VDC SINKING OUTPUT ELECTRONIC SHORT CIRCUIT PROTECTED F2 16TD2P 16 PT 12 24VDC SOURCING OUTPUT ELECTRONIC SHORT CIRCUIT PROTECTED DL205 AC DC I O Relay Outputs D2 04TRS 4PT ISOLATED RELAY OUTPUT 5 30VDC OR 5 250VAC D2 08
94. Rate Auto End Start Auto 3MC Soft Stop Smoothing Low Voltage Soft Stop N otes Application Type Default Auto Start Pedestal 10 Stop Pedestal Start Time s Soft Stop Time s Current Limit Level x FLC Current Limit Time s O ptimize Rate Auto End Start Auto 3MC Soft Stop Smoothing Low Voltage Soft Stop N otes Application Type Small Pump Start Pedestal 10 Stop Pedestal Start Time s 5 Soft Stop Time s Current Limit Level x FLC Current Limit Time s Optimize Rate Auto End Start Auto 3MC Soft Stop Smoothing Low Voltage Soft Stop Notes Application Type Large Pump Start Pedestal 10 Stop Pedestal 96 StartTime s 7 Soft Stop Time s Current Limit Level x FLC Current Limit Time s O ptimize Rate Auto End Start O Auto 3MC Soft Stop Smoothing MI Low Voltage Soft Stop N otes B 2 SR44 Series Soft Starter User Manual Auto Pedestal O Auto Bypass M Auto Ramp O Auto Pedestal M Auto Bypass M Auto Ramp M Auto Pedestal M Auto Bypass M Auto Ramp O Auto Pedestal M Auto Bypass M Auto Ramp O Auto Jog O Auto Stop O Auto End Stop O Auto Jog O Auto Stop M Auto End Stop O Auto Jog O Auto Stop M Auto End Stop M Auto Jog Auto Stop Auto End Stop 1st Ed RevA 09 2011 1st Ed Rev A SR44 Applications Data continued Application Type Start Pedestal Start Time s Current Limit Level x FLC Optimize Rate Auto End Start Soft Stop Smoothing N otes Application T
95. Start Time Range 1 to 255 seconds Default 5s Scaling 1 Type R W Soft Start Time sets the soft start time period over which the unit ramps voltage to the motor Start times are normally in the 5 30s range Long ramp times over 1minute are for special applications only The start without current limit is purely a voltage ramp Lightly loaded motors will normally reach full speed before the end of a long ramp Type Setting Range Description R Read Only R W Read Write Scaling Scaling applies ONLY when using SERIAL COMMUNICATION to read and write parameters When READING from parameters MULTIPLY the serial comm value by the scaling factor When WRITING to parameters DIVIDE your desired value by the scaling factor multiply by the inverse of the scaling factor Refer to Chapter 6 Serial Communications for scaling example 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual 5 23 Chapter 5 Keypad Menu Items and Parameters Ho kppppppppp pprrerprrvpp pprppppJlpppppppPp rb EEEEEE we U 5 4 2 Applications Menu This menu contains a list of typical applications for which a set of parameters have been predefined by the manufacturer This feature provides a quick and easy way of setting up the unit There are three exceptions to this list 1 The first menu item Settings provides a brief report on the basic settings of t
96. Synchronous speed However most induction motors are designed to have a standard characteristic that provides a compromise between starting torque and operating efficiency To summarize an induction motor will only start and accelerate when it produces more torque than the connected load absorbs This is true for all speeds including standstill and full speed 3 3 3 Starting Induction Motors Starting a de magnetized induction motor from standstill is a demanding and complex process At the instant of switching all the energy must be present that is necessary to magnetize the motor to provide the acceleration force to supply the kinetic energy of the rotor and load and to overcome the mechanical and electrical losses To do so at full supply voltage places considerable stresses on the supply the motor windings and the iron cores of the stator and rotor Excessive acceleration of a rotor when the mechanical load is small can produce torque oscillations in the shaft causing severe wear to transmissions gears and drives Excessive acceleration when the load inertia is high such as in centrifugal fans causes belts to slip on the pulleys producing rapid wear and early failure 3 10 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 3 Applications M 3 3 4 Electro M echanical M ethods Of Starting Method A Direct on Line The most simple means of controlling energy flow to an induction motor is to interrupt the po
97. T When Start PB is pressed C21 is set and a value of 7 is loaded into V6000 which is the register that is written to P124 of the soft starter Start PB Start SoftStart C20 C21 SET OUT Command Register P124 V6000 When the status of Starting or Top of Ramp turns ON the Starting sequence is reset Starting Start SoftStart C101 C21 RST Top of Ramp C103 6 26 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 6 Serial Communications 6 7 2 DirectLOGIC PLC Example Program continued When Stop PB is pressed C23 is set and a value of 8 is loaded into V6000 which is the register that is written to P124 of the soft starter Stop PB Stop SoftStart C22 C22 T SET OUT Command Register P124 V6000 When the status of Stopped or Stopping turns ON the Stopping sequence is reset Stopped Stop PB Stop SoftStart C100 C22 C23 RST Stopping C107 These next 2 rungs will handle changing P12 Soft Start Time Since the soft starter is 8 bit based there has to be a conversion operation to get the proper value Updates the Soft Start Time P12 value of the SoftStart Ramp Comm Interlock MRX Port 2 Busy Enable Ramp Comm Ramp Comm Intlk CPU DCM Slot SP116 C11 C12 Port Number Slave Address Function Code 03 Read Holding Registers Start Slave Memory Address K40012 Start Master Memory Address Number of Elements Modbus Data type
98. TY3000 DC OUTPUT MODULE P3 32TD2 32PT SOURCE OUTPUT 20 30VDC PRODUCTIVITY 3000 DC OUTPUT MODULE P3 64TD1 64PT SINKING OUTPUT 6 27VDC PRODUCTIVITY3000 DC OUTPUT MODULE P3 64TD2 64PT SOURCE OUTPUT 20 30VDC PRODUCTIVITY 3000 DC OUTPUT MODULE P3000 AC DC I O Relay Outputs P3 08TAS 8PT ISOLATED OUTPUT 80 288VAC PRODUCTIVITY3000 AC OUTPUT MODULE P3 O8TRS 8PT ISOLATED RELAY 8 FORM A PRODUCTIVITY3000 RELAY OUTPUT MODULE P3 O8TRS 1 7 8CH ISOLATED 5A RELAY OUTPUT MODULE PRODUCTIVITY 3000 RELAY OUTPUT MODULE P3 16TA 16PT OUTPUT 80 288VAC PRODUCTIVITY 3000 AC OUTPUT MODULE P3 16TR 16PT OUTPUT RELAY 16 FORM A PRODUCTIVITY3000 RELAY OUTPUT MODULE D 6 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Appendix D Using AutomationDirect PLCs with SR44 Soft Starters mf Terminator I O Compatible with SR44 Soft Starters Terminator I O Compatible with SR44 Soft Starters Terminator I O Discrete Output Modules T1H 08TDS PT 12 24VDC ISOLATED OUTPUT SINK SOURCE 8 CMNS T1K 08TA 16PT 17 240VAC OUTPUT T1K 08TAS 8PT 17 240VAC OUTPUT ISOLATED COMMONS T1K 08TD1 8PT 12 24VDC SINK OUTPUT T1K 08TD2 1 16PT 12 24VDC SOURCE OUTPUT 8PT RELAY OUTPUT 5 30VDC OR 5 240VAC 8PT ISO RELAY OUTPUT 5 30VDC OR 5 240VAC TIK 16TA 16PT 17 240VAC OUTPUT T1K 16TD1 16PT 12 24VDC SINK OUTPUT TIK 16TD2 1 16P1 12 24VDC SOURCE OUTPUT T1K 16TR 16PT RELAY OUTPUT 5 30VDC OR 5 240VAC
99. Table of Contents continued next page 3 la APPLICATIONS Table of Contents continued from previous page 3 3 Concepts and Principles of Fixed Speed Induction Motor Starting and Control 3 8 3 3 1 IMWOGUCUON 126542 dus KAG NG NG de KARA Ra xRexqens He ee es 3 8 3 3 2 The Induction MOON 2222 kA AA NAG AAKALA oud Komeda euh s 3 8 3 3 3 Starting Induction Motors 2 3 Ka xa X ERR ERR eae eh Ka NY RA 3 10 3 3 4 Hectro Mechanical Methods Of Starting 3 11 3 3 5 The Semiconductor Motor Controller 3 12 3 3 6 Running Induction Motors eese 3 13 3 3 7 Reliability Considerations nee 3 14 3 4 Principles of the Optimizing Mode 3 15 3 4 1 Principles seeeeer RR hh 3 15 3 4 2 Advantages of Energy Optimizing aaa 3 16 3 4 3 Additional Benefits in Practice llle 3 16 3 4 4 Optimizing with the SR44 System 3 17 3 4 5 How Much Energy aevi R hah ARAL eee eiase ee oes 3 18 3 4 6 Estimating Energy Savings suuxcedces e xS ES REREe Sd y CE esd 3 19 3 5 Chapter 3 Glossary of Terms 3 20 3 6 Power Factor Conversion Chart 3 21 3 1b APPLICATIONS Chapter 3 Applications 3 1 Motor Suitability and Associated Considerations The SR44 Soft Starter is based on a series of microprocessor based optimizing soft sta
100. ULL Protection Mode when Delta Firing Mode is selected P 6 1 In PHASE LOSS ONLY Protection Mode P 7 0 the bottom 12 5 of starter current is ignored after TOR Top Of Ramp 5 32 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 5 Keypad Menu Items and Parameters eee SSS rr rj 5 4 5 Advanced Menu The Advanced Menu holds parameters that need to be changed only to solve specific sets of circumstances Advanced Menu Explanation Diagram Vioap Se Pha a a a a T L gt i o k Vstop a Stop Time P17 P15 s gt Optimizing Optimizing with Level Optimizing Rate P19 4 P2 Vicin Main Contactor Optimizing with Relay closes Optimizing Rate 5 here P19 307 Notes 1 Thisis the supply voltage minus the voltage thatis dropped across the SR44 2 Thisis the Kick Pedestal voltage P13 3 Thisis the Start Pedestal voltage P 11 to which the unit drops after the kick pedestal has passed Unit receives NS 4 Thisisthe Stop Pedestal voltage P 16 which can be set to values lower than 40 of Vmax START k Unit starts firing if Low Volts Stop is on i d at this point 5 This relay brings in the contactor that supplies the three phase AC mains to the unitin the standard a Contactor wiring configuration see Electrical Installation section 2 3 1 Delay P71 6 Represented by the thick dotted line 7 Represented by the thick unbr
101. User Manual 6 17 Chapter 6 Serial Communications rr mrm7mr ra q n b j 8r Z 59 5 5 3g g3BYjyp qZ y9yp9 Zj5 Z5 6A are A Qn 6 5 5 Read Exception Status Modbus Function 07 Starter 01 This function s format is per the M odbus standard but the bits in the value returned have different meanings shown below This is the quickest of the Modbus functions and should be used in the context of the SR44 to check if a station is present or check if it is busy Modbus Function 07 Transaction Table Query Response Field Hex Byte Field Hex Byte Slave Address 01 Slave Address 01 Function 07 Function 07 CRC Low 41 Exception Data 00 CRC High E2 CRC Low PLC amp SR44 automatically CRC High calculate CRC checksum values Returned Exception Data m Meaning Enabled Stopped Starting Current Limiting TOR Start Complete Cooling Alarm oui A W N rn O 6 5 6 Returned Errors If there is a communication error in the query the SR44 does not reply If the network communication is OK but for some reason the SR44 cannot correctly execute the query then it will return an error reply In an error reply the function byte is returned OR ed with 80h and the following byte contains the error number e g if Function 07 cannot be executed 87h will be returned Offline
102. VAC set volt tch dingl C or 23 C set voltage switch acordingly 3 Supply E STOP STOP START Paa Feeder cables Isolation and Protection Switch gear provided by the customer eee d apum Contactor O Control O Voltage i Switch 115V 230V Electrical Ground Induction Motor Important Be sure to set the Control Voltage Switch to the proper control voltage setting before applying voltage to the control circuit 2 4 SR44 Series Soft Starter User Manual lst Ed Rev A 09 2011 Chapter 2 Electrical Installation 2 3 2 Wiring Diagram for In Delta Connection of Motors For In Delta connections set the SR44 Parameter 6 Firing Mode to 1 Delta Figure 2 3 2 Wiring Diagram for In Delta Connection of 6 Lead Motors Mains Supply Ve Ped peat eee Feeder cables Isolation and Protection Switch gear forward provided by the customer wiring SinsqunuraguNATEEENEER IRTERERRRE connections 5 h T i I C1 Circuit kaa Contactor a In delta connections for correct rotation of motor Control Circuit Term T1 W1 3 V1 2 T2 V1 2 W1 3 T3 U1 1 U1 1 L1 V2 5 W2 6 L2 U2 4 U2 4 L3 W2 6 V2 5 Electrical Ground An in line isolation contactor controlled by the soft starter MU ST be used with the In D elta Firing Mode and motor connections C1 as shown in Figure 2 3 2 1st Ed Rev A 09 2011 SR44 Series Soft Starter User M anual 2 5 Chapter 2 Electr
103. able continued next page 5 20 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 5 Keypad Menu Items and Parameters ee 1 5 3 Parameter Basic Information continued Parameter Basic Information continued Name Function c A User Flags22 Low Voltage Soft Stop 2 Not Global Enable 1 2 Not Global Enable 2 2 Pod Start Stop 2 Board Start Stop 2 Main Contactor 2 Second Parm Set 2 Zero Start Time 2 U1 I P srce U1 I P Mask U1 O P Dest U1 O P Mask U2 I P srce U2 I P Mask U2 O P Dest U2 O P Mask Reserved CO Oo CO GO O O OF O O H O O O O O o k l CO o o o0 o o Fl ele ele ele H Reserved Reserved Reserved Bypass U pper Limit Bypass Lower Limit Reserved Status 4 60 Hz Phase Rotation Sequence Shearpin Under Current Thermistor not available 5 32 Timeout 6 64 Overload 7 128 Thermal Switch 113 Reserved Type R Read Only R W Read Write Scaling applies ONLY when using serial commuication details in Serial Communications chapter Table continued next page oO CO O O O O O O O 1st Ed RevA 09 2011 SR44 Series Soft Starter User Manual 5 21 Chapter
104. aedctace se 2 12 2 6 2 Motor Connections eveectueetseve vest aaeedatecaoeededt x 2 12 2 6 3 Control Circuit Electrical Supply 000 00 aaa 2 12 2 7 Control Card Connections 2 13 2 1 1 CON TO Npa aha kB KARA AG saved NERD CLA Na unsure BG 2 13 2 1 CON TO DUES sirgs pr dre ANG edb aed ue ducc ceded 2 13 2 8 Reserved for Future Use 2 13 2 9 Typical Motor Power at Rated Voltage 2 14 2 9 1 Chassis Size 1 Motor Power Ratings 2 14 2 9 2 Chassis Size 2 Motor Power Ratings 2 14 2 10 Fuse and Current Ratings 2 15 2 10 1 Full Load Current Limit and Short Circuit Protection 2 15 2 10 2 External Fuse Requirements 0 2 16 2 10 3 Overload Current Profile and Duty Cycle AC 53a 2 17 2 10 4 Overload Current Profile AC 53b 2 18 2 10 5 Overcurrent Trip Graph esed away E XEX cue VESTESREES 2 19 2 1b ELECTRICAL INSTALLATION Chapter 2 Electrical Installation 2 1 Warnings amp Agency Approvals 2 1 1 Isolation isolation For this reason isolation means must be installed in the power supply circuit in f Caution The SR44 uses semiconductor devices in the main circuit and is not designed to provide accordance with the appropriate wiring and safety regulations 2 1 2 Electrical Power and Control Supply Requirement
105. ags 2 2 Use with 2nd parameter set User Flags 2 2 is a set of individual bits for user control or system status Other User Flags are parameters 51 52 53 95 amp 121 P96 is a direct 2nd set for P52 Bit 0 Low Voltage Soft Stop Not Global Enable 1 bits 1 amp 2 must both be Off 0 to enable the starter Not Global Enable 2 bits 1 amp 2 must both be Off 0 to enable the starter Pod Start Stop Board Start Stop Main Contactor Second Parameter Set Oc Ui A W N HI Zero Start Time lstEd RevA 09 2011 SR44 Series Soft Starter User Manual 5 69 Chapter 5 Keypad Menu Items and Parameters re M an 5 4 11 Parameters Menu continued P 97 U1 I P srce Range 0 to 125 parameter Default 0 Scaling 1 Type R W The ipfl_addr parameter holds the parameter for the internal starter input function assigned to drive the P99 internal starter output function Works in conjunction with P98 User Flag mapping through parameters 97 98 99 100 97 98 the source flag address 97 parameter 98 bit mask 99 100 the destination flag address 99 parameter 100 bit mask P 98 U1 1 P Mask Range 0 to 128 bit mask Default 0 Scaling 1 Type R W The ipfl_mask parameter holds the parameter bit for the internal starter input function assigned to drive the P99 internal starter output function Works in conjunction with P97 User Flag mappin
106. al current transformer is installed Refer to P18 B2 Auto Bypass P 21 Internal PF Range 0 to 146 76 degrees Default 146 762 Scaling 0 57554 Type R Internal PF shows the Power Factor Angle of the load Refer to Ch 3 6 for PF degrees to ratio conversion This parameter is not available in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass P 22 Delay Angle Range 0 to 146 76 degrees Default 146 762 Scaling 0 57554 Type R Firing Delay Angle shows the firing delay angle thyristor off time This parameter is not available in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass P 23 Max Angle Range 17 27 to 146 76 deg Default 57 5549 Scaling 0 57554 Type R Maximum Optimizing Delay Angle shows the maximum allowed Firing Delay Angle during optimizing The O ptimize function reduces energy consumption by reducing voltage but the system also senses motor conditions and automatically adjusts the maximum delay angle by which the voltage can be reduced without allowing the motor to stall This parameter is not fully functional in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass P 24 Rated Amps hundreds Range 0 to 3000 amps Default 0A Scaling 100 Type R W Unit s Rated Curr
107. ameter bit is not available in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass 7 Thermal Switch heatsink is above max allowed temperature P 113 reserved P 114 StopProfile Range 0 to 100 Default 0 Scaling 1 Type R W Soft Switch Off system variable P 115 Last App Range 0 to 255 Default 0 Scaling 1 Type R W Selected App Value selected from application table P 116 CoolingTime Range 0 to 63 75 minutes Default varies per model Scaling 0 25 Type R W Cooling Inhibit Time Time for which the unit is not allowed to restart display shows Stopped Cooling Mainly for larger stacks to avoid destroying thyristors during commisioning This parameter holds the time in seconds that the soft start unit will ignore a start signal if Cooling is turned on P53 B5 By default this is set to zero 0 for units of less than 242A For units of 242A and above the default value is 420 seconds 7 mins Changes should be entered in seconds The default value can be extended but it should NOT be reduced as it will invalidate the manufacturer s warranty lstEd RevA 09 2011 SR44 Series Soft Starter User Manual 5 73 Chapter 5 Keypad Menu Items and Parameters rr 5 4 11 Parameters Menu continued P 117 reserved P 118 reserved P 119 reserved P 120 Status 5
108. ating resistor between the A and B RS485 lines on both the RJ45 and screw terminal connections Only the nodes at each physical end of the RS 485 network should have terminating resistors J5 This jumper connects a 1kQ resistor between screw terminal G and local ground Normally only the last starter in the network should have this jumper installed 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual 7 3 Chapter 7 Optional Hardware EEE M M t 7 2 SR44 KPD Remote Keypad 7 2 1 Remote Keypad General Information An optional Remote Keypad is available for use with SR44 Soft Starters Remote Keypad Part Number SR44 KPD Remote Keypad requires installation of an SR44 RS485 communication card Can be used with all SR44 series soft starters Connects with standard CAT5 RJ45 terminated Ethernet patch cable use ferrites if EM C compliance is required Includes 3 meter 10 ft RJ45 twisted pair CAT5 Ethernet patch cable with ferrites Can be mounted up to 10 meters 33 ft from the SR44 Soft Starter Can be used on a one to one basis or one Remote Keypad can control several soft starters one at a time multiple soft starter control requires optional SRA4 RS485 communication cards for each SR44 Soft Starter Seven buttons with individual Start and Stop Display via a 2 line 32 character LCD Eliminates panel mounted Start and Stop pushbuttons ammeters and pilot lights Gives continuou
109. ation Stopped and ready 2 Buttons on the keypad to be pressed by the user will be indicated by their name ENTER in all capital letters or by the appropriate symbol Thus W indicates the decrement or move down button Quick Start Once the unit is mounted and wired per the instructions in the Stellar SR44 Soft Starter Basic Quick start Guide or in the Mechanical Installation and Electrical Installation chapters of this User Manual then select a suitable application from the Applications Menu described later in this chapter 5 2 2 amp 5 4 2 The unit can then be started with the keypad This will give a good basic setup but fine tuning will be required in some instances Applications menu that is similar to your application If necessary you can then fine tune your We highly recommend that you configure the SR44 by first selecting and setting an application from the configuration by changing the settings of other parameters and menu items 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual 5 3 Chapter 5 Keypad Menu Items and Parameters ee 5 1 2 User Interface The Keypads There are three types of user interface for use with the SR44 Only one interface may be used at any one time e The unit s built in keypad Figure 5 1 2a e An optional remote keypad Figure 5 1 2b and Optional Hardware chapter Optional Modbus communications Modbus Protocol amp
110. ation unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass P 31 C L Time Current sub menu of Advanced menu Range 5 to 255 seconds Default 30s Scaling n a Type R W The Current Limit Time parameter sets the time in seconds that the unit must be in a current limit situation for a current limit trip to occur Refer to Current Limit Explanation Diagram Current Limit Explanation Diagram LOAD Note Current 25 Limit bh 0 ee TUN EK M o a W Level Notes 1 If I oap exceeds Current Limit Level for time Limit Time Out and C L Time Out is on the unit will trip at the thick dotted line If C L Time Out is off the unit will continue ramping until T O R and then enter the Dwell period 2 Ifthe unit current limits during start up the start time Time will be elongated by the amount of time that the unit was currentlimiting 3 The actual current rises slightly abovethe level set in CurrentLimit because the unitmanages the current through control of the thyristor firing delay angle Limit Time Out 1 Start Time 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual 5 35 Chapter 5 Keypad Menu Items and Parameters Current Sub menu of Advanced Menu continued P51 83 Shearpin Current sub menu of Advanced menu Range P51 B3 Default On Scaling n a Type R W T
111. ault n a Default Parameters loads all the parameters with their factory default values The Starting parameter is set to Remote by this menu item P51 bit 7 5 44 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 5 Keypad Menu Items and Parameters E mn 5 4 8 Password Menu P 5 Enter Password Range 0 to 255 Default 0 Scaling n a Type R W Password is used by the keypad Keypad sees 0s as no password set This option enables the user to temporarily unlock a unit by entering a previously set password When the unit is locked the user can read all parameters as usual but the user cannot write to any parameters The unit can be started and stopped while itislocked See Appendix A 1 10a Change Password Range Default 0 Change Password enables the user to change a previously set password to enter a password for the first time or to clear the password If the password is non zero then you must unlock the password using Enter Password previous to using Change Password This last action clear password is performed by changing the password to zero 0 and pressing Enter This action clears any set password but the control supply must be cycled or the unit reset by pressing the A and V buttons at the same time after the password has been cleared See Appendix A
112. b in Use 75 C copper CU 12 N m SR44 174 T1 T2 T3 conductor only and the wire 2 x to SR44 370 shall be installed with eyelet 250 MCM 0 i PE lug or use busbar The indicated conductor sizes are the maximum allowed by UL for each chassis size The actual conductors used must comply with local wiring regulations L1 L2 L3 T1 T2 T3 PED L1 L2 L3 Power to SR44 146 Size 2 M8 metric threaded studs Ground Power 2x 120 Ground 1st Ed Rev A 09 2011 2 3 SR44 Series Soft Starter User Manual Chapter 2 Electrical Installation lli D nn H M M t 2 3 Standard Wiring Configurations There are two standard wiring configurations for the connection of a motor a motor controller Soft Starter and the main power supply In line connection for D elta and Star W ye connected motors This is the recommended connection that is suitable for most motors In delta connection for Delta connected motors If required the SR44 can be electrically installed within the delta windings 2 3 1 Wiring Diagram for In Line Connection of Motors Figure 2 3 1 Wiring Diagram for In Line Connection of Motors Two legs of a 230V 3 phase power source can be used to provide 230V 1 phase control power N Le Control Supply L1 Mains 115VA 230
113. bled see section A 1 2 before carrying out the instructions the example will say so in its introduction The first diagram in every example section will be the Stopped and Ready screen or the Starter Disabled screen The box represents what will be seen onthe display before the action detailed inline 1 has been performed The box tothe right showing Applications Auto Features shows what will be displayed after the action in line 1 has been performed Acircled number refers to the text for that section at the line number given In this position the circled number indicates that Instruction 1 is associated with the Enter button so the instruction will probably read Press the Enter button The arrow thatis part of the button icon shows the direction of diagram flow if that button is pressed These icons represent the buttons on the keypad or remote keypad D A o Stopped and ready Applications _ _ Refer to section 5 1 2 amp Auto Features Press the Down Button multiple times or scroll until you reach the next menu item as shown This is the screen that will be displayed after instruction 2 has been completed and before instruction 3 has been started Outputs gt T EM Parameters O K1 Instruction 3 is associated vo d ra i withthe Enter button atthis position E I Y This is the screen that will be displayed after instruction 3 has been completed A do
114. button until Password takes its place on the top line 3 Press ENTER once to select the Password menu 4 Press ENTER with Enter Password shown on the top line of the display The unit will display its security status Locked on the bottom line of the display A cursor will also be visible on the bottom line of the display 5 Use the A or V button to enter the password 6 Press the ENTER button once 7 If the correct password has been entered the unit will display its security status Unlocked on the bottom line of the display To lock the unit again simply use the A or V buttons to enter any value apart from zero 0 and the password Press the ENTER button once and the display will now say that itis Locked 8 Press the button three times to return to Stopped and ready unlock the unit is cycled upon reboot the unit will be in a locked state Conversely if the password has never been Changed from zero cycling power will unlock the SR44 2 Stopped and ready Applications Password e Password O Auto Features Locked Un locked Q s If the control supply on an un locked unit i e the password has been set previously and then entered to 2 press button multiple times or hold to scroll i press button multiple times or scroll Q o ae o Enter Gara o Eus eod odios Password al Locked A 1 10b Clearing the Password 1 Pressthe A and V buttons simultaneously to
115. c Compatibility VJ wp V r rr Ai Kr cr eFrkr rr PPPrPrP P p88r F8gP PpV rarrr A M MM M V hhr eee zc erR F 8Z Va v FM 4 7 Basic EMC Considerations 4 7 1 Immunity The product standard for immunity requirements is EN 60947 4 2 1996 All SR44 Soft Starter products meet or exceed the industrial level immunity requirements laid down in this standard 4 7 2 Emissions Emissions are classified as low frequency below 9kHz known as harmonics and high or radio frequency above 9kHz Both radio frequency emissions and low frequency harmonics are generated by the action of the SR44 Soft Starter 4 7 3 Emissions Harmonics During normal operation soft starters turn their semiconductor switches on and off in order to vary the voltage at the motor terminals and this introduces supply discontinuities and generates harmonics However the mode of pulsing used by SR44 Soft Starters minimizes these harmonic effects since SR44 power circuits are configured as a fully controlled regulators W 3C Only non triplen integer multiples of the third harmonic odd harmonic frequencies are created starting with and diminishing rapidly from the fifth harmonic and virtually disappearing by the nineteenth harmonic consideration Until these limits have been defined harmonic filters are not required for any SR44 Soft Starter E 4 7 4 Emissions Radio Frequency RF Radio frequency
116. caling Certain parameters have non unity scaling factors which must be applied when using serial communication to read and write the parameters Parameter scaling factors are shown in Chapter 5 Keypad Menu Items and Parameters Scaling applies only when using serial communication to read and write parameters Scaling Factor Maximum Parameter Value 255 When READING from parameters MULTIPLY the serial comm value by the scaling factor When WRITING to parameters DIVIDE your desired value by the scaling factor multiply by the inverse of the scaling factor Parameter Scaling Example P 71 Contactor Delay Default value 160 ms Scaling Factor 4 For default value 2 160 ms Keypad shows 160 ms Comms data reads 40 multiply by 4 to get actual value of 160 To change value to 200 ms Enter 200 through keypad or W rite 50 through serial comm divide by 4 to determine value to write Keypad display will show 200 ms serial comm will read 50 multiply by 4 to get actual value To change value to 240 ms Enter 240 through keypad or W rite 60 through serial comm divide by 4 to determine value to write Keypad display will show 240 ms serial comm will read 60 multiply by 4 to get actual value IE The minimum value that a scaled parameter can be changed is equal to that parameter s scaling factor Parameters referenced in the following examples Modbus Function 03 example 6 5 1 e P 73 Last T
117. caling 1 Type R W Current Limit Time sets the maximum time allowed for the current limit before it trips or continues the ramp regardless of motor current level P 90 Current Limit Time 2 is the 2nd parameter set counterpart of P 31 Current Limit Time P 32 Shear Level Range 0 5 to 5 x le Default 3 125 x le Scaling 0 03125 Type R W Shearpin Level sets the level of current which will cause a quick trip Not active during Start or Stop This parameter is not available in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass P 91 Shearpin Level 2 is the 2nd parameter set counterpart of P 32 Shearpin Level lstEd RevA 09 2011 SR44 Series Soft Starter User Manual 5 55 Chapter 5 Keypad Menu Items and Parameters rr EEE Rr 5 4 11 Parameters Menu continued P 33 Shear Time Range 5 to 255 cycles Default 100 cycles Scaling 1 Type R W Shearpin Time sets the number of cycles a Shearpin Current must be present before tripping The shearpin is active only during the running phase not Start or Stop The shearpin flag P 112 B2 is updated even if tripping is not enabled This parameter is not available in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass P 92 Shearpin Time 2 is th
118. ce PAA BEL WALA een eee waded we ie de D 2 CLICK PLC I O Compatible with SR44 Soft Starters D 2 DLO5 DLO6 PLC I O Compatible with SR44 Soft Starters D 3 DL105 PLC I O Compatible with SR44 Soft Starters D 4 DL205 PLC I O Compatible with SR44 Soft Starters D 4 DL305 PLC I O Compatible with SR44 Soft Starters D 5 DL405 PLC I O Compatible with SR44 Soft Starters D 6 P3000 PLC I O Compatible with SR44 Soft Starters D 6 Terminator I O Compatible with SR44 Soft Starters D 7 1st Ed RevA 09 2011 SR44 Series Soft Starter User Manual Table of Contents rr IV SR44 Series Soft Starter User Manual 1st Ed RevA 09 2011 M ECHANICAL INSTALLATION Contents of this Chapter Manual Overview eeee n 1 2 Overview of this Publication sssse nne 1 2 Who Should Read This Manual s 33 ent xc RES lt e he oad CRGO EC KAG 1 2 Supplemental Publications 3m wes quad Rund ais HORE WEE CR GE EE ae aes 1 2 Technical SHDDOLEE s pampam AGAD Ore oo NAIPADALA OS abo tee ee et ord 1 2 special Smibals sosedwuegieryeEERAdSeSdEWeGIA QUEE TAE ne e NA eee 1 2 1 Mechanical Installation ius ous o Y 1 3 Lol M OUDUEIQ 6 344 b e d EOD REESE e US EO db ER 1 3 1 2 Requirements for an Enclosure llle 1 3 123 VENOM DTP 1 3 LA Storage and Derating auus mak eactoveien see te eee AN NG NANG Ba kx 1 3 1 5
119. celerating an induction motor and its load Method D Other Electro M echanical Systems Other control methods such as auto transformer starting popular in North America primary reactance starting etc are employed to a greater or lesser extent to compensate for some of the disadvantages of each type of starter discussed Nevertheless the fundamental problems of electro mechanical starters remain and it is only in the last decade or two that their dominance has been challenged by the introduction of power semiconductors controlled by electronics 3 3 5 The Semiconductor Motor Controller During the 1950s much effort was put into the development of a four layer transistor device which had the power to switch large currents at high voltages when triggered by a very small pulse of current This device became known as the silicon controlled rectifier SCR or in Europe the Thyristor and it is the basis on which all soft starting systems are built The characteristic of most interest is the ability of the thyristor to switch rapidly in about 5 millionths of a second from OFF to ON when pulsed and to remain ON until the current through the device falls to zero which conveniently happens at the end of each half cycle in alternating current supplies By controlling the switch on point of a thyristor relative to the voltage zero crossing in each half wave of an alternating current it is possible to regulate the energy
120. cing ramp up when a load has a high breakaway torque and the standard settings of pedestal voltage may not allow sufficient torque to be developed by the motor to cause acceleration O verload Level The level of current at which the controller overload begins to integrate For the SR44 the overload detector is always active and provides protection against prolonged over current operation Pedestal Voltage The voltage that the unit applies to the motor at start up It is expressed as a percentage of the rated supply voltage Power Factor The ratio expressed as a trigonometric cosine of the real power consumption to the apparent power consumption Top of Ramp TOR The unit achieves Top of Ramp TOR when it completes the start up stage of motor control This occurs when the voltage applied to the motor first equals the main supply voltage Soft start The regulation by electronic means of the supply voltage from an initial low value to full voltage during the starting process This over comes the inherent drawbacks of a switched supply The motor torque is modified in proportion to the square of the voltage applied Trip A trip occurs when the unit removes power to the motor because its Operation equals the limit imposed by one of its self protection features 3 20 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 3 Applications ee 3 6 Power Factor Conversion Chart Parameter 20 is the reference power factor tha
121. connection to a Remote Keypad or RS 485 serial network at 9600 baud 8 N 1 Allows maximum network lengths 25 meters 82 ft for RJ45 connections 1200m 3937 ft for RS 485 screw terminal connections Allows connection via RJ45 connectors or through screw terminals 2 wire SR44 Main Location of Circuit Board SR44 RS485 Serial Card Keypad fitted on Cable SR44 main circuit board SR44 RS485 Card A Alternative Network 4 Screw Terminals Std CAT 5E Network Cables SR44 RS485 Communication we dotfor Card and Switch alignment SR44 Main PCB not to scale w L L B TT NENG Ld ti KR J7 Connector EG TUS PITY 22415 alternate RS 485 2 wire connection for HMI or PLC connection for on board keypad y Fault 4 pin i ee socket K Receive baa d Board Power ON O 2 pin socket J1 5 B III 669 SR44 RS485 primary 2ndary d md not to scale connections for socket socket 26 pin connector Remote Keypad amp f A addtn l soft starters for future use Serial Communication and the soft starter s integral Local Keypad are mutually exclusive communication options selection gt links jumpers connection for Local Remote switch Only one function can control the starter at a time Switching to Local will always disable remote control of the starter 7 2 SR44 Series Soft Starter User Manual 1
122. ctive for a short period because the user is Starting or Stopping the soft starter This rung will write the value contained in V6000 to the Command Register P124 The values of 7 and 8 will Start and Stop the soft starter respectively Note that 124 is added to the starting address of 40001 and we have 40125 for the Start Slave Memory Adaress C21 Starting and C23 Stopping are located lower in the ladder and they will enable Comms to the soft starter until the pertinent Status bits relfect the desired operation of the soft starter then those Status bits will reset C21 and C23 Updates the Soft Start Time P12 value of the SoftStart MWX Port 2 Busy Start SoftStart Enable Ramp Comm CPU DCM Slot SP116 C21 C11 Port Number Slave Address Function Code 06 Preset Single Register Stop SoftStart Start Slave Memory Address K40125 C23 Start Master Memory Address V6000 Number of Elements n a Modbus Data type 584 984 Mode Exception Response Buffer V403 Status Comm Interlock Status Comm Intlk C10 RST This rung will reset the Status Comm Interlock if no attempt is made to write to the soft starter This will allow rung 3 to read the status again Status will be read continuously from the starter and writes will be done by excepton that is when the user causes it Status Comm Interlock Status Comm Interlock Status Comm Intlk Start SoftStart Stop SoftStart Status Comm Intlk C10 C21 C23 C10 RS
123. ctive in this configuration b By running the soft starter in phase loss only mode W here a special purpose system filter has been applied at the point of common coupling additional filtering of individual drives is not necessary and may introduce undesirable effects due to resonance For the purposes of EMC the connections between the SR44 controller and motor are considered to be an extension of the enclosure and preferably should be contained within grounded metallic trucking or conduit Armored cable may be used providing itis correctly terminated although the EMC performance will be slightly inferior Shielded cable is not necessary An alternative method of achieving the residential environment EM C requirements is to insert a special purpose filter designed for use with variable frequency drives Care must be taken to ensure that the short term current rating of the filter will allow for the starting currents experienced If this method is adopted it is essential that the motor controller connections are kept within 10 meters All associated electrical and electronic equipment near to the controller complies with the emission and immunity requirements of the EM C Directive 4 6 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 KEYPAD MENU ITEMS AND PARAMETERS Contents of this Chapter 5 0 How to Use This Chapter elles 5 2 5 0 1 How Keypad Menu Items and Parameters are Arranged ID SNe fe
124. cy Loss Characteristic 09 2011 SR44 Series Soft Starter User Manual 3 13 Chapter 3 Applications _ _ rrrrrhhkrrhr m nmha V arr 718 v v p vvp er er hi jk hik 78 p JvVJV mr r p 7 mnmrHrm r7 F v 8 pppraerr All SR44 Soft Starters are microprocessor controlled and this gives them a number of advantages Firstly there are no adjustments to be made for the energy saving function all calculations necessary to find the best degree of phase back of the thyristors for any load condition is made by the microprocessor Secondly the start always synchronizes with the supply voltage and a special structure of turn on pulses virtually eliminates the inrush currents normally associated with motor start up This happens every time Lastly there is the absolutely stepless starting process otherwise found only with primary resistance or reactance electromechanical starters but without the wasted energy and with the opportunity to control the maximum current allowed to flow during the starting process Other features such as soft stopping are included to give considerable control over all modes of induction motor operation 3 3 7 Reliability Considerations Reliability is an aspect which is of increasing concern regarding electronic controllers for induction motors There is little point in installing an expens
125. d RevA 09 2011 SR44 Series Soft Starter User Manual 3 7 Chapter 3 Applications AA LEE rJ gJper vv vv rrrrKrrRRr FF K K KF F F rRKkKrvJ FV mKm XKkrrRr rp F FrR FR RrIR prpr P I r pnp RR RR qt 3 3 Concepts and Principles of Fixed Speed Induction Motor Starting and Control Since its invention one hundred years ago the standard three phase induction motor has become one of the most familiar items of industrial equipment ever known Due to its simplicity of construction low cost reliability and relatively high efficiency it is likely to remain the prime source of mechanical energy for the foreseeable future 3 3 1 Introduction Energy conversion from the electrical supply to rotating mechanical energy is a characteristic of all motors To regulate energy flow most motor circuits require a mechanism to connect and disconnect them from their electrical power source Electro mechanical switches known as contactors are the standard means of achieving this control Even today more than one hundred years after their introduction contactor based systems remain the most widely used method of motor control N evertheless there is a definite trend towards more sophisticated electronic systems of control being applied to fixed speed motor drives This section will discuss these forms of control namely electronic microprocessor controlled optimizing soft starters such as th
126. d M enu Items and Parameters Keypad Menu Structure Complete Keypad Menu Structure This section contains tables that list all of the Keypad M enu Items and Parameters arranged in the same groups and sequential order as they can be accessed through a keypad menu Parameter Basic Information This section contains tables that list and briefly describe all of the Parameters They are listed in their numerical sequence which is the same sequence as they can be accessed through the Parameters menu of the keypad Some of the parameters may be accessed alternately through some of the other menu groups of the keypad Menu Settings and Parameter Descriptions This section contains detailed descriptions of all of the available M enu Items and Parameters These items are presented in the same groups and sequential order as they can be accessed through a keypad menu Some of the Parameters can be accessed through non parameter menu groups and they are listed in the same sequence as they can be accessed through those groups regardless of their numerical order All of the Parameters can be accessed through the Parameters menu group in numerical sequence Therefore they are listed in the Parameters menu group in numerical order 5 2 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 5 Keypad Menu Items and Parameters 5 1 Configuring the SR44 Soft Starter 5 1 1 General Configuration Information WARNING The ow
127. d be approximately 3 5 96 0 5 96 x 37 5 kW 1 125 kW 3 37 5 kW 2 pole low slip motor From Table 1 use the estimated savings figure for the next higher rating ie 55 kW From Table 2 apply the pole number factor of 0 5 and the slip factor of 0 5 The savings would be approximately 3 5 96 0 5 1st Ed RevA 09 2011 0 5 96 x 37 5 kW 0 938 kW SR44 Series Soft Starter User Manual 3 19 Chapter 3 Applications _ _ _ eee oo M e nR 3 5 Chapter 3 Glossary of Terms Breakaway Torque The minimum torque required to achieve rotor movement for the motor with its load Current Limit The current at which the ramp is held For the SR44 current limit is only active during start up where it contributes to the motor control function This feature is particularly useful when starting high inertia loads that require an extended start up period See also Overload Level Direct O n Line DOL The direct connection and disconnection of a motor from the AC main supply by means of a contactor or switch Acceleration and operation is at full mains voltage only Inrush Current or Locked Rotor Current The current that flows at the instant of connection of a motor to the power source Itis limited by the impedance presented by a de energized motor and the applied voltage Usually expressed as a multiple of motor full load Current Kick start Voltage The percentage of supply voltage applied before commen
128. d here the longer a given Overload will take to result in a trip n Refer to O verload Explanation Diagram O verload Explanation D iagram Overload Start Point 1000 Seconds to Trip 100 10 1 Delay 140 Default Delay 80 0 1 Delay 30 Delay 10 7 2x FLC Shearpin Cutoff 0 01 H H HAL HT 1 2 3 4 5 6 7 8 910 Notes Fault Current Motor Current x N 1 Delay Overload Delay 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual 5 37 Chapter 5 Keypad Menu Items and Parameters rrr 5 4 5 Advanced Menu continued P 19 Opt Rate Range 4 to 30 Default 5 Scaling n a Type R W Optimize Rate sets the speed at which the SR44 will reduce the voltage during optimizing Some unstable loads benefit from a slower optimizing rate P121 B4 Optimise Range P121 B4 Default Off Scaling n a Type R W Optimize gains the maximum amount of energy savings on variable loads For lightly loaded motors the soft starter provides energy savings in Energy Optimizing mode For fully loaded motors a bypass contactor provides better energy savings Requires an external user supplied bypass contactor and current transformer Associated with P109 Upper Limit and P110 Lower Limit When motor is lightly loaded as set in P110 the bypass contactor is de energized to run the motor from the soft starter in Energy O ptimiz
129. d scree cr Gee MAA SER NAK AA ae Pea Se ewes 5 2 5 1 Configuring the SR44 Soft Starter 5 3 5 1 1 General Configuration Information 0 0 0 es 5 3 5 k2 User Interface 229v 33 xq dda YAAD ESS ERE RE d E Oo RR 5 4 5 1 3 System Status Mode 3 3 wq xapbx Xp ES 38S RO ERE Pob en 5 5 5 1 4 Menu Navigation Mode 2 c 2scs0eescen ERR X ERE TIS SCA 5 5 5 55 Data Entry Mode e sui se eed REEXT ESPERE Sen ee EE 5 6 5 1 6 Changing Parameter Value aa 5 6 5 1 7 Soft Starter Data Types aa 5 6 ba Bt MIKS geen X E Wk Ak a ee ERE NA PN ge NAG NAY NA 5 7 5 1 9 Keypad Boot up Messages tees 5 7 5 2 Keypad Menu Structure 0 0 cee eee 5 8 5 2 1 Abbreviated Map of Keypad Structure sisse RR E ERE XES 5 8 5 2 2 Complete Keypad Menu Structure 00 0c a a 5 9 5 3 Parameter Basic Information 5 15 Table of Contents continued next page 5 la KEYPAD MENU ITEMS AND PARAMETERS Table of Contents continued from previous page 5 4 Menu Settings and Parameter Descriptions 5 23 5 4 0 Restoring Defaults 22 25 S Ed erkEERERSERERPEES REPE ead 5 23 5 4 1 Example of Menu Settings and Parameters Descriptions 5 23 5 4 2 Applications Menu eee nnn 5 24 5 4 3 ANO Features MENU usas acci va ARR NYAN KA WAR 5 27 5 4 4 Basic Menu ee eee eee eens 5 30 5 4 5 Advanced Menu 73 2a ha a py NGA
130. d this parameter by individual bits Bit 0 K1 Relay K1 Status K2 Relay K2 Status unused unused I p 1 Input 1 Status unused unused TI OO Ui A WU N HI unused 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual 5 51 Chapter 5 Keypad Menu Items and Parameters aQ q9 pg EE E E E EEEEE z z z_zz_ _ _ _ _ __ eyyqy 5 4 11 Parameters Menu continued P 11 Start Ped Range 10 to 60 percent Default 2096 Scaling 1 Type R W Start Pedestal sets the percentage of the unit s rated supply voltage that is applied to the load before the ramp starts P 79 Start Ped 2 is the 2nd parameter set counterpart of P 11 Start Ped P 12 Start Time Range 1 to 255 seconds Default 5s Scaling 1 Type R W Soft Start Time sets the soft start time period over which the unit ramps voltage to the motor Start times are normally in the 5 30s range Long ramp times over 1minute are for special applications only The start without current limit is purely a voltage ramp Lightly loaded motors will normally reach full speed before the end of a long ramp P 80 Soft Start Time 2 is the 2nd parameter set counterpart of P 12 Soft Start Time P 13 Kick Ped Range 60 to 90 percent Default 75 Scaling 1 Type R W Kick Pedestal provides a short kick of voltage at start of ramp to dislodge sticky
131. ded system seek advice from your supplier before fitting a capacitive high frequency filter to an SR44 Soft Starter It is essential that the specifying authority user or installer has a clear knowledge of the type of network to which the product is to be installed before making decisions as to which EMC strategy to adopt As supplied all SR44 products comply with the conducted emissions requirements for Equipment class A soft starters as defined by EN 60947 4 2 1996 Table 14 However the length and type of cable connecting the motor to the starter module materially affects the level of emissions generated and can amplify them greatly The standard also allows different levels of emissions depending on motor rated current which also affects the need to fit filters The EN 60947 4 2 1996 standard only requires consideration of steady state conditions for EMC purposes and expressly excludes varying conditions such as those during ramp up and ramp down Therefore closing a bypass contactor around the module during the run condition will remove the need for any high frequency filters However some of the features protection optimizing etc which are active during the run state are disabled when the bypass contactor is closed Users need to assess the cost and merit of fitting a bypass contactor compared with the cost of a filter when it is required Finally statistics show that the number of disturbances arising from soft starters operating i
132. driven by the P101 internal starter input function Works in conjunction with P103 User Flag mapping through parameters 101 102 103 104 101 102 the source flag address 101 parameter 102 bit mask 103 104 the destination flag address 103 parameter 104 bit mask Ist Ed RevA 09 2011 SR44 Series Soft Starter User M anual 5 71 Chapter 5 Keypad Menu Items and Parameters rr EEE 7 rmrm 7m1ma 9 9 r F P pp r P 105 P 106 P 107 P 108 P 109 P 110 P 111 5 4 11 Parameters Menu continued reserved reserved reserved reserved Bypass Upper Limit Range 1 to 50 Default 12 Scaling 1 Type R W Bypass U pper Limit e Associated with P121 B4 Optimize e This parameter bit is not fully functional in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass Typically set about 80 of motor FLC Current required motor FLC SR44 FLC 32 Bypass Lower Limit Range 0 to 150 Default 10 Scaling 1 Type R W Bypass Lower Limit Associated with P121 B4 Optimize e This parameter bit is not fully functional in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass Typically set about 40 of motor FLC Cur
133. duces heating of the surrounding atmosphere in the process If the atmosphere is subject to air conditioning reducing the heat input will reduce the air conditioning costs Reduced starting and running currents reduces cable losses and contactor switching operations are carried out under the most advantageous conditions No current flows on switch on since all switching is carried out by the thyristors which virtually eliminates the need for contact replacement Indeed there are a growing number of installations where contactors are no longer employed being replaced by controllable circuit breakers or isolators instead In summary electronic controllers for most fixed speed applications are opening new ways of increasing the efficient operation of induction motors as well as offering significant benefits in control Prospective users should ensure themselves of the quality and performance of any products they expect to fit and this can be reasonably expected if compliance with the appropriate IEC standards is demanded 3 14 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 3 Applications M 3 4 Principles of the Optimizing Mode 3 4 1 Principles Every wound field electric motor must consume some minimum amount of energy to provide a magnetic field which enables it to work at all With DC motors the field is under separate control so that the amount of magnetizing energy can be adjusted to be sufficient to overcom
134. e 2nd parameter set counterpart of P 33 Shearpin Time P 34 Ovld Level Range 0 5 to 1 25 x le Default 1 0938 x le Scaling 0 03125 Type R W Start of O verload Level sets the level at which the on board single phase O verload starts to integrate This O verload does NOT replace an overload for the motor The overload is designed to detect Soft Start overloads This parameter is not available in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass P 93 Start of O verload Level 2 is the 2nd parameter set counterpart of P 34 Start of O verload Level P 35 Ovld Delay Range 10 to 140 Default 140 Scaling 1 Type R W Overload Delay sets an arbitrary delay to slow Overload integration down The overload delay mapping is designed primarily for protection of the thyrisors P 94 Overload Delay 2 is the 2nd parameter set counterpart of P 35 Overload Delay P 36 Yo Overload Range 0 to 100 percent Default 0 Scaling 0 39216 Type R Overload is a status value showing how close the O verload is to tripping 100 tripped ee This parameter is not available in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass P 37 reserved P 38 UserFlags 5 reserved Range O to 255 flags Default 0 Scaling 1 Type
135. e Optimize function reduces energy consumption by reducing voltage but the system also senses motor conditions and automatically adjusts the maximum delay angle by which the voltage can be reduced without allowing the motor to stall P 20 P20 Reference PF Range 0 to 146 76 degrees Default 146 76 Scaling n a Type R Reference PF shows the Power Factor Angle that the SR44 has calculated as the target for the optimizing control loop Refer to Ch 3 6 for PF degrees to ratio conversion P 21 P21 Internal PF Range 0 to 146 76 degrees Default 146 76 Scaling n a Type R Internal PF shows the Power Factor Angle of the load Refer to Ch 3 6 for PF degrees to ratio conversion 1stEd RevA 09 2011 SR44 Series Soft Starter User Manual 5 43 Chapter 5 Keypad Menu Items and Parameters ee aa 5 4 7 Permanent Store Menu Save Param Range n a Default n a Save Parameters saves all the parameter settings to a permanent store This means that if the control supply is removed from the main control board the parameters will still remain stored and will be recalled the next time the unit boots up Power on Param Range n a Default n a Power on Parameters recalls all the parameter settings from the last Save Param and loads the current parameters with these recalled values xxx Default Param Range n a Def
136. e SR44 3 3 2 The Induction Motor In order to appreciate the benefits of using an electronic controller it is important to have some understanding of the characteristics and limitations of the induction motor and the electro mechanical systems currently used to control them The standard fixed speed induction motor fulfils two basic requirements To accelerate itself and its load to full speed or speeds with multi speed motors To maintain the load at full speed efficiently and effectively over the full range of loadings Due to the constraints of materials and design it can be difficult to achieve both objectives effectively and economically in one machine So how does a motor start in the first place As mentioned previously motors convert electrical energy drawn from the power supply into a mechanical form usually as a shaft rotating at a speed fixed by the frequency of the supply The power available from the shaft is equal to the torque moment multiplied by the shaft speed rpm From an initial value at standstill the torque varies up or down as the machine accelerates until reaching a peak at about two thirds of full speed and then dropping to zero at synchronous speed This characteristic means that induction motors always run at slightly less than synchronous speed in order to develop power the slip speed and hence the term asynchronous Figure 3 3 2 1 shows a graph is of an induction motor torque speed curve
137. e losses and provide an armature reaction appropriate to the load The squirrel cage AC induction motor has no such provision with the result that energy is wasted at any load less than its rated full load at full speed When a squirrel cage motor is supplied at a constant terminal voltage as when it is connected directly to the supply without a controller of any kind the strength of the field flux is fixed by the supply voltage At normal running speed the field will take a fixed quantity of energy regardless of the torque demanded by the mechanical load The energy required to support the load torque is determined by the torque demand As load torque increases the rotor slows down a little ie slip increases causing induced rotor currents to also increase in order to increase the torque These additional currents in the rotor are balanced by additional current in the stator coils Conversely if load torque demand falls the slip decreases the rotor currents decrease and the current in the stator decreases accordingly But at constant terminal voltage the current providing the stator field flux remains unchanged at any level of load torque demand As a consequence the efficiency of an induction motor decreases as the load decreases Figure 3 4 1 1 Typical duty cycle for a machine load where the Torque D emand varies Load Torque Demand at working speed 40 60 80 100 120 140 160 seconds Figure 3 4 1 2 Torque Demand converted to an
138. e ramp for high start pedestals Auto 3MC applies only to Start Pedestal voltages set above 50 P 11 or P 79 The SR44 normally does a very brief low voltage ramp up to the pedestal voltage level before the start ramp begins but Auto 3M C applies a higher starting torque and eliminates this initial pedestal ramp for pedestal voltages above 50 2 Auto Bypass enable automatic bypass contactor detection Auto Bypass turns On and Off the automatic detection of a bypass contactor When On a bypass contactor will be automatically detected Soft starter thyristor trips and thyristor short circuit trips will be disabled during Run after full voltage is reached Thyristor protection and thyristor short circuit protection are still available during the start ramp and phase loss protection is available during both Start and Run An external user supplied current transformer is required if any of the current or power pte related trip or monitoring features are needed in bypass mode Parameters 8 B2 9 B1 B2 20 21 22 23 26 28 30 32 33 34 36 39 51 B1 B2 B3 B4 87 89 91 93 112 B0 B1 B2 B3 B6 121 B4 Refer to Electrical Installation Chapter 2 subsections 2 4 1 amp 2 5 2 for wiring information Auto Bypass detects the presence of a bypass contactor and should be ON when using one Using a bypass contactor with Auto Bypass in the OFF state can cause thyristor faults 3 Auto Jog enable automa
139. ection characterize the standard setup of each particular application j This example assumes that the unit has been disabled see section A 1 2 1 With Starter Disabled shown on the display press the ENTER button 2 With Applications shown on the top line of the display press the ENTER button 3 With Settings shown at the top of the display press W button until large pump is shown at top of display 4 Press ENTER to select large pump The display will indicate which parameters are to be changed 5 With the top line of the display showing Send to store press ENTER to save the settings for a large pump If the button is pressed instead at this point the unit will flash the message Cancelled three times The display will flash the message Storing twice to indicate this has been done 6 At any of the above stages pressing will return the user to the previous menu The unit will not start until the display indicates Stopped and ready j There is no need to save the changed parameter values as they are automatically saved at instruction 5 D Starter Disabled Applications Qo Settings 1 V To Enable O Auto Features O Default keypad 6 v r i press button multiple times or hold to scroll ati ext Pump eM to store men No e yes Lom NN al lri Cancelled til 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual
140. ed In this example only P 124 is changed by the write instruction PLC addresses are any valid user assigned memory addresses Modbus Function 06 Transaction Table Query Response Field Hex Byte Field Hex Byte Slave Address 01 Slave Address 01 Function 06 Function 06 Address High 00 Address High 00 Address Low 7D decimal 125 Address Low 7D P 124 Force Data High n a doesn t matter Force Data High n a ignored Force Data Low 02 Enable Starter Force Data Low 02 Enable Starter CRC Low PLC amp SR44 automatically CRC Low PLC amp SR44 automatically CRC High calculate CRC checksum values CRC High calculate CRC checksum values SR44 has a Modbus offset of one address for registers amp bits PLC targets one address higher 6 16 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 6 Serial Communications 6 5 4 P 124 Offline Commands The SR44 has a mechanism for carrying out common functions or offline ones which take a long time and require the SR44 to be off and disabled Commands are carried out by writing various values to a Command Register parameter 124 For example writing a 1 to P 124 using function 06 disables the starter Once a value has been written to this special register further M odbus queries will receive a slave busy error until the command execution is completed If an error occurred during the execution of the co
141. ed Thyristor Sensing Trip Type B 16 1020 Trip 4 Enabled SCR Firing Thyristor Sensing Trip Type C 5 32 1021 Trip 5 Enabled SCR Signal Edge Sensing Trip 6 64 1022 45E Trip 6 Enabled SCR Signal Sensing Trip Type A 7 128 1023 45F Trip 7 Enabled Sensing Signal Sensing Trip Type B Modbus addresses apply only to Function 06 Write Single Register or to only the first parameter of Function 03 Read Holding Registers Parameter Bit s apply only to Function 05 Write Single Coil Type R Read Only R W Read Write 1 2 4 8 0 1 2 3 4 6 12 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 6 Serial Communications 6 5 Serial Communication to SR44 SR44 parameters are stored in 8 bit bytes Modbus reads the values from the slave as 16 bit words Therefore two SR44 parameter bytes are packed into each Modbus word The lowest parameter is in the data High of the word and the next parameter is in the data Low This also means that even when the read request is for one register two SR44 parameters are read Up to four contiguous words 8 parameters may be read with one query j SR44 has a Modbus offset of one address for registers and bits PLC programs should target one address higher than desired e g PLC targets SR44 address 40019 to read write to from address 40018 P 18 6 5 0 Parameter S
142. emissions are propagated in two ways 1 Conduction along the leads supplying the soft starter 2 Radiation from the operating equipment They also have two sources 1 The high frequency currents associated with the control electronics this includes the microprocessor 2 The action of the semiconductor devices forming the power switching elements located in the controller main circuits The radiation measurements made from operating versions of SR44 Soft Starters show levels lower than the allowed limits Further enclosures or cubicles of metallic construction provide additional shielding for SRA4 Soft Starters mounted within them The only radiated interference effect that might arise from a soft starter would be if mobile telephones walkie talkies etc were to be used in very close proximity to a unit which was operating with the enclosure door open For this reason any enclosure must display a label that brings the possibility of electromagnetic interference to the attention of the operator under these circumstances 4 4 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 4 Electromagnetic Compatibility aan 4 7 5 Emissions Conducted Conducted emissions are able to travel great distances and may cause interference to any neighboring consumers connected to the common low voltage supply network Allowable levels for conducted emissions generated by semiconductor motor controllers and starters are influenced b
143. en the display will appear blank for a couple of seconds Temp Alt D erated This message will be displayed if the unit has been derated for temperature or altitude If no deratinghas been set then the display will appear blank for a couple of seconds 5 24 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 5 Keypad Menu Items and Parameters SS eeeee_oe_e_eeeeee aaya 5 4 2 Applications Menu continued Applications Menu User configurable settings These Applications auto features preset the SR44 for the selected application xxx Default keypad Range n a Default n a The Default keypad setting provides a way to RESTORE all DEFAULT VALUES to the starter It also sets the starter for starting and stopping from the local or remote KEYPAD Provides a way of loading the default parameter values with Keypad Starting as the choice for the starting option see Appendix A 1 4 xxx Default Auto Range n a Default n a The Default Auto setting provides a way to RESTORE all DEFAULT VALUES to the starter It also sets the starter for starting and stopping from the Auto Features menu Loads default parameter values and additionally turns on a number of features from the Auto Features menu Further details can be found in section 5 4 7 and Appendix B Applications Data Small Pump Setting for Small Pump lt 60 hp application See App
144. endix B Applications Data for details Large Pump Setting for Large Pump 275 hp application See Appendix B Applications Data for details Conveyor Setting for Conveyor application See Appendix B Applications Data for details Low Inertia Fan Setting for Low Inertia Fan application See Appendix B Applications Data for details Hi Inertia Fan Setting for High Inertia Fan application See Appendix B Applications Data for details Recip Compressor Setting for Reciprocal Compressor application See Appendix B Applications Data for details Screw Compressor Setting for Screw Compressor application See Appendix B Applications D ata for details Rotry Compressor Setting for Rotary Compressor application See Appendix B Applications Data for details 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual 5 25 Chapter 5 Keypad Menu Items and Parameters rrr 5 4 2 Applications Menu continued Crusher Setting for Crusher application See Appendix B Applications Data for details Grinder Setting for Grinder application See Appendix B Applications Data for details Hi Start Torque Setting for application requiring High Starting Torque See Appendix B Applications Data for details Motor Gen
145. ent is stored in two bytes parameters 24 amp 25 Parameter 24 holds the number of hundreds Parameter 25 holds the number of units These parameters should not be changed since they go hand in hand with the burden resistors installed to the board P 25 Rated Amps Range 1 to 99 amps Default 5A Scaling 1 Type R W Refer to P 24 for explanation P 26 Current Range 0 to 7 9688 Amps Default 0A Scaling 0 03125 Type R Running Current displays the current that the motor is taking as monitored in one phase This is the source parameter for the O verload Current Limit Shearpin Under Current Trip etc The divisor is 32 and the multiplier is the rated current of the unit This parameter is not available in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass 5 54 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 5 Keypad Menu Items and Parameters eee SSS aaa 5 4 11 Parameters Menu continued P 27 Peak Start Range 0 to 255 Amps Default 0A Scaling 1 Type R Peak Start Current displays the peak current seen by the unit during the last start Scaling is per the running current P 28 Low I Level Range 0 031 to 0 7813 Xx le Default 0 0938 x le Scaling 0 03125 Type R W The Low Current Level parameter if enabled sets a level of current u
146. equivalent current with the motor magnetizing current added Current Demand due to torque and flux 7 Magnetizing current L Torque current 0 40 60 80 100 120 140 160 seconds 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual 3 15 Chapter 3 Applications ro j rrrvrvvvr r V J dd C 3 4 2 Advantages of Energy Optimizing A soft starter with an energy optimizing feature alters the motor operation The energy optimizing function reduces the terminal voltage applied to the motor so that the energy needed to supply the field is more closely proportioned to the torque demand The effect is shown in the Figure below Figure 3 4 2 1 Full Speed end of the conventional Torque Current curves Voltage Torque balance Bex Torque at rated voltage The present considerations do not affect A nad al Full load Torque reduced voltage at rated voltage soft starting options or strategies i F r Reduced Point A on the current curve is the 100 M Ka Torque operating point of the motor when the demand motor terminal voltage is at its nominal 8096 M or rated value and when the load is the maximum for which the motor is rated If the load decreases a motor supplied at a fixed voltage will speed up slightly the current demand will reduce and the operating point moves along the curve to point B Because the torque developed by a motor is proportional t
147. evels up to the design full load torque Most modern three phase induction motors have characteristics that are wholly suitable for use with soft starters However the characteristics vary considerably between different manufacturers and design types It is important that the motor is capable of providing sufficient torque to drive the load at all speeds from standstill to rated speed to enable the SR44 to function properly It is particularly important that the motor to be soft started does not have a low pull up or saddle torque or the load may not be accelerated correctly The primary function of the soft starter is to act as a torque regulating device It cannot apply a torque greater than that which the motor generates For this reason problematic applications for which many different starting methods have been tried but failed may need analysis of the motor or load performance before a soft starter can be successfully applied 3 1 3 Rating For most applications except high inertia loads the starting demands and the inertia of the rotating masses are small enough to be insignificant This means that no special consideration needs to be given to the rating of the soft starter other than to ensure that it is equal or marginally greater than the rated voltage and current of the controlled motor Alternatively if the number of poles of the motor and the moments of inertia of the load Jigaq and motor rotor Jmotor are known a soft starter
148. extended but it should NOT be reduced as it will invalidate the manufacturer s warranty P 123 Temp Alt Derate Range 0 to 50 Default 0 Scaling n a Type R W This parameter enables the user to derate by percentage of Unit Full Load current where local temperature or altitude is outside of the normal operating range Refer to the Mechanical Installation chapter for temperature and altitude specs P121 83 Line Contactor Breaker Present Range P121 B3 Default On 0 Scaling n a Type R W This menu item turns On and O ff the Line Contactor function which selects the use by the customer of an in line contactor in his wiring configuration However if the decision is made to use a breaker instead a new mode has been introduced so that the Soft Start can trip the breaker via the alarm relay when it is in the Stopped and ready state see section 5 1 3 This helps to eliminate the problems that arise when the breaker is closed and a faulty Soft Start has short circuit devices The breaker option is selected by turning this menu item Line Contactor Off or by enabling bit 3 of User Flags 4 P121 e P121 B3 2 0 Line Contactor e P121 B3 z1 Breaker Present VR An in line contactor MUST be used with In Delta mode and the use of an in line contactor HR is always recommended 5 40 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011
149. eypad Menu Items and Parameters eee rr eu 5 4 4 Basic Menu continued P51 87 Starting Range P51 B7 Default On Scaling n a Type R W The Starting setting sets the source for the start signal If set to OFF Keypad the unit will Start Stop when the Start Stop button on the user interface is pressed If setto ON Remote the unit will start when signalled to do so by an external circuit P 11 Start Pedestal Range 10 to 60 percent Default 2096 Scaling n a Type R W Start Pedestal sets the percentage of the unit s rated supply voltage that is applied to the load before the ramp starts P 12 Start Time Range 1 to 255 seconds Default 5s Scaling n a Type R W Soft Start Time sets the soft start time period over which the unit ramps voltage to the motor Start times are normally in the 5 30s range Long ramp times over 1minute are for special applications only The start without current limit is purely a voltage ramp Lightly loaded motors will normally reach full speed before the end of a long ramp P 16 Stop Pedestal Range 10 to 60 percent Default 1096 Scaling n a Type R W Soft Stop Pedestal sets the percentage of supply voltage at which the Soft Stop will cease The actual value is affected by certain load variations P 17 Stop Time Range 0 to 255 seconds Default Os Scaling n a Type R
150. f the display press ENTER once 5 With Map To on the top line of the display press ENTER once 6 With 52 Parameter showing press the W button until 7 Parameter is displayed 7 Press ENTER once to accept the change 8 Press once to return to Map To continued next page n Stopped and ready Applications O Auto Features Po Q 2 press button multiple times or hold to scroll Sie 6b Lebe Le Outputs O Digital i p 2 O Bit Number 0 52 Parameter G Q 6 scroll Q l l Bi Map From Map To mo l oe continued next page Y lstEd RevA 09 2011 SR44 Series Soft Starter User Manual A 23 Appendix A Setup Examples FEE M 4 A 2 4 Selecting Optimizing with Programmable Input 1 continued continued from previous page 9 With Map To on the top line of the display press the W button once until Bit Number is displayed 10 Press ENTER once to select Bit Number 11 Press the OPTIMISE button four times so that the cursor moves to bit 4 12 Press the W button once to change the bit state of bit 4 to zero 0 13 Press the OPTIMISE button three times so the cursor moves to bit 7 14 Press the A button once to change the bit state of bit 7 to one 1 15 Press ENTER once to accept the change The display will flash once to confirm that the change has been accepted 16 Press once to return to Bit Number 17 With B
151. from the unit turn on the Stop sequence is reset Stopped Start PB Stop SoftStart B C100 B C22 B C23 RST Stopping C107 The next 2 rungs Receive and Send P12 Soft Start Time to the unit This is complex because 2 hex values are actually retrieved P11 and P12 by reading 1 Modbus address The 2 rungs will synch themselves and communicate until the value that is sent to the unit is also confirmed by being read back from the unit Once that occurs the sequence resets Port 2 Enable Time Ready Flag Comm Receive Port3 MODBUS Time Comm BI SC100 BIC11 Slave ID 1 Receiving e Modbus Function Code 03 B C206 Slave Addr 400012 NO of Master Addresses 1 Receiving Word Swap OFF Status Comm Time Comm Time Comm Success Receiving Success B C207 B C206 B C207 P11 and P12 from Strtr HI DH10 Success Master Status Comm Read Error C208 6 22 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 6 Serial Communications ei 6 7 1 CLICK PLC Example Program continued _Port_2_ Enable Time Ready_Flag Comm Send Port3 MODBUS Control Comm B SC100 BIC11 Slave ID 1 Sending Modbus Function Code 06 C210 Slave Addr 400013 I C 12 m Time Comm Control Comm oo Success Success Old SoftStart Time Entry B C211 C207 C211 I DS32 Success O Master
152. g E7 8 9 Sensing Signal E10 SCR Shorted E11 Low Current E12 C L Time Out E13 Overload E14 Shearpin E15 Thermistor not available E16 External trip E17 Comms Timeout 5 62 SR44 Series Soft Starter User M anual 1st Ed RevA 09 2011 Chapter 5 Keypad Menu Items and Parameters eee SSS aaa 5 4 11 Parameters Menu continued P 76 4th Last Trp Range 0 to 17 trip number Default 0 Scaling 1 Type R Ath Last Trip holds the number of the fourth to last trip e Trip EO no trip E1 Phase Loss E2 Too Hot E3 5 6 SCR Signal E4 SCR Firing E7 8 9 Sensing Signal E10 SCR Shorted E11 Low Current E12 C L Time Out E13 Overload E14 Shearpin E15 Thermistor not available E16 External trip E17 Comms Timeout P 77 5th Last Trp Range 0 to 17 trip number Default 0 Scaling 1 Type R 5th Last Trip holds the number of the fifth to last trip e Trip EO no trip E1 Phase Loss E2 Too Hot E3 5 6 SCR Signal E4 SCR Firing E7 8 9 Sensing Signal E10 SCR Shorted E11 Low Current E12 C L Time O ut E13 Overload E14 Shearpin E15 Thermistor not available E16 External trip E17 Comms Timeout 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual 5 63 Chapter 5 Keypad Menu Items and Parameters p 78 P 79 P 80 P 81
153. g of the line contactor with the soft starter run relay contacts 3 1 7 Motors Installed with Integral Brakes M otors that include an integral electrically operated brake internally connected to the motor input terminals can only be soft started when the brake is re connected to the supply through its own contactor Do NOT soft start the brake 3 1 8 Older Motors The action of the fully controlled soft starter introduces harmonic currents and voltages to the motor Therefore it is important to ensure that the motor employs techniques such as rotor skewing in its construction to suppress the effects of harmonic fluxes and avoid rough starting This is rarely a problem with modern motors because nearly all motors designed in the last 20 years employ these techniques 3 1 9 Wound rotor or Slip ring Motors Slip ring induction motors ALWAYS need some resistance in the rotor circuit to ensure that sufficient rotational torque is generated to overcome any alignment torque which is present at start up The resistance can be safely shorted out in the normal fashion with a contactor controlled by the programmable relay set as top of ramp contacts 3 1 10 Enclosures Thyristors are not perfect conductors and the passage of current through them causes heat dissipation in the body of the soft starter which in turn causes the heatsink temperature to increase As a guide the heat generated is 1 watt amp phase which equates to a dissipat
154. g through parameters 97 98 99 100 97 98 the source flag address 97 parameter 98 bit mask 99 100 the destination flag address 99 parameter 100 bit mask P 99 U1 O P Dest Range 0 to 125 parameter Default 0 Scaling 1 Type R W The opf1 addr parameter holds the parameter for the internal starter output function assigned to be driven by the P97 internal starter input function Works in conjunction with P100 User Flag mapping through parameters 97 98 99 100 97 98 the source flag address 97 parameter 98 bit mask 99 100 the destination flag address 99 parameter 100 bit mask U1 O P Mask Range 0 to 255 bit mask Default 0 Scaling 1 Type R W The opf1 mask parameter holds the parameter bit for the internal starter ouput function assigned to be driven by the P97 internal starter input function Works in conjunction with P99 User Flag mapping through parameters 97 98 99 100 97 98 the source flag address 97 parameter 98 bit mask 99 100 the destination flag address 99 parameter 100 bit mask 5 70 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 5 Keypad Menu Items and Parameters E n 5 4 11 Parameters Menu continued P 101 U21 Psrce Range O to 125 parameter Default 0 Scaling 1 Type R W The ipf2 addr parameter holds the parame
155. grammable Input 1 continued continued from previous page 7 With 8 Parameter showing press the A button until 10 Parameter is displayed 8 Press ENTER to apply the change 9 Press once to return to Map From 10 With Map From on the top line of the display press W button until Bit Number is displayed 11 Press ENTER to select Bit Number 12 Press the Optimise button three times so the cursor is displayed on bit 3 13 Press the W button to change the bit state to zero 0 14 Press the Optimise button once so the cursor is displayed on bit 4 15 Press the A button once to change the bit state to one 1 16 Press ENTER once to accept the change 17 Press four times to return to Stopped and Ready j To keep the above settings they must be permanently saved See section A 1 5 l li mE From brine From i M From mE 2 Number Tu brine Parameter Tag NAG seal Parameter O 4 4 continued from previous page T press button multiple times or hold to scroll O l L_a Map From Paano Bit Number 7e Ama Number Tem ES Number lo E Number AN Number Polarity ka Mask 00001000 Mask 00000000 Mask AN Mask NA l l s Number URN Number s Mask URN Mask Albo A 18 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Appendix A Setup Examples A 2 Advanced Setup Examples A 2 1 Using an Alternative Parameter Group For appl
156. gs for UL Applications Table 2 10 1 Short Circuit UL Recognized JFHR2 Fuse l Model A 2 4 Current Bussman Ferraz m RMS Model Model SR44 9 9 SR44 16 16 SR44 23 23 SR44 30 30 SR44 44 44 170M 3114 6 9 URD 30 D08A 0160 SR44 59 59 170M 3115 6 9 URD 30 D08A 0200 SR44 72 72 SR44 85 85 SR44 105 105 SR44 146 146 SR44 174 174 SR44 202 202 SR44 242 242 SR44 300 300 SR44 370 370 170M 4116 6 9 URD 31 D08A 0630 170M 3110 6 9 URD 30 D08A 0063 170M 3112 6 9 URD 30 D08A 0100 170M 3116 6 9 URD 30 D08A 0250 170M3119 6 9 URD 30 D08A 0400 170M 3121 6 9 URD 30 D08A 0500 170M4114 6 9 URD 31 D08A 0500 These fuses are for short circuit protection of the semiconductors and must be mounted externally by the user between the unit and the main power supply UL requires Recognized special purpose fuses JFH R2 for the protection of semi conductor devices rated 700 VAC as indicated in Table 2 10 1 be used to obtain the short circuit ratings required by UL Suitable for use on a circuit capable of delivering not more than the RMS Symmetrical Amperes indicated in Table 2 10 1 at maximum rated operational voltage when protected by Semiconductor Fuse type Manufactured by Company and Model Number indicated in Table 2 10 1 Fuse rated 700 VAC Amps as indicated in Table 2 10 1 It is the responsibility of the installer and system designer specifier to
157. h could be in addressing wiring or PLC SR44 setup Port 2 Busy SP116 CT10 Port 2 Error SP117 CT11 This rung will be doing nearly all the Comms with the soft starter It reads the Status Bits from the soft starter from P8 and P9 Note that 8 is added for the starting address of 40001 40001 8 P8 s address and the result is 40009 for the Start Slave Memory Address field in the MRX P8 and P9 are read as one 16 bit word and they are stored as a word starting at C100 so the bits C100 C117 will reflect the status of the starter and those bits can be used in ladder as desired Updates the Soft Start Time P12 value of Status Comm Interlock the SoftStart MRX Port 2 Busy Status Comm Intlk Enable Ramp Comm CPU DCM Slot SP116 C10 C11 Port Number 3 Slave Address Function Code 03 Read Holding Registers Start Slave Memory Address K40009 Start Master Memory Address VC100 Number of Elements K1 Modbus Data type 584 984 Mode Exception Response Buffer V400 Status Comm Interlock Status Comm Intlk C10 SET lstEd RevA 09 2011 SR44 Series Soft Starter User Manual 6 25 Chapter 6 Serial Communications llli P DDnm o 6 7 2 DirectLOGIC PLC Example Program continued This rung will be used when the user activates it Ordinarily it will only be a
158. hange Password will be displayed on the top line Press ENTER to select Change Password A cursor will be visible on the bottom line of the display 6 Use the A or V button to enter a new password number 7 Press the ENTER button once 8 The display will flash New Password twice to confirm that the change has been made 9 Press the button three times to return to Starter Disabled Uv e N otes 1 The unit must be unlocked section A 1 10 in order to change the password 2 Setting the password to zero 0 deletes any set password and leaves the unit unlocked AFTER the Control supply has been cycled or the keypad remote keypad has been reset 3 It is not necessary to save the password since it is stored automatically every time that its value is changed CD Starter Disabled o Applications 1 V To Enable O Auto Features 9 Q 2 press button multiple times or hold to scroll 8 O o l li Password o Enter Password Change Password o Inputs o Change Password ite 4 6 press button multiple times or scroll LI S O Change Password o Change Password Q 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual A 11 Appendix A Setup Examples rrr A 1 10a Unlocking and Locking the Keypad 1 With Stopped and ready displayed press the ENTER button once 2 With Applications shown on the top line of the display press the W
159. he Shearpin menu item turns On and Off the Shearpin trip The Shearpin trip is intended to catch transient current peaks which exceed the value specified in the Shearpin Level parameter for a time that is specified in the Shearpin Time parameter P33 Refer to Shearpin Explanation Diagram This parameter bit is not available in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass The Shearpin trip is automatically turned off during starting and stopping See also the Special Case in the Overload Level entry P 32 Shearpin Level Current sub menu of Advanced menu Range 0 5 to 5 x le Default 3 125 x le Scaling n a Type R W The Shear Level parameter holds the level in Amps at and above which a Shearpin trip condition will exist Refer to Shearpin Explanation Diagram This parameter is not available in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass P 33 Shearpin Time Current sub menu of Advanced menu Range 5 to 255 cycles Default 100 cycles Scaling n a Type R W This parameter holds the time in supply frequency cycles that a Shearpin trip condition must exist before a trip occurs The default value is 100 cycles at the supply frequency For 60 Hz 100
160. he settings must be permanently saved See section A 1 5 CD Stopped and ready o Applications O Auto Features 6 Q 2 press button multiple times or hold to scroll O o E LS Staring Q saring Advanced Start Pedestal Keypad starting o Q eoi s 6 Starting Remote starting A 6 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Appendix A Setup Examples A 1 5 Permanently Saving Parameters Set by the User Follow this procedure to save parameters set by the customer j This example assumes that the unit has been disabled see section A 1 2 1 With Starter Disabled shown on the display press ENTER button 2 With Applications shown on the top line of the display press W button until Permanent Store is shown at top of display 3 Press ENTER to select Permanent Store menu 4 With Save Param shown at top of display press ENTER to permanently save parameters The display will flash twice to indicate this has been done 5 At any of the above stages pressing will return the user to the previous menu Disabled EE Y To Enable E Features Q m i press button multiple times or hold to scroll l l FamanarSae Store Te eem param Tem as oe eem on param 4 4 NA 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual A 7 Appendix A Setup Examples A 1 6 Loading the Default Parameter Values with Keypad Starting
161. he unit see below and Appendix A 1 6 2 The second menu item Default keypad provides a way of loading the default parameter values with Keypad Starting as the choice for the starting option see Appendix A 1 4 3 The third menu item Default Auto loads default parameter values and additionally turns on a number of features from the Auto Features menu Further details can be found in the SR44 Applications Data and SR44 Bit Parameters sections of the Electromagnetic Compatibility chapter 4 Applications Menu Read O nly Settings Settings Range n a Default n a Displays information relevant to the SR44 s current state V1 069LM 10 12 16 This message shows the keypad firmware version number and release date date displayed in European format YY MM DD SMC V56 11 This message gives the version number of the firmware in the SR44 control board Menu V1 023 This message gives the version number of the navigating menu Remote Keypad Starting This message indicates whether the Starting Parameter has been set to keypad or remote starting Full Full amp O pt Start amp Bypass Phase Loss O nly This message shows what protection mode has been set in the Protection Parameter Small Pump This next message will show what if any application has been set from the Application menu Small Pump is shown as an example If no application has been set th
162. hrough Modbus addressing as described in the Serial Communications chapter Scaling applies O NLY when using serial commuication as described in the Serial Communications chapter Parameter Basic Information umber Name Function dummy parameter Station No Language Program Type Software Ver Password Firing Mode yO JU RUN HO Protection Status 1 Stopped Starting Current Limit CO 0 o o o UB H o Minimum Plelelele e e e Scaling Top of Ramp Dwell Full Conduction Energy Saving Stopping Status 2 Alarm Overload Integrating Stall Forced O verride Noise Inhibit Start DC I p Level Reached Reserved CO oo O 0 OC CO CO CO OF D O 0 0 CO O O Type R Read Only R W Read Write Scaling applies ONLY when using serial commuication details in Serial Communications chapter Table continued next page 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual 5 15 Chapter 5 Keypad Menu Items and Parameters ee EEE 5 3 Parameter Basic Information continued Parameter Basic Information continued Name Function Default Status 3 Relay K1 Status Relay K2 Status unused unused Input 1 Status unused unused unused Start Ped Start Time Kick Ped
163. i plMap Range 0 to 123 parameter Default 52 parameter Scaling 1 Type R W I pl Map To holds the Parameter of the User Flag that contains the internal starter function assigned to be driven by the I p1 input S1 S0 Works in conjunction with P66 User Flag mapping through parameters 65 66 65 66 the source User Flag address 65 parameter 66 bit mask P 66 i p1 bit Msk Range 0 to 128 bit mask Default 16 Scaling 1 Type R W p1 Bit Mask holds the parameter bit of the User Flag that contains the internal starter function assigned to be driven by the I p1 input S1 S0 Works in conjunction with P65 User Flag mapping through parameters 65 66 65 66 the source User Flag address 65 parameter 66 bit mask 5 60 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 5 Keypad Menu Items and Parameters ee fil 5 4 11 Parameters Menu continued P 67 reserved P 68 reserved P 69 reserved P 70 reserved P 71 Cntactor Dly Range 100 to 800 milli seconds Default 160 ms Scaling 4 Type R W Contactor D elay Following a start command this is the delay allowed for the main incoming contactor to close After this time a phase loss detection routine checks the incoming supply P 72 Trip Snstvty Range 1to 15 Default 1 Scaling 1 Type R W Trip Sensitivity holds an arbitrary number to adjust the sens
164. ical Installation lg M Am M H HB Hnrw 2 4 Motor Control Circuits 2 4 1 Bypass Control A separate bypass contactor may be connected in parallel with an SR44 Soft Starter The bypass contactor allows a solid connection of the motor to the Main Supply which will eliminate the heating effect associated with Soft Starter thyristor losses Soft Starting and Soft Stopping remain active as normal when the wiring is configured as in Figure 2 4 1 Atthe completion of the starting ramp a bypass contactor is closed around the main power supply connections of the Soft Starter to remove the thyristors from the circuit The contactor is controlled by a programmable relay set as Bypass Relay which is the default for relay K2 This configuration ensures that bypassing only occurs after the Soft Starter has completed the start P8 B3 1 and the motor terminal voltage is at supply voltage The default configuration will detect the use of a bypass contactor when using this circuit arrangement since Auto bypass is set as standard You can also pre set the protection mode to either START BY PASS or PHASE LO SS ONLY for motor bypassing configurations When using a bypass contactor the Auto Bypass Auto Feature should be ON P18 B2 P86 B2 Using a bypass contactor with Auto Bypass in the OFF state can cause thyristor faults wee An external u
165. ication or if for any reason you need additional technical assistance please call technical support at 770 844 4200 We are available weekdays from 9 00 a m to 6 00 p m Eastern Time We also encourage you to visit our web site where you can find technical and non technical information about our products and our company Visit us at www automationdirect com Special Symbols When you see the notepad icon in the left hand margin the paragraph to its immediate right will be a special note right will be aWARNING This information could prevent injury loss of property or even death in When you see the exclamation mark icon in the left hand margin the paragraph to its immediate extreme cases 1 2 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 1 Mechanical Installation 1 Mechanical Installation 1 1 Mounting Mount the unit to a flat vertical surface using the mounting holes or slots on its base plate The mechanical outline diagrams shown in the Mechanical Outline section 1 9 give the dimensions and mounting hole positions for each model Ensure that The orientation of the unit has the TO P uppermost The location allows adequate front access You can view the alphanumeric display 1 2 Requirements for an Enclosure For a typical industrial environment an enclosure should provide the following A single location for the unit and its protection isolation s
166. ications that require the control of two motors or where the user requires different control characteristics for a single motor at different stages of the duty cycle the SR44 Soft Starter offers two parameter groups The Primary parameter group holds the parameters considered necessary for motor starting and stopping and it is this group to which the starter defaults The Secondary parameter group is a mirror of the parameters in the first parameter group but NOT necessarily a mirror of the values in the first parameter group The parameters in each group are shown in Table 1st Ed RevA A 2 1 Table A 2 1 Primary and Secondary Parameter Groups Parameter Primary Group Secondary Group Protection Mode P7 P78 Start Pedestal P11 P79 Start Time P12 P80 Kick Pedestal P13 P81 Kick Time P14 P82 Dwell Time P15 P83 Stop Pedestal P16 P84 Stop Time P17 P85 Auto Config P18 P86 Low Current Level P28 P87 Low Current Time P29 P88 Current Limit Level P30 P89 Current Limit Time P31 P90 Shearpin Level P32 P91 Shearpin Time P33 P92 Overload Level P34 P93 Overload Delay P35 P94 User Flags 1 P51 P95 User Flags 2 P52 P96 The Primary group parameters can also be changed via the menu structure However the Secondary group parameters
167. ice to confirm the user s selection 8 Press the button three 3 times to return to Stopped and ready To keep the above settings they must be permanently saved See section A 1 5 Stopped and ready Applications e Auto Features 2 press button multiple times or hold to scroll O a SOM Parameters O K2 Q i K2 Map From O Bit Number 6 i press button multiple times or scroll as O o K CurrentLimitng K CurrentLimitng TTL 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual A 13 Appendix A Setup Examples aaa aaa A 1 12 Setting the Low Amps Level and Using the K2 Relay to Display the Status of Low Current Bit This example shows the user how to set the Low Amps Level and how to monitor the status of the Low Current bit via the K2 relay see section 5 4 5 1 With Stopped and ready shown on the display press the EN TER button 2 With Applications shown on the top line of the display press the W button until Advanced is shown on the top line 3 Press the ENTER button to select the Advanced menu 4 With Current on the top line of the display press ENTER to select the Current menu 5 With Rated Current on the top line of the display press the W button until Low Amps Level is shown on the top line 6 With Low Amps Level on the top line of the display press ENTER continued next page Sto
168. ideration to the reverse function rather than the start as the motor will initially be plug braked then be stationary for a moment and finally undergo a normal soft start 1st Ed Rev A 09 2011 SR44 Series Soft Starter User Manual 2 7 Chapter 2 Electrical Installation 2 4 6 Wiring Diagram for Motor Reversing Figure 2 4 6 Typical Power and Contactor Control Circuits for Motor Reversing L Control Supply gt N 115VAC or 230VAC set voltage switch acordingly STOP FORWARD E srop OFF ENABLE X2 O Control Q Voltage i Switch 115V 230V Important A before applying voltage to the control circuit 2 8 SR44 Series Soft Starter User M anual e Mains L3 Supply Sepp fre Feeder cables Isolation and Protection Switch gear H provided by the customer Mechanical Interlock C2 Reversing Contactor C1 Forward Contactor Electrical Ground Induction Motor Be sure to set the Control Voltage Switch to the proper control voltage setting 1st Ed RevA 09 2011 Chapter 2 Electrical Installation 2 5 Electrical Connections Terminal Locations 2 5 1 General Electrical Connections Figure 2 5 1a SR44 Chassis Size 1 Electrical Connections CONTROL VOLTAGE TERMINALS X1 X2 Input CONTROL VOLTAGE SELECTOR SWITCH Ensure that the selector switch position corresponds to the control supply used either 115V or 230V before you apply the
169. ified by IEC standard 60947 4 2 SR44 146 to SR44 202 IEC Index Ratings for bypassed operation are comprised of Rated O perational Current la Utilization Category AC 53b Overload Current Profile X T and O FF time AC 53b Overload Current Profiles applicable to specified Soft Starter models ya E OFF Ti Soft Starter Model Overload Current Duration of same multiple of le Overload seconds seconds SR44 9 35 120 to SR44 105 4 120 SR44 146 35 120 to SR44 202 6 120 SR44 242 35 420 to SR44 370 6 420 Index Rating Example Bypassed Operation AC 53b Utilization Category per IEC 60947 4 2 9 to 105 AC 53b 5 4 120 OFF time The unit can accommodate 120 120s minimum OFF time before restart 5 x le for 4 seconds but Overload Current Profile X Tx requires 120 seconds before 5 4 5 times rated current le for 4s initiating any subsequent restart Utilization Category AC 53b controller semiconductors provide squirrel cage motor Start control only bypassed for Run and Stop Rated Operational Current le 9 to 105 controllers with Rated Operational Currents from 9A to 105A 2 18 SR44 Series Soft Starter User Manual lstEd RevA 09 2011 Chapter 2 Electrical Installation 2 10 5 Overcurrent Trip Graph Overload start point adjustable by P34 or P93 default setting 110 1000 Seconds to trip 100 10 P35 or P94 t 1
170. ilable P 3 Program Type Range 5 to 56 Default 5 Scaling 1 Type R Program Type shows the generic firmware type always 5 something P 4 Software Ver Range 0 to 255 Default 11 Scaling 1 Type R Software Version shows the issue number for particular firmware type P 5 Password Range 0 to 255 Default 0 Scaling 1 Type R W Password is used by the keypad Has no effect on the firmware Keypad sees Os as no password set This option enables the user to unlock a unit by entering a previously set password When the unit is locked the user can read all parameters as usual but the user cannot write to any parameters The unit can be started and stopped while it is locked 1st Ed RevA 09 2011 SR44 Series Soft Starter User Manual 5 49 Chapter 5 Keypad Menu Items and Parameters 5 4 11 Parameters Menu continued Firing Mode Range 0 to 1 Default 0 Scaling 1 Type R W Firing Mode 0 Normal M otor outside delta or star w ye e 1 Delta inside delta no optimizing An in line isolation contactor controlled by the soft starter M UST be used with the In Delta Firing Mode and motor connections Protection Range 0 to 192 Default 192 Scaling 1 Type R W Protection Mode controls which trips are available 64 FULL full protection with full volts after top of ramp optimizing functi
171. in Figure 2 3 2 of the Electrical Installation chapter gives detailed instructions for this configuration If motor rotation is incorrect the connections should be changed as detailed in Figure 2 3 2 It should be noted that six connections are required between the motor and soft starter Parameter P6 must be set to 1 for delta mode which also disables optimizing An in line isolation contactor controlled by the soft starter M U ST be used with the In Delta Firing Mode and motor connections 3 2 2 High Inertia Loads High inertia loads such as centrifugal and axial fans grinders flywheel presses etc may require a larger size soft starter than the motor For example a 75kW 100 hp starter may be needed for a 55kW 75 hp motor This is necessary to allow for the extra heating effects of the prolonged over current on the soft starter thyristors during the extended starting time If very high inertia loads are involved then an analysis of the starting characteristics should be made This requires accurate data about the motor and the load Complete motor data Current Voltage Power Speed Rotor Inertia Soeed Torque Current curves Complete load data Type of load Speed Inertia Speed Torque curve Power absorbed or Full load Torque Consideration must also be given to thermal overload and fuse protection systems when extended start times are involved This is the case for heavy duty starting as a standard thermal overload will trip
172. ing mode When motor is heavily loaded as set in P109 the bypass contactor is energized to eliminate the soft starter thyristor losses Optimise requires an external user supplied bypass contactor and current transformer c Refer to Electrical Installation Chapter 2 subsections 2 4 1 amp 2 5 2 for details P51 B0 Kick Start Range P51 BO Default Off Scaling n a Type R W This menu item turns the Kick Start function On or Off The Kick Start applies a short lived voltage kick at the beginning of the start ramp to dislodge sticky loads P 13 Kick Pedestal Range 60 to 90 percent Default 75 Scaling n a Type R W Kick Pedestal provides a short kick of voltage at start of ramp to dislodge sticky load P 14 Kick Time Range 10 to 40 cycles Default 25 cycles Scaling n a Type R W Kick Time sets the number of cycles for which Kick Ped P13 is applied if selected P51 BO P 15 Dwell Time Range 1 to 255 seconds Default 5s Scaling n a Type R W Dwell Time provides a period of time following soft start allowing the load to settle and to ensure that it is up to speed before optimizing commences if selected 5 38 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 5 Keypad Menu Items and Parameters eee SSS aaa 5 4 5 Advanced Menu continued P52 B0 Low Volts Stop Range P52 BO
173. inued P 51 User Flags 1 Range 0 to 255 flags Default 142 Scaling 1 Type R W User Flags 1 is a set of individual bits for user control or system status Other User Flags are parameters 52 53 95 96 amp 121 P95 is a direct 2nd set for P51 Bit 0 Kickstart selects Kickstart except in 3MC mode 1 Current Limit Timeout Selected selects Trip or Continue on Current Limit Timeout This parameter bit is not available in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass 2 Overload Selected selects O verload operation e This parameter bit is not available in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass 3 Shearpin Selected selects Shearpin operation This parameter bit is not available in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass 4 Under Current Selected selects Under Current operation e This parameter bit is not available in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass 5 Thermistor Selected not available 6 unused 7 Terminal Starting Start Stop through onboard terminals P 52 User Flags 2 Range O to 255 flags Default 0 Scaling 1 Type R W User Flag
174. ion of 30 watts from the heatsink for a line current of 10 amps Therefore all cabinets or enclosures that house soft starters should have adequate ventilation Refer to the M echanical Installation procedures sections 1 6 to 1 8 for more detailed information 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual 3 3 Chapter 3 Applications rs 3 1 11 Efficiency Although the use of the soft starter introduces a power loss the system still retains an overall efficiency of approximately 99 5 If the optimizing function is selected then the gain in motor efficiency at partial loads is far greater than the loss of efficiency arising from thyristor heat losses If prolonged operation at full load is expected the thyristor loss can be eliminated as in some matched motor pump drives by closing a bypass contactor around the soft starter This contactor is readily controlled by the programmable relay set as top of ramp contacts as the circuit in section 2 4 1 shows 3 1 12 High Efficiency Motors Due to an inherently steep front to the speed torque curve high efficiency motors can exhibit instability when lightly loaded and the optimizing rate parameter P19 may need to be adjusted to compensate 3 1 13 EU Compliance with the EMC Directive When considering the use or fitting of any Soft Starter users and installers in European countries must comply with the EMC Directive 89 336 EEC The manufacturer of the soft starter
175. is a trip which can be triggered by the customer via a variety of means e g through the serial comms or via a programmable input 5 78 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 5 Keypad Menu Items and Parameters MM Mn 5 5 Definitions for Chapter 5 Dwell This is the period between Top of Ramp and Run which is designed to give unstable loads a chance to settle down and to ensure that they are up to speed Index Rating The Index Rating defines the duty of the starter Jog Small movements of a three phase induction motor usually used when commissioning the motor or load Keypad The keypad is the internally mounted user interface The user can start stop program and query the unit s status through this interface Fitting of the keypad precludes fitting of a remote keypad Keypad Remote The remote keypad is the externally mounted user interface The user can start stop program and query the unit s status through this interface Fitting of the remote keypad precludes fitting of the internal keypad Kick Start This is an optional extra kick of voltage to start sticky loads Load Current The current drawn by the application or load Optimize This is an optional energy saving feature The SR44 will reduce voltage to a lightly loaded motor Refer to the Applications chapter of this user manual for a detailed explanation Overload An O verload is a sustained over current w
176. it Number on the top line of the display press the W button until Polarity is displayed on the top line 18 Press ENTER once to select Polarity 19 With Positive Logic displayed press ENTER once to change to Inverse Logic The display will flash once to confirm that the change has been accepted 20 Press four times to return to Stopped and ready To keep the above settings they must be permanently saved See section A 1 5 continued from previous page l l i L_ Map To gt Bit Number 09 i B Bit Number o Bit Number e Bit Number O Bit Number Eoo Mask MM Number Polarity O 00010000 Mask 00010000 Mask 00000000 Mask 20000007 Mask 4 20 NA li KE O eum Number oma Bit Number Gt Mask Bit Number eum RD Md Mask T Mask I Y amp 1 48 l NA li E NN pake Le pi aa ion ine Logic Inverse Logic 1 NA 20 A 24 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 APPLICATIONS DATA Contents of this Appendix SR44 Applications Data aaa Appendix B Applications Data SR44 Applications Data The Application tables show the specific individual settings that are configured by the SR44 Applications menu Level 2 settings Application Type Default Keypad Start Pedestal 20 Stop Pedestal Start Time s 5 Soft Stop Time s Current Limit Level x FLC 3 5 Current Limit Time s Optimize
177. it must be set to Firing Mode 1 The current displayed is now the phase current 58 of the line current No 3 Subject Running Inside the Delta 2 When running with Firing Mode 1 the maximum cable length between starter and motor is reduced to 50M No 4 Subject Running Inside the Delta 3 An in line contactor must be used when running in the Delta 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual C 3 Appendix C Technical Hints ll C 4 SR44 Series Soft Starter User Manual lstEd RevA 09 2011 USING AUTOMATIONDIRECT PLCs WITH SR44 Sort STARTERS Contents of this Appendix Compatibility Overview 0 cee D 2 CLICK PLC I O Compatible with SR44 Soft Starters D 2 DLO5 DLO6 PLC I O Compatible with SR44 Soft Starters D 3 DL105 PLC I O Compatible with SR44 Soft Starters D 4 DL205 PLC I O Compatible with SR44 Soft Starters D 4 DL305 PLC I O Compatible with SR44 Soft Starters D 5 DL405 PLC I O Compatible with SR44 Soft Starters D 6 P3000 PLC I O Compatible with SR44 Soft Starters D 6 Terminator I O Compatible with SR44 Soft Starters D 7 Appendix D Using AutomationDirect PLCs with SR44 Soft Starters Compatibility Overview The SR44 control input accepts 12 24 VDC and 115 230 VAC The SR44 relay outputs are rated for 230 VAC 3A and 24 VDC 3A The inp
178. ith a duration of seconds or minutes rather than cycles that might or might not end in a trip Changes in the load characteristics might cause an overload An O verload generally draws less current than a Shearpin Parameter A parameter is a menu item that directly relates to an internal parameter of the Soft Starter Rated Current This is the nominal current in Amps at which the unit has been designed to run Shearpin Shearpin is also an over current but of a much shorter duration cycles rather than seconds and is generally a higher current than an O verload Stall The point at which the load placed on a motor threatens to stop a motor s rotational movement lstEd RevA 09 2011 SR44 Series Soft Starter User Manual 5 79 Chapter 5 Keypad Menu Items and Parameters rr EEE EE HH P n 5 5 Definitions for Chapter 5 continued Static Static as in static loads This term refers to loads with no moving parts so induction motors linear motors etc are non static loads An example of a static load would be a resistor bank Top of Ramp This is the point at which the Soft Starter reaches maximum output voltage Unit Full Load Current This is another name for the Rated Current of the unit Writeable Parameters A parameter that can be written to by the user as well as being read by the user as opposed to a read only parameter which can only be read by the user 5 80 SR44 Series Soft Starter User Manual 1stEd RevA 09
179. itivity of some of the fault trips The larger the number the slower the trip P 73 Last Trip Range 0 to 17 trip number Default 0 Scaling 1 Type R Last Trip holds the number of the last trip e Trip EO no trip E1 Phase Loss E2 Too Hot E3 5 6 SCR Signal E4 SCR Firing E7 8 9 Sensing Signal E10 SCR Shorted E11 Low Current E12 C L Time O ut E13 Overload E14 Shearpin E15 Thermistor not available E16 External trip E17 Comms Timeout lstEd RevA 09 2011 SR44 Series Soft Starter User Manual 5 61 Chapter 5 Keypad Menu Items and Parameters gpppprprrrrrrrpza p KmrmKrrkrwmk wkkr r krRr p rrr PP 5 4 11 Parameters Menu continued P 74 2nd Last Trp Range 0 to 17 trip number Default 0 Scaling 1 Type R 2nd Last Trip holds the number of the second to last trip e Trip E0 no trip E1 Phase Loss E2 Too Hot E3 5 6 SCR Signal E4 SCR Firing E7 8 9 Sensing Signal E10 SCR Shorted E11 Low Current E12 C L Time Out E13 Overload E14 Shearpin E15 Thermistor not available E16 External trip E17 Comms Timeout P 75 3rd Last Trp Range 0 to 17 trip number Default 0 Scaling 1 Type R 3rd Last Trip holds the number of the third to last trip e Trip E0 no trip E1 Phase Loss E2 Too Hot E3 5 6 SCR Signal E4 SCR Firin
180. ive item of electronic equipment to save potentially considerable amounts of money if the device is unreliable to the point that vital processes are constantly interrupted There are electronic products in the market place which appear to offer soft starting more cheaply However they almost always rely on less advantageous technologies such as analog control or half control where one of the two thyristors in each phase is replaced with a diode There are systems which only control the energy flow in one phase while the other two are directly connected Owing to the variable quality and performance of many so called inverters and soft starters available to the unsuspecting purchaser international standards for these products have been developed So far IEC 60947 4 2 AC Semiconductor M otor Controllers and Starters defines the soft starter in every important respect including thermal and overload performance as well as electromagnetic compatibility By ensuring that any motor controller equipment purchased conforms to IEC 60947 4 2 a user should be reasonably safeguarded from shoddy or inadequate products when specifying equipment for future installations A particular advantage of the use of the optimizing soft starter is its impact on the maintenance requirements of associated electro mechanical equipment Optimizing lowers the surface temperature of the motor by reducing the losses within the motor This prolongs the motor life and re
181. ld then see a display similar to the one below Parameter N ame P18 Auto Config Bit Data 00000110 Flags Bit N umber 7 0 Note Only the text shown in the shaded box would actually be displayed by the user interface A cursor would be flashing at the character on the display which represents the Least Significant Bit LSB also known as bit 0 i e the O or 1 on the right hand side of the eight 0 s and or 1 s This character is actually underlined for clarity in the example above The cursor represents the user s current input point and the value of the bit highlighted by the cursor can now be changed To move the cursor one place to the left the user needs to press the OPTIMISE key and the user will then be able to edit bit1 Pressing the OPTIMISE key repeatedly will continue to move the cursor one place to the left until bit 7 or the Most Significant Bit M SB the 0 or 1 on the left of the eight 0 s and or 1 s is reached after which pressing the O PTIMISE button again will wrap the cursor around to bit 0 To continue with the example let us suppose that the user wishes to enable the Auto Pedestal bit 7 and disable the Auto Bypass bit 2 The user should first press the O PTIMISE button twice to move the cursor two places to the left to bit 2 Then to change the value of bit 2 from 1 to 0 the user would simply press the V key once To move the cursor to the Auto Pedestal bit bit 7 the user would now press
182. le Starter was previously chosen There is another situation in which the user may need to disable the starter That is when trying to write to a parameter to which write access is denied when the unit is enabled Given such a situation for instance trying to load default parameters the unit will ask the user whether he she wishes to disable the starter The user must then press the pound button to answer no or the ENTER button to answer yes If the SR44 is disabled while running a load it will stop running the load as soon as it is disabled To sum up when the unit is disabled all writable parameters can be written to When the unit is enabled most but not all writable parameters can be written to Examples of parameters that cannot be written to while the unit is enabled are the Password and the currently loaded application Also default parameter values cannot be loaded while the unit is enabled A 4 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Appendix A Setup Examples Note for A 1 Setup Examples In the following examples the default parameters are assumed to have been loaded before the start of the example unless otherwise stated This is to provide a common reference point for the instructions A 1 3 Loading the Large Pump Application into Memory There are a number of pre programmed applications included in the SR44 for speed and ease of setup The parameters loaded by each sel
183. le of starting parallel connected motors simultaneously provided each motor has similar characteristics and load For such configurations the unit rating should be at least the sum of the current ratings of all the motors Alternatively the SR44 can start and stop motors sequentially using bypass contactors under the control of the programmable relay set as a Top of Ramp relay The dual setting feature allows for the control of motors with different start up requirements 2 4 3 External Motor Protection Relay The rating for a motor protection relay should be for Direct on Line DO L starting and if itis an electronic relay then the user should confirm it s suitability for use with a soft starter If the motor load is high inertia extended start time then a longer trip time may be required 2 4 4 Motor Reversing The diagram in figure 2 4 6 shows a typical motor reversing circuit using two contactors C1 and C2 to interchange two phases of the 3 phase power supply connections For this application the soft stop must be set to zero We also recommend the following A period of 150 350 ms elapses between the FORWARD and REVERSE commands f the reversing rate is high the SR44 current rating may need to be increased compared to the operational current of the motor Refer to sections 2 10 3 8 2 10 4 and also the O vercurrent trip curves shown in section 2 10 5 The current limit and the overload must be set with more cons
184. learing the Password leeren A 12 A 1 11 Using the Pre programmed Relay Options A 13 A 1 12 Setting the Low Amps Level and Using the K2 Relay to Display the Status of LOW Current BIE 4 2 vias weed oy a 319 NG KA UR ACE NAA AGA A 14 A 1 13 Using the K2 Relay to Mimic Programmable Input 1 A 17 A 2 Advanced Setup Examples 05 A 19 A 2 1 Using an Alternative Parameter Group A 19 A 2 2 Changing the Parameter Group After the Unit Has Passed Top of Ramp eee ee Ore ee ee Tee AA rere errr re ees A 20 A 2 3 Reserved for Future Use nassau naaa aaa RR IR A 23 A 2 4 Selecting Optimizing with Programmable Input 1 A 23 Appendix A Setup Examples res A 1 Setup Examples This section holds common programming examples that any customer might wish to use They explain how to set up the SR44 for common tasks More advanced examples are given in section A 2 A 1 1 How to Read the Setup Examples Each example consists of numbered step by step instructions which take the user through every action needed to complete the particular programming example In addition there are diagrams which reference the text The form these diagrams take are briefly explained below Note that the actual instructions in the diagrams in this section A 1 1 are for display only and are not intended to make sense as instructions If the unit needs to be Disa
185. lled Refer to P18 B2 Auto Bypass P 28 Low Amps Level Current sub menu of Advanced menu Range 0 031 to 0 7813 x le Default 0 0938 x le Scaling n a Type R W The Low Amps Level menu item specifies the current level below which a Low Current trip can occur Refer to Low Current Protection Explanation Diagram This parameter is not available in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass P 29 Low Amps Time Current sub menu of Advanced menu Range 5 to 255 cycles Default 50 cycles Scaling n a Type R W The Low Amps Time menu item specifies the time that the current must remain below the level specified by the Low Amps Level P28 before a Low Current P51 B4 trip occurs The time is specified in supply frequency cycles The default value is 50 cycles at the supply frequency For 60 Hz 50 cycles 60 cycles s 0 8335 Refer to Low Current Protection Explanation Diagram Low Current Protection Explanation D iagram LOAD Notes 1 low Low Amps Level 2 Ifl pap drops below Low Amps Level Low Current is set to on and Low Amps Time is set to minimum then the unit will trip as indicated by the short thick dotted line 3 If Low Amps Time is set to maximum and I ap rises above Low Amps Level before
186. lue of Response for MWX TMR the SoftStart Write to P12 Enable Ramp Comm Port 2 Busy Excptn Rspnse T10 C11 SP116 V411 KO 13 x K3 Updates the Soft Start Time P12 value of the SoftStart Enable Ramp Comm T10 on 14 c RT 6 28 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 6 Serial Communications 6 7 2 DirectLOGIC PLC Example Program continued Converts the values from P11 and P12 which are retrieved as a single 16 bit value into 2 separate BCD values P11 is Soft Start Pedestal P12 is Soft Start Time Since values are stored in bytes a single Modbus Read will obtain 2 values This sequence will take the retrieved value Shift Left by 25 bits to zero out the higher bits then Shift Right by the same amount to put it back in its original location convert to BCD and this leaves the value for P12 and place itin V6012 Next perfom a similar operation different of bits to extract P11 and place the value into V6013 These values are read from rung 10 by Exception that is when the user causes it _On SP1 SE P11 and P12 15 V6010 OUT Soft Start Time P12 Value V6012 LDD P11 and P12 V6010 OUT Soft Start Time P11 Value V6013 16 Ist Ed RevA 09 2011 SR44 Series Soft Starter User Manual 6 29 Chapter 6 Serial Communications 1 1 1 2 1 3 2 1 2 2 2 3 6 7 3 Productivity3000 PLC Example Program This information provided by Automa
187. luid before the firing of the thyristors is stopped Otherwise the surge pressure may still be present Soft stopping can also be successfully applied to loads such as conveyer belt systems where sensitive items such as bottles are being transported 3 2 8 Reversing Drives and Plug braking SR44 Soft Starters used in conjunction with contactor controlled reversing and plug braked motors show considerable benefits to the user by reducing mechanical and electrical stresses particularly when utilizing the current limited start feature This type of application requires inserting a 150 350 ms delay between the opening of one contactor and the closing of the other to allow any residual flux in the rotor to die away When plug braking there should be some form of zero speed detection to stop the drive after braking has been completed otherwise the drive may either accelerate the motor in the reverse direction or switch off before zero speed has been reached The SR44 has a dual parameter setting feature which is particularly useful in plug braking where the braking settings need to be different from the normal starting ramp time and current limit level See section 2 4 4 and Figure 2 4 6 of the Electrical Installation chapter for details 3 2 9 Replacement of Fluid Couplings Soft starters can replace fluid couplings yielding benefits of higher efficiency running and lower costs to the user If the coupling is used to magnify the available breakawa
188. me Reserved System U se Only Reserved Status 5 960 420 O ver Temperature 961 421 Offline Command Fail 962 422 unused 963 423 Fan Status 964 424 unused 5 32 965 425 unused 6 64 966 426 unused 7 128 967 427 unused Modbus addresses apply only to Function 06 Write Single Register or to only the first parameter of Function 03 Read Holding Registers Parameter Bit s apply only to Function 05 Write Single Coil Type R Read Only R W Read Write Table continued next page 1stEd RevA 09 2011 SR44 Series Soft Starter User Manual 6 11 Chapter 6 Serial Communications l M UM I H rk a a cjhkbyrre 6 4 Parameter Memory Addresses continued Parameter Memory Addresses continued Parameter Bit s Hi Name Function I U serFlags 4 Impact Load unused Auto Soft Stop Smoothing Breaker Present Optimise Quick Ramp Times Two Stop Bits Auto Stop 2 Stop Smooth Temp Alt D erate OffLine Command Bus BaudRate Comms Trip Trip Flags 1 1016 Trip 1 Enabled Phase Loss 2 1017 Trip 8 Enabled SCR Loss Motor M otor Side Thyristor Loss 4 1018 Trip 9 Enabled Sensing Signal Thyristor Sensing Trip Type A 8 1019 Trip 10 Enabled SCR Short
189. me following soft start allowing the load to settle and to ensure that it is up to speed before optimizing commences if selected P 15 Dwell Time is the 1st parameter set counterpart of P 83 Dwell Time 2 P 84 Stop ped 2 Range 10 to 60 percent Default 10 Scaling 1 Type R W Soft Stop Pedestal 2 Use with 2nd parameter set Soft Stop Pedestal 2 sets the percentage of supply voltage at which the Soft Stop will cease The actual value is affected by certain load variations P 16 Soft Stop Pedestal is the 1st parameter set counterpart of P 84 Soft Stop Pedestal 2 P 85 Stop Time 2 Range 0 to 255 seconds Default Os Scaling 1 Type R W Soft Stop Time 2 Use with 2nd parameter set Soft Stop Time 2 sets the time period over which the Soft Stop Ramp is performed P 17 Soft Stop Time is the 1st parameter set counterpart of P 85 Soft Stop Time 2 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual 5 65 Chapter 5 Keypad Menu Items and Parameters ll s HH nm 5 4 11 Parameters Menu continued P 86 AutoConfig 2 Range 0 to 255 flags Default 6 Scaling 1 Type R W Auto Configuration 2 Use with 2nd parameter set Set this parameter by individual bits Bit 0 Auto Ramp gently ramps voltage to starter acts somewhat like a
190. mmand say the unit was not disabled before execution then the Offline Command failed flag will be set If function 7 has been used to poll the SR44 then once the busy period is over this flag is available in the returned status byte position 80h Parameter 124 Command Codes Command Active Meaning Stop the SR44 responding to start commands remote or local Disable Starter Always If running the SR44 will stop immediately The status of any start signal is not changed Enable Starter Always The SR44 will respond to new or existing start commands Bus Starting Always The SR44 responds to start requests from the keypad bus port Remote Starting Always The SR44 responds to start requests from the hardware input Reset Starter Always The SR44 is forced to a cold start Reset Trip Always Resets the SR44 to stopped and ready state Bus Start When Enabled If Starting bus amp unit is enabled SR44 will start Bus Stop W hen Enabled SR44 will always stop The working RAM is loaded with factory default values his may take up to 5 seconds Factory D efault When Disabled Power On Default When Disabled The working RAM is loaded with the permanent store values The working RAM is saved to the permanent store for future use This may take up to 5 seconds Use only Function Code 06 for P 124 0 ffline Commands Save RAM When Disabled 1st Ed RevA 09 2011 SR44 Series Soft Starter
191. n a very wide variety of applications and networks throughout the world is insignificant Where EMC disturbances occur itis very unlikely that they can be genuinely attributed to a soft starter 1st Ed RevA 09 2011 SR44 Series Soft Starter User Manual 4 5 Chapter 4 Electromagnetic Compatibility EEE E yr 4 7 7 Strategies for Attaining and Maintaining EMC Compliance Where possible minimize the effect of electrical interference by using the strategies listed below Locate the SR44 Soft Starter unit as close as reasonably possible to the motor terminal box in order to minimize cable length Ensure that within any enclosure the control wiring does not run parallel to the power wiring W here this is unavoidable maintain a 100 mm 3 9 in separation between control cables and power cables Where possible ensure that the control wiring crosses at right angles to the power wiring This practice reduces the cross coupling between cables Shield any cables carrying sensitive signals The digital control inputs to a SR44 are opto isolated and do not normally require buffering e g through a small relay or shielding Compliance in residential environments Equipment class B can be achieved by one of the following two methods a Bypassing the soft starter with an AC1 rated contactor controlled by the programmable relay set to the top of ramp The ramp up and ramp down features remain effe
192. n automatic current limit 1 Auto 3MC enable automatic removal of low voltage ramp for high start pedestals Auto 3M C applies only to Start Pedestal voltages set above 50 P 11 or P 79 The SR44 normally does a very brief low voltage ramp up to the pedestal voltage level before the start ramp begins but Auto 3MC applies a higher starting torque and eliminates this initial pedestal ramp for pedestal voltages above 5096 2 Auto Bypass enable automatic bypass contactor detection Auto Bypass turns On and Off the automatic detection of a bypass contactor When On a bypass contactor will be automatically detected Soft starter thyristor trips and thyristor short circuit trips will be disabled during Run after full voltage is reached Thyristor protection and thyristor short circuit protection are still available during the start ramp and phase loss protection is available during both Start and Run An external user supplied current transformer is required if any of the current or power related trip or monitoring features are needed in bypass mode j Parameters 8 B2 9 B1 B2 20 21 22 23 26 28 30 32 33 34 36 39 HER 51 B1 B2 B3 B4 87 89 91 93 112 B0 B1 B2 B3 B6 121 B4 Refer to Electrical Installation Chapter 2 subsections 2 4 1 amp 2 5 2 for wiring information Auto Bypass detects the presence of a bypass contactor and should be ON when using one Using a bypass contactor with Auto
193. n electronic and electrical products is a desirable objective Technical standards are increasingly stipulating levels of EMC performance which compliant products are required to meet The decision by the European Union EU to implement a community wide directive covering EMC caused considerable activity among electrical and electronic equipment manufacturers and suppliers to identify understand and mitigate the sources of electromagnetic interference within their products and systems 4 2 Applicable Standard Within the EU The product standard which defines EMC performance for soft starters is IEC 60947 4 2 AC Semiconductor M otor Controllers and Starters The Official Journal of the EC will list this standard as EN 60947 4 2 The SR44 has been type tested in accordance with the test procedures and levels laid down in the product standard 4 3 Mandatory Requirements Within the EU Applicable to any person involved in the installation and operation of the equipment The EU Directive 89 336 EEC describes the required EMC performance of all electrical equipment which is to be connected to a low voltage supply network It imposes an obligation on the manufacturer of the soft starter to provide sufficient information for installers system integrators users and anyone else connected with the installation and operation of the equipment This section provides the technical information to support the obligation of the manufacturer The p
194. n the bottom line of the display if writing is permitted W riteable values may be changed by using the Up and Down keys for a numerical value or by pressing ENTER for a change in a logic value In the first case a numerical value the ENTER key must be pressed to confirm the changed value The user interface display will flash once to confirm the change To keep Menu Item and Parameter setting changes they must be permanently saved using the Permanent Store menu See section A 1 5 for more information 5 1 6 Changing Parameter Values All parameters can be read by the user and some parameters can also be written to by the user The full list of parameters and their values can be found in the Parameter M enu and subsequent sub menus The most commonly read and written to parameters can also be found under the other Level 1 see Figure 5 2 1 menus such as Basic and Applications A simple example of how to view and change a parameter value is given in Appendix A 1 3 To keep Menu Item and Parameter setting changes they must be permanently saved using the Permanent Store menu See section A 1 5 for more information 5 1 7 Soft Starter Data Types 5 6 There are basically four types of data held in parameters Analog Multiple Percentile and Bit data Their definitions are given below Analog D ata O ne of a range of values between two extremes usually 0 255 0 50 or 0 10 that represent units such as Volt
195. nable Source Destination kal I SoftStartTimeEntr OldSoftStartTime SoftStartTime WriteReadTime SET Once the value read back from the unit is equal to the new value the sequence is reset SoftStartTimeEntry SoftStartTimeResult i WriteReadTime H RST END 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual 6 33 Chapter 6 Serial Communications EE 6 34 SR44 Series Soft Starter User Manual lstEd RevA 09 2011 OPTIONAL HARDWARE Contents of this Chapter 7 1 SR44 RS485 Communication Card 7 2 7 1 1 Communication Card General Information 7 1 2 Connecting the Communication Card 7 2 SR44 KPD Remote Keypad 7 4 7 2 1 Remote Keypad General information 7 2 2 Connecting the Remote Keypad Chapter 7 Optional Hardware Ee 9 egerr cc er r 2 T Zi 7 1 SR44 RS485 Communication Card 7 1 1 Communication Card General Information An optional RS 485 communication adapter card is available for use with SR44 Soft Starters Communication Adapter Part Number SR44 RS485 Allows control to be switched between an integral Keypad or alternately through an external isolated network based on the Modbus standard Provides the ability to set up control and monitor single or multiple SR44 Soft Starters Provides an RS 485 interface with 50V isolation for demanding industrial applications Suitable for
196. nbiwedeteeetbiwsa eben Rp 5 8 5 3 Parameter Basic Information a 5 15 5 4 Menu Settings and Parameter Descriptions 5 23 5 5 Definitions for Chapter 5 leeeeer ees 5 79 Chapter 6 Serial Communications les 6 1 6 1 Overview uu securam edendi ee arg ace OEE Sure Ver E eRe p ir 6 2 6 2 QUICK SAE nre 94 30 83 den teen dues 1 SoE EE AKDA RU COR ded d 6 2 6 3 Specifications s oca 0 bcr Gene eee DC RACE E ERROR HE RR RC dd 6 3 6 4 Parameter Memory Addresses 000 ees 6 4 6 5 Serial Communication to SR44 es 6 13 6 7 Example PLC Communications Programs 6 19 Chapter 7 Optional Hardware lees 7 1 7 1 SR44 RS485 Communication Card 0 cc ellen 7 2 7 2 SR44 KPD Remote Keypad 0 cc cee ee ees 1 4 Appendix A Setup Examples 0 0 00 eee A 1 A 1 Setup Examples acte se KAM KAWALAN KAM Oro RU hones cous A 2 A 2 Advanced Setup Examples 0 aaa A 19 Appendix B Applications Data B 1 SR44 Applications Dad s ue rmn eee eee KWEK eee ee eee x B 2 il SR44 Series Soft Starter User Manual Ist Ed RevA 09 2011 Table of Contents eS Appendix C Technical Hints 0 0 00 eee eee C 1 20 Ea kN NT RET TERRIER ee we oe eke Be es TUTTI C 2 Appendix D Using AutomationDirect PLCs with SR44 Soft Starters D 1 Compatibility Overview sa
197. nder which the unit will trip This low current trip level is not active during the starting or stopping phases The Low Current Level flag P 112 B3 is continually updated even if tripping is disabled This parameter is not available in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass P 87 Low Current Level 2 is the 2nd parameter set counterpart of P 28 Low Current Level P 29 Low Time Range 5 to 255 cycles Default 50 cycles Scaling 1 Type R W Low Current Time sets the number of cycles for which an Under Current situation must exist before tripping P 88 Low Current Time 2 is the 2nd parameter set counterpart of P 29 Low Current Time p 30 C L Level Range 0 375 to 7 9688 Xle Default 3 5 x le Scaling 0 03125 Type R W Current Limit Level sets the current level at which the the Soft Start ramp will be held The Current Limit only holds the ramp if its level is reached The current naturally falls as motor speed increases allowing the ramp to continue e This parameter is not fully functional in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass P 89 Current Limit Level 2 is the 2nd parameter set counterpart of P 30 Current Limit Level P 31 C LTime Range 5 to 255 seconds Default 30s S
198. ner installer and user are responsible for the correct installation and use of the SR44 and must ensure that only qualified personnel install the SR44 The owner installer and user must ensure that the installation operation and maintenance of the SR44 complies with the relevant Codes of Practice Regulations and Statutory Requirements The Manufacturer or his agent do not IN assume any liability expressed or implied for any consequence resulting from inappropriate negligent or incorrect installation application use or adjustment of the product or circuit design or from the mismatch of the SR44 to a motor To prevent an electrical shock hazard the SR44 must be properly connected to a safety ground The SR44 is not designed for use in hazardous areas Use in such an area may invalidate the hazardous area certification Firmware Versions This manual applies to all versions of SR44 firmware Useful Information Additional useful quick start information can be found in the following document which is available on our website www automationdirect com Stellar SR44 Soft Starter Basic Q uick start Guide Conventions The following typographical conventions are used in this programming chapter of this user manual 1 Characters that are quoted directly from the SR44 display are quoted within single quote marks This includes Menu names Basic Parameter names Start Time Parameter values 5 Seconds Status inform
199. nit reaches Top of Ramp P8 B3 1 K Alarm Energizes when an Alarm condition is present K Current Limitng Energizes when the unit is current limiting K Ovld Integrating Energizes when the SR44 s overload is integrating K Stall Energizes when the motor is stalling K Cooling Energizes when the SR44 is cooling start inhibited K Enable Status Energizes when the SR44 is enabled K z I P1 K 60H2 K RYB Phase sequence ABC or L1 L2 L3 K Shearpin K Undercurrent K C L Timeout K Thermistor not available K Overload K Thermal Switch A worked example showing how to program a relay is given in Appendix A 1 11 5 48 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 5 Keypad Menu Items and Parameters E M n 5 4 11 Parameters Menu P 0 dummy parameter Range 0 to 255 Default 0 Scaling 1 Type R Dummy used for mapping unused bit parameters etc No keypad access P 1 Station No Range 1 32 Default 1 Scaling 1 Type R W Station Number assigns the Local Network ID of this card P 2 Language Range 1to 255 Default 44 Scaling 1 Type R W Language sets the international language code for country e g English 44 U sed by keypads to determine which language to use English is the only language ava
200. ns are not affected by so doing 2 1 5 Agency Approvals CE RoHS UL E333109 2 2 SR44 Series Soft Starter User Manual lstEd RevA 09 2011 Chapter 2 Electrical Installation 2 2 Electrical Connections Specifications 2 2 1 Electrical Supplies The SR44 requires two AC electrical power sources 1 A balanced 3 phase main source to provide the power for the controlled motor 2 A single phase supply 115V or 230V 50Hz 60Hz for the internal control circuitry The unit will not operate unless the control supply voltage is within the specified limits We recommend that the control supply be maintained between starts to ensure overload integrity since the overload will reset on control supply removal lE 2 2 2 Control Power and Ground Terminations Control Terminal Specifications SR44 Control Terminal Specifications Cable Cross Section AWG Min Max Wire Type Terminal Type Tightening Terminals Torque mm Max x1 X2 screw clamp S0 S1 11 12 14 21 22 24 terminals with captive Screws solid or stranded 22 14 2 5 4 4 Ib in 0 5 N m Power and Ground Terminal Specifications SR44 Power and Ground Terminal Specifications Cable Cross Section AWG Terminal Tightening Type Terminals Torque Conductor Type mm2 Use 75 C copper CU conductor only and the wire 10 50 shall be installed with eyelet lug 106 I
201. nstallation Personnel and System Designers lleleeelsree 4 2 4 5 EMC Basic Criteria eee aa 4 3 4 6 Purchasing Implications of Meeting an EMC Standard 4 3 4 7 Basic EMC Considerations 4 4 aru AUNG soia pd O1 entree EE Ee ent a e ed 4 4 Ao EMISSONGS hone cate Chae hve E AW WA ERR Bac Su ddp Rari 4 4 4 7 3 Emissions Harmonics aaau GN we be G4 RES Sie was LNG 4 4 4 7 4 Emissions Radio Frequency RF 00 0 0 cece eee eae 4 4 4 7 5 Emissions Conducted 0 ee eee ees 4 5 4 7 6 Important Systems Information 00 00 a 4 5 4 7 7 Strategies for Attaining and Maintaining EMC Compliance 4 6 Chapter 4 Electromagnetic Compatibility 4 0 Electromagnetic Compatibility EMC As supplied all SR44 Soft Starters meet the standards of emission and immunity levels defined in the IEC 60947 4 2 and EN 60947 4 2 product standards for AC Semiconductor M otor Controllers and Starters However the EMC performance of the controller can be significantly affected by the manner in which itis incorporated into the system in which it is intended to operate To prevent inadvertent degradation of EMC performance attention must be given to motor cable lengths wiring configurations the nature of the power supply etc at the design construction and implementation stages of a project 4 1 Introduction It is widely accepted that electromagnetic compatibility betwee
202. ntinued Parameter Memory Addresses continued Parameter Bit s g Name Function 1 O Polarity K1 Polarity 433 K2 Polarity Unused Unused 436 p 1 Polarity Unused Unused Unused 55 40055 Reserved 56 40056 Reserved 57 40057 KI Map 58 40058 K1 Bit Mask 59 40059 K2 Map 60 40060 K2 Bit Mask 61 40061 Reserved 62 40062 Reserved 63 40063 Reserved 64 40064 Reserved 65 40065 i p1 Map 66 40066 i pl bit M sk 67 40067 Reserved 68 40068 Reserved 69 40069 Reserved 70 40070 Reserved 71 40071 Cntactor Dly 72 40072 Trip Snstvty 73 40073 Last Trip 74 40074 2nd Last Trp 75 40075 3rd Last Trp 76 40076 4thLast Trp 77 40077 5th Last Trp Modbus addresses apply only to Function 06 Write Single Register or to only the first parameter of Function 03 Read Holding Registers Parameter Bit s apply only to Function 05 Write Single Coil Type R Read Only R W Read Write Table continued next page 6 8 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 6 Serial Communications m 6 4 Parameter Memory Addresses continued Parameter M emory Addresses continued Parameter Bit s amp f x Name Function I Protec
203. nts The requirements for equipment installed in heavy industrial environments fed from their own isolated low voltage power supply differ from those installed in residential commercial light industrial and health care applications directly connected to a public low voltage network Generally industrial installations require higher immunity levels and permit higher levels of conducted and radiated emissions than those for non industrial installations On the other hand lower levels of emissions output and lower immunity levels are specified for installations connected directly to the public low voltage network 4 6 Purchasing Implications of Meeting an EMC Standard Before purchasing components for the installation the specifier must evaluate the expected source of power for the Soft Starter and understand exactly the implications for meeting EMC requirements It is likely that failure to do so will result in the purchase and installation of inappropriate equipment Close consultation with your supplier will avoid these unnecessary problems particularly when you do not understand or are unclear about any part of the guidelines given later in this section If you have any doubt please ask IMPORTANT The information and guidance given in section 4 7 forms part of the statutory requirements of the European Union Directive 89 336 EEC on EMC lstEd RevA 09 2011 SR44 Series Soft Starter User Manual 4 3 Chapter 4 Electromagneti
204. nued Application Type Screw Compressor Start Pedestal 40 Stop Pedestal 0 StartTime s 7 Soft Stop Time s 0 Current Limit Level x FLC 7 185 Current LimitTime s 25 O ptimize Rate Auto Pedestal vi Auto Jog O Auto End Start MI Auto 3MC M Auto Bypass Mi Auto Stop O Soft Stop Smoothing O Low Voltage Soft Stop O Auto Ramp O Auto End Stop O Notes Application Type Rotary Compressor Start Pedestal 35 Stop Pedestal StartTime s 7 Soft Stop Time s Current Limit Level x FLC Current Limit Time s O ptimize Rate Auto Pedestal MI Auto Jog O Auto End Start Auto 3MC Auto Bypass M Auto Stop O Soft Stop Smoothing Low Voltage Soft Stop Auto Ramp 1 Auto End Stop 1 Notes Application Type Crusher Start Pedestal 40 Stop Pedestal StartTime s 3 Soft Stop Time s Current Limit Level x FLC Current Limit Time s O ptimize Rate Auto Pedestal MI Auto Jog O Auto End Start Auto 3MC Auto Bypass MW Auto Stop O Soft Stop Smoothing Low Voltage Soft Stop Auto Ramp Auto End Stop O N otes Application Type Grinder Start Pedestal 9o 40 Stop Pedestal 0 StartTime s 3 Soft Stop Time s 0 Current Limit Level x FLC Current LimitTime s 60 O ptimize Rate Auto Pedestal MI Auto Jog O Auto End Start Auto 3MC M Auto Bypass M Auto Stop O Soft Stop Smoothing Low Voltage Soft Stop O Auto Ramp O Auto End Stop O N otes B 4 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 SR44 Applications Data continued
205. o Start Pedestal voltages set above 50 P 11 or P 79 The SR44 normally does a very brief low voltage ramp up to the pedestal voltage level before the start ramp begins but Auto 3MC applies a higher starting torque and eliminates this initial pedestal ramp for pedestal voltages above 50 P18 80 Auto Ramp Range P18 BO Default Off Scaling n a Type R W Auto Ramp automatically detects motor acceleration and dynamically adjusts the ramp to give smoother acceleration This menu item works in conjunction with the Start Time parameter P12 which should be set to the estimated start time of the load This would be suitable for starts with varying loads Auto All gt OFF Range n a Default n a Auto All gt OFF turns Off all the Auto options all options contained in this submenu except Stop Smoothing The only action of this menu item is to turn Off these Auto options when the menu item is activated P122 81 P122 Stop Smooth Range P121 B1 Default Off Scaling n a Type R W Auto Soft Stop Smoothing P121 B1 turns On and Off the Stop Smoothing function P122 When turned On this menu item attempts to eliminate any oscillations that may occur when the unit Soft Stops with an unstable load 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual 5 29 Chapter 5 Keypad Menu Items and Parameters lli
206. o 2 Subject Load 1 The Soft Starter will trip 8 if a start is attempted with no motor connected on the output No 3 Subject Intermittent 7 Sensing Signal Trip Normally caused by a noisy site First try increasing the optimize rate secondly increase trip sensitivity No 4 Subject Stopped Cooling This message is displayed during the cooling time pnu116 and is the period allowed for the unitto cool before a restart No 5 Subject Keypad Displays 2 Comms Failure Check that the unit has its original front cover and keypad No 6 Subject No Current Display If the motor current drops below 12 596 la while running in Phase Loss only or Start amp Bypass then no value is displayed No 7 Subject Cancelled 1 If trying to change from Keypad to Remote Starting with a start signal present the display flashes cancelled No 8 Subject Commissioning 2 If the Soft Start trips on overload during the start check that the starter is large enough for the load No 9 Subject Too Hot Check ventilation into the cabinet If the unit has worked for a long time check fans and airflow through unit Category Wiring Subject When Replacing Star Delta Wye Delta Starters If you are planning to re use the existing overload and contactor ensure that they are sized for the full motor line current not just for delta phase current No 2 Subject Running Inside the Delta 1 The un
207. o the square of the applied voltage lowering the terminal voltage reduces the torque If the reduced voltage is correctly chosen the working point at the reduced torque demand becomes the point A By reducing the terminal voltage the motor has in effect been exchanged for one which has a lower rated power output A reduced terminal voltage also means a reduced field energy requirement and this simple relationship enables the optimizing function to maintain the efficiency of the motor over nearly the entire load range from no load upwards In practical terms no load means no external load There are still internal mechanical and electrical losses to overcome friction and windage of the rotor at speed and the electrical heating and hysteresis losses The ideal response to the no load condition would be to supply precisely the amount of magnetizing current needed to provide the armature reaction to balance the losses This is what the energy optimizing feature of a soft starter seeks to do automatically and continuously 3 4 3 Additional Benefits in Practice It is normal to select a standard motor with a rating somewhat higher than the maximum demand of the driven load The motor selected for any given application will almost certainly be over rated for this reason alone and therefore energy could be saved even at full load when supplied at rated voltage Furthermore there are those applications where the size of moto
208. oad demand This can produce a significant reduction in the kVA demand This is an operating condition that may at light or partial load conditions provide the benefit of energy saving and if selected is continuous from the dwell period until a STOP command is initiated or the mode is disabled It should be noted that this function is inhibited by the software if the current being drawn by the motor exceeds 80 of the set current of the SR44 at full voltage when the motor enters its running stage with the optimizing mode selected The method of power factor management described does not affect motor performance nor does it detract from the motor s capability to respond to changes in load demand This feature of the SR44 Soft Starter is a purely electrical function which has the effect of ensuring that the motor delivers the torque demanded at all times but allows it to draw only the precise amount of magnetizing current required to support that torque output Without this feature the motor would draw the maximum magnetizing current regardless of load The optimizing function cannot improve the power factor beyond what it would ordinarily be at full load but it does make the optimum improvement possible at any partial load 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual 3 17 Chapter 3 Applications lli 11044949 3 4 5 How Much Energy The amount of energy used by a sq
209. oken line NB Please note that the above diagram is intended for use as a GUIDE ONLY Advanced Menu continued Current Current provides access to the Current submenu which contains all the parameters associated with the Unit Full Load Current and its associated trip levels P24 amp 25 Rated Current Current sub menu of Advanced menu Range P24 amp P25 Default n a Scaling n a Type R The Rated Current la menu item holds the value of the Soft Starter s rated current It cannot be altered by the user 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual 5 33 Chapter 5 Keypad Menu Items and Parameters re I 6 k 6HE v F n7m7 Current Sub menu of Advanced Menu continued P51 B4 Low Current Current sub menu of Advanced menu Range P51 B4 Default O ff Scaling n a Type R W The Low Current menu item turns On and Off the Low Current trip A Low Current trip occurs when the current output measured by the unit falls below the level specified by the Low Amps Level parameter P28 for a length of time specified by the Low Amps Time parameter P29 Refer to Low Current Protection Explanation Diagram This parameter bit is not available in Bypass O peration unless a user supplied external current transformer is insta
210. ol using screw terminals and Belden 9841 or equivalent shielded twisted pair cabling Legend for J1 J5 SR44 SR44 SR44 Jumpers Soft Start Soft Start Soft Start Station 1 Station 2 Station 3 LEIDULT ooooooooo SG SR44 RS485 SR44 RS485 SR44 RS485 Jumpers G Comms Card Comms Card Comms Card Uninstalled Jumpers J1 J5 Jumpers J1 J5 Jumpers J1 J5 ird dE Jumpers installed Jumpers installed J4 J5 Jumpers Middle Starters Middle Starters Jumpers installed Installed Resistor 1000 Last Starter Network End The Network Start terminating resistor is installed at the PLC and Station 1 is jumpered as a Middle Starter For RS 485 connection to only one SR44 install jumpers 4 5 Network Start Functions of SR44 RS485 Jumpers J1 J5 e J1 This jumper is for use only with the SR44 KPD Remote Keypad and only the starter closest to the keypad should have this jumper installed It passes 12V through to the RJ45 connectors to supply power to the remote keypad e J2 This jumper is for use only with the SR44 KPD Remote Keypad and only the starter closest to the keypad should have this jumper installed It shorts out the 1k9 grounding resistor J3 This jumper connects the serial comms isolated ground to the local unit ground If multiple SR44s with SR44 RS485 are connected one of them must have this jumper shorted J4 This jumper is for use only with RS 485 networks It connects a 1009 termin
211. on Slave Modbus Starting Address 8 Response String ReadStarterException Modbus Decimal Addressing Modbus Function Code 3 Read Holding Registers Tag Name Mapping Non Array Enable 4 Ta ig StarterStatusWord 16 MODBUS WRITE Serial Port CPU 485 In Progress WriteStarterlnProg Slave Node Number 1 Complete WriteStarterComp Automatic Polling 300 20 Success WriteStarterSuccess Don t Skip Execution Error WriteStarterError 3 No Word Swap Timeout WriteStarterTO StartUnitCommand Enable Map 32 bit data to 16 bit Exception Slave Modbus Starting Address 125 Response String WriteStarterException Modbus Decimal Addressing StopUnitCommand Modbus Function Code 6 Write Single Register Tag Name Mapping Non Array Tag P124 Starter Control This rung controlled by StarterUnit input usually a pushbutton input to the P3 activates the Start Unit sequence by setting the Bool StartUnitCommand Then a value of 7 Bus Start is written to tag P124 Starter Control This will begin writing the tag value to the SoftStart until the status bits being read from the SoftStart show the unit is acting on the command Then the sequence resets StartUnit StartUnitCommand SET COPY DATA Source Destination 7 P124 Starter Control Enable TopOfRamp and Starting are Bool tags used to display the status of the unit When either of these tags turns on the sequence
212. on four times to return to Stopped and ready To keep the above settings they must be permanently saved See section A 1 5 continued from previous page L_a Map From gt Bit Number Q PAT 7e Hee emo Bit HEN omm Meu le PAT Hee Mask 00100000 Mask 00101000 Mask 00101000 Mask 2 Q1 Mu Y poor vase 00001000 Mask 00001000 Mask HNS A 16 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Appendix A Setup Examples l A 1 13 Using the K2 Relay to Mimic Programmable Input 1 This example shows the user how to energize a relay via the start signal 1 With Stopped and Ready shown on the display press the ENTER button 2 With Applications shown on the top line of the display press the W button until O utputs is shown at the top of the display 3 Press ENTER to select the O utputs menu 4 With K1 on the top line of the display press the W button until K2 is shown at the top of the display 5 Press the ENTER button to select K2 6 With Map From on the top line of the display press EN TER continued next page Stopped and ready Applications O Auto Features D eo i press button multiple times or hold to scroll O o e l o koa C r a M E EM From E REM Number 1 I Y continued next page 2 1st Ed RevA 09 2011 SR44 Series Soft Starter User Manual A 17 Appendix A Setup Examples EE MM 7 ff A 1 13 Using the K2 Relay to Mimic Pro
213. on turned off 192 FULL 0 PTIMIZE full protection optimize 128 START BY PASS protection during start then bypass 0 PHASE LOSS ONLY p phase loss detection only Start and O ptimize mode is forced to FULL Protection Mode when Delta Firing Mode is selected P 6 2 1 In PHASE LOSS ONLY Protection Mode P 7 0 the bottom 12 5 of starter current is ignored after TOR Top Of Ramp P 78 Protection Mode 2 is the second parameter set counterpart of P 7 Protection Mode Status 1 Range 0 to 255 flags Default 0 Scaling 1 Type R Status 1 flags Read this parameter by individual bits Bit 0 Stopped start stop signal inactive thyristors off main contactor open 1 Starting starter is in start ramp 2 Current Limit during a softstart indicates motor has reached Current Limit level and ramp is being held e This parameter bit is not fully functional in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass 3 Top of Ramp the unit has finished the Start Ramp and any Current Limit 4 Dwell period of time at end of Start Ramp where motor is held at full volts before entering optimizing to allow the load to stabilize and to ensure that it is up to speed 5 Full Conduction thyristors are fully on 6 Energy Saving starter is monitoring motor power factor and adjusting applied voltage to bring i
214. onctionnement sont conformes aux exigences de la version la plus r cente de ces codes Vous devez tout le moins respecter toutes les sections applicables du Code national de pr vention des incendies du Code national de l lectricit et des codes de la National Electrical Manufacturer s Association NEMA Des organismes de r glementation ou des services gouvernementaux locaux peuvent galement vous aider d terminer les codes ainsi que les normes respecter pour assurer une installation et un fonctionnement s rs L omission de respecter la totalit des codes et des normes applicables peut entrainer des dommages l quipement ou causer de graves blessures au personnel Nous ne garantissons pas que les produits d crits dans cette publication conviennent votre application particuli re et nous n assumons aucune responsabilit l gard de la conception de l installation ou du fonctionnement de votre produit Nos produits ne sont pas insensibles aux d faillances et ne sont ni con us ni fabriqu s pour l utilisation ou la revente en tant qu quipement de commande en ligne dans des environnements dangereux n cessitant une s curit absolue par exemple l exploitation d installations nucl aires les syst mes de navigation a rienne ou de communication le contr le de la circulation a rienne les quipements de survie ou les syst mes d armes pour lesquels la d faillance du produit peut provoquer la mort des blessures c
215. ontinued P 124 Off Line Command Range 0 to 255 Default 0 Scaling 1 Type R W Used by serial communication 1 Disable 2 Enable 3 Bus Starting 4 Remote Starting 5 Reset Starter 6 Reset Trip 7 Bus Start 8 Bus Stop 9 Load EEROM from Defaults 10 Load RAM from EEROM 11 Save RAM to EERO M P 125 reserved P 126 Comms Trip Range 0 to 255 Default 0 Scaling 1 Type R W Bus Action on Fail Action following a bus failure Active only with certain Comms Options 0 No Trip 1 Trip P 127 Trip Flags Range 0 to 255 flags Default 0 Scaling 1 Type R W Hidden Trip Flags Enable or Disable certain trips Read Write this parameter by individual bits This parameter is for Diagnostic Purposes 0 Trip Disabled 1 Trip Enabled Bit 0 Trip 1 Enabled enable or disable Trip 1 Phase Loss Trip 8 Enabled enable or disable Trip 8 SCR Loss Motor Motor Side Thyristor Loss Trip 9 Enabled enable or disable Trip 9 Sensing Signal Thyristor Sensing Trip Type A Trip 10 Enabled enable or disable Trip 10 SCR Shorted Thyristor Sensing Trip Type B Trip 4 Enabled enable or disable Trip 4 SCR Firing Thyristor Sensing Trip Type C Trip 5 Enabled enable or disable Trip 5 SCR Signal Edge Sensing Trip Trip 6 Enabled enable or disable Trip 6 SCR Signal Sensing Trip Type A Trip 7 Enabled enable o
216. orporelles ou de graves dommages mat riels ou environnementaux activit s risque lev La soci t AutomationDirect nie toute garantie expresse ou implicite d aptitude l emploi en ce qui a trait aux activit s risque lev Pour des renseignements additionnels touchant la garantie et la s curit veuillez consulter la section Modalit s et conditions de notre documentation Si vous avez des questions au sujet de l installation ou du fonctionnement de cet quipement ou encore si vous avez besoin de renseignements suppl mentaires n h sitez pas nous t l phoner au 770 844 4200 Cette publication s appuie sur l information qui tait disponible au moment de l impression la soci t AutomationD irect nous nous efforcons constamment d am liorer nos produits et services C est pourquoi nous nous r servons le droit d apporter des modifications aux produits ou aux publications en tout temps sans pr avis ni quelque obligation que ce soit La pr sente publication peut aussi porter sur des caract ristiques susceptibles de ne pas tre offertes dans certaines versions r vis es du produit Marques de commerce La pr sente publication peut contenir des r f rences a des produits fabriqu s ou offerts par d autres entreprises Les d signations des produits et des entreprises peuvent tre des marques de commerce et appartiennent exclusivement a leurs propri taires respectifs AutomationDirect nie tout int r t dans les
217. otor torque LRT that is at least twice the breakaway torque e g for a reciprocating compressor the FLT is normally in the region of 50 motor LRT Asa general rule the higher the motor LRT is above the load breakaway torque the greater the control over the starting process 3 6 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Table 3 2 13 Applications Chapter 3 Applications aaa Application Breakaway Torque FLT Agitator 35 Air compressor rotary unloaded start 25 35 Air compressor reciprocating unloaded start 50 100 Air compressor screw type unloaded start 30 Usually two pole motor Ball mill 30 50 Eccentric load needs high starting torque motor Carding machine 100 O ften high inertia Centrifuge 50 90 Usually high inertia Centrifugal fan dampers closed 10 25 Usually high inertia Centrifugal fan dampers open 10 25 Usually high inertia very long ramp times Centrifugal blower valve closed 25 35 Centrifugal blower valve open 30 40 Can have long ramp time Chillers 10 25 Usually started unloaded two pole motor Conveyor horizontal unloaded 10 50 Conveyor horizontal loaded 100 150 Conveyor vertical lifting unloaded 50 85 Conveyor vertical lifting loaded 100 175 Conveyor vertical lowering unloaded 10 40 Conveyor vertical lowering loaded
218. p Sensitivity Trip 2 P126 Comms Trip Trip 3 Cooling Trip 4 Use Enter key to scroll right aa apa y g Use key to scroll left Use A amp V keys to scroll up amp down 1st Ed RevA 09 2011 5 8 SR44 Series Soft Starter User Manual Chapter 5 Keypad Menu Items and Parameters 5 2 2 Complete Keypad Menu Structure eaaaan We highly recommend that you configure the SR44 by first selecting and setting an application from the JE Applications menu that is similar to your application If necessary you can then fine tune your Configuration by changing the settings of other parameters and menu items To keep Menu Item and Parameter setting changes they must be permanently saved using the Permanent Store menu See section A 1 5 for more information Keypad Menu Structure Horizontal Keypad Scrolling Enter key right forward key left back Level Level Parameter Parameter 0 1 Level 2 Bit Level 3 Bit Settings Default Keypad Default Auto Small Pump up Large Pump Conveyor Low Inertia Fan Hi Inertia Fan Recip Compressor Screw Compressor down Up Arrow key Rotry Compressor Crusher Grinder Hi Torque Start Motor Gen Set aerator Flywheel Press Moulder Settings P18 Auto Jog O n O ff P18 B3 Auto Pedestal O n O ff P18 B7 Auto End Start O n O ff P18 B6 Au
219. passing through the device The closer the turn on point is to the voltage zero crossing point the longer the energy is allowed to flow during the half cycle Conversely delaying the turn on point reduces the time for the energy to flow Putting two thyristors back to back or anti parallel in each of the phase connections to a motor and by precisely controlling their turn on points an electronic soft starter continuously adjusts the passage of energy from the supply so that it is just sufficient for the motor to perform satisfactorily So for instance by starting with a large delay to the turn on point in each half cycle and progressively reducing it over a selected time period the voltage applied to the motor starts from a relatively low value and increases to full voltage Due to the motor torque being proportional to the square of the applied voltage the starting torque follows the same pattern giving the characteristic smooth stepless start of the soft starter 3 12 SR44 Series Soft Starter User Manual lstEd RevA 09 2011 Chapter 3 Applications 3 3 6 Running Induction Motors 1st Ed Rev A Once a start has been completed the motor operating efficiency becomes of interest When working at or near full load the typical three phase induction motor is relatively efficient and readily achieves efficiencies of 85 to 95 However as shown below motor efficiency falls dramatically when the load falls to less than 50 of rated
220. pped and ready Applications Auto Features Q3 LI 2 press button multiple times or hold to scroll Q o E o E E ems Current Permanent E E E Rate Low ems 9 press button multiple times E 1 or hold to scroll O o Low Amps Level 7 o ial Low Amps Time y continued next page A 14 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Appendix A Setup Examples LY A 1 12 Setting the Low Amps Level and Using the K2 Relay to Display the Status of Low Current Bit continued continued from previous page 7 With Low Amps Level showing on the top line press the A or W buttons until the required level is set 8 Press ENTER to confirm the change The display will flash to confirm that the change has been made 9 Press the button twice to return to the Advanced menu 10 With Advanced on the top line of the display press the V button until Outputs is displayed on the top line 11 Press the ENTER button to select Outputs 12 Press the W button until K2 is shown on the top line of the display 13 Press the ENTER button to select K2 14 With Map From on the top line of the display press ENTER 15 With 8 Parameter showing press the A button until 112 Parameter is displayed 16 Press the ENTER button to confirm the change and the display will flash once 17 Press the button once to return to Map From continued
221. r 400008 NO of Master Addresses 1 Word Swap OFF Status Comm Receiving Port 2 Read Status Enable Time S Ready Flag Interlock Comm Bo one cM c1 Status Word from Strtr H DH1 Success Master Status Comm Read Error C202 1 DS100 ErrCode Read Status Interlock B C10 SET This rung will be used for Start Stop control of the unit It will only be activated when the user activates the Start and Stop inputs which will send a value of 7 Start or 8 Stop contained in DS30 to the Command Register P124 of the unit Send Port3 MODBUS Control Comm Slave ID 1 Sending Modbus Function Code 06 C210 Slave Addr 400125 sci C Control Comm Success C211 Success O Control Comm Error B C212 Port 2 Enable Time Start SoftStart Ready Flag Comm B C21 B SC100 B C11 Stop SoftStart B C23 DS105 ErrCode 6 20 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 6 Serial Communications 6 7 1 CLICK PLC Example Program continued This rung controls the interlocking of the 2 previous comm instructions Since the Receive instruction is programmed to read continuously this logic resets the interlock UNLESS the CLICK program calls for the Start Stop Send instruction to be activated Read Status Read Status Interlock Start SoftStart Stop SoftStart Interlock B C10 B C21 B C23 B C10
222. r Limit When motor is lightly loaded as setin P110 the bypass contactor is de energized to run the motor from the soft starter in Energy O ptimizing mode When motor is heavily loaded as set in P109 the bypass contactor is energized to eliminate the soft starter thyristor losses Optimise requires an external user supplied bypass contactor and current transformer See Electrical Installation Chapter 2 subsections 2 4 1 amp 2 5 2 for details 5 Quick Ramp Times selects ramp times to be 10 times faster than the value entered although min 0 3 seconds 6 Two Stop Bits when set the comms will have two stop bits 7 Auto Stop 2 alternative stopping method 5 74 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 5 Keypad Menu Items and Parameters ee el 5 4 11 Parameters Menu continued P 122 Stop Smooth Range 1 to 25 Default 5 Scaling 1 Type R W Auto Soft Stop Smoothing is an arbitrary filter to smooth soft stop jitters caused by unstable load This feature is turned ON or OFF by Bit 2 of Parameter 121 P 123 Temp Alt Derate Range 0 to 50 percent Default 096 Scaling 1 Type R W This parameter enables the user to derate by percentage of Unit Full Load current where local temperature or altitude is outside of the normal operating range Refer to the M echanical Installation chapter for temperature and altitude specs 5 4 11 Parameters Menu c
223. r disable Trip 7 Sensing Signal Sensing Trip Type B O Ui 4 WN HI 1st Ed RevA 09 2011 SR44 Series Soft Starter User Manual 5 75 Chapter 5 Keypad Menu Items and Parameters ee PF cr 5 4 12 Trips Menu This menu holds all the parameters that are associated with control of the various trips Trips Range 0 to 17 trip number Default 0 The Trips sub menu accesses a trip history of the unit s last five trips These trips are recorded automatically and need no intervention from the user They are useful in troubleshooting a unit Most trips can be turned off either via this menu or through the Trip Byte P127 or via the Current menu for the current related trips Below is a list of each trip condition used by the SR44 Trip Numbers and Explanations 01 Phase Loss One or more input phases are missing at start during the ramp and after full voltage even when running on bypass See section 5 4 5 Line Contactor 02 Too Hot Soft starter heat sink is too hot This trip applies only to units SR44 30 and larger 03 Comms Errors in serial communications while communications are still active between the user interface and the Soft Starter 04 SCR Firing Thyristor Sensing Trip Type C Short circuit thyristor after full voltage 05 SCR Signal Edge Sensing Trip Short circuit thyristor during the ramp and after full voltage
224. r has to be chosen to provide for high loadings which occur only intermittently or for an arduous start even though the load demand at most times is much lower 3 16 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 3 Applications MM 3 4 4 Optimizing with the SR44 System During start up the SR44 software uses a patented method to compute and store a reference value for the power factor When the motor has reached full speed and is driving the load at the demanded torque the SR44 enters the motor running stage At this stage if required the motor may also operate in Optimizing Mode Entering this mode can be pre set from the SR44 keypad and stored for automatic operation which will suit the majority of applications where it is required This is the default operating mode for the SR44 It can also be toggled on and off while running by using either the O PTIMIZE button on the keypad or through external circuitry connected to one of the programmable inputs and controlled by the driven process In this mode the reference power factor is continuously compared with the running power factor The software continuously uses this comparison to compute and adjust the firing point of the thyristors in order to maintain the best power factor This method of continuous control minimizes wasted energy caused by overfluxing the motor It also maintains the power factor at the most appropriate value for every condition of l
225. rced O verride 76 4C Noise 77 4D Inhibit Start 78 4E DC p Level Reached 7 128 79 4F Reserved Modbus addresses apply only to Function 06 Write Single Register or to only the first parameter of Function 03 Read Holding Registers Parameter Bit s apply only to Function 05 Write Single Coil Type R Read Only R W Read Write Table continued next page 6 4 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 6 Serial Communications 6 4 Parameter Memory Addresses continued Parameter M emory Addresses continued Parameter Bit s amp f j Name Function Status 3 80 Relay K1 Status 81 Relay K2 Status 82 unused 83 unused 84 Input 1 Status 85 unused 86 unused 87 unused Start Ped Start Time Kick Ped Kick Time D well Time Stop Ped Stop Time Auto Config Auto Ramp Auto 3MC Auto Bypass Auto Jog Auto end stop Auto stop Auto end start Auto Pedestal 19 40019 O pt Rate 20 40020 Reference PF 21 40021 Internal PF 22 40022 D elay Angle 23 40023 Max Angle Modbus addresses apply only to Function 06 Write Single Register or to only the first parameter of Function 03 Read Holding Registers Parameter Bit s apply only to Function 05 Wri
226. rection Capacitors 3 3 3 1 6 Lightly Loaded Small Motors ana dew KAKA d NA NG NG NG KA 3 3 3 1 7 Motors Installed with Integral Brakes sess 3 3 3 1 8 Older Motors 2252065 or rU dee iod e xe Seed eee aeea we 3 3 3 1 9 Wound rotor or Slip ring Motors 4 aaa 3 3 3 1 10 EBDEIOSN BS io btbe these ERES beth LEeEBSEREM EDS dd Pd ds x 3 3 3 1 11 EMGEECY T 3 4 3 1 12 High Efficiency Motors eens 3 4 3 1 13 EU Compliance with the EMC Directive 3 4 CMM Gigi cee eee e Asay ene eee e ea e a ares 3 4 3 2 Rules for Specific Applications 3 5 3 2 1 In Delta Operation 633994593 3109013 1 en drap eant ND ER D 3 5 3 2 2 Higlidertalboeatls ie acc uude pig ELEESSCREEE See Pd ds 3 5 3 2 3 Reserved e nnns 3 5 3 2 4 Resistive Loads nnn 3 5 3 2 5 Frequent ASIN usado seeds du corvos PREM edd ava 3 5 3 5 e ODUMIAING ionetestheecice ad dee heteen er US ATO CENE 3 5 Bag Soft HOPPING 5 2 2 2 3 2 209 5 9 RREGUR Cw NGA KING BORD EE X4 o CHORI Bo 3 6 3 2 8 Reversing Drives and Plug braking 0 00 0 aaa 3 6 3 2 9 Replacement of Fluid Couplings aaa 3 6 3 2 10 Two speed Motor Applications ces 3 6 3 2 11 Multiple Motor Starting ee 3 6 3 2 12 Overhauling Loads 22 03 622i dewedwedigcwddicedbuedw anid 3 6 3 2 13 Application Table waaa aasa KAAGAW AKLAT SO ADR wed ees 3 6
227. rent required motor FLC SR44 FLC 32 reserved 5 72 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 5 Keypad Menu Items and Parameters E n 5 4 11 Parameters Menu continued P 112 Status 4 Range O to 255 flags Default 0 Scaling 1 Type R Status 4 flags Read this parameter by individual bits Bit 0 60 Hz the unitis using 60 Hz parameters This parameter bit is not fully functional in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass 1 Phase Rotation Sequence the phase rotation detected at start was e This parameter bit is not fully functional in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass 2 Shearpin current is above Shearpin level e This parameter bit is not available in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass 3 Under Current current is below Under Current level This parameter bit is not available in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass 4 Thermistor not available 5 Timeout Current Limit has timed out 6 Overload overload has passed Trip Level This par
228. required network station number slave address b If not continously polling the unit at least once every 5 seconds set P 126 to 0 turning off comms timeout trip c Make any changes to Parameter 121 bit 6 0 1 Stop bit 1 2 Stop bits d Store changes to EERO M save RAM The Local Remote switch must be set to Remote to use the optional communication interface SR44 RS485 When this switch is set to Local serial communication is ignored and the integrated local keypad controls the soft starter Refer to Chapter 7 Optional Hardware for information about installing and using the optional Local Remote switch 4 Register and coil addresses start at zero 3 SR44 has a Modbus offset of one address for registers and bits PLC programs should target one address c higher than desired e g PLC targets SR44 address 40019 to read write to from address 40018 P 18 Allowed address ranges are Register numbers 0 127 EEPROM Registers 1000 1127 Coils flags 0 1024 Refer to the Parameter M emory Addresses section of this chapter for more information 6 2 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 6 Serial Communications 6 2 Quick Start continued 5 Function 06 Write Single Register Parameters in the SR44 are 8 bit bytes which are written to by 16 bit Modbus words Only the low byte of the M odbus word in the PLC gets sent to the SR44 parameter Func
229. ress higher 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual 6 15 Chapter 6 Serial Communications Wo j J v gp ppr ppprprrrrr pvJ v v pppp PrrPrrrrr pr F rF v EP rrrrriir xm wg w595 6 5 3 Writing Single Register Modbus Function 06 This function is used to set the value of a single parameter It differs from the M odbus protocol in that only the data low byte of the query is written to the parameter address The data high byte is ignored The normal response for correct operation is an echo of the data If the PLC uses Function 06 to write one word of data into the SR44 only the low byte of the PLC data is used The PLC low byte is written into the SR44 parameter and the PLC high byte is ignored Example Modbus Function 06 PLC writes Enable to SR44 send a value of 2 to P 124 Start Slave Address SR44 40125 Start M aster Address PLC internal PLC register 1 value 2 SR44 PLC Data Value Hex Decimal Hex Data Address Parameter Address Byte internal PLC P 124 OffLine Command 40125 high 02 02 00 02 register 1 SR44 Modbus addresses have an offset of one address from the parameter The PLC needs to target slave address 40125 in order to change P 124 4 For Function 06 single write instructions the SR44 accepts only the low byte of the PLC word the high byte is ignor
230. rip e P 74 2nd Last Trip P 75 3rd Last Trip e P 76 4th Last Trip e P 77 5th Last Trip e P 78 Protection 2 Modbus Function 05 example 6 5 2 e P 52 B 6 User Flags 2 2nd parameter set Modbus Function 06 example 6 5 3 e P 124 OffLine Command lstEd RevA 09 2011 SR44 Series Soft Starter User Manual 6 13 Chapter 6 Serial Communications lr Pa rr rr rr 7 7 vvV p p 7p rEeppp ppr v ij 6 5 1 Reading Holding Registers Modbus Function 03 This function is used to read a group of up to eight parameters from the SR44 The allowable address range for this function is 0 127 for working parameters and 1000 1127 for offline EERO M parameters Example Modbus Function 03 Read the fault history P 73 P 77 from SR44 slave 1 into a PLC Start Slave Address SR44 40074 Start M aster Address PLC internal PLC register 1 Number of Elements 3 SR44 PLC Data Value Parameter Address Byte Address Decimal P 73 Last Trip 40073 high 0 no trip 00 internal PLC P 74 2nd Last Trip 40073 low 2 too hot 02 register 1 P 75 3rd Last Trip 40074 high 13 overload 0D internal PLC P 76 4th Last Trip 40074 low 14 shearpin OE register 2 P 77 5th Last Trip 40075 high 16 external trip 10 internal PLC P 78 Protection2 40075 low 192 fulltoptimize CO register 3 SR44 Modbus addresses are variable
231. riteReadTime Word Swap Timeout ReadStarterO Enable No Mapping Exception 9 Slave Modbus Starting Address 12 Response String ReadStarterException Modbus Decimal Addressing Modbus Function Code 3 Read Holding Registers Tag Name Mapping Non Array Tag P11 12Ped Time This rung takes the value in tag P11 12 which was retrieved from the SoftStart and performs some Shift operations on it to isolate the 2 values that actually are retrieved from the SoftStart due to its 8 bit architecture First the value is Shifted Left by 8 bits to zero out the data and the result is placed in tag Shift1 Next tag Shift1 is Shifted Right by 8 bits to return the value to its original location The resulting value is stored in tag SoftStartTimeResult Finally P11 12 is Shifted Right to move the upper byte to the lower byte and the value is stored in tag SoftStartPedestalResult This is the value that is used to demonstrate how to Write Read with the unit since the Soft Start Time would be the most commonly changed parameter after Start Stop SHIFT ROTATE BITS Input P11 12Ped Time Output Shift1 10 Enable la Number of Bits 8 Shift Left Bit to ShiftIn 0 Don t Include Sign Bit SHIFT ROTATE BITS Input Shift1 Output SoftStartTimeResult Number of Bits 8 4 Shift Right 10 1 Enable Bit to ShiftIn 0 Don t Include Sign Bit SHIFT ROTATE BITS Input P11 12Ped Time Output Sof
232. rn to Stopped and Ready To keep the above settings they must be permanently saved See section A 1 5 continued from previous page l l P98 UTP Mask gt P99 U1 O P Dest an i A U1 SF Dest aang U1 O P Dest Ng panao P99 U1 O P Dest P100 U1 SANA Mask o aang Parameter eg Parameter 9 VN l P99 U1 EET Dest a P99 U1 O P Dest Pe U1 O P Mask Ex Parameters I Q 3 KE U1 O P Mask guida U1 O P Mask Sooo mas P100 U1 O P Mask DCN Mask ee Mask 5 A wl 11 2 P100 U1 Fame Mask P100 U1 ie Mask Hg Mask HAN Mask A 22 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Appendix A Setup Examples A 2 3 Reserved for Future Use A 2 4 Selecting Optimizing with Programmable Input 1 This example programs the S1 input to turn the O ptimizing function Off and On When the specified voltage is applied to and removed from the S1 input the energy optimizing function is turned Off and On note the inverse action If input S1 is assigned to toggle the O ptimizing function it toggles with inverse action Voltage applied to S1 O ptimizing Off No voltage at S1 Optimizing On 1 With Stopped and Ready shown on the display press ENTER button once 2 With Applications shown on the top line of the display press W button until Inputs is shown at the top of the display 3 Press ENTER once to select the Inputs menu 4 With Digital i p 1 on the top line o
233. rovide isolation For this reason isolation device s must be installed in the power supply circuit in accordance with the applicable wiring and safety regulations WARNING AC input power must be disconnected before performing any maintenance Do not connect or disconnect wires or connectors while power is applied to the circuit Maintenance must be performed only by a qualified technician components are especially sensitive to static electricity To avoid damage to these components do not touch these components or the circuit boards with metal objects or your bare hands WARNING Always replace the cover panel on the unit after gaining access to the electrical connections WARNING The SR44 may be destroyed beyond repair if incorrect cables are connected to the input output terminals Never connect the SR44 output terminals T1 T2 and T3 directly to the AC main circuit power supply WARNING Ground the SR44 soft starter using the ground terminal The grounding method must comply with the laws of the country where the SR44 is to be installed Refer to Chapter 2 Electrical Installation 1 WARNING There are highly sensitive electronic components on the printed circuit boards and these 1st Ed RevA 09 2011 SR44 Series Soft Starter User Manual W 3 w 4 SR44 Series Soft Starter User Manual Ist Ed RevA 09 2011 STELLAR SR44 Sort STARTER UsER MANUAL Please include the Manual Number and the Manual Issue both shown below
234. rovision and maintenance of compatibility extends from the manufacturer to the panel builder assembler systems integrator and ultimately to the installer and user Anyone involved in the installation and operation of the equipment through a lack of knowledge misdirection or for other reasons can completely negate the initial EMC performance of the equipment 4 4 Guidance for Installation Personnel and System Designers For safety reasons all SR44 products are intended to be installed and set to work by skilled personnel who are capable of interpreting and following EMC guidelines correctly Any person not fully trained in the appropriate technology should not attempt the installation If you do not understand or if you are unclear about any part of these guidelines then please consult your supplier Often consultation with the supplier can avoid unnecessary problems in specifying and installing the correct combination of equipment 4 2 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 4 Electromagnetic Compatibility 4 5 EMC Basic Criteria The electromagnetic compatibility of a product is defined by two criteria 1 Immunity to electromagnetic disturbances generated externally to the product 2 The type and amount of conducted and radiated electromagnetic emissions emanating from the product Ascertaining the nature of the power supply is of primary consideration when deciding on appropriate EMC requireme
235. rrent Nominal Power Soft Starter Model Rating Consumption SR44 9 to SR44 23 up to 23A 8VA SR44 30 to SR44 44 30A amp 44A 10 VA SR44 59 to SR44 146 59A to 146A 12VA SR44 174 to SR44 370 174A to 370A 18VA 2 12 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 2 Electrical Installation 2 7 Control Card Connections All the control inputs and outputs are on the Electronic Control Card ELC which is mounted within the unit Diagrams in section 2 5 show the location of the electronic control card 2 7 1 Control Inputs Control Card Inputs Identification Description Programmable Input Control Input 1 S1 S0 Application of a voltage between S1 and S0 will either SET normal logic sense or CLEAR inverted logic sense the parameter mapped to by parameter P65 Removal of this voltage will either CLEAR normal logic sense or SET inverted logic sense the parameter mapped to by parameter P65 Default setting is P52 Bit 4 Start Stop which is active only when the operator selects and enters REMOTE STARTING at the keypad The application of a voltage as specified between these terminals will initiate a START The removal of this voltage will initiate a STOP Start Stop 12 24VDC or 115 230 VAC 2 7 2 Control Outputs Control Card Outputs Identification Description Programmable O utput Relay K1 A bit 1 on the parameter bit selected by P57
236. rs These messages CRC Error Slave Busy Illegal Address and Illegal Function tell the user when there has been a Modbus Comms Error See the Modbus chapter for more details Running Status This message indicates which running mode the unit is in either Starting Full Volts or Optimizing The second line of the message gives a current indication in Amps If an overload condition exists then a bar graph indicating the state of overload integration will be shown across both lines on the right hand side of the display 5 1 4 Menu Navigation Mode The Menu Navigation Mode is entered as soon as the ENTER button is pressed in the System Status Mode In this mode the user can navigate through all levels of the menu structure using the relevant buttons on the keypad See Figures 5 1 2a amp 5 1 2b 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual 5 5 Chapter 5 Keypad Menu Items and Parameters 5 1 5 Data Entry Mode The Data Entry Mode is entered as soon as the bottom level of the menu structure for that particular menu branch is reached i e a menu item or parameter name is displayed in the top line of the keypad display and the associated value is displayed in the bottom line of the display Not all parameter values can be changed by the user as some are read only A user can tell whether the menu item or parameter is writeable as there will be a flashing cursor present o
237. rter User Manual 1stEd RevA 09 2011 Chapter 5 Keypad Menu Items and Parameters 5 4 3 Auto Features Menu continued P18 82 Auto Bypass Range P18 B2 Default On Scaling n a Type R W Auto Bypass turns On and Off the automatic detection of a bypass contactor When On a bypass contactor will be automatically detected Soft starter thyristor trips and thyristor short circuit trips will be disabled during Run after full voltage is reached Thyristor protection and thyristor short circuit protection are still available during the start ramp and phase loss protection is available during both Start and Run An external user supplied current transformer is required if any of the current or power related trip or monitoring features are needed in bypass mode Parameters 8 B2 9 B1 B2 20 21 22 23 26 28 30 32 33 34 36 39 51 B1 B2 B3 B4 87 89 91 93 112 B0 B1 B2 B3 B6 121 B4 Refer to Electrical Installation Chapter 2 subsections 2 4 1 amp 2 5 2 for wiring information Auto Bypass detects the presence of a bypass contactor and should be ON when using one Using a bypass contactor with Auto Bypass in the OFF state can cause thyristor faults P18 81 Auto 3MC Range P18 B1 Default On Scaling n a Type R W Auto 3MC turns On and Off the automatic removal of the low voltage ramp for high pedestal starts Auto 3MC applies only t
238. rters which have been used world wide in more than 100 000 critical and non critical systems Since 1983 these soft starters have successfully operated with almost every type of load and environment from the Antarctic to the Jungle The design has proven to be both reliable and adaptable and provides a powerful mechanism with which to control fixed speed induction motors However due to the intrinsic differences between electronic and electro mechanical starting systems there are a number of simple rules and observations to follow when using the SR44 Soft Starter This section introduces guidelines for the user and those incorporating the unit as part of their system design 3 1 1 Suitability In principle any three phase induction motor can be started by a soft starter Normally the breakaway torque of the load should be less than the full load torque of the motor unless a motor with a high locked rotor torque characteristic is employed As a quick assessment any load which has a low or no load start with a moderate starting time or which can be started with a star delta wye delta starter auto transformer or other forms of reduced voltage starting can be considered a potential application for a soft starter 3 1 2 Induction Motor Characteristics Three phase induction motors are required to provide sufficient torque to accelerate the motor and its load from standstill to full speed and to maintain full speed efficiently at all torque l
239. s A 1 2 Enabling and Disabling the SR44 The effect of this parameter is that the user cannot start the SR44 running the motor without enabling the unit first Whenever the control supply to the SR44 is turned on the unit powers up in an enabled state and the display will indicate whether or not the unit is enabled If the SR44 is enabled the display will look like this If the SR44 is disabled the display will look like this 1 V To Enable If the unit has been disabled there are two ways to enable the unit 1 By pressing the down button when presented with the Start Disabled screen shown above 2 By following the instructions below Starter Disabled o Applications 1 V To Enable Auto Features press button multiple times or hold to scroll 1 Dae Starter Advanced eo Enable Starter O Y l li Ed e Ed Starter Starting E add 4 4 I With Starter Disabled on the screen press the ENTER button once Press the down button until Basic appears on the top line of the display Press the ENTER button once and with Disable Starter showing press the down button once until Enable Starter is on the top line of the display Press the ENTER button once and the display will flash once confirming the change There is only one menu driven way to disable the unit and that follows the same procedure as above except choosing Disable Starter at the point where Enab
240. s All electrical connections are made to power input and output terminals control terminals and a ground stud Before you apply control voltage to the control supply terminals ensure that the control UN voltage selector switch is set to the correct voltage being used The diagrams in section 2 5 show the location of this selector switch Make electrical connections only to those terminals specified If you connect to other terminals then you may cause damage to the SR44 internal control circuitry Do NOT install power factor correction capacitors on the output side of the SR44 2 1 3 Access IN Caution Always replace the cover on the Soft Starter after gaining access to the electrical connections 2 1 4 Fuse Protection The Main Supply and the Control Supply each require protection Although all units have electronic overload protection for the Soft Starter the installer should always install fuses for motor protection between the Soft Starter and the Main Supply NOT between the Soft Starter and the motor Semiconductor fuses can be supplied as an option for short circuit protection of the semiconductors These fuses must be installed externally to the SR44 chassis to comply with UL standards Chassis size uN 2 has the capability of installing fuses internally by replacing the fuse links in the power circuit It is the responsibility of the installer and system designer specifier to ensure that the required standards or regulatio
241. s Amps seconds etc For example Start Time Stopped amp ready gt Basic gt Start Time would be set at 5 seconds by default but can be set to a maximum of 255 seconds Multiple Data A multiple of an absolute quantity For example the running current displayed by the unit is a multiple of the value of the unit s Rated Current e g 1 0 x Rated Current to 8 0 x Rated Current Note that the unit s Rated Current normally approximates the motor or load Full Load Current Percentile D ata Percentage value of an absolute quantity ranging from 0 10096 For example the Kick Pedestal Stopped amp ready gt Advanced gt Kick Pedestal is the percentage of supply voltage applied to the unit during an optional start up kick Bit Data This represents the selection or non selection turning On or turning O ff of whichever bit parameter is in question SR44 Series Soft Starter User M anual 1stEd RevA 09 2011 Chapter 5 Keypad Menu Items and Parameters 5 1 8 Bit Masks Some parameters can also be addressed via the appropriate Bit Parameter instead of or as well as being accessed via the more commonly used menus These Bit Parameters can only be accessed by the Parameters menu i e the menu path for the Auto Config Bit Parameter would be Stopped amp ready gt Parameters 5 P1 to P20 gt P18 Auto Config The user wou
242. s 2 is a second set of individual bits for user control or system status Other User Flags are parameters 51 53 95 96 amp 121 P96 is a direct 2nd set for P52 Bit 0 Low Voltage Soft Stop Not Global Enable 1 bits 1 amp 2 must both be Off 0 to enable the starter Not Global Enable 2 bits 1 amp 2 must both be Off 0 to enable the starter Pod Start Stop Board Start Stop Main Contactor Second Parameter Set TI Oc Ui A U N HI Zero Start Time 5 58 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 5 Keypad Menu Items and Parameters eee SSS aaa 5 4 11 Parameters Menu continued P 53 User Flags 3 Range 0 to 255 flags Default 51 Scaling 1 Type R W User Flags 3 is a second set of individual bits for user control or system status O ther User Flags are parameters 51 52 95 96 amp 121 e Bit 0 pf1 polarity pf2 polarity User Current Limit UserTrip Invert Controller Input Cooling Inhibit Restart Unused Unused TI HO Ui A W N HI P 54 1 O Polarity Range 0 to 255 flags Default 255 Scaling 1 Type R W I O Polarity sets the I O polarity for output relays K1 amp K2 and input I p1 i e 1 to 1 or 1 to 0 Bit 0 KI Polarity K2 Polarity Unused Unused I p 1 Polarity Unused Unused Unused P 55 reserved P 56 reserved YO Ui A
243. s display of motor phase current and control status Starting Stopping Full Volts O ptimizing Current Limitation O verload and Fault Indication for one soft starter Local Remote switch supplied with SR44 RS485 on the side of each SR44 Soft Starter can quickly swap starter control from remote keypad to integral keypad 4in 102 mm approximate 2 500 in 63 5 mm DU E A A A 4 EE Four Places Tapped mounting holes use 29 drill and 8 32 tap SR44 KPD Remote Keypad Clearance mounting holes use 19 or 0 166 in drill Use RTV sealant if NEMA 4X rating is required i A c1 tn SR44 KPD Remote Keypad Mounting Dimensions i we S co 6 12 YR on indi ma Soh ot be 1 11 16 in diameter hole 5 3 NAN i use 1 25 in conduit knockout u 13 O S E v E 8 BB SG m 3 LY bias LA mag Y 1 250 in 1 250 in lt gt 31 75 mm 31 75 mm 7 4 SR44 Series Soft Starter User M anual 1st Ed RevA 09 2011 Chapter 7 Optional Hardware 7 2 2 Connecting the Remote Keypad Remote Keypad requires installation of an SR44 RS485 communication card 1 The RJ45 cable that is supplied with the remote keypad has two ferrites installed on it to ensure EMC compliance Plug the end with the thinner ferrite into the Communication Card primary RJ45 socket 2 Secure the ferrite to the starter using a
244. s publication are suitable for your particular application nor do we assume any responsibility for your product design installation or operation Our products are not fault tolerant and are not designed manufactured or intended for use or resale as on line control equipment in hazardous environments requiring fail safe performance such as in the operation of nuclear facilities aircraft navigation or communication systems air traffic control direct life support machines or weapons systems in which the failure of the product could lead directly to death personal injury or severe physical or environmental damage High Risk Activities AutomationDirect specifically disclaims any expressed or implied warranty of fitness for High Risk Activities For additional warranty and safety information see the Terms and Conditions section of our catalog If you have any questions concerning the installation or operation of this equipment or if you need additional information please call us at 770 844 4200 This publication is based on information that was available at the time it was printed At AutomationDirect we constantly strive to improve our products and services so we reserve the right to make changes to the products and or publications at any time without notice and without any obligation This publication may also discuss features that may not be available in certain revisions of the product This publication may contain references to produc
245. s shown on the top line of the display 5 Press the ENTER button and the display will flash indicating that default parameters have been loaded The display will then show the selected starting option Remote and the selected protection option Full O ptimise before returning Default Param to the top line of the display 6 Press the button twice to return to Starter Disabled There is no need to save the parameters as they have automatically been saved when the system was resetto default values D Starter Disabled o Applications 1 V To Enable o Auto Features 6 v O i press button multiple times or hold to scroll O o Permanent Store o Password O Power on Param Q 4 press button multiple times or hold to scroll 1 9 Al Default Param e EY lstEd RevA 09 2011 SR44 Series Soft Starter User Manual A 9 Appendix A Setup Examples ll MM BH arvr rrwwwwwwivrvrvrhrrrrxrrrpppp pv vp v p ppa A 1 8 Viewing Basic Operating Parameter Values via the Settings Menu Option 1 With Stopped and Ready shown on the display press the EN TER button 2 With Applications shown on the top line of the display press the EN TER button again 3 With Settings on the top line of the display press the ENTER button and a downwards pointing arrow will appear on the right hand side of the top line While this icon is displayed
246. s used to set or clear a single bit within the Read W rite parameters between 0 through 127 Only the bits within parameters designated as Read W rite can be preset with this function Parameters 18 51 52 53 54 86 95 96 121 amp 127 Example Modbus Function 05 PLC writes Select 2nd Parameter Group to SR44 send a value of 1 to Bit 6 of P 52 Start Slave Bit Number SR44 423 Start M aster Address PLC internal PLC bit address 1 value 1 SR44 PLC Data Value Parameter Bit Address Address Decimal Hex internal PLC bit address 1 P 52 Bit 06 Second Parm Set 423 1 l l SR44 bit addresses have an offset of one address from the parameter bit The PLC needs to target slave bit 423 in order to change bit 422 PLC addresses are any valid user assigned bit addresses Modbus Function 05 Transaction Table Query Response Field Hex Byte Field Hex Byte Slave Address 01 Slave Address 01 Function 05 Function 05 Bit Address 1A7 decimal 423 Bit Address 1A7 bit 4224 bit 06 of P 52 Force Data 01 select 2nd parameter set Force Data 01 select 2nd parameter set CRC Low PLC amp SR44 automatically CRC Low Byte PLC amp SR44 automatically CRC High calculate CRC checksum values CRC High Byte calculate CRC checksum values SR44 has a Modbus offset of one address for registers amp bits PLC targets one add
247. ser supplied current transformer is required if any of the current or power related trip or Monitoring features are needed in bypass mode Parameters 8 B2 9 B1 B2 20 21 22 23 26 JE 28 30 32 33 34 36 39 51 B1 B2 B3 B4 87 89 91 93 112 B0 B1 B2 B3 B6 121 B4 CT must be installed in the L3 T3 power phase OUTSIDE of the bypass circuit See control section 2 5 2 Figure 2 4 1 Power and Contactor Control Circuits for Motor Bypassing L 4 Control Supply N 115VAC or 230VAC set voltage switch acordingly E STOP STOP START Isolation and Protection Switch gear provided by the customer C1 Circuit Contactor Current Transformer optional CT must be installed in L3 phase see control wiring info section 2 5 2 O Control O Voltage Switch 115V 230V C3 Bypass Contactor Electrical Ground OL if not using CT To Current Transformer optional Set the Control Voltage Switch to the proper control voltage setting before applying voltage to the control circuit CT Specifications U ser Supplied 1000 1 ratio class 1 1 accuracy Crompton M 93R 1000 1 Ohio Semitronics CTY 1000C 1 Mitchell Instrument Co 2547ASH 1000 1 or equivalent Induction Motor 2 6 SR44 Series Soft Starter User Manual 1st Ed RevA 09 2011 Chapter 2 Electrical Installation l 2 4 2 Multiple Motor Starting amp Stopping The SR44 is capab
248. stEd RevA 09 2011 Chapter 7 Optional Hardware 7 1 2 Connecting the Communication Card 1 Isolate the SR44 from all electrical power sources 2 Remove the front cover 3 For size 2 soft starters 174A amp higher insert the Local Remote extension cable through the starter and out the plugged hole in the bottom of the unit Then connect the Local Remote switch to the extension cable For size 1 soft starters 146A amp below discard the extension cable Install the Local Remote label and switch cable assembly supplied with SR44 RS485 in the plugged hole in the bottom left corner of the starter O rient the switch so that the white dot faces the Remote side of the label Install the SR44 RS485 communication card onto the J7 26 pin header lower middle of main PCB and then connect the cover keypad cable from the main PCB board to the 4 pin socket on the SR44 RS485 communication card 6 Install the Local Remote cable onto the SR44 RS485 board in the 2 pin socket 7 Set Communication Card jumpers J1 J5 as shown in Network Connections drawing The starter can now communicate via serial communications when the Local Remote switch is placed in Remote This setting disables the integral keypad on the cover of the starter Switching to Local will disable serial communication and enable the integral keypad lt eS ul lt lt One PLC Controlling Multiple SR44 Soft Starters via Serial Protoc
249. t trip A Current Limit Time O ut trip will occur if this menu item is set to On and the load is demanding more current than the level specified in the Current Limit parameter for longer than the time specified in the Limit Time Out parameter If the C L Time Out menu item is set to Off then no trip would occur in a similar situation P51 84 Low Current Range P51 B4 Default Off Scaling n a Type R W Under Current Selected selects Under Current operation P51 B3 Shearpin Range P51 B3 Default On Scaling n a Type R W Shearpin Selected selects Shearpin operation P51 82 Overload Range P51 B2 Default On Scaling n a Type R W Overload Selected selects Overload operation The Overload menu item switches On and Off the Overload Trip Special case If a load current exceeding 7 2 x FLC occurs for longer than 60 ms a Shearpin Trip is forced whenever the Overload is On P127 87 Sensing Signal Range P127 B7 Default On Scaling n a Type R W Hidden Trip Flag 7 enable or disable Trip 7 Sensing Trip Type B The Sensing Signal menu item switches On and Off Trip 7 This may be useful if there is excessive noise on the supply causing spurious Trip 7 Sensing Signal trips P53 B3 User Range P53 B3 Default Off Scaling na Type R W The User menu item
250. t 134 Scaling 1 Type R W User Flags 1 2 Use with 2nd parameter set User Flags 1 2 is a set of individual bits for user control or system status O ther User Flags are parameters 51 52 53 96 amp 121 P95 is a direct 2nd set for P51 e Bit 0 Kickstart selects Kickstart except in 3M C mode 1 Current Limit Timeout Selected selects Trip or Continue on Current Limit Timeout This parameter bit is not available in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass 2 Overload Selected selects O verload operation This parameter bit is not available in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass 3 Shearpin Selected selects Shearpin operation This parameter bit is not available in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass 4 Under Current Selected selects U nder Current operation This parameter bit is not available in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass 5 Thermistor Selected not available 6 unused 7 Terminal Starting Start Stop through onboard terminals P 96 User Flags22 Range O to 255 flags Default 64 Scaling 1 Type R W User Fl
251. t close to optimum 7 Stopping starter is performing a Stop Ramp 5 50 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 5 Keypad Menu Items and Parameters E n 5 4 11 Parameters Menu continued P 9 Status 2 Range 0 to 99 flags Default 0 Scaling 1 Type R Status 2 flags Read this parameter by individual bits Bit 0 Alarm starter has detected a Fault and has tripped 1 Overload Integrating onboard overload has detected O vercurrent and is integrating This parameter bit is not available in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass 2 Stall starter has detected that motor speed is slipping This parameter bit is not available in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass Forced O verride starter has turned off optimizing since the current has risen above 80 FLC Noise starter is experiencing poor mains reference signals Inhibit Start Start is Inhibited for a period to keep the unit within its allowable start duty DC p Level Reached DC I p has risen above the level specified in parameter 48 Yn Ui A W Reserved P 10 Status 3 Range 0 to 255 flags Default 0 Scaling 1 Type R Status 3 flags Rea
252. t Start Time 2 Use with 2nd parameter set Soft Start Time 2 sets the soft start time period over which the unit ramps voltage to the motor Start times are normally in the 5 30s range Long ramp times over 1minute are for special applications only The start without current limit is purely a voltage ramp Lightly loaded motors will normally reach full speed before the end of a long ramp P 12 Start Time is the 1st parameter set counterpart of P 80 Start Time 2 Kick Ped 2 Range 60 to 90 percent Default 7596 Scaling 1 Type R W Kick Pedestal 2 Use with 2nd parameter set Kick Pedestal 2 provides a short kick of voltage at start of ramp to dislodge sticky load P 13 Kick Pedestal is the 1st parameter set counterpart of P 81 Kick Pedestal 2 5 64 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 5 Keypad Menu Items and Parameters E MM n 5 4 11 Parameters Menu continued P 82 Kick Time 2 Range 10 to 40 cycles Default 25 cycles Scaling 1 Type R W Kick Time 2 Use with 2nd parameter set Kick Time 2 sets the number of cycles for which Kick Ped 2 P81 is applied if selected P95 BO P 14 Kick Time is the 1st parameter set counterpart of P 82 Kick Time 2 P 83 Dwell Time 2 Range 1 to 255 seconds Default 5s Scaling 1 Type R W Dwell Time 2 Use with 2nd parameter set Dwell Time 2 provides a period of ti
253. t Starter User Manual 5 67 Chapter 5 Keypad Menu Items and Parameters _ OEOEOOEOEEEEeEeE eE ee 5 4 11 Parameters Menu continued P 93 Ovid Level 2 Range 0 5 to 1 25 x le Default 1 0938 x le Scaling 0 03125 Type R W Start of O verload Level 2 Use with 2nd parameter set Start of O verload Level 2 sets the level at which the on board single phase O verload starts to integrate This O verload does NOT replace an overload for the motor The overload is designed to detect Soft Start overloads This parameter is not available in Bypass O peration unless a user supplied external current transformer is installed Refer to P18 B2 Auto Bypass P 34 Start of O verload Level is the 1st parameter set counterpart of P 93 Start of Overload Level 2 P 94 Ovid Delay 2 Range 10 to 140 Default 140 Scaling 1 Type R W Overload Delay 2 Use with 2nd parameter set Overload Delay sets an arbitrary delay to slow Overload integration down The overload delay mapping is designed primarily for protection of the thyrisors P 35 Overload Delay is the 1st parameter set counterpart of P 94 Overload Delay 2 5 68 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 5 Keypad Menu Items and Parameters ee el 5 4 11 Parameters Menu continued P 95 User Flags12 Range 0 to 255 flags Defaul
254. t the SR44 computes during the start Parameter 21 is the present power factor of the load The keypad display shows each of these parameters in angular degrees The table below can be used to convert this value 0 in degrees to the power factor cos 0 Power Factor Conversion Chart Power Factor 30 0 87 31 0 86 32 0 85 33 0 84 34 0 83 35 0 82 36 0 81 37 0 80 38 0 79 39 0 78 40 0 77 41 0 75 42 0 74 43 0 73 44 0 72 45 0 71 46 0 69 47 0 68 48 0 67 49 0 66 50 0 64 51 0 63 52 0 62 53 0 60 54 0 59 55 0 57 56 0 56 57 0 54 58 0 53 59 0 52 Degrees WO 00 NI ocu B W N H O 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual 3 21 Chapter 3 Applications ll same m 3 22 SR44 Series Soft Starter User Manual lstEd RevA 09 2011 ELECTROMAGNETIC COMPATIBILITY Contents of this Chapter 4 0 Electromagnetic Compatibility EMC 4 2 4 1 Introduction 0 00 cc ees 4 2 4 2 Applicable Standard Within the EU 4 2 4 3 Mandatory Requirements Within the EU 4 2 4 4 Guidance for I
255. tStartPedestalResult Enable N Number of Bits 8 10 2 Shift Right Bit to ShiftIn 0 Don t Include Sign Bit This rung will write to the unit updating P12 SoftStartTime with the latest entry coming from an HMI for example MODBUS WRITE Serial Port CPU 485 In Progress WriteStarterlnProg Slave Node Number 1 Complete WriteStarterComp Automatic Polling 300 50 Success WriteStarterSuccess Don t Skip Execution Error WriteStarterError No Word Swap Timeout WriteStarterTO WriteReadTime Map 32 bit data to 16 bit Exception 11 Enable 4 Slave Modbus Starting Address 13 Response String WriteStarterException Modbus Decimal Addressing Modbus Function Code 6 Write Single Register Tag Name Mapping Non Array Tag SoftStartTime 6 32 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 6 Serial Communications ee TV 12 12 1 13 14 6 7 3 Productivity3000 PLC Example Program continued This rung compares 1 tag SoftStartTimeEntry to another tag OldSoftStartTime This allows the ladder to perform a sequence if the first tag assumed for example purposes to be coming from an HMI but can also be changed from Data View It will Copy the new value to the old value tag and then start the Write Read confirmation sequence When the value read from the soft starter is equal to the new entry the sequence resets SoftStartTimeEntry OldSoftStartTime COPY DATA E
256. te Single Coil Type R Read Only R W Read Write Table continued next page lstEd RevA 09 2011 SR44 Series Soft Starter User Manual 6 5 Chapter 6 Serial Communications rrr 6 4 Parameter Memory Addresses continued Parameter Memory Addresses continued Parameter Bit s T t j Name Function i Reserved Rated Amps 100s Reserved Rated Amps Current Peak Start Low Level Low Time C L Level C L Time Shear Level Shear Time Ovid Level Ovid Delay Overload Reserved UserFlags 5 Reserved unused Reserved Reserved unused unused 39 40039 PF Angle 40 40040 Supply Volts 41 40041 Reserved 42 40042 Reserved 43 40043 Reserved 44 40044 Reserved 45 40045 Reserved 46 40046 Reserved 47 40047 Reserved Modbus addresses apply only to Function 06 Write Single Register or to only the first parameter of Function 03 Read Holding Registers Parameter Bit s apply only to Function 05 Write Single Coil Type R Read Only R W Read Write Table continued next page 6 6 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 6 Serial Communications
257. ted Menu Structure The menu structure of the user interface gives the operators two main routes by which they can change the operation of the SR44 the text based menus or the number based parameter list The M enu Items and Parameters which are most commonly used by operators are shown and described in section 5 2 Keypad M enu Structure Section 5 3 Parameter Basic Information shows basic information for the Parameters and section 5 4 Menu Settings and Parameter D escriptions provides more detailed information on both M enu Items and Parameters 5 4 SR44 Series Soft Starter User Manual lstEd RevA 09 2011 Chapter 5 Keypad Menu Items and Parameters rr a vr rF v V i v rr rj 5 1 3 System Status Mode Following the initial boot up report see section 5 1 9 the unit enters the Status Mode In this mode the operating status of the unit is constantly displayed resulting in a number of status messages Non Running Status Two messages indicate that the unit is not running the load at present Stopped and Ready indicates the unit is enabled and Starter Disabled indicates that the unit is disabled See Appendix A 1 2 Fault number Fault description This message indicates that a fault has occurred giving the fault number and a short fault description such as 1 Phase Loss The second line of the message tells the user to reset the unit with the key Temporary Comms Status Erro
258. tems and Parameters ll r M Jiz 9 89q 8989q n m 5 2 2 Complete Keypad Menu Structure continued Keypad Menu Structure continued Horizontal Keypad Scrolling Enter key right forward key left back Level Parameter Parameter 1 Level 2 Bit Level 3 Bit P1 to P21 P22 to P40 P41 to P60 See the Parameter Descriptions section and table for P61 to P80 parameter descriptions as they appear on the keypad P81 to P100 P101 to P up down Up Arrow key Last Trip 2nd Last Trip 3rd Last Trip 4th Last Trip 5th Last Trip Trip Sensitivity 1 P72 P126 Comms Trip O n O ff P126 Cooling O n O ff P53 B5 Thermistor Trip not available P51 B5 C L Time O ut O n O ff P51 B1 Low Current O n O ff P51 B4 Shearpin O n O ff P51 B3 Overload O n O ff P51 B2 Sensing Signal O n O ff P127 B7 User OK P53 B3 Stopped and Ready 1 or Starter Disabled 1 V to Enable E h 8 3 5 14 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 5 Keypad Menu Items and Parameters Ei 5 3 Parameter Basic Information The parameters are accessed through the Parameters menu in Level 1 of the Keypad Menu Structure For SR44s with optional communcations accessories the parameters can also be accessed t
259. ter for the internal starter input function assigned to drive the P103 internal starter output function Works in conjunction with P102 User Flag mapping through parameters 101 102 103 104 101 102 the source flag address 101 parameter 102 bit mask 103 104 the destination flag address 103 parameter 104 bit mask P 102 U2 1 P Mask Range 0 to 20 bit mask Default 0 Scaling 1 Type R W The ipf2 mask parameter holds the parameter bit for the internal starter input function assigned to drive the P103 internal starter output function Works in conjunction with P101 User Flag mapping through parameters 101 102 103 104 101 102 the source flag address 101 parameter 102 bit mask 103 104 the destination flag address 103 parameter 104 bit mask P 103 U2 O P Dest Range 0 to 125 parameter Default 0 Scaling 1 Type R W The opf2 addr parameter holds the parameter for the internal starter output function assigned to be driven by the P101 internal starter input function Works in conjunction with P104 User Flag mapping through parameters 101 102 103 104 101 102 the source flag address 101 parameter 102 bit mask 103 104 the destination flag address 103 parameter 104 bit mask P 104 U2 O P Mask Range 0 to 11 bit mask Default 0 Scaling 1 Type R W The opf2 mask parameter holds the parameter bit for the internal starter ouput function assigned to be
260. the unit P27 Peak Start Range 0 to 255 Amps Default 0 Scaling n a Type R Peak Start Current displays the peak current seen by the unit during the last start Scaling is per the running current P40 Supply Volts Range 108 to 1000 Volts Default 416V Scaling n a Type R Supply Volts is the manually entered main supply voltage It also works in conjunction with Bit 1 of User Flags 5 for voltages above 500V Real PF Range 0 to 127 5 degrees Default 0 Scaling n a Type R Real Power Factor Angle displays the angle by which the sine curve of the voltage in a circuit leads the sine curve on the current in that circuit calculated by the Soft Starter keypad 5 42 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 5 Keypad Menu Items and Parameters 5 4 6 Monitoring Menu continued U ser supplied current transformer is required if any of the current and power related monitoring features are needed in bypass mode Refer to Electrical Installation Chapter 2 sections 2 4 1 amp 2 5 2 for details P 22 P22 Delay Angle Range 0 to 146 76 degrees Default 146 76 Scaling n a Type R Firing Delay Angle shows the firing delay angle thyristor off time P 23 P23 Max Angle Range 17 27 to 146 76 degrees Default 57 554 Scaling n a Type R Maximum Optimizing Delay Angle shows the maximum allowed Firing Delay Angle during optimizing Th
261. thing is an arbitrary filter to smooth soft stop jitters caused by unstable load This feature is turned ON or OFF by Bit 2 of Parameter 121 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual 5 39 Chapter 5 Keypad Menu Items and Parameters es 5 4 5 Advanced Menu continued P53 B5 Cooling Range P53 B5 Default On Scaling n a Type R W This menu item turns On and Off the Cooling Inhibit Restart function Once this menu item has been turned On and the unit has been started and subsequently stopped the Cooling function inhibits the start command not allowing the unit to start until the time held in Cooling Time has elapsed measured from the last stop signal During this period the unit displays Stopped Cooling This menu item is mainly for use in commissioning soft start units that have large thyristor stacks and its purpose is to avoid damage to the thyristors during the commissioning process P 116 Cooling Time Range 0 to 63 75 minutes Default varies by unit model Scaling n a Type R W This parameter holds the time in seconds that the soft start unit will ignore a start signal if Cooling is turned on see above By default this is set to zero 0 for units of less than 242A For units of 242A and above the default value is 420 seconds 7 mins Changes should be entered in seconds The default value can be
262. tic Jog detection Stop requests within about 0 5 seconds of a Start request are forced to 0 stop time Use this feature for short jogging of light loads For details amp timing chart refer to subsection 5 4 3 Auto Features Menu 4 Auto Endstop enable Detect Stalled Motor during soft stop and turn off thyristors 5 Auto Stop detect variations in PF during stop smooth stall 6 Auto Endstart enable detection of full speed during Start and complete Start ramp 7 Auto Pedestal enable approximate detection of motor rotation at Start and adjust pedestal to suit P 86 Auto Configuration 2 is the 2nd parameter set counterpart of P 18 Auto Configuration P 19 Opt Rate Range 4 to 30 Default 5 Scaling 1 Type R W O ptimize Rate sets the speed at which the SR44 will reduce the voltage during optimizing Some unstable loads benefit from a slower optimizing rate 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual 5 53 Chapter 5 Keypad Menu Items and Parameters OE EEE ww 5 4 11 Parameters Menu continued P 20 Reference PF Range 0 to 146 76 degrees Default 146 762 Scaling 0 57554 Type R Reference PF shows the Power Factor Angle that the SR44 has calculated as the target for the optimizing control loop Refer to Ch 3 6 for PF degrees to ratio conversion e This parameter is not fully functional in Bypass O peration unless a user supplied extern
263. tings 3 2e Ir Rec ead m aC RC 2 15 Chapter 3 Applications eir 3x x xERISTAIRIAG 3 1 3 1 Motor Suitability and Associated Considerations 3 2 3 2 Rules for Specific Applications leere 3 5 3 3 Concepts and Principles of Fixed Speed Induction Motor Starting and CONTON ee seasea P MT 3 8 3 4 Principles of the Optimizing Mode 3 15 3 5 Chapter 3 Glossary of Terms 0a 3 20 3 6 Power Factor Conversion Chart seen 3 21 Table of Contents ll M 7 785P9 P r rP rkk Rrr Pr rpFpFpP B vv _ _ RENE RR Chapter 4 Electromagnetic Compatibility 4 1 4 0 Electromagnetic Compatibility EMC sese 4 2 4 1 Introduction AA AA 4 2 4 2 Applicable Standard Within the EU 20 0a 4 2 4 3 Mandatory Requirements Within the EU 00s 4 2 4 4 Guidance for Installation Personne and System Designers 4 2 4 5 EMC Base Criteria 4 ici mm rix dcin e dicm a 4 3 4 6 Purchasing Implications of Meeting an EMC Standard 4 3 4 7 Basic EMC Considerations eee 4 4 Chapter 5 Keypad Menu Items and Parameters 5 1 5 0 How to Use This Chapter co cur aux Ew x RE eR ER ne e 5 2 5 1 Configuring the SR44 Soft Starter 5 3 5 2 Keypad Menu Stricture 2iceu
264. tion 05 Write Single Coil This function is used to set or clear a single bit within the Read W rite parameters between 0 through 127 Only the bits within parameters designated as Read W rite can be preset with this function Parameters 18 51 52 53 54 86 95 96 121 amp 127 Function 03 Read Holding Registers This function reads 8 bit bytes back to the PLC If more than one byte is requested from the SR44 the PLC program will have to separate 16 bit M odbus words into the 8 bit SR44 bytes SR44 Status Bits U ser Flags are read as holding registers i e read register 9 to read Status2 bits For status bit writes bits are mapped one to one e g the Kickstart flag bit O of U ser Flags 1 P51 is bit no 51 8 0 bit 408 Refer to the Specifications section of this chapter for supported M odbus function codes a N Co 6 3 Specifications 1 Refer to Modicon Modbus Protocol Reference Guide PI M BU 5 300 at www modbus org for full protocol specification 2 Baud rate is 9600 3 8 data bits no parity 1 stop default or 8 data bits no parity two stop bits 4 Modbus timeout is 3 5 character times The in message timeout is also 3 5 character times unlike the standard which is 1 5 character times Further it is possible that the SR44 will be delayed in responding to a request if it is checking a fault condition Broadcast is not supported SR44 parameters retain their normal numbers 0 127 Status
265. tion 2 Start Ped 2 Start Time 2 Kick Ped 2 Kick Time 2 D well Time 2 Stop ped 2 Stop Time 2 AutoConfig 2 Auto Ramp Auto 3MC Auto Bypass Auto Jog Auto Endstop Auto Stop Auto Endstart Auto Pedestal 87 40087 Low 12 R W 88 40088 Low time 2 RW 89 40089 C L 2 R W 90 40090 C L Time 2 R W 91 40091 Shearpin 2 RW 92 40092 Shear time 2 RW 93 40093 O vld Level 2 RW 94 40094 O vld Delay 2 R W Modbus addresses apply only to Function 06 Write Single Register or to only the first parameter of Function 03 Read Holding Registers Parameter Bit s apply only to Function 05 Write Single Coil Type R Read Only R W Read Write Table continued next page 1st Ed RevA 09 2011 SR44 Series Soft Starter User Manual 6 9 Chapter 6 Serial Communications ll rx 5 5 5 5 5 5 A r rqw2rs 85 6 4 Parameter Memory Addresses continued Parameter Memory Addresses continued Parameter Bit s ig x Name Function 3 i U ser Flags12 Kickstart 2 761 Current Limit Timeout Sel d 2 762 Overload Selected 2 763 Shearpin Selected 2 Under Current Selected 2 765 Thermistor Selected 2 Unused 767 Terminal Starting 2 User Flags22 768 Lo
266. tionDirect com Technical Support is provided as is without a guarantee of any kind These documents are provided by our Technical Support Department to assist others We do not guarantee that the data is suitable for your application nor do we assume any responsibility for them in your application This program is for illustrational purposes only and is not intended for a true application Task StatusBits This rung breaks down the tag StarterStatusWord16 retrieved from the Soft Start Parameters 8 amp 9 We use the Unpack Bits instruction which converts the 16 bit tag into 16 separate Boolean tags These Bool tags can be monitored or used in the program for status alerts alarms etc UNPACK BITS Input StarterStatusWord16 Bit Number Output Stopped Starting CurrentLimit TopOfRamp Dwell FullConduction Enable EnergySaving Stopping Alarm Overloadlntegrating Stall ForcedOverride Noise InhibitStart DC IP reached 4 20maLevelReached END Task Comms This rung monitors our Comm InProgress attempts to the SoftStarter The 2 inputs are the Bool tags that are assigned in the MRX and MWX instructions It has a preset of 9999 and will reset itself These 2 counters give us an easy way to monitor comms to verify attempts and the occurence of errors If both counters are counting up in synch then there are problems which could be in addressing wiring or the slave itself
267. tivity of some of the fault trips The larger the number the slower the trip P 126 P126 Comms Trip Range 0 to 255 Default 0 Scaling n a Type R W Bus Action on Fail Action following a bus failure Active only with certain Comms Options 0 No Trip 1 Trip P53 85 Cooling Range P53 B5 Default On Scaling n a Type R W This menu item turns On and Off the Cooling function Once this menu item has been turned On and the unit has been started and subsequently stopped the Cooling function inhibits the start command not allowing the unit to start until the time held in Cooling Time has elapsed measured from the last stop signal During this period the unit displays Stopped Cooling This menu item is mainly for use in commissioning soft start units that have large thyristor stacks and its purpose is to avoid damage to the thyristors during the commissioning process 0 No Trip 1 Trip P51 55 Thermistor Trip reserved Range P51 B5 Default Off Scaling n a Type R W Thermistor Selected not available 1st Ed RevA 09 2011 SR44 Series Soft Starter User Manual 5 77 Chapter 5 Keypad Menu Items and Parameters rr 5 4 12 Trips Menu continued P51 B1 C L Time Out Range P51 B1 Default On Scaling n a Type R W The C L Time Out menu item turns On and Off the Current Limit Time Ou
268. to Stop O n O ff P18 B5 Auto End Stop O n O ff P18 B4 Auto Bypass O n O ff P18 B2 Auto 3MC On Off P18 B1 Auto Ramp O n O ff P18 BO Auto All O n O ff P122 Stop Smoothing On Off P121 B2 Table continued next page Stopped and Ready 1 or Starter Disabled 1 V to Enable E 3 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual 5 9 Chapter 5 Keypad Menu Items and Parameters lll J E RUM o p r 5 2 2 Complete Keypad Menu Structure continued Keypad Menu Structure continued Horizontal Keypad Scrolling Enter key right forward key left back up Level Level 0 1 Level 2 Parameter Bit 4 Parameter Fever a Bit Disable Starter Enable Starter P52 B1 amp B2 Starting Keypad Remote P51 B7 Start Pedestal 20 P11 Start Time 5s P12 down Up Arrow key Stop Pedestal 1096 P16 Stop Time 0s P17 Current Limit 3 5xlg P30 i 3 Stopped and Ready 1 or Starter Disabled 1 V to Enable Down Arrow key Protection Full P7 B6 Full Optimise P7 B6 amp B7 Start Bypass P7 B7 Phase Loss O nly P7 BO Table continued next page 5 10 SR44 Series Soft Starter User Manual 1st Ed Rev A 09 2011 Chapter 5 Keypad Menu
269. ts produced and or offered by other companies The product and company names may be trademarked and are the sole property of their respective owners AutomationDirect disclaims any proprietary interest in the marks and names of others Copyright 2011 Automationdirect com Incorporated All Rights Reserved No part of this manual shall be copied reproduced or transmitted in any way without the prior written consent of Automationdirect com Incorporated AutomationDirect retains the exclusive rights to all information included in this document 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual W 1 M MVERTISSEMENT Nous vous remercions d avoir achet l quipement d automatisation de Automationdirect com en faisant des affaires comme AutomationDirect Nous tenons ce que votre nouvel quipement d automatisation fonctionne en toute s curit Toute personne qui installe ou utilise cet quipement doit lire la pr sente publication et toutes les autres publications pertinentes avant de l installer ou de l utiliser Afin de r duire au minimum le risque d ventuels probl mes de s curit vous devez respecter tous les codes locaux et nationaux applicables r gissant l installation et le fonctionnement de votre quipement Ces codes diff rent d une r gion l autre et habituellement voluent au fil du temps Il vous incombe de d terminer les codes respecter et de vous assurer que l quipement l installation et le f
270. tted arrow in this position i e pointing downwards means that the diagram continues on the following page A 2 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Appendix A Setup Examples A 1 1 How to Read the Setup Examples continued Press the button to cancel the instruction or the Enter button to confirm it 9 NA l li Map From Map From gt Map From sim O e O Ta Press the Up Button multiple times or scroll until you reach the next QO menu item as shown 8 Parameter Theseicons representthe buttons on the Keypad ana aa remote keypad Refer to Adotted arrowin this position i e pointing sectio horizontally means that the diagram is continuing from another page and that this is the start point for this page 0 om n Number TEE Number mmo KON Number La Bit PA 9 P Number n TEE Mask 00001001 Mask 00001001 Mask 00000001 Mask e ecce The screen on the left is t displayed before instruction ex Es 13has been started and the Bit Number screen on the right after it When the circled number in this position has been completed TY itis associated with the lower button icon the button in this case This graphic represents the screen flashing which it will do to confirm thatan instruction or a change in value has been accepted 1st Ed RevA 09 2011 SR44 Series Soft Starter User M anual A 3 Appendix A Setup Example
271. uirrel cage induction motor operating with a soft starter in energy optimizing mode is shown in the following figure Figure 3 4 5 1 for the same duty cycle as Figure 3 4 1 2 By reducing the voltage when torque demand is below maximum the magnetizing current is proportioned to the torque current Compare Figure 3 4 5 1 energy optimizing with Figure 3 4 1 2 non optimizing These graphical representations are illustrative only and not to scale Arriving at any exact figure for the energy cost saved requires each individual case to be examined in detail taking into account the motor rating type and any special characteristics such as load load characteristics duty cycle supply voltage and the cost of electricity Figure 3 4 5 1 Energy Savings Current demand with Energy Saving in operation 7 Magnetizing current L Torque current 0 40 60 seconds The calculations to cover all the likely or possible conditions would be laborious An empirical method for arriving at a usefully realistic estimate has been devised Used with a proper sense of engineering circumspection the tables in Section 3 4 6 allow a user to gain a reasonably close estimate of the savings to be achieved within the motor by using the SR44 optimizing Soft Starter The method does not include any additional savings and benefits conferred by other sources such as reduction of heating losses in cabling because of the lower voltages potential reduction
272. uts and outputs are compatible with PLC I O as shown in the following tables CLICK PLC I O Compatible with SR44 Soft Starters CLICK PLCs Compatible with SR44 Soft Starters PLC 8 AC IN 6 RELAY OUT MICRO PLC REQUIRES 24VDC POWER PLC 8 DC IN 6 SINKING DC OUT MICRO PLC REQUIRES 24VDC POWER PLC 8 DC IN 6 SOURCING DC OUT MICRO PLC REQUIRES 24VDC POWER PLC 8 DC IN 6 RELAY OUT MICRO PLC REQUIRES 24VDC POWER MICRO ANLG PLC 4 DC IN 4 SINK OUT 2 CH IN 2 CH OUT REQUIRES 24VDC PWR MICRO ANLG PLC 4 DC IN 4 SOURCE OUT 2 CH IN 2 CH OUT REQUIRES 24VDC PWR MICRO ANLG PLC 4 DC IN 4 RELAY OUT 2 CH IN 2 CH OUT REQUIRES 24VDC PWR CLICK AC I O amp Relay Outputs 4PT 6 240VAC 6 27VDC ISO LATED RELAY OUTPUT SPDT 7A PER POINT 8PT 17 240VAC OUTPUT MODULE 0 3AMPS PER POINT 8PT 6 240VAC 6 27VDC RELAY OUTPUT 1A 2 ISOLATED COMMONS 8PT 12 24VDC OUTPUT MODULE SINKING OUTPUTS 8PT 12 24VDC OUTPUT MODULE SOURCING OUTPUTS C0 16TD1 16PT 12 24VDC OUTPUT MODULE SINKING OUTPUTS C0 16TD2 16PT 12 24VDC OUTPUT MODULE SOURCING OUTPUTS D 2 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Appendix D Using AutomationDirect PLCs with SR44 Soft Starters Eee i DLO5 DLO6 PLC I O Compatible with SR44 Soft Starters DLO5 PLCs DLO5 DLO6 PLCs Compatible with SR44 Soft Starters DO 05AA 8 AC IN 6AC OUT MICRO PLC W AC P S D0 05AD 8 AC IN 6 DC OUT MICRO PLC W AC P S
273. voltage No 4 Subject Slip Ring Motors 2 Slip rings may be shorted at partial voltage by forcing a user current limit at start and then using the current limit timeout flag to control K2 and hence the shorting contactor No 5 Subject Commissioning 1 Itis a good idea to start by using one of the standard applications Refer to Applications Menu Settings in Ch 5 No 6 Subject Sizing Starters Starters may need to be de rated for high start frequency current ambient temperature altitude or long starts No 7 Subject Contactors Contactors marked for example K1 on wiring diagrams are not included within the Soft Starters No 8 Subject Soft Starts Soft Starters reduce motor starting current at the expense of reducing starting torque and increasing start time No 9 Subject Start Time with Auto Ramp When Auto Ramp is selected the ramp time is an arbitrary number with 1 being fastest up to 255 the slowest The unit will be accelerated to full speed by the microprocessor with a varying ramp profile while trying to keep the start current to a minimum C 2 SR44 Series Soft Starter User M anual 1stEd RevA 09 2011 Appendix C Technical Hints a Technical Hints continued Category Troubleshooting Subject Reset Trip Trips can be reset by pressing the key on the keypad or by changing the Start Stop I p to Start if control is set to remote N
274. w Voltage Soft Stop 2 769 Not Global Enable 1 2 Not Global Enable 2 2 771 Pod Start Stop 2 772 Board Start Stop 2 773 Main Contactor 2 Second Parm Set 2 775 Zero Start Time 2 40097 U1 I P srce 40098 U1 1 P Mask 99 40099 U1 O P Dest 100 40100 U1 O P Mask 101 40101 U2 I P srce 102 40102 U2 I P Mask 103 40103 U2 O P Dest 104 40104 U2 O P Mask 105 40105 Reserved 106 40106 Reserved 107 40107 Reserved 108 40108 Reserved Modbus addresses apply only to Function 06 Write Single Register or to only the first parameter of Function 03 Read Holding Registers Parameter Bit s apply only to Function 05 Write Single Coil Type R Read Only R W Read Write Table continued next page 6 10 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 6 Serial Communications m 6 4 Parameter Memory Addresses continued Parameter M emory Addresses continued Parameter Bit s T j Name Function n a Bypass Lower Limit Bypass U pper Limit Reserved Status 4 60 Hz Phase Rotation Sequence Shearpin Under Current Thermistor Timeout O verload Thermal Switch Reserved StopProfile Last App CoolingTi
275. wer supply by a single contactor Very widely applied the method is known variously as direct on line across the line direct etc and is the usual form of control where low cost is the first and most important consideration As a result it is most often used on small motor sizes up to approx 22 kW 30 hp or where the supply is strong enough to withstand the inrush and starting current surges without causing unacceptable voltage drops The harsh damaging effects described earlier are all imposed by direct on line starting and as a control method it is the most destructive of equipment Its simplicity and apparent low cost although attractive at first sight hide large cost penalties in the shape of increased maintenance reduced transmission equipment life and higher risk of motor failure particularly when frequent starting and stopping is needed In larger sized motors special strengthening is necessary at higher cost before they can be safely used with direct on line starting However the shortcomings of the direct on line starter have been recognized ever since motors have been used and alternative systems have been developed over the years to reduce the damaging effects of this form of control Method B Wye D elta and other Reduced Voltage Starting Systems Reduced voltage starting makes use of the fact that motor torque is proportional to the square of the terminal voltage The most familiar type of reduced
276. will be suitable if the figures comply with the criteria given in the bottom row of Table 3 1 3 Table 3 1 3 Number of Poles Synchronous Speed rpm 9 60 Hz loadY motor less than Section 3 2 13 contains a table showing the more common applications 3 2 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 3 Applications MM 3 1 4 Maximum Motor Cable Length The length of the cable between the output terminals of the starter and the motor should not normally be greater than 100 meters 328 ft 3 1 5 Power Factor Correction Capacitors Power factor correction capacitors applied to a single motor must ALWAYS be connected by a separate contactor placed on the SU PPLY side of the SR44 Soft Starter Capacitors should be switched into the circuit after top of ramp full line voltage is reached and switched out of the circuit before a stop is initiated It is important that any total system PFC scheme that automatically corrects for a range of inductive loads is not operated in such a way as to leave it heavily over compensated since this might introduce oscillations leading to damaging over voltages 3 1 6 Lightly Loaded Small Motors Lightly loaded small sized less than 2kW 2 7 hp star connected motors can produce high voltages at the motor terminals when shut down by simply opening the line contactor As these voltages can damage the soft starter it is safer to control the openin
277. witch gear The safe termination of cabling and or bus bars Means to effect proper air flow through the enclosure 1 3 Ventilation The installer must ensure that the enclosure can maintain the operating temperature below 40 9C 104 F or with derating 60 9C 140 9F To ensure that the unit operates within a suitable temperature range periodically measure the internal temperature of the enclosure If you situate the unit above equipment that generates a significant amount of heat reduce the unit full load rating 1 4 Storage and Derating Above 40 C 1049F derate linearly by 2 of unit FLC C to maximum of 40 at 60 C 1409F Temperature Minimum Maximum Storage continuous 25 9C 13 9F 460 C 140 F Storage not exceeding 24 hours 25 13 9F 75 C 167 F Operating without derating 0 9C 32 F 440 9C 104 9F Operating with maximum derating 0 9C 32 9F 460 C 140 F Above 40 C 1049F derate linearly by 2 of unit FLC 2C to maximum of 40 at 60 C 1409F Unit FLC Soft Starter rated Full Load Current NOT motor Full Load Current Humidity Max 85 non condensing not exceeding 50 at 40 C 104 F 1 5 Altitude Condition Maximum Height Above Sea Level Operating without derating 1000m 3281 ft Operating with maximum derating 2000m 6562 ft Derating Above 1000m 3281 ft derate linearly by 1 Unit FLC per 100m to a maximum of 20
278. y the American National Electrical Code and are where possible normal motor sizes 2 9 1 Chassis Size 1 Motor Power Ratings SR44 Chassis Size 1 Motor Power Ratings Model Current 208 Volts 230 Volts 400 Volts 460 Volts Amps kw HP kw HP kw HP kw HP SR44 9 9 1 5 2 2 2 3 4 5 4 5 SR44 16 16 2 2 3 3 7 5 7 5 10 7 5 10 SR44 23 23 3 75 5 6 3 1 5 11 15 11 15 SR44 30 30 5 5 7 5 7 5 10 15 20 15 20 SR44 44 44 7 5 10 11 15 22 30 22 30 SR44 59 59 11 15 16 20 30 40 32 40 SR44 72 72 15 20 20 25 37 50 40 50 SR44 85 85 25 22 30 45 60 45 60 SR44 105 105 22 30 30 40 55 75 55 75 SR44 146 146 37 50 45 60 75 100 80 100 208V applications are UL listed only as low as 196V 2 9 2 Chassis Size 2 Motor Power Ratings SR44 Chassis Size 2 Motor Power Ratings 208 Volts 230 Volts 400 Volts 460 Volts kW HP kW HP kW HP kW HP SR44 174 174 45 60 55 75 90 100 110 150 Model SR44 202 202 45 60 63 75 110 150 132 175 SR44 242 242 55 75 75 100 132 175 150 200 SR44 300 300 75 100 90 100 160 200 185 250 SR44 370 370 90 125 110 150 200 250 220 300 208V applications are UL listed only as low as 196V 2 14 SR44 Series Soft Starter User Manual 1stEd RevA 09 2011 Chapter 2 Electrical Installation 2 10 Fuse and Current Ratings 2 10 1 Full Load Current Limit and Short Circuit Protection SR44 Fuse and Current Ratin
279. y the nature of the low voltage power distribution network The determining factor is whether the source of power is either a a private supply with a single consumer whose Point of Common Coupling PCC is ata high or medium voltage transformer or b a public low voltage network with more than one consumer where the individual PCC is made directly to the network itself The first type of supply a is identified as Industrial and requires the use of soft starters compliant with EN 60947 4 2 Table 14 Equipment Class A Emission Levels The second type of supply b is identified as Residential and requires the use of Equipment Class B Apparatus SR44 Soft Starters are able to comply with either classification provided the appropriate action is taken Section 4 7 7 describes the strategies for attaining and maintaining compliance 4 7 6 Important Systems Information The specification limits for both equipment classes assume systems are grounded at the star wye point of the supply transformer through low impedance connections Certain industries particularly continuous process industries employ distribution systems that operate either with a ground connection through a high impedance or without a ground at all These systems may cause severe problems of operator safety when installed with capacitive high frequency filters Such systems are not considered in this document In the case of an isolated or high impedance groun
280. y torque it may be necessary to replace the installed motor with another of a larger size or one with a high starting torque characteristic before a soft starter can be employed 3 2 10 Two speed Motor Applications Two speed motors whether Dahlander connected or with dual windings can be soft started at each speed provided that the start is initiated when the actual motor speed is less than the synchronous speed for the winding selected This is particularly important when changing from high to low speeds The SR44 has a dual setting feature which allows different operating settings for the high and low speeds and the ability to switch rapidly between them 3 2 11 Multiple Motor Starting See section 2 4 2 of the Electrical Installation chapter for details 3 2 12 Overhauling Loads Certain applications can overspeed the motor as part of normal operation Power then flows from the motor to the power supply It is important to disable Optimizing Mode during over speed conditions and reinstate O ptimizing during normal conditions External control is required to disable and reinstate O ptimizing M ode 3 2 13 Application Table The table on the following page shows many common motor applications that suit the SR44 Soft Starter It lists typical breakaway torque requirements as a percentage of motor full load torque FLT For the most satisfactory soft starter in a given application the motor should have a full voltage locked r
281. ype Start Pedestal Start Time s Current Limit Level x FLC O ptimize Rate Auto End Start Soft Stop Smoothing N otes Application Type Start Pedestal Start Time s Current Limit Level x FLC Optimize Rate Auto End Start Soft Stop Smoothing Notes Application Type Start Pedestal 96 Start Time s Current Limit Level x FLC O ptimize Rate Auto End Start Soft Stop Smoothing N otes 09 2011 Conveyor 10 Stop Pedestal 96 10 Soft Stop Time s Current Limit Time s Auto 3MC Low Voltage Soft Stop Low Inertia Fan 30 Stop Pedestal 96 15 Soft Stop Time s Current Limit Time s Auto 3MC Low Voltage Soft Stop High Inertia Fan 40 Stop Pedestal 96 3 Soft Stop Time s 2 8125 Current LimitTime s MI Auto 3MC VI Low Voltage Soft Stop Reciprocating Compressor Stop Pedestal Soft Stop Time s Current Limit Time s Auto 3MC Low Voltage Soft Stop SR44 Series Soft Starter User Manual 0 7 30 Ira Ira Appendix B Applications Data Auto Pedestal MI Auto Bypass M Auto Ramp O Auto Pedestal Auto Bypass MI Auto Ramp O Auto Pedestal m Auto Bypass M Auto Ramp O Auto Pedestal VI Auto Bypass M Auto Ramp O T Auto Jog O Auto Stop M Auto End Stop M Auto Jog O Auto Stop O Auto End Stop O Auto Jog O Auto Stop O Auto End Stop O Auto Jog O Auto Stop O Auto End Stop O B 3 Appendix B Applications Data res SR44 Applications Data conti

stellar™ sr44 soft starter user manual

Contents

Download Pdf Manuals

Related Search

Related Contents

stellar&trade; sr44 soft starter user manual

Contents

Download Pdf Manuals

Related Search

Related Contents

stellar™ sr44 soft starter user manual