MN03901003E Installation Directions
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2014-10-17
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S611 Soft Starter Quick Start Installation Guide Effective January 2012 Supersedes June 2011 S611 Soft Starter Disclaimer of Warranties and Limitation of Liability The information, recommendations, descriptions and safety notations in this document are based on Eaton Corporation’s (“Eaton”) experience and judgment and may not cover all contingencies. If further information is required, an Eaton sales office should be consulted. Sale of the product shown in this literature is subject to the terms and conditions outlined in appropriate Eaton selling policies or other contractual agreement between Eaton and the purchaser. THERE ARE NO UNDERSTANDINGS, AGREEMENTS, WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OTHER THAN THOSE SPECIFICALLY SET OUT IN ANY EXISTING CONTRACT BETWEEN THE PARTIES. ANY SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF EATON. THE CONTENTS OF THIS DOCUMENT SHALL NOT BECOME PART OF OR MODIFY ANY CONTRACT BETWEEN THE PARTIES. In no event will Eaton be responsible to the purchaser or user in contract, in tort (including negligence), strict liability or otherwise for any special, indirect, incidental or consequential damage or loss whatsoever, including but not limited to damage or loss of use of equipment, plant or power system, cost of capital, loss of power, additional expenses in the use of existing power facilities, or claims against the purchaser or user by its customers resulting from the use of the information, recommendations and descriptions contained herein. The information contained in this manual is subject to change without notice. Cover Photo: S611 Soft Starter S611 Soft Starter MN03901003E—January 2012 www.eaton.com i S611 Soft Starter Support Services The goal of Eaton is to ensure your greatest possible satisfaction with the operation of our products. We are dedicated to providing fast, friendly, and accurate assistance. That is why we offer you so many ways to get the support you need. Whether it’s by phone, fax, or e-mail, you can access Eaton’s support information 24 hours a day, seven days a week. Our wide range of services is listed below. You should contact your local distributor for product pricing, availability, ordering, expediting, and repairs. Web Site Use the Eaton web site to find product information. You can also find information on local distributors or Eaton’s sales offices. Web Site Address www.eaton.com/electrical EatonCare Customer Support Center Call the EatonCare Support Center if you need assistance with placing an order, stock availability or proof of shipment, expediting an existing order, emergency shipments, product price information, returns other than warranty returns, and information on local distributors or sales offices. Voice: 877-ETN-CARE (386-2273) (8:00 a.m.–6:00 p.m. EST) FAX: 800-752-8602 After-Hours Emergency: 800-543-7038 (6:00 p.m.–8:00 a.m. EST) If you are in the U.S. or Canada, and have OI or PLC questions, you can take advantage of our toll-free line for technical assistance with hardware and software product selection, system design and installation, and system debugging and diagnostics. Technical support engineers are available for calls during regular business hours. Technical Resource Center Voice: 877-ETN-CARE (386-2273) (8:00 a.m.–5:00 p.m. EST) FAX: 828-651-0549 e-mail: TRC@Eaton.com European PanelMate Support Center This engineering company, located in Zurich, Switzerland, provides high-level quality support and repair assistance for your PanelMate products. You will receive technical and application support. For Customers in Europe, contact: BFA Solutions, Ltd. Voice: +41 1 806.64.44 (9:00 a.m.–5:00 p.m. CET) e-mail: gk@bfa.ch www.bfa.ch Repair and Upgrade Service Additional support is also available from our well-equipped Repair and Upgrade Service department. If you have questions regarding the repair or upgrade of an OI product, contact your local distributor. Repair and Upgrade Service (support for OI) Voice: 877-ETN-CARE (877-386-2273) (8:00 a.m.–5:00 p.m. EST) 414-449-7100 (8:00 a.m.–5:00 p.m. EST) FAX: 614-882-3414 e-mail: TRC@eaton.com ii S611 Soft Starter MN03901003E—January 2012 www.eaton.com Installation Installation For detailed information please refer to the User Manual (publication no. MN03902011E) at www.eaton.com/ softstarters. Power Wiring Diagram 1 L1 3 L2 5 L3 Mounting Required mounting hardware is Grade 5, 3/8-16, quantity four minimum (two upper and two lower). S611 Unit Weight Frame Size Weight of Unit Lbs (kg) A 24 (11) B 24 (11) C 33 (15) D 38 (17) E 86 (39) F 102 (46) 2 T1 4 T2 6 T3 M 3 ˜ Lug Bolt Torque Support Power Wiring WARNING Hazardous voltage can cause electric shock and burns. To avoid shock hazard, disconnect all power to the controller, motor or other control devices before any work is performed on this equipment. Failure to do so will result in personal injury, death or substantial property damage. Do not apply a disconnect device on the output of the S611 soft starter unless a means to turn off the soft starter when disconnect switch is open is used. Opening disconnect while the soft starter is operating may cause a malfunction. Closing disconnect switch while the soft starter is operating will result in a soft starter failure and potential equipment damage and personnel hazard. Note: Short circuit protection must be applied on the line side of the soft starter. Do not attempt to lift the soft starter by the cover only. Lug Installation Install the lugs below the bus bar to assure anti-rotation. Refer to figure “Lug and Bolt Torque Support” on this page. Note: When securing the lugs onto the bus bars of the soft starters, use a suitable tool such as another wrench to counteract the bolt torque and prevent excessive side loads being placed on the supports. Refer to figure “Lug and Bolt Torque Support” above. Remove the tie wraps for CTs on Frames C, D, E, and F. Move each CT to the load cables during assembly as shown in the figure “CT Location” on Page 2. Each CT should be properly supported with tie wraps ensuring that the CT is not supported by the leads. Properly secure CT leads. When securing the Current Transformers (CTs) onto the T1, T2, and T3 bus bars of the soft starter, correct orientation of the CT must be observed to ensure proper operation of the soft starter. Each CT is marked with a symbol “IX” adjacent to the leads. This symbol shown in the figure “CT Polarity Identification” on Page 2 indicates the line side (or voltage source side) of the device. S611 Soft Starter MN03901003E—January 2012 www.eaton.com 1 Installation CT Polarity Identification CT Location Line and Load Power Wiring Current Rating Conductor Size Number of Conductors Mechanical Lug— Ilsco Part Number Torque lb-in Mechanical Lug Range Soft Starter Catalog Number Mechanical Lug— Eaton Catalog Number 52A 6 AWG 1 TA-2/0 120 14 AWG–2/0 S611A052XXX S611-LUG-MO1 65A 4 AWG 1 TA-2/0 120 14 AWG–2/0 S611A065XXX S611-LUG-MO1 77A 3 AWG 1 TA-2/0 120 14 AWG–2/0 S611A072XXX S611-LUG-MO1 99A 1/0 AWG 1 TA-300 275 14 AWG–2/0 S611B099XXX S611-LUG-MO2 125A 2/0 AWG 1 TA-300 275 2 AWG–600 kcmil S611B125XXX S611-LUG-MO2 156A 3/0 AWG 1 TA-600 500 2 AWG–600 kcmil S611C156XXX S611-LUG-MO3 180A 4/0 AWG 1 TA-600 500 2 AWG–600 kcmil S611C180XXX S611-LUG-MO3 242A 350 kcmil 1 TA-600 500 2 AWG–600 kcmil S611D242XXX S611-LUG-MO3 302A 3/0 AWG 2 AU-600-2NS 500 2 AWG–600 kcmil S611E302XXX S611-LUG-MO4 361A 4/0 AWG 2 AU-600-2NS 500 2 AWG–600 kcmil S611E361XXX S611-LUG-MO4 414A 300 kcmil 2 AU-600-2NS 500 300–800 kcmil S611F414XXX S611-LUG-MO4 Notes Additional lug selection may be found in Appendix D of the User Manual, Publication No. MN03902011E. Each lug kit consists of three lugs. Two kits are required for both line and load connections. Wire size based on 125% of UL 508 Table 43.2. Short-Circuit Rating Suitable for use on a circuit capable of delivering not more than 100,000 rms symmetrical amperes, 600 volts maximum when protected by Class RK5 fuses or a circuit breaker having an interrupting rating not less than 65,000 rms symmetrical amperes, 480 volts maximum. 2 S611 Soft Starter MN03901003E—January 2012 www.eaton.com Installation Mounting Hole Dimensions Approximate Dimensions in mm [Inches] Frames A through D 70.0 [2.76] Frames E and F 127,0 [5.00] 127,0 [5.00] 70.0 [2.76] 155.0 [6.10] 110.0 [4.33] 464.7 [18.30] 80.0 [3.15] 90.0 [3.54] 80.0 [3.15] 562.0 [22.13] Ø 10.0 [0.39] 127,0 [5.00] 127,0 [5.00] Ø 10.0 [0.39] 155.0 [6.10] S611 Soft Starter MN03901003E—January 2012 www.eaton.com 3 Installation Typical Control Wiring Diagrams For a single conductor, a minimum wire of 14 AWG (2.5 mm2) should be used between the control power transformer and the supply terminals. Basic Connection Diagram for 120 Vac Three-Wire Pushbutton Basic Connection Diagram for 120 Vac Two-Wire Pushbutton E-Stop E-Stop Reset Reset Start Maintained Stop Momentary Momentary D1 Common +24V D0 Comms Port B D1 Common TB5 (Connector) User Interface Module Number of Conductors Torque Requirements Run Enable 22–16 AWG (0.33–2.5 mm2) 2 3.5 lb-in (0.4 Nm) Network 14–12 AWG (4.0 mm2) 1 3.5 lb-in (0.4 Nm) Momentary Relay 2 Relay 1 TB2 Relays TB1 120 Vac Supply N–Network L–Network N–Permissive L–Permissive N–Startl L–Start N–Reset L–Reset Ground N–Tap Neutral L–Tap Line 98 97 96 13 14 TB3 120 Vac Control +24V D0 D1 Common TB4 Comms Port A TB5 (Module) TB4 Comms Port B TB5 (Connector) User Interface Module 4 N–Network L–Network N–Permissive L–Permissive N–Start L–Start N–Reset L–Reset Terminal Block Wiring Capacity Wire Size Maintained Comms Modbus Comms Port B TB5 (Connector) Reset E-Stop DeviceNet Modbus PROFIBUS TB3 120 Vac Control User Interface Module Basic Connection Diagram for 120 Vac Network Control Comms Adapter Relay 1 TB1 120 Vac Supply TB3 120 Vac Control TB4 Comms Port A +24V D0 Relay 2 TB2 Relays TB4 Comms Port A TB1 120 Vac Supply Ground N–Tap Neutral L–Tap Line Relay 1 TB2 Relays 98 97 96 13 14 N–Network L–Network N–Permissive L–Permissive N–Start L–Start N–Reset L–Reset Ground N–Tap Neutral L–Tap Line 98 97 96 13 14 Relay 2 Maintained Start/Run S611 Soft Starter MN03901003E—January 2012 www.eaton.com User Interface User Interface User Interface Module (UI) Mode LEDs Unit LEDs Phase LEDs Protection/ Operation LEDs ● ● ● ● Mode/Cancel ● Navigate the Protection, Operation, and Monitor modes ● Exits parameter editing mode without saving value Up/Down Arrow ● Navigate Protection/Operation LED list ● Navigates through display parameter list in Monitor mode Edit/Save ● Selects/Saves parameter values in Protection/Operation modes ● Selects Advanced Config. Menu parameters ● Selects/Saves parameter values in Advanced Config. Parameters ● No function in Monitor mode Fault Log ● ● Status LEDs View 10 most recent fault codes Reset ● Trip reset button if no active faults are present S611 Soft Starter MN03901003E—January 2012 www.eaton.com 5 Setup and Starting—Initial Configuration Setup and Starting—Initial Configuration 1. 2. 3. The S611 Operation and Protection parameters may be edited when 120 Vac control power is applied to 120 Vac supply (TB1). Mains power is not required to edit and save Operation and/or Protection parameters. f. 4. If Stall Faults occur at the end of the ramp time, increase Initial Torque, Kick Start Torque and Time and/or Soft Start Time to achieve bypass before the Soft Start time elapses. Verify that the motor is not overloaded. To setup the S611 Operating parameters (Operation mode), perform the following steps: Enter motor FLA. b. Enter motor rated voltage. c. Select start method if required (default = voltage ramp, or pump start). d. Enter Start time from table on Page 7 (default = 20 seconds). e. Enter initial torque from table on Page 7 (default = 45%). Application Notes Adjust Initial Torque for smooth start, motor rotation should begin within 2 seconds. If any 120 Vac power source other than the normal system control power source is used to power the control circuit to edit parameters, connections must be made in compliance with all local, state, and national electrical codes. a. Enter Stop time, Kick Start time, and Kick Start torque if desired (default = 0). After suitable performance has been achieved with either method, determine the starting time to bypass and set Soft Start Time at 1.25 times this time. For example, if it takes 10 seconds to accelerate the motor and go into bypass, set the Soft Start Time for 12.5 seconds. 5. In the Protection Mode, set the Protection parameters to the desired values. Refer to table on Page 7. 6. For optional advanced configuration parameters refer to the user manual. Operating Parameters Operating Parameter Units Motor FLA Frame Size A–52 Amps Min Max Default Notes 26 52 26 Frame Size A–65 32.5 65 32.5 Motor FLA parameter must be set to motor nameplate FLA to achieve proper overload protection Frame Size A–77 38.5 77 38.5 Frame Size B–99 48 99 48 Frame Size B–125 62.5 125 62.5 Frame Size C–156 78 156 78 Frame Size C–180 90 180 90 Frame Size D–242 120 242 120 Frame Size E–302 151 302 151 Frame Size E–361 180.5 361 180.5 207 414 207 Motor rated voltage Frame Size F–414 Volts 200 600 480 — Start method — 0 2 0 0 = Voltage ramp 1 = Current limit 2 = Pump start (option) Start time Seconds 0.5 180 20 — Initial torque % 0 100 45 — Stop time Seconds 0 60 0 — Kick start time Seconds 0 2 0 — Kick start torque % 0 100 0 — Auto reset mode — 0 1 0 0 = Manual 1 = Auto Advanced config — — — — Refer to User Manual, Publication No. MN03902011E Notes For the device with pump option, the default value is 2 for pump start. 6 S611 Soft Starter MN03901003E—January 2012 www.eaton.com Setup and Starting—Initial Configuration Protection Parameters Torque Settings and Corresponding Current Values Protection Parameter Units Min Max Default Trip class — Off, 5 30 20 Jam trip % Off, 150 400 300 Start stall trip % Off, 150 400 200 Current imbalance % Off, 1 100 20 Under load % Off, 1 50 6 Phase loss % Off, 1 100 40 Under voltage % Off, 1 99 90 Over voltage % Off, 101 120 110 Voltage imbalance % Off, 1 20 6 Phase sequence — Off, ABC ACB ABC Note: Editing the Trip Class parameter to “OFF” will disable overload protection. Torque Setting Current as % Locked Rotor Initial Motor Torque 85% 92% Maximum 71% 84% — 56% 75% — 45% 67% Default value 36% 60% — 33% 57% Wye-delta equivalent 27% 52% — 19% 44% Minimum for current limit 14% 37% — 9% 30% — 1% 10% Minimum Start Parameter Values for Various Applications Application t-Start t-Stop u-Start Breakaway Torque Remarks Crusher, empty at start 20s — 56% 75% Possible high inertia Conveyor, horizontal, loaded 25s 30s 76% 150% — Conveyor, horizontal, unloaded 25s 30s 48% 50% — Chiller 5s — 37% 25% — Piston compressor, unloaded 10s — 64% 100% — Circular saw 20s — 48% 50% Possible high inertia Ball mill 20s — 48% 50% Eccentric load Mixer, liquids 10s — 37% 40% — Mixer, dry materials 15s — 56% 75% — Pump, piston 25s 30s 82% 175% Possible high starting torque Pump, centrifugal 10s 30s 37% 25% — Escalator 10s — 48% 50% — Rotary compressor, unloaded 20s — 42% 35% — Agitator 15s — 42% 35% — Feed screw 20s — 82% 175% Possible high starting torque Press, flywheel 25s — 76% 150% Possible high starting torque Drier, rotating 20s — 64% 100% — Blower, axial fan, flaps open 30s — 37% 25% — Blower, centrifugal fan, valve open 30s — 35% 20% — S611 Soft Starter MN03901003E—January 2012 www.eaton.com 7 Troubleshooting Troubleshooting S611 Fault Codes Code Fault Condition Solution 3 Watchdog • Firmware fault — 5 Internal Memory • Internal FRam memory error • • Component failure on printed circuit board Contact EatonCare for service 6 User Interface Communications Failure • • • • Communications to UI have been interrupted Possible hardware failure Firmware is not communicating internally Cycle 120 Vac control voltage power to attempt to clear problem 7 Internal Program Memory • • Corrupted firmware or memory Flash CRC • • Cycle 120 Vac control power to the S611 Contact EatonCare for service 8 Voltage Zero Cross Lost • • • Mains voltage lost Phase L1 or L3 lost Load disconnected • • Restore mains or lost phases Verify that the load is connected and any disconnect devices are properly engaged Contact EatonCare for service 9 Communications Loss Port A • Communications to a remote network controller was lost during run cycle Device disconnected Connection lost • Reattach network controller, verify that the unit is recognized by the system controller Communications to a remote network controller was lost during run cycle Device disconnected Connection lost • Reattach network controller, verify that the unit is recognized by the system controller Comms Port B adapter module failed or disconnected SCR temperature is above limits Operating environment above specified maximum temperature Ventilation holes blocked Fans are not operational Starts/hour exceed specifications Sensor failure on power pole Bypass contactor(s) failed to close • • • • Internal bypass contactor(s) not closed and/or electrically sealed after ramp time Contactor(s) opened in bypass • • • • • 10 Communications Loss Port B • • • 15 Power Pole Over Temperature • • • • • • • 16 Bypass Failure • • • • • • • 17 SCR Not Firing • • • 8 SCR is not conducting when gated Incoming phase lost Special application—undersized or high impedance motor Load disconnected S611 Soft Starter MN03901003E—January 2012 www.eaton.com • • • • • Ventilate to specified maximum temperatures Clear obstructions Verify fans are operational Verify system is not exceeding the specified maximum starts per hour Verify bypass contacts are closing at the end of ramp time Reduce excessive cabinet temperature Verify all bypass contactor(s) close (audible noise) Verify all bypass contactor(s) not opening during run cycle due to excessive vibration and/or shock Reduce levels of vibration and/or shock Verify control power and wire size meet specifications Verify that the control power supply meets the 120 Vac voltage and current requirements of the IT. soft starter SCR failure Re-apply lost phase Review S611 application Circuitry damaged by megger testing Contact EatonCare for service Troubleshooting S611 Fault Codes, continued Code Fault Condition Solution 18 Shorted SCR • • • SCR is shorted Internal bypass contactor welded shut No load on the SCRs when START command is issued • • Test resistance of each phase Contact EatonCare for service 19 Instantaneous Overcurrent • • Excessive starting current Excessive load • • 20 Overload • Motor overloaded for an extended period of time Thermal memory is over 100% • • Reduce starting load Increase soft starter capacity (be sure model ratings can handle current demands) Reduce the motor’s load Verify the Overld Trip FLA and/or Ovrld Trip Class for proper adjustment Note: Exceeding nameplate ratings will shorten equipment life Fault during motor start: Verify system is not exceeding the specified maximum starts per hour Increase the initial torque and/or reduce ramp time to bring the motor up to speed faster Increase Trip Class setting (5–30 maximum) and/or reduce ramp time setting Replace fuses, close disconnect, or reset breaker • • • • • 21 Mains AC Voltage Loss 22 Under Voltage • • • • 23 Over Voltage • 24 Phase Reversal • • • 25 Start Stall • • Fuses or breaker open Disconnect open Incoming AC line voltage below trip threshold Incorrect mains supply voltage • Incoming AC line voltage above trip threshold Incorrect mains supply voltage Incoming line phase rotation sequence opposite of device setting Single-phase missing and/or open fuse or breaker • • Motor not at rated RPM at end of start ramp time and/or current is in excess of trip threshold Bypass contactors not closed at the end of the start time (start current low/ramp time short) • • • • • • • • • • 27 SCR Overcurrent • • 28 Under Load • • • Excessive SCR current during the start ramp Only active when Stall Fault is disabled Loss of motor load Trip threshold set too high Excessive current fluctuation during operation • • • • • • Connect to correct supply voltage Verify that mains voltage is within acceptable values Verify Motor Rated Voltage in the Operation mode is set to the correct value Connect to correct supply voltage Verify Motor Rated Voltage in the Operation mode is set to correct value Set Phase Sequence to match incoming sequence OR Exchange two incoming mains phases Verify that all circuit breakers are closed or fuses are serviceable Lengthen Soft Start Time and/or increase Initial Torque in the Operations mode Increase trip threshold Loads that are heavily loaded (high inertia) during a start such as fans will often need an initial torque setting much greater than the factory default Set Kick Start parameters Increase Soft Start Time and/or Initial Torque parameters in Operation mode Reduce starting load Verify S611 is properly rated for current Inspect for failed motor coupling or pump cavitation Reduce trip threshold Increase trip delay time to ride through transient load changes Note Shorted SCRs are the most common mode of SCR failure. With power completely removed from the unit, measure the resistance of each pole, line to load. If the resistance is near zero (less than 5 ohms), it is most likely that the SCR is shorted. Resistance of a serviceable SCR is approximately 10k ohms. Resistance typically moves to a lower value as the SCR ages. This feature may be disabled (not recommended). S611 Soft Starter MN03901003E—January 2012 www.eaton.com 9 Troubleshooting S611 Fault Codes, continued Code Fault Condition Solution 29 Current Unbalance • The current imbalance of the incoming phases exceeds the trip threshold • • • Correct imbalance problem with mains Increase the Current Imbalance parameters Disable the fault if the other issues cannot be resolved 30 Current Phase Loss • • • Incoming phase disconnected Open fuse or breaker Phase imbalance exceeds specifications or trip parameter Severe voltage phase imbalance • • • Repair broken connection Replace fuse Inspect system for phase imbalance conditions 31 Voltage Phase Imbalance • The voltage imbalance of the incoming phases exceeds the trip threshold • • • Correct imbalance problem with mains Increase the Voltage Fault Imbalance parameters Disable the fault if the other issues cannot be resolved 33 Jam • Soft starter in bypass: Motor below rated RPM and/or current exceeds 3 x motor FLA • • • Remove obstruction Verify proper FLA setting in Operation mode Jam fault can be disabled if trips occur during normal operation (Overcurrent fault will provide protection at a higher current threshold of 4 x catalog FLA) 34 Contactor Overcurrent • Only active in bypass if the jam fault is disabled Current exceeds the fault threshold of 4 x catalog FLA • • Remove obstruction in motor drive train Verify S611 is properly sized for the application Temperature sensor failure Internal connection failure • • • Internal hardware failure (sensor and/or cable) Note: Disabling this feature (Temp Sense fault in Protection menu) will remove protection from excessive temperature exposure (not recommended) Not field repairable, contact Eaton Support • • 35 Missing Temp Sensor • • * Cannot RESET fault • • Fault condition still exists Soft starter has not received RESET signal • • Troubleshoot fault and correct defective condition Attempt alternate methods of RESET NC No communication • Firmware not programmed, firmware corrupted • Contact EatonCare for service Note: All mains and control power connections must be completed and voltage applied prior to a START command. Failure to make all connections will result in one or more faults. All isolation and/or reversing contactors must be staged prior to any START commands. Manipulating contactors after the START command will result in one or more faults. 10 S611 Soft Starter MN03901003E—January 2012 www.eaton.com Eaton is dedicated to ensuring that reliable, efficient and safe power is available when it’s needed most. With unparalleled knowledge of electrical power management across industries, experts at Eaton deliver customized, integrated solutions to solve our customers’ most critical challenges. Our focus is on delivering the right solution for the application. But, decision makers demand more than just innovative products. They turn to Eaton for an unwavering commitment to personal support that makes customer success a top priority. For more information, visit www.eaton.com/electrical. Eaton Corporation Electrical Sector 1111 Superior Ave. Cleveland, OH 44114 United States Eaton.com © 2012 Eaton Corporation All Rights Reserved Printed in USA Publication No. MN03901003E / Z11687 January 2012 Eaton is a registered trademark of Eaton Corporation. All other trademarks are property of their respective owners.
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