114342 2 Weg Soft Starter Users Manual SSW 06 Inglês User
User Manual: Pump 114342 2 Weg Soft Starter Users Manual
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SOFT-STARTER MANUAL SSW-06 Serie: SSW-06 Software: version 1.3X 0899.5579 E/6 12/2006 ATTENTION! It is very important to check if the Soft-Starter Software is the same as mentioned above. Summary of Revisions The table below describes the revisions made to this manual. Revision 1 2 Description First Edition Section - General Revision - 3 General Revision - 4 New Software Version - 5 Implementation of the following current: 412A, Chap 3 480A, 604A, 670A, 820A, 950A, 1100A and 1400A. and 10 New software version with: braking methods 3, 4, 6 FWD/REV and Jog. and 8 P140 was changed. E73 was eliminated. E71 and E76 were changed. 6 General Revision - Summary Quick Parameter Reference, Fault and Status Messages I II III Parameters ..................................................................................... 09 Fault Messages .............................................................................. 17 Other Messages ............................................................................. 17 CHAPTER 1 Safety Notices 1.1 Safety Notices in the Manual .......................................................... 18 1.2 Safety Notice on the Product .......................................................... 18 1.3 Preliminary Recommendations ....................................................... 19 CHAPTER 2 General Information 2.1 2.2 2.3 2.4 2.5 About this Manual .......................................................................... Software Version ............................................................................. About the Soft-Starter SSW-06 ....................................................... Soft-Starter SSW-06 Identification .................................................. Receiving and Storage .................................................................... 20 20 20 23 25 CHAPTER 3 Installation and Connection 3.1 Mechanical Installation ..................................................................... 3.1.1 Environment Conditions .............................................................. 3.1.2 Dimensions of the Soft-Starter SSW-06 ...................................... 3.1.3 Mounting Specifications .............................................................. 3.1.3.1 Mounting inside a Panel .................................................... 3.1.3.2 Mounting on a surface ....................................................... 3.2 Electrical Installation ......................................................................... 3.2.1 Power Terminals ......................................................................... 3.2.2 Location of the Power/ Grounding, Control Connections and Fan Voltage Selection ................................................................ 3.2.3 Recommended Power/Grounding Cables ................................... 3.2.4 AC Input Connection ................................................................... 3.2.4.1 Power Supply Capacity ..................................................... 3.2.4.2 Recommended Fuses ....................................................... 3.2.5 Output Connection ...................................................................... 3.2.5.1 Standard Three-Wire Connection (P150=0=Inactive) .......... 3.2.5.2 Inside Delta Motor Connection (P150=1=Active) ............... 3.2.6 Grounding Connections .............................................................. 3.2.7 Fan Connection and Selection of Fan Voltage ............................ 3.2.8 Signal and Contro Connections .................................................. 3.2.9 RS-232, X2 Serial Communication Connection ........................... 26 26 26 27 28 30 31 32 36 38 39 40 40 41 41 42 43 44 45 48 Summary 3.2.10 RS-485, XC8 Isolated Serial Communication Board Connection .................................................................... 3.2.11 XC6 Fieldbus Communication Board Connection ...................... 3.3 Recommended Set-Ups .................................................................... 3.3.1 Recommended Set-ups by Keypad (HMI) Command with Isolating Contactor. Notes in 3 .3. ....................................... 3.3.2 Recommended Set-ups by Keypad (HMI) Command with Circuit-breaker. Notes in 3.3. ............................................... 3.3.3 Recommended Set-ups with Command via Two-wire Digital Inputs. Notes in 3.3. ........................................................ 3.3.4 Recommended Set-ups with Command via Three-wire Digital Inputs. Notes in 3.3. ........................................................ 3.3.5 Recommended Set-ups with Command via Three-wire Digital Input and Inside Delta Motor Connection. Notes in 3.3 and 3.2.5.2. ................................................................................ 3.3.6 Recommended Set-ups with Command via Three-wire Digital Input or Serial Communication. Notes in 3.3. .................. 3.3.7 Recommended Set-ups with Command via Three-wire Digital Input or Fieldbus Communication. Notes in 3.3. .............. 3.3.8 Recommended Setup with Command via Digital Inputs and direction of rotation ..................................................................... 3.3.9 Recommended Setup with Command via Digital Inputs and Reverse Braking ......................................................................... 3.3.10 Recommended Setup with Command via Digital Inputs and Optimal Braking ....................................................................... 3.3.11 Recommended Setup with Command via Digital Inputs and DC-Braking ............................................................................... 3.3.12 Recommended Setup with Command via Digital Inputs and External By-pass Contactor ..................................................... 3.3.13 Symbols ................................................................................... 3.4 European Directives for Electromagnetic Compatibility Requirements for installation .......................................................... 3.4.1 Installation .................................................................................. 48 48 48 50 50 51 51 52 52 53 53 54 54 55 55 56 57 57 CHAPTER 4 Keypad (HMI) Operation 4.1 Description of the Keypad (HMI-SSW-06) ..................................... 59 4.2 Use of the Keypad (HMI) ................................................................ 61 4.2.1 Keypad Use for Soft-Starter SSW-06 Operation ......................... 61 4.2.2 HMI Display-Signaling indications ............................................... 62 4.2.3 Parameter Viewing and Programming ......................................... 63 CHAPTER 5 Start-up 5.1 Power-up Preparation ..................................................................... 65 5.2 Initial Power-up ............................................................................... 66 5.3 Start-up ........................................................................................... 73 5.3.1 Start-up Operation via Keypad (HMI) - Summary Type of Control: Voltage Ramp .................................................. 74 CHAPTER 6 Detailed Parameter Description 6.1 6.2 6.3 6.4 6.5 6.6 6.7 Access and Read-Only Parameters - P000 to P099 ...................... 77 Regulation Parameters - P100 to P199 .......................................... 82 Configuration Parameters - P200 to P299 ....................................... 91 Communication Parameters - P300 to P399 .................................. 104 Motor Parameters - P400 to P499 .................................................. 106 Special Function Parameters - P500 to P599 ................................. 107 Protection Parameters - P600 to P699 ........................................... 113 CHAPTER 7 Applications and Programming 7.1 Applications and Programming ......................................................... 121 7.1.1 Starting by Voltage Ramp (P202=0) ............................................ 123 7.1.2 Starting by Current Limit (P202=1) .............................................. 124 7.1.3 Starting by Current Ramp (P202=4) ............................................ 125 7.1.4 Starting by Current Ramp (P202=4) ............................................ 126 7.1.5 Starting with Pump Control (P202=2) .......................................... 127 7.1.6 Starting with Torque Control (P202=3) ......................................... 129 7.1.6.1 Loads with constant torque (P202=3 and P120=1 point) .... 130 7.1.6.2 Loads with high initial torque (P202=3 and P120=3 points) 130 7.1.6.3 Loads with constant torque and S speed curve (P202=3 and P120=3 points) ............................................. 131 7.1.6.4 Loads with quadratic torque and S speed curve (P202=3 and P120=2 points) ............................................. 131 7.1.6.5 Loads with quadratic torque and linear speed curve (P202=3 and P120=3 points) ............................................. 132 7.1.6.6 Loads with quadratic torque and higher initial torque (P202=3 and P120=3 points) ............................................. 132 7.1.6.7 Hydraulic pump load type (P202=3) .................................... 133 7.2 Protections and Programming .......................................................... 136 7.2.1 Thermal Classes ......................................................................... 136 7.2.1.1 Suggestions about thermal class setting ............................ 136 7.2.1.2 Example of how to program the Thermal Class .................. 137 7.2.1.3 Time reduction when changing from cold starting to hot starting ..................................................................... 138 7.2.1.4 Service Factor .................................................................... 138 CHAPTER 8 Diagnosis and Troubleshooting 8.1 Faults and Possible Causes ............................................................. 139 8.2 Troubleshooting ................................................................................ 143 Summary 8.3 Contacting WEG Telephone/Fax/E-mail for Contact (Servicing) ........ 143 8.4 Preventive Maintenance .................................................................... 144 8.4.1 Cleaning Instructions .................................................................. 145 8.5 Spare Parts List ................................................................................ 145 CHAPTER 9 Options and Accessories 9.1 Remote Keypad (HMI) and Cables .................................................... 146 9.2 RS-485 for the Soft-Starter SSW-06 ................................................. 148 9.2.1 RS-485 Communication Kit for the SSW-06 ............................... 148 9.2.2 Optional MIW-02 Module ............................................................ 149 9.3 Fieldbus Communication Kits ........................................................... 149 9.3.1 Fieldbus DeviceNet Communication Kit for the SSW-06 ............. 149 9.3.2 Fieldbus Profibus DP Communication kit for the SSW-06 .......... 150 CHAPTER 10 Technical Specifications 10.1 10.2 10.3 10.4 10.5 Currents and Ratings According to Ul508 ....................................... 151 Currents and Ratings for IP55, IV Pole Weg Motor ......................... 152 Power Data ..................................................................................... 153 Electronics/Programming Data ....................................................... 153 Mechanical Data ............................................................................. 155 SSW-06 - QUICK PARAMETER REFERENCE QUICK PARAMETER REFERENCE, FAULT AND STATUS MESSAGES Software: V1.3X Application: Model: Serial Number: Person Responsible: Date: / / . I. Parameters Parameter P000 Description Access Parameter Adjustable Range 0 to 999 Factory Setting Unit User´s Setting Page 0 - 77 0 to 999.9 - % 78 READ ONLY PARAMETERS P001 to P099 P001 Soft-Starter Current (%In of the Soft-Starter) P002 Motor Current (%In of the Motor) 0 to 999.9 - % 78 P003 Motor Current 0 to 9999.9 - A 78 P004 Power Supply Voltage 0 to 999 - V 78 P005 Network Frequency 0 to 99.9 - Hz 78 P006 Soft-Starter Status 0=rdy - ready - - 78 1=Sub - Sub 2=Exx - Error 3=ruP - Run Up 4=FuLL - Full Volt. 5=PASS - By-pass 6=ECO - Reserved 7=rdo - Run Down 8=br - Braking 9=rE - FWD/REV 10=JOG - JOG 11=dly - Delay P630 12=G.di - Gen. Disable P007 Output Voltage 0 to 999 - V 79 P008 Power Factor 0 to 1.00 - - 79 P009 Motor Torque (% Tn of the Motor) 0 to 999.9 - % 79 P010 Output Power 0 to 6553.5 - kW 79 P011 Apparent Output Power 0 to 6553.5 - kVA 79 P012 Digital Input Status Dl1 to Dl6 0 = Inactive - - 80 P013 Status RL1, RL2 and RL3 - - 80 1 = Active 0 = Inactive 1 = Active P014 Last Fault 03 to 77 - - 81 P015 Second Previous Fault 03 to 77 - - 81 P016 Third Previous Fault 03 to 77 - - 81 P017 Fourth Previous Fault 03 to 77 - - 81 P023 Software Version X.XX - - 81 P030 Current of Phase R 0 to 9999.9 - A 81 P031 Current of Phase S 0 to 9999.9 - A 81 P032 Current of Phase T 0 to 9999.9 - A 81 P033 R-S Line Voltage 0 to 999 - V 81 P034 S-T Line Voltage 0 to 999 - V 81 P035 T-R Line Voltage 0 to 999 - V 81 9 SSW-06 - QUICK PARAMETER REFERENCE Parameter Description Adjustable Range Factory Setting Unit User´s Setting Page P042 Time Powered 0 to 65530 - h 81 P043 Time Enabled 0 to 6553 - h 82 P050 Motor Thermal Protection Status 0 to 250 - % 82 P085 Fieldbus Communication Board Status 0=Off - - 82 30 % 82 1=Board Inactive 2=Board Active and Offline 3=Board Active and Online REGULATION PARAMETERS P100 TO P199 Voltage Ramp P101 Initial Voltage (% Un of the motor) 25 to 90 P102 Acceleration Ramp Time 1 to 999 P103 Deceleration Voltage Step 100=Inactive (% Un of the motor) 99 to 60 P104 Deceleration Ramp Time 0=Inactive P105 End Deceleration Voltage 20 s 83 100=Inactive % 84 0=Inactive s 84 30 to 55 30 % 84 150 to 500 300 % 84 150 to 500 150 % 85 1 to 99 20 % 85 1=Constant - 86 1 to 299 (% Un of the Motor) Current Limit P110 Current Limit (%In of the Motor current) P111 Initial Current for the Current Ramp (% In of the Motor) P112 Time for the Current Ramp (% of P102) Torque Control P120 (1) Starting Torque Characteristics 1=Constant 2=Linear 3=Quadratic P121 Initial Starting Torque (% Tn of Motor) 10 to 400 30 % 87 P122 End Starting Torque (% Tn of Motor) 10 to 400 110 % 87 Minimum Starting Torque 10 to 400 27 % 87 1 to 99 20 % 87 1=Constant - 88 P123 (% Tn of the Motor) P124 Time for the Minimum Start Torque (% of P102) P125 (1) Stopping Torque Characteristics 1=Constant 2=Linear 3=Quadratic P126 End Stop Torque (% Tn of the Motor) 10 to 100 20 % 88 P127 Minimum Stop Torque 10 to 100 50 % 89 1 to 99 50 % 89 0= Pump I - 89 0=Inactive - 89 (% Tn of the Motor) P128 Time for the Minimum Stop Torque (% of P104) Pump Control P130 (1) Pump Control 0= Pump I 1= Pump II By-pass P140 (1) External By-pass Contactor 0=Inactive 1=Active 10 SSW-06 - QUICK PARAMETER REFERENCE Parameter Description Adjustable Range Factory Setting Unit User´s Setting Page Inside Delta P150 (1) (2) Inside Delta Motor Connection 0=Inactive 0=Inactive - 90 1=Active - 91 To be defined - 91 0=Voltage Ramp - 91 0=Not use - 94 2=P003 - 95 0=Inactive s 95 0=Inactive - 96 127 - 97 2=HMI(L) - 97 1=Active CONFIGURATION PARAMETERS P200 to P399 P200 Password P201 (2) Language Selection 0=Inactive 1=Active 0=Portuguese 1=English by the user 2=Spanish 3=German P202 (1) Type of the Control 0=Voltage Ramp 1=Current limiting 2=Pump Control 3=Torque Control 4=Current Ramp P204 (1) Load/Save Parameters 0=Not use 1=Not use 2=Not use 3=Reset P043 4=Not use 5=Loads Factory Default 6=Not use 7=Loads User Default 1 8=Loads User Default 2 9=Not use 10=Saves User Default 1 11=Saves User Default 2 P205 Display Default Selection 0=P001 1=P002 2=P003 3=P004 4=P005 5=P006 6=P007 7=P008 P206 Auto-Reset Time 0=Inactive 1 to 600 P215(1) Keypad Copy Function 0=Inactive 1=SSW HMI 2=HMI SSW P218 LCD Display Contrast Adjust. P220 (1) Local/Remote Source Selection 0 to 150 Local/Remote Definition 0=Always Local 1=Always Remote 2=HMI(L) 3=HMI(R) 4=DI4 to DI6 5=Serial(L) 6=Serial(R) 7=Fieldbus(L) 8=Fieldbus(R) 11 SSW-06 - QUICK PARAMETER REFERENCE Parameter P229 (1) Description Local StatusCommand Selection Adjustable Range 0=Keys HMI Factory Setting Unit User´s Setting Page 0=Keys HMI - 97 1=DIx Terminals - 97 0=Not used - 98 0=Not used - 99 1.000 - 99 0= Not used - 99 1= Digital Inputs DIx 2=Serial 3=Fieldbus P230 (1) Remote StatusCommand Selection 0=Keys HMI 1= Digital Inputs DIx 2=Serial 3=Fieldbus P231 (1) FWD/REV Selection 0=Not used 1=By Contactor 2=JOG Only Analog Outputs P251 AO1 (0 to 10)V Output Function 0=Not used 1= Current (%In of the SSW) 2=Input Voltage (%Un of the SSW) 3=Output voltage (%Un of the SSW) 4=Power Factor 5=Thermal Protection 6=Power (in W) 7=Power (in VA) 8=Torque (%Tn of Motor) 9=Fieldbus 10=Serial P252 AO1 Analog Output Gain 0.000 to 9.999 P253 AO2 (0 to 20)mA or (4 to 20)mA 0=Not used Output Function 1= Current (%In of the SSW) 2=Input Voltage (%Un of the SSW) 3=Output voltage (%Un of the SSW) 4=Power Factor 5=Thermal Protection 6=Power (in W) 7=Power (in VA) 8=Torque (%Tn of the Motor) 9=Fieldbus 10=Serial P254 AO2 Analog Output Gain 0.000 to 9.999 P255 AO2 Analog Output Selection 0=0 to 20 1.000 - 99 0=0 to 20 mA 99 2= Reset - 100 0=Not used - 100 1=4 to 20 Digital Inputs P264 (1) DI2 Digital Input Function 0=Not Used 1=Stop (Three-Wire) 2=Reset P265 (1) DI3 Digital Input Function 0=Not Used 1=General Enable 2=Reset 12 SSW-06 - QUICK PARAMETER REFERENCE Parameter P266 (1) Description DI4 Digital Input Function Adjustable Range 0=Not Used Factory Setting Unit User´s Setting Page 0=Not Used - 100 0=Not used - 101 0=Not used - 101 1=Running - 102 2=Full Voltage - 102 6= No Fault - 102 1=FWD/REV 2=Local/Remote 3=No External Fault 4=JOG 5=Brake Off 6=Reset P267 (1) DI5 Digital Input Function 0=Not Used 1=FWD/REV 2=Local/Remote 3=No External Fault 4=JOG 5=Brake Off 6=Reset P268 (1) DI6 Digital Input Function 0=Not used 1=FWD/REV 2=Local/Remote 3=No external Fault 4=JOG 5=Brake Off 6=Reset 7=Motor Thermistor Digital Outputs P277 (1) RL1 Relay Function 0=Not used 1=Running 2=Full voltage 3=External By-pass 4=FWD/REV-K1 5=DC-Brake 6= No Fault 7=Fault 8=Fieldbus 9=Serial P278 (1) RL2 Relay Function 0=Not used 1=Running 2=Full voltage 3=External By-pass 4=FWD/REV-K2 5=DC-Brake 6= No Fault 7=Fault 8=Fieldbus 9=Serial P279 (1) RL3 Relay Function 0=Inactive 1=Running 2=Full voltage 3=External By-pass 4= Not used 5=DC-Brake 6= No Fault 13 SSW-06 - QUICK PARAMETER REFERENCE Parameter Description Adjustable Range Factory Setting Unit User´s Setting A 103 V 103 1 - 104 0=Inactive - 104 Page 7=Fault 8=Fieldbus 9=Serial Soft-Starter Data P295 (1)(2) SSW Rated Current 0=10A 11=312A According to 1=16A 12=365A Soft-Starter 2=23A 13=412A Rated Current 3=30A 14=480A 4=45A 15=604A 5=60A 16=670A 6=85A 17=820A 7=130A 18=954A 8=170A 19=1100A 9=205A 20=1411A 10=255A P296 (1) (2) Rated Voltage 0=220/575V According to 1=575/690V Soft-Starter Voltage PARÂMETROS DE COMUNICAÇÃO SERIAL P300 a P399 P308 (1)(2) Soft-Starter Address on the Serial 1 to 247 Communication Network P309 (1)(2) Fieldbus Communication 0=Inactive Board Enabling 1=Profibus-DP (1 Inputs and 1 Outputs) 2=Profibus-DP (4 Inputs and 4 Outputs) 3=Profibus-DP (7 Inputs and 7 Outputs) 4=DeviceNet (1 Inputs and 1 Outputs) 5=DeviceNet (4 Inputs and 4 Outputs) 6=DeviceNet (7 Inputs and 7 Outputs) P312 (1)(2) Protocol Type and Serial 1=Modbus-RTU Communication Transfer Rate (9600bps, no parity) (9600bps, 2=Modbus-RTU no parity) (9600bps, odd) 3=Modbus-RTU (9600bps, even) 4=Modbus-RTU (19200bps, no parity) 5=Modbus-RTU (19200bps, odd) 6=Modbus-RTU (19200bps, even) 7=Modbus-RTU (38400bps, no parity) 8=Modbus-RTU (38400bps, odd) 14 1=Modbus-RTU 104 SSW-06 - QUICK PARAMETER REFERENCE Parameter Description Adjustable Range Factory Setting Unit User´s Setting Page 9=Modbus-RTU (38400bps, even) P313 Serial and Fieldbus Communication 0=Inactive Error Actions (E28, E29 and E30) 1=Disable 0=Inactive 104 2=General Enable 3=Changes to Local (1) P314 Timeout Time for Serial 0 to 999 0= Inactive s 105 Communication Telegram Reception P315 (1) Read Parameter via Fieldbus 1 0 to 999 0 - 105 P316 (1) Read Parameter via Fieldbus 2 0 to 999 0 - 105 (1) Read Parameter via Fieldbus 3 0 to 999 0 - 105 P317 MOTOR PARAMETERS P400 to P499 P400 (1) Rated Motor Voltage 0 to 999 380 V 106 P401 (1) Rated Motor Current 0.0 to 1500 20 A 106 P403 (1) Rated Motor Speed 400 to 3600 1780 rpm 106 P404 (1) Rated Motor Power 0.1 to 2650 75 kW 106 P405 (1) Motor Power Factor 0 to 1.00 0.89 - 106 P406 (1) Service Factor 0 to 1.50 1.00 - 106 0=Inactive - 107 SPECIAL PARAMETERS P500 to P599 Braking P500 (1) Braking Methods 0=Inactive 1=Reverse Braking 2=Optimal Braking 3=DC-Braking P501 Braking Time 1 to 299 10 s 110 P502 Braking Voltage Level 30 to 70 30 % 110 P503 Braking End Detection 0=Inactive 0=Inactive - 110 0=Inactive - 111 10 to 100 30 % 111 Kick Start Torque Pulse 0=Inactive 0=Inactive - 112 1=Automatic JOG P510 (1) Jog P511 Jog Level 0=Inactive 1=Active Kick Start P520 (1) (according to P202) 1=Active P521 Kick Start Pulse Time 0.1 to 2 0.1 s 112 P522 Kick Start Voltage Pulse Level 70 to 90 70 % 112 300 to 700 500 % 112 (% Un of the Motor) P523 Kick Start Current Pulse Level (% In of the Motor) PROTECTION PARAMETERS P600 to P699 Voltage Protection P600 (1) P601 (1) Undervoltage (% Un of the motor) 0 to 30 20 % 113 Immediate Undervoltage Time 0=Inactive 1 s 113 1 to 99 P602 (1) P603 (1) Overvoltage (% Un of the motor) 0 to 20 15 % 113 Immediate Overvoltage Time 0=Inactive 1 s 113 15 % 114 1 to 99 P604 (1) Voltage Imbalance Between Phases 0 to 30 (% Un of the motor) 15 SSW-06 - QUICK PARAMETER REFERENCE Factory Setting Unit 1 s 114 20 % 114 0=Inactive s 114 20 % 114 0=Inactive s 114 0 to 30 15 % 115 Current Imbalance Between 0=Inactive 1 s 115 Phase Times 1 to 99 1=Active - 115 1=Active - 115 0=Inactive - 115 2 s 115 6=30 - 117 0=Inactive s 120 Parameter P605 (1) Description Phase Voltage Imbalance Time Adjustable Range 0=Inactive User´s Setting Page 1 to 99 Current Protection P610 (1) Immediate Undercurrent 0 to 99 (% In of the motor) P611 (1) Immediate Undercurrent Time 0=Inactive 1 to 99 P612 (1) Immediate Overcurrent 0 to 99 (% In of the motor) P613 (1) Immediate Overcurrent Time 0=Inactive 1 to 99 P614 (1) Current Imbalance between Phases (% In of the motor) P615 (1) P616 (1) P617 Undercurrent before Closing 0=Inactive of Internal By-pass 1=Active Motor Overcurrent before By-pass 0=Inactive 1=Active Phase Sequence P620 (1) RST Phase Current Sequence 0=Inactive 1=Active Interval between Starts P630 Interval of Time after Stop 2 to 999 Motor Thermal Protection P640 (1) P641 (1) Motor Protection Thermal Class 0=Inactive 5=25 of Motor Protection 1=5 2=10 3=15 4=20 6=30 7=35 8=40 9=45 Auto-Reset of thermal Memory 0=Inactive 1 to 600 Notes presented on quick parameter description: (1) This parameter can only be changed with the motor stopped. (2) This parameter does not change when factory defaults are loaded (P204=5). 16 SSW-06 - QUICK PARAMETER REFERENCE II. Fault Messages Display E03 Description Undervoltage, Phase Fault or Phase Page 139 Unbalancing E04 Overtemperature at the Power Assembly 139 E05 Motor Overload 139 E06 External Fault (DI) 139 E10 Copy Function Fault 139 E15 Motor is not Connected or SCRs in Short-circuit 139 E16 Overvoltage 139 E24 Programming Error 140 E28 Timeout in the Telegram Reception 140 E29 Fieldbus Communication is Inactive 140 E30 Fieldbus Board is Inactive 140 E31 HMI Connection Fault 140 E32 Motor Overtemperature (DI) 140 E41 Self-Diagnosis Fault 140 E62 Start Limiting Time 140 E63 Locked Rotor 140 E65 Undercurrent 141 E66 Overcurrent 141 E67 Inverted Phase Sequence 141 E70 Undervoltage at the Electronics 141 E71 Bypass Contact is Open 141 E72 Overcurrent before By-pass Contact 141 E74 Current Imbalance 141 E75 Frequency of Supply Line 141 out of Permitted Range E76 Undercurrent before By-pass 141 E77 Bypass Contact is closed or SCRs in Short-circuit 141 For more details see table 8.1 in chapter 8. III. Other Messages Display Description rdy Soft-Starter is ready to be enabled ruP Soft-Starter is enabled according to “ramp up” FuLL Soft-Starter is enabled at “full voltage” PASS Soft-Starter is enabled with “By-pass” rdo Soft-Starter is enabled according to “ramp down” br Soft-Starter is enabled according to “braking” rE Soft-Starter is enabled according to “reversing” JOG Soft-Starter is enabled according to “jog” Sub Soft-Starter under voltage fault Exx Soft-Starter fault dly Soft-Starter esperando o tempo após parada "delay" G.di Soft-Starter com desabilita geral "general disable" ECO Reserved 17 CHAPTER 1 SAFETY NOTICES This Manual contains all necessary information for the correct installation and operation of the SSW-06 Soft-Starter. The SSW-06 Instruction Manual has been written for qualified personnel with suitable training or technical qualifications to operate this type of equipment. 1.1 SAFETY NOTICES IN THE MANUAL The following Safety Notices will be used in this Manual: DANGER! If the recommended Safety Instructions are not strictly observed, serious or fatal injuries of personnel and/or equipment damage can occur. ATTENTION! Failure to observe the recommended Safety Procedures can lead to material damage. NOTE! The content of this Manual supplies important information for the correct understanding of operation and proper performance of the equipment. 1.2 SAFETY NOTICES ON THE PRODUCT The following symbols may be attached to the product, serving as Safety Notices: High Voltages Components are sensitive to electrostatic discharge. Do not touch them without following proper grounding procedures. Mandatory connection to ground protection (PE) Shield connection to ground 18 CHAPTER 1 - SAFETY NOTICES 1.3 PRELIMINARY RECOMMENDATIONS DANGER! Only qualified personnel should plan or implement the installation, start-up, operation and maintenance of this equipment. Personnel must review this entire Manual before attempting to install, operate or troubleshoot the SSW-06. These personnel must follow all safety instructions included in this Manual and/or defined by local regulations. Failure to comply with these instructions may result in personnel injury and/or equipment damage. NOTE! In this Manual, qualified personnel are defined as people that are trained to: 1. Install, ground, power-up and operate the SSW-06 according to this Manual and the local required safety procedures; 2. Use of safety equipment according to the local regulations; 3. Administer First Aid Treatment. DANGER! Always disconnect the main power supply before touching any electrical component associated to the SSW-06 Soft-Starter. High voltages and spinning parts (fans) may be present even after switching off the power supply. Wait at least 3 minutes for the complete discharge of the capacitors. Always connect the equipment frame to the protection earth (PE) in the appropriate place for this. ATTENTION! All electronic boards have components that are sensitive to electrostatic discharges. Never touch any of the electrical components or connectors without following proper grounding procedures. If necessary to do so, touch the properly grounded metallic frame or use a suitable ground strap. Do not apply high voltage (High Pot) test on Soft-Starter SSW-06! If this test is necessary, contact the manufacturer NOTE! Soft-Starter SSW-06 can interfere with other electronic equipment. In order to reduce this interference, adopt the measures recommended in Section 3 “Installation”. NOTE! Read this entire manual carefully and completely before installing or operating the Soft-Starter SSW-06. 19 CHAPTER 2 GENERAL INFORMATION This chapter defines the contents and purpose of this manual and describes the main characteristics of the SSW-06 Soft-Starter. Identification of the SSW-06, receiving and storage requirements are also provided. 2.1 ABOUT THIS MANUAL This Manual is divided into 10 Chapters, providing information to the user on how to receive, install, start-up and operate the Soft-Starter SSW-06. Chapter 1 - Safety Notices; Chapter 2 - General Information; Receiving and Storing of the SSW-06; Chapter 3 - Information about Installation and Connection of the Soft-Starter SSW-06 power and control circuit), how to install options and recommended drives; Chapter 4 - Using the Keypad (Human Machine Interface - HMI); Chapter 5 - Information about running and steps to be followed; Chapter 6 - Detailed description of all Soft-Starter SSW-06 programming parameters; Chapter 7- Information and suggestions on how to program the types of control and protections Chapter 8 - Information about Diagnostics and Troubleshooting, cleaning instructions and preventive maintenance; Chapter 9 - SW-06 Soft-Starter optional devices; Chapter 10 - Tables and technical information about the power lines of the Soft-Starter SSW-06; This Manual provides information for the correct use of the Soft-Starter SSW-06. Due to the various functions of the Soft-Starter SSW-06 many different modes of operation are possible. As the Soft-Starter SSW-06 can be applied in several ways, it is impossible to describe here all application possibilities, neither can WEG assume any responsibility when the Soft-Starter SSW-06 is not used according to this Manual. No part of this Manual may be reproduced in any form, without written permission from WEG. 2.2 SOFTWARE VERSION It is important to note the Software Version installed in the Soft-Starter SSW-06, since it defines the functions and the programming parameters of the Soft-Starter. This Manual refers to the Software version indicated on the inside cover. For example, the Version 1.0X applies to versions 1.00 to 1.09, where “X” is a variable that will change due to minor software revisions. The Software Version can be read the Parameter P023. 2.3 ABOUT THE SOFT- STARTER SSW-06 The Soft-Starter SSW-06 is a high performance Drive that permits the start Control of three-phase AC induction motors. The Soft-Starter SSW-06 prevents mechanical shocks on the load and current peaks in the supply line. Among the main characteristics of this product is its line and connection fault detection capacity thus enabling the customer to chose the best way of protecting his the motor, such as: 20 CHAPTER 2 - GENERAL INFORMATION Programmable protections against line undervoltage and overvoltage, and line phase imbalance; Thermal class may be programmed up to Class 45 for large motors. The thermal memory is saved on EEPROM even in case of an electronic supply fault. Special functions such as: Display of the number of hours, running time, supply voltage phase, motor current per phase, motor current in amperes, motor current as a % of the Soft-Starter SSW-06 rated current and the rated current as a % of the motor current, status of the digital inputs and outputs; Setting sequence after reset to factory default; Very flexible selection of start/stop control type, enabling the following selections: Voltage Ramp, Constant Current Limiting or by Ramp, Pump Control and Constant, Linear or Quadratic Torque Control; Totally flexible Torque Control providing very high performance for the most demanding applications; Possibility of using all digital inputs, digital outputs and analog outputs as remote PLC via Fieldbus communication; Possibility of monitoring the power supply voltage measurements in a PLC network via Fieldbus communication. Control Hardware: Keypad, referred to as the Human Machine Interface (HMI) with Liquid-Crystal Display and easy programming. Fault conditions can be displayed in several languages. 32Bit Microprocessor calculates the True rms voltage and current; Measurement of the voltage and current in the three phases; Isolated digital input for the motor PTC; Fieldbus boards and RS-485 as options. Power Hardware: Compact size; Power Supply input and output connections: Models 85A to 820A - Input through the top and output through the bottom of the SSW-06.Models 950A to 1400A - Input and output through the bottom. Easy assembly and maintenance services; Measurements of heat sink temperature in models 255A to 820A through two thermostats:One thermostat to switch-on the internal fans and the other to monitor over-heating. Soft-Starter SSW-06 can be coupled to the motor by a standard connection or an inside delta motor connection without requiring optional devices. Incorporated By-pass contactor makes the Soft-Starter SSW- 06 (85A to 820A): More resistant to supply line oscillations after starting; Save energy that would be dissipated through the thyristors after the start, thus reducing the number of fans required for control panel cooling. 21 CHAPTER 2 - GENERAL INFORMATION (1) Three-Phase Power Supply Three-Phase Motor (1) (1) Input Voltage Output Voltage Current PE POWER BOARD Control Supply Supply PE CONTROL BOARD Digital Inputs Programmable Digital Inputs DI1...DI6 Analog Outputs Serial Interface RS-232 PC, PLC, MFW, Super Drive, ModBUS-RTU Serial Interface (optional) RS-485 PC, PLC Fieldbus (optional) Profibus DP DeviceNet HMI (Remote) Programmable Analog Outputs AO1 and AO2 CPU Digital Outputs HMI (1) Models 950, 1100 and 1400 do not have an internal By-pass contactor. Figure 2.1 - Soft-Starter SSW-06 block diagram 22 Programmable Digital Outputs RL1... RL3 CHAPTER 2 - GENERAL INFORMATION 2.4 SOFT-STARTER SSW-06 IDENTIFICATION Software Version SSW-06 Model Hardware Revision Input Data (Voltage, Number of Phases, Current, Frequency) Output Data (Voltage, Number of Phases, Current) Control Power Supply Data (Voltage, Frequency) Serial Number WEG Item Number Manufacturing Date Figure 2.2 - Soft-Starter SSW-06 nameplate Location of Soft-Starter SSW-06 nameplate: FRONT VIEW FRONTAL VIEWDE X X VISTA A X VER DETALHE "A" A View Detail Identification nameplate of the SSW-06 (Internal Cover) Figure 2.3 - Detail of the Soft-Starter SSW-06 nameplate 23 24 0085=85A 0130=130A 0170=170A 0205=205A 0255=255A 0312=312A 0365=365A 0412=412A 0480=480A 0604=604A 0670=670A 0820=820A 0950=950A 1100=1100A 1400=1400A Rated Output Current: 0023 2257 P Thee-phase Power Supply Manual Power Voltage: Language: Supply 2257 = P= portuguese (220 to 575)V E=English S=Spanish G=German T S=Standard O=with options Options: O Blank = standard SI= without keypad HumanMachine Interface (Keypad): __ Blank = standard H1 = 115V Ventilation (Model 950A) H2 = 230V Ventilation (Models 950A, 1100A and 1400A) Special Hardware: __ Blank = standard S1=Special Software Special Software: __ End of Code Z Obs.: The communication kits are optional, see chapter 9. The standard product is defined as described here: Degree of protection:IP00 from 85A to 1400A Human-Machine-Interface: HMI-SSW06 (with LCD and LED displays). If there are accessories, the spaces must be filled out in the correct sequence until the code ends with the letter zero. The option field (S or O) defines if the Soft-Starter SSW-6 is a standard version or if it is equipped with any optional devices. If the standard version is required, the code ends here. The model number always has the letter Z at the end. For example: SSW060085T2257ESZ = Standard Soft-Starter SSW-06 with current of 85A and 220V to 575V with Manual in English. NOTES! Soft-Starter SSW-06 WEG Series SSW-06 HOW TO SPECIFY THE SSW-06 MODEL: CHAPTER 2 - GENERAL INFORMATION CHAPTER 2 - GENERAL INFORMATION 2.5 RECEIVING AND STORAGE The SSW-06 is supplied in packaging according to the model: -Models 85A to 205A in a cardboard box; -Models 255A to 365A in a cardboard box over a wooden box; -Models 412A to 1400A in a wooden box. The outside of the packing container has a nameplate that is identical to that on the Soft-Starter SSW-06. Please check if the nameplate data matches the ordered data. The models up to 205A must be placed and opened on a table with the help of two or more people, open the box, remove the foam protection and remove Soft-Starter SSW-06. The models up to 205A must be placed and opened on a table with the help of two or more persons. Open the box, remove the foam protection and remove Soft-Starter SSW-06 with the help of two or more persons. Models greater than 255A must be opened on the floor. Open the box and, remove the bolts that fasten the Soft-Starter SSW-06 on the pallet. The Soft-Starter SSW-06 must be handled with a hoist. Check if: The Soft-Starter SSW-06 nameplate data matches the purchase order; The equipment has not been damaged during transportation. If any problem is detected, contact the carrier immediately. If the Soft-Starter SSW-06 is not to be installed immediately, store it within its original cardboard box in a clean and dry room (Storage temperatures between - 10°C (14ºF) and 65°C (149ºF)). 25 CHAPTER INSTALLATION AND CONNECTION 3 This chapter describes the electric and mechanic installation procedures of the SSW-06 Soft-Starters. The orientations and suggestions must be followed for correct product functioning. 3.1 MECHANICAL INSTALLATION 3.1.1 Environment Conditions The location of the Soft-Starter SSW-06 installation is an important factor to assure good performance and high product reliability. For proper installation of the SSW-06 Soft-Starter, we make the following recommendations: Avoid direct exposure to sunlight, rain, excessive humidity or marine environment; Gases or explosive or corrosive liquids; Excessive vibration, dust or metallic and/or oil particles in the air. Allowed Environment Conditions: Temperature: 0ºC to 55ºC (32ºF to 131ºF) – Rated conditions for models 85A to 820A; 0ºC to 40ºC (32ºF to 104ºF) – Rated conditions for models 950A to 1400A. 2% Current reduction for each degree Celsius above the specification in the rated conditions. Relative Air Humidity: 5% to 90%, non-condensing. Maximum Altitude:1000m ( 3,300 ft) - rated conditions. From 1000m to 4000m (3,300ft to 13,200ft) - with 1% current reduction for each 100m (330ft) above 1000m (3,300ft). Degree of Pollution: 2 (according to UL508). Water, condensation or conductive dust/particles are not allowed in the air. 3.1.2 Dimensions of the Soft-Starter SSW-06 D2 B 26 D W H A External dimensions and mounting holes follow Figure 3.1 and Table 3.1. C Figure 3.1 - Dimensional Drawings of the Soft-Starter SSW-06 CHAPTER 3 - INSTALLATION AND CONNECTION Model Height H mm (in) Width W mm (in) Depth. D mm (in) A mm (in) B mm (in) C mm (in) D2 mm (in) Mounting sc re w mm (in) Weight Kg (lb) SSW-06.0085 370 132 244 75 350 28.5 8.5 M5 8.5 SSW-06.0130 (14.57) (5.20) (9.61) (2.95) (13.78) (1.12) (0.33) (1/4") (18.74) SSW-06.0170 440 223 278 150 425 36.5 5.9 M6 18.5 SSW-06.0205 (17.32) (8.78) (10.94) (5.91) (16.73) (1.44) (0.23) (1/4") (40.79) SSW-06.0255 550 370 311 200 527.5 84.8 10 M6 39.5 SSW-06.0312 (21.65) (14.57) (12.24) (7.87) (20.77) (3.34) (0.39) (1/4") (87.08) Degree of Protection SSW-06.0365 SSW06.0412 650 369.5 347 200 627.5 84.75 11.25 M6 55.0 SSW06.0480 (25.59) (14.55) (13.67) (7.87) (24.7) (3.33) (0.44) (1/4") (121.27) IP00 SSW06.0604 SSW06.0670 795 540 357.12 250 775 145 10 M8 120.0 SSW06.0820 (31.3) (21.26) (14.06) (9.84) (30.51) (5.71) (0.39) (5/16") (264.60) SSW06.0950 894.5 568.2 345.15 400 810 84.1 10 M8 107.0 (35.22) (22.37) (13.59) (15.75) (31.89) (3.31) (0.39) (5/16") (235.93) SSW06.1100 1234.8 685 432.94 500 1110 92.5 15 M8 217.5 SSW06.1400 (48.61) (26.97) (17.04) (19.68) (43.7) (3.64) (0.59) (5/16") (479.59) Table 3.1 - Installation Data with dimensions in mm (in) 3.1.3 Positioning / Fixing At least the spaces around the soft-starter must be left open for the installation of the SSW-06 Soft-Starter, according to Figure 3.2, as follows. The dimensions of each space are described in table 3.2. Install the Soft-Starter SSW-06 in the vertical position according to the following recommendations: 1) Install the SSW-06 Soft-Starter on a flat surface; 2) Do not place heat sensitive components on top of the SSW-06 SoftStarter; ATTENTION! If the Soft-Starters are installed one next to the other, use minimum distance B. When a Soft-Starter is installed on top of another, use minimum distance A+C and avoid to the Soft-Starter above the hot air that comes from the Soft-Starter below. ATTENTION! Foresee independent conduits or electroducts for physically separating the signal, control and power conductors (see item 3.2, electrical installation). 27 CHAPTER 3 - INSTALLATION AND CONNECTION Air Flow Outlet A B B Y Air Flow Inlet C Figure 3.2 - Free spaces for cooling Model SSW-06.0085 A B C Y mm (in) mm (in) mm (in) mm (in) 150 (5.90) 30 (1.18) 150 (5.90) 50 (1.96) 150 (5.90) 30 (1.18) 150 (5.90) 50 (1.96) 150 (5.90) 30 (1.18) 150 (5.90) 50 (1.96) 150 (5.90) 30 (1.18) 150 (5.90) 50 (1.96) 150 (5.90) 30 (1.18) 150 (5.90) 50 (1.96) SSW-06.0130 SSW-06.0170 SSW-06.0205 SSW-06.0255 SSW-06.0312 SSW-06.0365 SSW-06.0412 SSW-06.0480 SSW-06.0604 SSW-06.0670 SSW-06.0820 SSW-06.0950 150 (5.90) 30 (1.18) 150 (5.90) 50 (1.96) SSW-06.1100 150 (5.90) 100 (3.93) 150 (5.90) 50 (1.96) SSW-06.1400 Table 3.2 - Recommended free spaces 3.1.3.1 Mounting inside a Panel 28 When the Soft-Starter SSW-06 are installed in panels or closed metallic boxes, adequate cooling is required to ensure that the temperature around the inverter will not exceed the maximum allowed temperature. See Dissipated Power in the table 3.4. CHAPTER 3 - INSTALLATION AND CONNECTION Use the minimum recommended panel dimensions and its cooling requirements: Panel Dimensions Width Hiegth Depth mm (in) mm (in) mm (in) SSW-06.0130 600 1200 400 SSW-06.0170 (23.62) (47.24) (15.75) Model Cooling CFM (m3/min) SSW-06.0085 - SSW-06.0205 SSW-06.0255 600 (23.62) 1600 (63.00) 600 (23.62) SSW-06.0312 600 2000 600 SSW-06.0365 (23.62) (78.74) (23.62) SSW-06.0412 SSW-06.0480 600 2000 600 (23.62) (78.74) (23.62) - - SSW-06.0604 SSW-06.0670 800 2000 600 SSW-06.0820 (31.50) (78.74) (23.62) SSW-06.0950 800 (31.50) 2000 (78.74) 600 (23.62) 1757.30 (49.80) SSW-06.1100 800 600 1757.30 (49.80) SSW-06.1400 (31.50) (23.62) 2648.44 (75.00) 2000 (78.74) - Table 3.3 - Panel Dimensions and Cooling Requirements SSW-06.0085 Power Losses In the eletronics W 33 SSW-06.0130 33 - 0 = By-pass 117.0 150.0 SSW-06.0170 33 - 0 = By-pass 153.0 186.0 SSW-06.0205 33 - 0 = By-pass 184.5 217.5 SSW-06.0255 33 0 = By-pass 229.5 320.5 SSW-06.0312 33 0 = By-pass 280.8 371.8 SSW-06.0365 33 0 = By-pass 328.5 419.5 SSW-06.0412 33 0 = By-pass 370.8 461.8 SSW-06.0480 33 0 = By-pass 432.0 523.0 SSW-06.0604 33 0 = By-pass 543.6 634.6 SSW-06.0670 33 0 = By-pass 603.0 723.0 SSW-06.0820 33 0 = By-pass 738.0 858.0 SSW-06.0950 33 3420 427.5 3898.0 SSW-06.1100 SSW-06.1400 33 33 528mA@110Vac 264mA@220Vac 58 528mA@110Vac 264mA@220Vac 58 528mA@110Vac 264mA@220Vac 58 528mA@110Vac 264mA@220Vac 58 528mA@110Vac 264mA@220Vac 58 528mA@110Vac 264mA@220Vac 87 396mA@110Vac 972mA@220Vac 87 396mA@110Vac 1391mA@220Vac 160 727mA@110Vac 955mA@220Vac 210 955mA@220Vac 210 955mA@220Vac 3960 5040 495.0 630.0 4533.0 5703.0 Model W - Total Power losses in the SCRs in Full Voltage W 0 = By-pass Average power losses-10 starts/h 3xln@30s W 76.5 Total average power losses-10 starts/h 3xIn@30s W 109.5 Fan Power 58 Table 3.4 - Power losses for panel fan dimensioning NOTE! The fans above are recommended for duties of 10 starts/hour with 3 x In of the Soft-Starter during 30s. 29 CHAPTER 3 - INSTALLATION AND CONNECTION The total power losses can be determined through the equation below: (Petc) (1.2V Ip3tp) (1.2V In3tr) Ptd tc where: Pe = power losses at the electronics (W) tc = working cycle time (s) Ip = start current (A) tp = start time (s) In = current at rated duty (A), with By-pass In=0 tr = rated duty time (Full Voltage) (s) Ptd = total power losses (W) P(W) I(A) Ip In Pe 0 tp tr t(s) tc Figure 3.3 - Soft-Starter SSW-06 working cycle for power loss determination 3.1.3.2 Mounting on a Surface The figure 3.4 shows the installation of the Soft-Starter SSW-06 on a mounting plate. Figure 3.4 - Mounting procedures for the SSW-06 on a flat surface 30 CHAPTER 3 - INSTALLATION AND CONNECTION First install and partially tighten the mounting bolts, in agreement with figures 3,1 and 3,4 and table 3.1, then install the Soft- Starter SSW-06 and tighten the mouthing bolts. Figure 3.5 - Procedures for HMI removal and front cover opening of the control connections 3.2 ELECTRICAL INSTALLATION DANGER! The Soft-Starter SSW-06 cannot be used as an emergency stop device. DANGER! Be sure that the AC input power is disconnected before making any terminal connections. ATTENTION! The information below will be a guide to achieve a proper installation. Also follow all applicable local standards for electrical installations. Provide at least a 0.25m (10 in) space between the sensitive equipment and wiring from the Soft-Starter SSW-06, and the cables between the Soft-Starter SSW-06 and the motor. Example: PLC, temperature wiring, thermocouple cables, etc. Circuit-breaker T S R Line Fuses R/1L1 S/3L2 T/5L3 U/2T1 V/4T2 W/6T3 PE Figure 3.6 - Standard power/grounding connections 31 CHAPTER 3 - INSTALLATION AND CONNECTION Circuit-breaker T S R Line Fuses R/1T1 S/3L2 T/5T3 R/1L1 S/3T2 T/5L3 U/2T1 V/4T2 W/6T3 PE PE Figure 3.7 - Power/Grounding connections for inside delta motor connection 3.2.1 The power connection terminals can be of different sizes and configurations, depending on the Soft-Starer SSW-06 model as shown in Figures 3.8 and 3.9. Terminals: R / 1L1, S / 3L2 and T / 5L3 : AC supply line U / 2T1, V / 4T2 and W / 6T3: Motor connection. Power Terminals a) Models: 85A and 130A 39 (1.54) 79.5 (3.13) 39 (1.54) 20 (0.79) Input Terminal Power 24.5 (0.96) Output Terminal Power 20 (0.79) 30.6 (1.20) 27 (1.06) 25 (0.98) Stell M6 (6x) 79.5 (3.13) * Dimensions in mm (in) Figura 3.8 a) - Maximum tightening torque for power connection 32 CHAPTER 3 - INSTALLATION AND CONNECTION b) Models: 170A and 205A 56.3 (1.30) 56.3 (1.30) 132 (5.20) 20 (0.79) 39.5 (1.56) 55.3 (2.18) Output Terminal Input Terminal Power 29.4 (1.16) 20 (0.79) Power 40 (1.57) 112 (4.41) Stell M8 (6x) * Dimensions in mm (in) 41 (1.30) 63.5 (2.50) 41 (1.30) 63.5 (2.50) 41 (1.30) 35 (1.38) 59.8 (2.35) 179.5 (7.07) Input Terminal Power 30 (1.18) 25 (0.98) Output Terminal Power 25 (0.98) c) Models: 225A, 312A, 365A, 412A, 480A and 604A 80 (3.15) Stell M10 (12x) 179.5 (7.07) * Dimensions in mm (in) Figura 3.8 b) c) – Power terminals 33 CHAPTER 3 - INSTALLATION AND CONNECTION 85 (3.35) 60 (2.36) 60 (2.36) 85 (3.35) 60 (2.36) 214.3 (8.44) 29.7 (1.17) 95 (3.74) 25 (0.98) d) Models: 670A and 820A Input Terminal Output Terminal Power 25 (0.98) 23.9 (0.94) Power 120 (4.72) 214.3 (8.44) Stell M12 (12x) * Dimensions in mm (in) e) Models: 950A 98.8 (3.89) 49.7 (1.96) 110.3 (4.34) 49.7 (1.96) 100 (3.94) 110.3 (4.34) 49.7 (1.96) 40 20 (0.79) (1.57) 51.7 (2.04) Stell M12 (12x) 212.2 (8.35) Input Bus Bar Power 53.4 (2.10) 22 (0.87) 156 (6.14) 156 22 (0.87) 50 (1.97) 22 (0.87) 14 (0.55) 49.5 (1.95) 22 (0.87) Stell M10 (6x) Output Bus Bar Power * Dimensions in mm (in) Figura 3.8 d) e) – Power terminals 34 66.1 (2.60) CHAPTER 3 - INSTALLATION AND CONNECTION 40 (1.57) 120 (4.72) 163 (6.42) 50 (1.97) 20 40 (0.79) (1.57) 158 (6.22) 158 (6.22) 40.7 (1.57) Stell M12 (12x) 104.5 (4.11) 50 (1.97) 100 (3.94) 262 (10.31) Input Bus Bar Power 58 (2.28) 129.4 40 (5.09) (1.57) 20 40 (0.79)(1.57) 60.3 (2.37) f) Models: 1100A and 1400A 163 50 (6.42) (1.97) Stell M12 (12x) 89 Output Bus Bar (3.50) Power * Dimensions in mm (in) Figura 3.8 f) – Power terminals Line / Motor SSW-06 Bolt Torque Grounding Bolt Torque Nm (lb.in) Nm (lb.in) SSW-06.0085 M6 8.3 M6 8.3 SSW-06.0130 (1/4") (74.38) (1/4") (74.38) SSW-06.0170 M8 19 M6 8.3 SSW-06.0205 (5/16") (166.25) (1/4") (74.38) SSW-06.0255 M10 37 M10 37 SSW-06.0312 (3/8") (328.12) (3/8") (328.12) M10 37 M10 37 M12 61 M10 37 SSW-06.0950 M12 61 M10 37 SSW-06.1100 M12 61 M10 37 SSW-06.0365 SSW-06.0412 SSW-06.0480 SSW-06.0604 SSW-06.0670 SSW-06.0820 SSW-06.1400 Table 3.5 - Maximum tightening Torque for power connection 35 CHAPTER 3 - INSTALLATION AND CONNECTION 3.2.2 Location of the Power/ Grounding, Control Connections and Fan Voltage Selection a) Models 85A and 130A b) Models 170A and 205A Grounding Grounding Grounding Intput Terminal Power Intput Terminal Power c) Models 255A ,312A and 365A Intput Terminal Power Fan Voltage Selection 110/220V Power Power Fan Supply Control Control Power Control Output Terminal Power Output Terminal Power Output Terminal Power e) Models 670A and 820A d) Models 412A, 480A and 640A Grounding Intput terminal Power Grounding Intput terminal Power Power Fan Voltage Selection 110/220V Control Power Output Terminal Power Fan Supply Fan Supply Fan Voltage Selection 110/220V Control Output Terminal Power Figura 3.9 a) to e) - Location of the Power/ Grounding, Control Connections and Fan Voltage Selection 36 CHAPTER 3 - INSTALLATION AND CONNECTION g) Models 1100A to 1400A f) Model 950A Grounding Grounding Power Control Power Control Fan Supply Fan Supply Intput Terminal Power Output Terminal Power Intput Terminal Power Output Terminal Power Figure 3.9 f) and g) – Location of the Power, Grounding, Control and Selection Connections 37 CHAPTER 3 - INSTALLATION AND CONNECTION 3.2.3 Recommended Power/ Grounding Cables The described specifications in tables 3,6 and 3,7 are valid only for the following conditions: Copper wires with PVC 70°C (158ºF) PVC insulation, for room temperature of 40°C (104ºF) , installed in perforated and nonagglomerated conduits Naked or silver coared copper busbars with round edges and radius equal to 1 mm with room temperature of 40°C (104ºF) and bus temperature of 80°C (176ºF). Obs.: When external By-pass contactors are applied, use the same cables or busbar applied for the motor connection. NOTE! For correct cable dimensioning, consider the installation condition and the maximum permitted line voltage drop. Model Current Cables Bus Grounding 100% In (mm²) (mm x mm) Cables (A) (mm²) SSW-06.0085 85 25 12 x 2 10 SSW-06.0130 130 50 20 x 3 25 SSW-06.0170 170 70 20 x 3 35 SSW-06.0205 205 95 20 x 3 50 SSW-06.0255 255 120 25 x 5 70 SSW-06.0312 312 185 25 x 5 95 SSW-06.0365 365 240 25 x 5 120 SSW-06.0412 412 240 30x5 120 SSW-06.0480 480 300 40x5 150 SSW-06.0604 604 2 x 150 40x5 150 SSW-06.0670 670 2 x 185 40x10 185 SSW-06.0820 820 2 x 240 40x10 240 SSW-06.0950 950 2 x 300 50x10 300 SSW-06.1100 1100 4 x 150 60x10 2 x 150 SSW-06.1400 1400 4 x 185 80x10 2 x 185 Table 3.6 - Minimum specification of cables and busbars for standard connection 38 CHAPTER 3 - INSTALLATION AND CONNECTION Current Line Motor Grounding 100% In (A) Cables Bus Cables (mm²) (mm x mm) SSW-06.0085 (mm²) 20 x 3 25 12 x 2 10 95 20 x 3 50 20 x 3 25 294 150 25 x 5 70 20 x 3 35 355 185 25 x 5 95 20 x 3 50 SSW-06.0255 441 300 30 x 5 120 25 x 5 70 SSW-06.0312 540 400 40 x 5 185 25 x 5 95 SSW-06.0365 631 500 60 x 5 240 25 x 5 120 SSW-06.0412 713 2 x 185 40x10 240 30x5 120 SSW-06.0480 831 2 x 240 40x10 300 40x5 150 SSW-06.0604 1046 4 x 120 50x10 2 x 150 40x5 150 SSW-06.0670 1160 4 x 150 60x10 2 x 185 40x10 185 SSW-06.0820 1420 4 x 185 80x10 2 x 240 40x10 240 SSW-06.0950 1645 4 x 240 100x10 2 x 300 50x10 300 SSW-06.1100 1905 4 x 300 120x10 4 x 150 60x10 2 x 150 SSW-06.1400 2424 4 x 500 160x10 4 x 185 80x10 2 x 185 Line Motor Cables Bus (mm²) (mm x mm) 147 70 SSW-06.0130 225 SSW-06.0170 SSW-06.0205 Model Table 3.7 - Recommended cables for inside delta motor connection 3.2.4 Connection of the Power Supply to the Soft-Starter DANGER! The AC input voltage must be compatible with the Soft-Starter SSW-06 rated voltage. DANGER! Provide power supply disconnecting switch. This disconnecting switch must disconnect the AC input voltage from the Soft-Starter SSW-06, always when required (for instance during maintenance services). DANGER! If a disconnect switch or a contactor is inserted in the motor supply line, DO NOT operate these devices with running motor or when Soft-Starter SSW-06 is enabled. ATTENTION! Control of overvoltage in the line that supplies the Soft-Starter must be made using surge protection with a voltage of 680 Vac (phase to phase connection) and energy absorption capacity of 40 joules (for models from 85A to 205A) or 80 joules (for models from 255A to 1400A). NOTE! Use wire sizing and fuses as recommended in Table 3.6, 3.7 and 3.9. The connector tightening torque is as indicated in Table 3.5. Use 70ºC (158ºF) copper wires only. 39 CHAPTER 3 - INSTALLATION AND CONNECTION 3.2.4.1 Power Supply Capacity The SSW-06 Soft-Starter is suitable to use in a circuit capable of supplying at most the current (symmetric Arms) established for each model, and, respective voltage (V) according to table 3.8. This, when protected by high speed semiconductor fuses. Standard Inside - Delta Connection Connection 220-575V (kA) 220-575V (kA) SSW-06.0085 10 10 SSW-06.0130 10 18 SSW-06.0170 10 18 SSW-06.0205 10 18 SSW-06.0255 18 30 SSW-06.0312 18 30 SSW-06.0365 18 42 SSW-06.0412 30 42 SSW-06.0480 30 42 SSW-06.0604 42 85 SSW-06.0670 42 85 SSW-06.0820 85 85 SSW-06.0950 85 100 SSW-06.1100 85 100 SSW-06.1400 85 125 Model Table 3.8 - Maximum current capacity of the power supply 3.2.4.2 Recommended Fuses The fuses to be used in the input must be high speed semiconductor fuses with l2t lower of equal to 75% of the SCR value indicated above (A2s). These fuses will protect the SRCs in case of a short-circuit. Normal fuses can also be used, instead of the high speed, which will protect the installation from short-circuits, but the SCRs will not be protected. Standard Delta - Inside I²t of the SCR Connection Connection (kA²s) In (A) In (A) SSW-06.0085 200 315 SSW-06.0130 250 350 84 SSW-06.0170 450 500 245 SSW-06.0205 500 550 320 SSW-06.0255 500 700 238 SSW-06.0312 500 700 238 SSW-06.0365 550 700 320 SSW-06.0412 700 1250 1452 SSW-06.0480 900 1400 4250 SSW-06.0604 900 1600 4250 SSW-06.0670 900 1600 4250 SSW-06.0820 1400 2000 4250 SSW-06.0950 1600 2200 14000 SSW-06.1100 1600 2500 14000 SSW-06.1400 2000 3000 15125 Model Table 3.9 - Recommended Fuses. 40 80 CHAPTER 3 - INSTALLATION AND CONNECTION 3.2.5 Connection of the SSW-06 Soft-Starter to the motor DANGER! Power factor correction capacitors should never be installed at the output of the Soft-Starter SSW-06 (U / 2T1, V / 4T2 and W / 6T3). ATTENTION! For the protections based on the current reading and indication to work correctly, in case of overload protection, the rated current of the motor cannot be lower than 30% of the rated current of the SSW-06 Soft-Starter. It is not recommended to use motors with the load working duty lower than 50% of its rated current. NOTE! Use wire sizing and fuses as recommended in Table 3.6, 3.7 and 3.9. The connector tightening torque is as indicated in Table 3.5. Use 70ºC (158ºF) copper wires only. NOTE! Soft-Starter SSW-06 is provided with an electronic protection against motor overload. This protection must be set according to the specific motor. When several motors are connected the same Soft-Starter SSW-06, use individual overload relays for each motor. The SSW-06 Soft-Starter can be connected to the motor in two ways, according to 3.2.5.1 and 3.2.5.2. 3.2.5.1 Standard Three-Wire Connection (P150=0=Inactive) The standard 3 wires connection allows the SSW-06 Soft-Starter line current to be equal to the motor current. R S T N PE R S T N PE S R T V U 4/U2 1/U1 W 2/V1 6/W2 T S R U 2/V1 4/U2 W V 5/V2 6/W2 5/V2 1/U1 3/W1 3/W1 Figure 3.10 - Soft-Starter SSW-06 with standard connection 41 CHAPTER 3 - INSTALLATION AND CONNECTION 3.2.5.2 Inside Delta Motor Connection (P150=1=Active) In this kind of connection, the SSW-06 Soft-Starter line current is equal to approximately 58% of the rated current of the motor. R S T N PE S S 4/U2 2/V1 V U 1/U1 5/V2 6/W2 R R W T T 3/W1 Figure 3.11 - Soft-Starter SSW-06 Inside Delta Motor Connection R S T N PE S S 10/U4 2/V1 V 4/U2 7/U3 8/V3 5/V2 U 1/U1 R 12/W4 11/V4 W 6/W2 R T 3/W1 9/W3 T Figure 3.12 - Soft-Starter SSW-06 Inside Delta Motor Connection - motor with double delta series connected. R S T N PE S S 4/U2 10/U4 1/U1 U 2/V1 V 8/V3 5/V2 7/U3 R 12/W4 11/V4 9/W3 W R T T 6/W2 3/W1 Figure 3.13 - Soft-Starter SSW-06 Inside Delta Motor Connection - motor with double delta parallel connected. 42 CHAPTER 3 - INSTALLATION AND CONNECTION ATTENTION! For the connection inside the delta of the motor, the motor must have a delta connection in the desired voltage. NOTES! 1) In the motor inside delta connection, the SSW-06 Soft-Starter connection cables to the power supply, fuses and/or the main contactor must support the rated current of the motor. The motor connection cables to the Soft-Starter and/or the external By-pass contactor connection must support 58% of the rated current of the motor. 2) Due to the presence of high currents and large cable sizes requirements, we also recommend the use of copper busbars for connecting the Soft-Starter SSW-06 to the power supply. 3) During the start of the motor current in relation to the Soft-Starter is 1.50. However in full voltage condition (after the start time of the motor) the current relation is 1.73. ATTENTION! Pay attention to the connection of the motor to the SSW-06 Soft-Starter, respect the connection diagrams shown in the figures above according to the type of motor windings. If it is necessary to change the motor speed direction, only invert the SSW-06 Soft-Starter connections to the power supply. Maintain the electronics turned off during the connection changes. ATTENTION! Ensure correct setting of Parameter P150 before the motor is switched ON. Soft-Starter SSW-06 may be damaged, when this parameter setting is not correct P150 Action 0 (Inactive) Soft-Starter SSW-06 with standard connection to motor 1 (Active) Soft-Starter SSW-06 inside of the delta motor connection Table 3.10 - Connection of the Soft-Starter to the motor 3.2.6 Grounding Connections DANGER! The Soft-Starter SSW-06 must be grounded for safety purposes (PE). The earth or ground connection must comply with the local regulations. For grounding, use cables with cross section as indicated in Table 3.6. Make the ground connection to a grounding bar or to the general grounding point (resistance 10 ohms). DANGER! The AC input for the Soft-Starter SSW-06 must be grounded. DANGER! Do not use the neutral conductor for grounding purpose. Use a specific ground conductor. ATTENTION! Do not share the ground wiring with other equipment that operate with high currents (for instance, high voltage motors, welding machines, etc). When more than one self-starter SSW-06 used, see 3.14 figure. 43 CHAPTER 3 - INSTALLATION AND CONNECTION Grounding bar Internal to the Panel Grounding bar Internal to the Panel Figure 3.14 - Grounding connections for more than one Soft-Starter SSW-06 EMI – Electromagnetic interference: The Soft-Starter SSW-06 is developed to be used in industrial systems (Class A) as per Norm EN60947-4-2. It’s necessary to have a distance of 0,25m (10in) between the SoftStarter SSW-06 and the cables between the Soft-Starter SSW-07 and the motor. Example: PLC wiring, temperature controllers, thermocouple cables, etc. Grounding the motor frame: Always ground the motor frame. Ground the motor in the panel where the Soft-Starter SSW-06 is installed. The Soft-Starter SSW-06 output wiring to the motor must be laid separately from the input wiring, as well as from the control and signal cables. 3.2.7 Fan Connections Available in models 255A to 820A. The rated voltage of the fans can also be selected. SELEÇÃO Voltage Selection DE TENSÃO 110/220V 110/220V Fan ATTENTION! SELECT THE FAN VOLTAGE IN ACCORDANCE WITH THE VOLTAGE APPLIED TO THE TERMINALS X1:33 AND X1:34 ATENCION! SELECCIONAR LA TENSION DE LOS VENTILADORES DE ACUERDO CON LA TENSION APLICADA A LOS BORNES X1:33 Y X1:34 ! ATENÇÃO! SELECIONE A TENSÃO DOS VENTILADORES DE ACORDO COM A TENSÃO APLICADA AOS BORNES X1:33 E X1:34 X1E ALIMENTAÇÃO Fan Power Supply VENTILADOR Figura 3.15 – Selection of the Fan Voltage Connector X1E pins 33 and 34. More details see figure 3.16. 44 CHAPTER 3 - INSTALLATION AND CONNECTION NOTE! The fans are switched on if the heatsink temperature is above 70ºC (158ºF). Do not forget to connect the fan power supply and select the fan supply voltage for the models higher than 255A. 3.2.8 Signal and Control Connections The signal connections (analog outputs) and control (relay inputs and outputs) are made on the electronic card connectors. Conectors: CCS6 and CPS63 to the models 85A to 365A and 950A to 1400A. CCS6 and CPS64 to the models 412A to 820A. 1 Conector X1A Phase 2 Neutral PE Ground PTC Connector X1B Description Eletronic Supply (110 to 230)Vac (-15% to +10%) or (94 to 253)Vac Operation Current: 280nA Max. Factory Standard Function Specifications 3 DI1 Motor Enable/Disable 4 DI2 Error Reset 5 DI3 Not Used 6 DI4 Not Used 7 DI5 Not Used 8 COM Common point of the Digital Inputs 9 COM Common point of the Digital Inputs 10 DGND 0V reference of the 24Vdc source 11 24Vcc Digital Input Supply 12 13 PTCB PTCA 14 AGND 15 AO1 16 AGND 17 AO2 Conector X1C 18 RL1 NA 19 RL1 NA 20 RL2 NA 21 RL2 NA 22 RL3 NA 23 RL3 C 24 RL3 NF Conector X1D 25 TERM. 26 TERM. 27 TC 1/R VER 28 TC 1/R PRET 29 TC 2/S VER 30 TC 2/S PRET 31 TC 3/T VER 32 TC 3/T PRET Connector X1E 33 Phase 34 Neutral Specifications 5 isolated digital inputs Minimum high level: 18Vdc Maximum low level: 3Vdc Maximum voltage: 30Vdc Input current: 11mA@24Vdc Only use for Digital Inputs DI6 - Not Used Operation: 3k9 Release: 1k6 Minimum resistance: 110 PTCB referenced to DGND Through 249 resistor Input for motor Thermistor (0 to 10)V, RL 10k (maximum load) Resolution: 11 bits Analog Output 1 - Not used (0 to 20)mA or (4 to 20)mA RL=500/1%@10V Resolution: 11 bits Factory Standard Function Specifications Relay Output - Run Relay Output - Full Voltage Contactor capacity: 1A 24Vac Relay Output – No Error Description Specifications Over-temperature thermostat Current transformer phase R Internal connection of the Soft-Starter Current transformer phase S Current transformer phase T Descrição Specifications Fan Supply (from model 255A) (101 to 127)Vac or (207 to 253)Vac Operation current: see table 3.4 Nota: NC = Normally Closed Contact NO = Normally Open Contact C = Common Figure 3.16 - Control Terminal Description 45 CHAPTER 3 - INSTALLATION AND CONNECTION X1B X1C X2 X1D X1A XO To be used for grounding of shield of the signal an control cables Figure 3.17 - Control connector disposition For signal and control wire installation, adopt the following procedures: 1) The connections of the SSW-06 digital inputs can be carried out in several ways. They can be supplied by auxiliary internal +24Vdc source by using the 0V as a common point or by the +24Vdc source. Depending on the application requirements,they can also be supplied by external +24Vdc source , connected to PLCs, by using the 0V as common point or by the +24Vdc source.: Connector X1B Connector X1B 3 DI1 3 DI1 4 DI2 4 DI2 5 DI3 5 DI3 6 DI4 6 DI4 7 DI5 7 DI5 8 COM 8 COM 9 COM 9 COM 10 DGND 10 DGND 11 11 24Vdc 24Vdc Figure 3.18 - Connection diagram of the digital inputs using an the auxiliary internal source + 24Vdc Connector X1B Connector X1B 3 DI1 3 DI1 4 DI2 4 DI2 5 DI3 5 DI3 6 DI4 6 DI4 7 DI5 7 DI5 8 COM 8 COM 9 COM + 9 COM 10 DGND 11 24Vdc 24Vdc 10 DGND 11 24Vdc Figure 3.19 - Connection diagram of the digital inputs using an external source 46 CHAPTER 3 - INSTALLATION AND CONNECTION NOTE! 1) The auxiliary electronic power supply of the SSW-06 Soft-Starter of +24Vdc shall only be used for the supply of the digital inputs. 2) The SSW-06 Soft-Starter factory default is with the pins 8 and 10 of the X1B connector switched on (wire bridge). 3) Cable cross section (0,5 to 1,5) mm2; 4) Maximum torque: 0.50 N.m (4.50 ibf.in). 5) X1B wiring must be connected with shielded cables and installed separately from other wiring (power, control at 110V/220V, etc.), according to Table 3.11. Wiring Length Min. separation distance 30 m (98.4 ft) 10 cm (3.94 in) > 30 m (98.4 ft) 25 cm (9.84 in) Table 3.11 - Wiring separation distances If the crossing of these cables is unavoidable, install them perpendicular, maintaining a minimum separation distance of 5cm (2 in) at the crossing point. Connect the shield as shown below: Insulate with tape Soft-Starter side Do not ground Connect to ground Screw located on the CCS6 board Figure 3.20 - Shield connection 6) For wiring distances longer than 50m (150ft), it is necessary to use galvanic isolators for the X1B:3...17signals. 7) Relays, contactors, solenoids or electromagnetic braking coils installed near Soft-Starters can generate interference in the control circuit. In order to eliminate this interference, connect RC suppressors in parallel with the coils of AC relays. Connect a free - wheeling diode in case of DC relays/coils. 8) When an external keypad (HMI) is used (Refer to Chapter 8), separate the cable that connects the keypad to the Soft-Starter SSW-06 from other cables, maintaining a minimum distance of 4 in (10 cm) between them. 47 CHAPTER 3 - INSTALLATION AND CONNECTION 3.2.9 RS-232, X2 Serial Communication Connection This connector is used to make a standard RS232 communication line between the Soft-Starter SSW-06 and a PC and/or PLC. For more details see the Serial Communication Manual of the Soft-Starter SSW-06. 3.2.10 RS-485, XC8 Isolated Serial Communication Board Connection An optional board of serial communication, standard RS-485 with galvanic insulation, can be attached to this connector. For more details see the Serial Communication Manual of the Soft-Starter SSW-06. 3.2.11 XC6 Fieldbus Communication Board Connection An optional Profibus DP or DeviceNet Communication board can be attached to this connector. For more details see the Profibus DP or DeviceNet Communication Manual of the Soft-Starter SSW-06 and chapter 9. Figure 3.21 – X2, XC6 and XC8 Connector 3.3 RECOMMENDED SET-UPS In this item some suggestive starters are presented, which can be used completely or in part to elaborate the desired control. The main warnings, for all the suggestive starters, listed below, are related in the diagrams through their respective numbers. NOTES! 1 48 For the protection of all of the electrical installation, the use of fuses or circuit breakers in the main power supply circuit is necessary. The use of high speed semiconductor fuses are not necessary for the functioning of the SSW-06 Soft-Starter, but its use is recommended for the complete protection of the thyristors. 2 The transformer “T1” is optional and should be used when the line voltage is different from the electronics and fan voltage; 3 To protect the motor against destruction by possible shortcircuits in the power circuit of the Soft-Starter SSW-06 use an isolating contactor (K1) or circuit-breaker (Q1); CHAPTER 3 - INSTALLATION AND CONNECTION 4 X1E (33 and 34) is only available in the models fitted with cooling fans; 5 For integral motor protection the installation of one or more PTC thermistors (PTC at the DI6) or thermostats (external fault at the DI4 to DI6) is recommended; 6 Remember that when a command via two-wire digital input is used (the switch is normally open with retention), every time the power supply returns, after any fault, the motor starts immediately if the switch remains closed; 7 8 In case of maintenance services, remove the power supply fuses or disconnect the power supply, thus ensuring complete equipment disconnection from the power supply; The emergency stop can be obtained by disconnecting the electronics power supply. 9 The contactors must be of the same model and must support the motor starting current. For safety reasons, auxiliary contacts must be used to keep both contactors from closing at the same time. 10 Use a digital input set to “General Enable” to dissable the motor without braking. Use a digital input set to “No Braking”, for safety reasons, with the possibility of putting a motor stop sensor to disable the braking. 11 12 The use of an external By-pass contactor is optional for models 950A to 1400A that do not have an internal By-pass contactor. This contactor is also recommended, in models with an internal by-passs, for use in applications where the motor can frequently present a blocked rotor during the full operation cycle. To maintain the current indications and protections, when using the external By-pass contactor, it is necessary to place the current transformers in the soft starter output. The current transformers must be placed in the correct positions and directions as indicated. ATTENTION! In the first power-up, in the models of 85A to 365A, if a contactor or a circuit-breaker of insulation of the power supply with under voltage release will not be used, to connecting the control power supply first, program the minimum necessary parameters and only after connecting the power supply. 49 CHAPTER 3 - INSTALLATION AND CONNECTION 3.3.1 Recommended Set-ups by Keypad (HMI) Command With Isolating Contactor. T1 P220 =0 R S T P229 =0 PE P277 =1 P279 =6 K1 Fault K1 R S T 1 2 PE 33 34 X1A X1E 18 19 20 21 RL1 22 23 RL2 24 RL3 X1C X1B Dl1 3 U V W Dl2 4 Dl3 5 Dl4 6 Dl5 7 COM 8 9 24V PTC B A 11 12 13 0V 10 See note in 3.3 + to M 3~ PTC Figure 3.22 - Recommended Set-ups by Keypad (HMI) command with isolating contactor 3.3.2 Recommended Set-ups by Keypad (HMI) Command with Circuit-breaker. P220 =0 P229 =0 T1 R S T PE Q2 P279 =7 Fault Q1 Q1 Circuitbreaker with under voltage release 18 33 34 1 2 PE R S T X1A X1E 19 21 20 RL2 RL1 22 23 24 RL3 X1C X1B Dl1 3 U V W Dl2 4 Dl3 5 Dl4 6 Dl5 7 CO M 8 9 0V 10 24V PTC B A 11 12 13 See note in 3.3 + to M 3~ PTC Figure 3.23 - Recommended Set-ups by Keypad (HMI) command with circuit-breaker 50 CHAPTER 3 - INSTALLATION AND CONNECTION 3.3.3 Recommended Set-ups with Command via Two-wire Digital Inputs. P220 =1 P230 =1 T1 R S T PE P277 =1 K1 P279 Fault K1 =6 R S T 1 2 PE 33 34 X1A X1E 18 20 19 21 22 23 24 RL2 RL1 RL3 X1C X1B Dl2 4 Dl1 3 Enable Disabela U V W See note in 3.3 M 3~ Dl3 5 Dl4 6 Dl5 7 24V PTC B A 11 12 13 0V 10 COM 8 9 6 + to PTC Figure 3.24 - Recommended set-ups with command via two-wire digital inputs Recommended Set-ups with Command via Three-wire Digital Inputs. P220 =1 P230 =1 P264 =1 T1 R S T PE K1 P277 =1 P279 =6 Fault K1 R S T 1 2 PE 33 34 X1A X1E 18 19 21 20 RL1 22 23 24 RL3 RL2 X1C X1B U V W See note 3.3. Dl3 5 Dl4 6 Dl5 7 COM 8 9 0V 10 24V PTC B A 11 12 13 Disable Dl2 4 Dl1 3 Enable 3.3.4 + to M 3~ PTC Figure 3.25 – Recommended set-ups with command via three-wire digital inputs 51 CHAPTER 3 - INSTALLATION AND CONNECTION 3.3.5 Recommended Set-ups with Command via Three-wire Digital Input and Inside Delta Motor Connection. P150 =1 P220 =1 P230 =1 T1 R S T PE K1 P264 =1 P277 =1 P279 Fault K1 R S T 1 2 PE 33 34 X1A X1E 19 18 21 22 20 RL1 RL2 23 24 RL3 X1C =6 X1B Dl2 4 U V W Enable See notes 3.3 and 3.2.5.2. Dl3 5 Dl4 6 Dl5 7 0V 10 COM 8 9 24V PTC B A 11 12 13 Disable Dl1 3 + to M 3~ PTC Figure 3.26 – Recommended set-ups with command via three-wire digital input and inside delta motor connection. 3.3.6 Recommended Set-ups with Command via Three-wire Digital Input or Serial Communication. P220 =4 P229 =1 P230 =2 T1 R S T PE K1 P264 =1 P277 =1 Fault K1 1 2 PE X1A R S T 18 33 34 X1E 19 RL1 20 21 22 23 24 RL2 RL3 X1C X2 Dl1 3 Enable U V W See note 3.3 M 3~ Dl2 4 Dl3 5 Dl4 6 X1B Dl5 COM 7 8 9 PC 0V 10 24V PTC B A 11 12 13 Local Remote =6 Disable P279 + to PTC Figure 3.27 - Recommended set-ups with command via three-wire digital input or serial communication 52 CHAPTER 3 - INSTALLATION AND CONNECTION 3.3.7 Recommended Set-ups with Command via Three-wire Digital Input or Fieldbus Communication. P220 =4 P229 =1 P230 =3 T1 R S T PE K1 P264 =1 P277 =1 Fault K1 19 18 33 34 1 2 PE X1A R S T X1E 21 22 23 24 20 RL1 RL2 RL3 X1C X2 =6 X1B Dl2 4 Enable See note 3.3 M 3~ Dl3 5 Dl4 6 Dl5 7 0V 10 COM 8 9 24V PTC B A 11 12 13 PLC Local Remote Dl1 3 U V W Disable P279 + to PTC Figure 3.28 - Recommended set-ups with command via three-wire digital input or fieldbus communication Recommended Setup with Command via Digital Inputs and direction of rotation. P220 =1 P230 =1 P231 =1 T1 R S T PE K2 P264 =1 P266 =1 K1 K1 19 18 33 34 1 2 PE X1A R S T X1E RL1 Fault K2 21 22 23 24 20 RL2 RL3 X1C =4 =4 P279 =6 See note 3.3 M 3~ + to Dl2 4 Dl3 5 Dl4 6 X1B Dl5 COM 8 9 7 0V 10 24V PTC B A 11 12 13 Direction of Rotation P278 Dl1 3 U V W Disable P277 Enable 3.3.8 10 PTC Figure 3.29 - Recommended Setup with Command via Digital Inputs and direction of rotation. 53 CHAPTER 3 - INSTALLATION AND CONNECTION 3.3.9 Recommended Setup with Command via Digital Inputs and Reverse Braking P220 =1 P230 =1 P264 =1 P265 =1 T1 R S T PE K2 K1 K1 1 2 PE X1A R S T P266 =5 19 18 33 34 X1E Fault K2 21 22 23 24 20 RL1 RL2 RL3 X1C X1B P279 =6 P500 =1 Dl3 5 24V PTC B A 11 12 13 0V 10 10 + to M 3~ COM 8 9 Dl5 7 Dl4 6 Without Braking =4 Enable P278 Dl2 4 Dl1 3 U V W Gen. Enable =4 Disable P277 PTC See note 3.3 Figure 3.30 - Recommended Setup with Command via Digital Inputs and Reverse Braking. 3.3.10 Recommended Setup with Command via Digital Inputs and Optimal Braking P230 =1 PE P264 =1 P265 =1 T1 K1 1 2 PE X1A R S T P266 =5 P277 =1 P500 =2 See note 3.3 X1E 19 21 22 23 24 20 RL1 RL2 RL3 X1B Dl2 4 Dl1 3 Enable =6 18 33 34 X1C U V W P279 Fault K1 M 3~ Dl3 5 Dl4 6 Dl5 7 COM 8 9 0V 10 24V PTC B A 11 12 13 Without Braking R S T Gen. Enable =1 Disable P220 + to PTC Figure 3.31 - Recommended Setup with Command via Digital Inputs and Optimal Braking. 54 CHAPTER 3 - INSTALLATION AND CONNECTION 3.3.11 Recommended Setup with Command via Digital Inputs and DC-Braking P220 =1 P230 =1 P264 =1 T1 R S T PE K1 K1 P265 =1 P266 =5 Fault K2 19 18 33 34 1 2 PE X1A R S T X1E 21 22 23 24 20 RL1 RL2 RL3 X1C =1 =6 K2 P500 =3 Dl5 7 0V 10 COM 8 9 24V PTC B A 11 12 13 Without Braking P279 Dl4 6 Gen. Enable =5 Dl3 5 Disable P278 X1B Dl2 4 Dl1 3 U V W Enable P277 + to M 3~ See note 3.3 PTC Figure 3.32 - Recommended Setup with Command via Digital Inputs and DC-Braking. 3.3.12 Recommended Setup with Command via Digital Inputs and External By-pass Contactor P140 =1 P220 =1 P230 =1 T1 R S T PE K1 K1 P264 =1 P277 =1 Fault K2 1 2 PE X1A R S T 18 33 34 X1E 19 21 22 23 24 20 RL1 RL2 RL3 X1C See note 3.3 X1B X1D Dl2 Dl3 Dl4 Dl5 4 5 6 7 COM 0V 8 9 10 24V PTC B A 11 12 13 Disable U V W Dl1 3 Enable =6 K2 Red Black Red Black Red Black P279 =3 27 28 29 30 31 32 P278 + to M 3~ PTC Figure 3.33 - Recommended Setup with Command via Digital Inputs and External By-pass Contactor. 55 CHAPTER 3 - INSTALLATION AND CONNECTION 3.3.13Symbols Fuse Electrical connection between two signal Thyristor/SCR Connection Terminals Coil - Relay, Contactor Normally Open Contact (NO) Indicator light Circuit-breaker M 3~ Three-phase Motor Emergency Button Transformer N.O. Contact (with retention) (opens under load) Resistor Capacitor Normally Closed (NC) Push-button Normally Open (NO) Push-button Circuit-breaker with under voltage release 56 CHAPTER 3 - INSTALLATION AND CONNECTION 3.4 European Directives for Electromagnetic Compatibility Requirements for installation. The SSW-06 series Soft-Starters were designed considering all the safety and electromagnetic compatibility aspects. SSW-06 Soft-Starters do not have any intrinsic function if they are not connected to other components (for example, with a motor). For this reason, the basic product does not have the CE label indicating conformity with the electromagnetic compatibility directive. The SSW-06 attends all the requirements of the electromagnetic compatibility directive (89/336/EEC), as defined by Product Standard EN60947-4-2 (2000) + A1 (2002) - “low-voltage switchgear and controlgear part 4.2: Ac Semi-conductor Motor controllers and Starters” specific standard for drives. The conformity of all the SSW-06 series is based on tests of some representative models. A Technical Construction File (TCF) was checked and approved by a competent body. 3.4.1 Installation To install the Soft-Starter(s) in conformity with the EN60947-4-2 standard, it is necessary to attend the following requirements: 1) The cables used for control (inputs and outputs) and signal wiring must be armored or installed in metallic electroducts (conduits) or in metallic channel with equivalent attenuation. 2) It is indispensable to follow the recommendations for earthing presented in this manual. 3) Models 85A to 1400A SSW-06 Soft-Starters are classified for use in “Class A”, individual use with no need of external filters or armored power cables. Description of the conducted emission classes according to Standard EN60947-4-2 (2000) + A1 (2002): - Class B: residential environment (first environment), unrestricted distribution - Class A: industrial environment (second environment), unrestricted distribution. 57 CHAPTER 4 KEYPAD (HMI) OPERATION This Chapter describes the operation of the standard Keypad (HMI) of the Soft-Starter SSW-06, providing the following information: General Keypad (HMI) Description; Use of the Keypad; Soft-Starter SSW-06 Parameters organization; Parameter programming; Description of the Status Indicators. 4.1 DESCRIPTION OF THE KEYPAD (HMI-SSW06) The standard Soft-Starter SSW-06 Keypad has one readout displays: a LED readout with a 4 digit, seven-segment display and al LCD display with two lines of 16 alphanumeric characters. There are also 4 indicator LED’s and 8 keys.Figure 4.1 shows the front view of the Keypad and indicates the position of the readouts, keys and status LED’s. Functions of the LED Display: Shows error and messages status (see Parameter, Error and State Message Quick Reference), the parameter number or its context. The unit display (to the right) indicates the unit of the indicated variable. Acurrent UVoltage Hfrequency Blankother parameters NOTE! When the indication is equal or higher than 1000 (A or U), the variable unit will not be indicated (ex.: 568.A, 999.A, 1000,1023, etc.) NOTE! When the indication is higher than 9999 (in A, for instance), the number corresponding to ten thousand will not be displayed (Ex.: 12345 A will be read as 2345 A).The correct indication will be displayed only on the LCD display. LED´s Display LCD-Display Green LED "Local" Green LED "Forward" Green LED "Remote" Red LED "Reverse" Figure 4.1 - SSW-06 HMI 59 CHAPTER 4 - KEYPAD (HMI) OPERATION Functions of the LCD Display: The LCD Display shows the parameter number and its value simultaneously, without the need of pressing the key. It also provides a brief description of each parameter and also the units (A, Hz, V, s, %) when necessary. It also provides a brief description of the fault code and inverter status. Local and Remote Led Functions: Soft-Starter in Local Mode: Green Led on and Red Led Off. Soft-Starter in Remote Mode: Green Led Off and Red Led on. Direction of Rotation (FWD/REV) LED Functions: Not implemented in this Software Version Speed Forward Forward Reverse 0 FWD / REV Command (key) ON OFF FLASHING Figure 4.2 - Direction of Rotation (FWD / REV) LED´s Operation of the Man Machine Interface (MMI) keys: Starts (Enable) the motor (start). Stops (Disables) the motor (stop). Also resets the Soft-Starter after a fault has occurred. Toggles the LED display between the parameter number and its value (position/content). Increases the number of the parameter or the value of the parameter. Decreases the number of the parameter or the value of the parameter. Reverses the direction of motor rotation between Forward/Reverse Toggles between this LOCAL or REMOTE modes of operation. 60 CHAPTER 4 - KEYPAD (HMI) OPERATION Performs the JOG function when pressed. Any DIx programmed for General Enable must be closed (and the SSW-06 must be stopped) to enable JOG function. 4.2 USE OF THE KEYPAD The keypad is used for programming and operating the Soft-Starter allowing the following functions: Indication of the Soft-Starter SSW-06 status and main operation variables; Fault indications; Viewing and programming of the setable parameters; Soft-Starter SSW-06 operation (via keys , and ). 4.2.1 Keypad use for Soft-Starter SSW-06 Opertation All functions relating to the Soft-Starter SSW-06 operation (Start, Stop, Increment, Decrement, JOG- Local/Remote condition) can be performed through the Keypad. All keypad keys are enabled when the Local Mode has been selected. All these functions can be executed individually through digital inputs. For this, all parameters related to these functions and to the corresponding inputs must be programmed. Operation of the Man Machine Interface (HMI) keys: When programmed (P220 = 2 or 3), it selects the command source, changing between "Local” and “Remote”. When programmed (P229 = 0 (key and/or P230 = 0 ( key , , “ Local” condition) “Remote condition”). Starts the motor via Acceleration Ramp. (motor accelerates according to acceleration ramp and load characteristics). Stops the motor via Deceleration Ramp. (motor decelerates according to deceleration ramp and stops). It resets the Soft-Starter after a fault trip (always active). Reverses the motor direction of rotation. Enabled when P220 = 2 (Keypad LOC), P229 = 0 (HMI Key), Local Mode, P231 = 1 (By Contactor) or P231 = 2 (JOG Only). Enabled when P220 = 3 (Keypad REM), P230 = 0 (HMI Key), Remote Mode, P231 = 1 (By Contactor) or P231 = 2 (JOG Only). When P231 = 1 (By Contactor), changes the motor direction of rotation via contactor, if the contactors are connect at the input power supply and P277 = 4 (FWD/REV-K1) and P278 = 4 (FWD/REV-K2). When P231 = 2 (JOG Only), changes the motor direction of rotation only to the Jog function. Contactors are not required. Enabled when P510 = 1 (Active). When the Jog key is pressed, it accelerates the motor to the Jog frequency conform the motor direction of rotation. When the Jog key is released, the motor decelerates and stops. When the Jog key is pressed, it accelerates the motor to the Jog frequency according to the motor direction of rotation. The motor must be disabled and the Soft-Starter SSW-06 is with General Enable. 61 CHAPTER 4 - KEYPAD (HMI) OPERATION 4.2.2 HMI Display - Signaling indications Parameters P001 to P099 are only Read Parameters. The first parameter to be displayed when the Soft-Starter is powered-up, can be programmed at P205. P205 Parameter to be displayed first 0 P001 (Motor current %In of the Soft-Starter) 1 P002 (Motor current %In of the Motor) 2 P003 (Motor current) 3 P004 (Line voltage) 4 P005 (Line Frequency) 5 P006 (Soft-Starter Status) 6 P007 (Output Voltage) 7 P008 (Power Factor) Table 4.1 - Parameter initially shown in the displays Soft-Starter Status: Soft-Starter is ready to be enabled SoftStarter Ready Soft-Starter is operated via acceleration ramp “ramp up” SoftStart. Status P006=ramp up SoftStart. Status P006=full voltage SoftStart. Status P006=bypass Soft-Starter is operated at “full voltage” Soft-Starter is operated with enabled By-pass. Soft-Starter is operated via deceleration ramp “ramp down” SoftStart. Status P006=run down Soft-Starter with fault SoftStart. Status P006=Exx 62 CHAPTER 4 - KEYPAD (HMI) OPERATION 7 Segment Display is flashing: The display flashes in the following conditions: trying to change a parameter value when it is not allowed; Soft-Starter in Fault condition (Refer to Chapter 7 - Diagnosis and Troubleshooting) 4.2.3 Parameter viewing and programming All Soft-Starter settings are made through the parameters. The parameters are shown on the display with the letter P followed by a number: Example (P101): 101= Parameter Number Init. Volt Start P101=30% Each parameter is associated to a numerical value (parameter content), that corresponds to an option selected among the options available for this parameters. The values of the parameters define the Soft-Starter programming or the value of a variable (and.g. current, frequency, voltage). For SoftStarter programming you should change the parameter(s) content(s). ACTION DISPLAY HMI LED DISPLAY HMI LCD DESCRIPTION SoftStarter Ready Press the key Motor Current P000=0.0% Use the keys Select the desired parameter and Init. Volt Start P101=30% 63 CHAPTER 4 - KEYPAD (HMI) OPERATION ACTION DISPLAY HMI LED DISPLAY HMI LCD Press the key Init. Volt Start P101=30% Use the keys and Init. Volt Start P101=35% Press the key DESCRIPTION Numeric value associated to the parameter (4) Sets the new desired value. (1) (4) (1) (2) (3) Init. Volt Start P101=35% (1) For parameters that can be changed with the motor running, the Soft-Starter will use the new value immediately after it has been set. For the parameters that can be changed only with the motor stopped, the Soft-Starter will use this new set value only after the key is pressed. (2) By pressing the key after the reprogramming, the new programmed value will be saved automatically and will remain stored until a new value is programmed. (3) If the last value programmed in the parameter is not functionally compatible with other parameter values already programmed, an E24 - Programming Error - will be displayed. Example of programming error: Programming two digital inputs (DIx) with the same function. Refer to Table 4.2 for the list of programming errors that will generate an E24 Programming Error. (4) To allow the reprogramming of any parameter value it is necessary to change parameter P000 to the password value. The factory default password value is 5. Otherwise you can only read the parameter values and not reprogram them. For more details see P000 description in Chapter 6. E24 - Programming Error Two or more parameters between P266 and P268 equal to 1 (LOC/REM) Two or more parameters between P266 and P268 equal to 2 (LOC/REM) (P202 = 2 and P520 = 1) if there is pump control with kick start (P202 = 3 and P520 = 1) if there is torque control with kick start (P150 = 1 and P500 = 3) if there is DC-Braking with Delta Inside Table 4.1 - Incompatibility between Parameters - E24 64 CHAPTER 5 START-UP This Chapter provides the following information: How to check and prepare the Soft-Starter SSW-06 before power-up; How to power-up and check for proper operation; How to operate the Soft-Starter SSW-06 (See Electrical Installation). 5.1 POWER-UP PREPARATION The Soft-Starter SSW-06 shall be installed according to Chapter 3 Installation. If the drive project is different from the typical recommended drives, the steps below may also followed. DANGER! Disconnect the AC input power before making any connections. 1) Check all connections: Check if the power, grounding and control connections are correct and well tightened. 2) Clean the inside of the Soft-Starter SSW-06: Remove all shipping material from the inside of the Soft-Starter SSW-06 or cabinet. 3) Checks the correct voltage selection: In models 255A to 820A, the fan supply voltage selection is correct. In models 950A to 1400A the single-phase supply voltage must be checked to make sure it is adequate to the voltage of the fans. 4) Check the motor: Check all motor connections and verify if their voltages, currents and frequencies match the Soft-Starter SSW-06 specifications. 5) Check the Soft-Starter SSW-06 motor connection type: Check if the standard three-wire connection should be used or if the Soft-Starter SSW-06 should be connected via inside delta of the motor. For more details, refer to Chapter 3. 6) Uncouple the load from the motor: If the motor cannot be uncoupled, make sure that the direction of rotation (FWD/REV) does cannot cause damage to the machine. 7) Close the Soft-Starter SSW-06 and/or cabinet cover. 65 CHAPTER 5 - START-UP 5.2 INITIAL POWER-UP (required parameter settings) After the Soft-Starter SSW-06 has been checked, AC power can be applied: 1) Check the supply voltage: Measure the line voltage and check if it is within the specified range (Rated Voltage - 15% to + 10% ). 2) Power-up the Electronics Supply: NOTE! Always energize the electronics supply before energizing the power and execute all adjustments/settings described in this item. 3) Check if the power-up has been successful When the Soft-Starter SSW-06 is powered up for the first time or when the factory default parameter values are loaded (P204 = 5), a start-up routine is run. This routine requests the user to program some basic parameters to ensure proper Soft-Starter SSW-06 and operation and motor operation.This routine sequence changes according to the selected type of control. For more details about the control type to be selected, refer to Parameter P202 in Chapter 6. The parameterization sequence for each control type is show in figure 5.1. ATTENTION! For correct programming of the protection parameters, please consider the catalog data and the motor nameplate data of the used motor. To protect the motor against overloads during the start process and at during operation, program the thermal class of the motor. For more details about programming of the Thermal Class, see description of Parameter P640 in Chapter 6. In this parameter setting sequence only the main parameters for learning about the Soft-Starter SSW-06 operation are shown. Please program all necessary parameters for correct operation of the Soft-Starter and motor protection, before operating it at rated operation conditions. 4) Close the input circuit-braker. 66 CHAPTER 5 - START-UP P201 P150 P202 Voltage Ramp Current Limit Pump Control Torque Control Current Ramp P101 P102 P130 P102 P102 P102 P110 P101 P120 P110 P400 P400 P102 Constant Linear P401 P401 P103 P121 P406 P406 P104 P640 P640 Square P111 P121 P121 P112 P122 P122 P400 P105 P123 P401 P400 P124 P406 P401 P610 P611 P620 P406 P640 P104 P125 Constant Linear Square P126 P126 P126 P127 P127 P640 P128 P400 P401 P402 P404 P405 P406 P640 Figure 5.1 – Parameter sequence during initial power-up 67 CHAPTER 5 - START-UP Shown below is a parameter programming example requested by this routine. Example: Soft-Starter SSW-06 SSW060130T2257PSZ Motor High Efficiency Plus Three-Phase Electric Motor- 4 Poles - 60Hz Power: 75 HP Frame size: 225S/M Speed: 1770 rpm Rated current at 380V: 101 A Service Factor: 1.15 Start mode Start-up by voltage ramp. Initial Power-up - Programming via Keypad (HMI) (Based on the example above): HMI LED DISPLAY HMI LCD DISPLAY ACTION After Power-up, the Display shows the following message Language P201 = Port Press the key programming mode to enter the DESCRIPTION Language Selection: 0=Portuguese 1=English 2=Spanish 3=German Enter the programming mode. Language P20 1 = Port Use the keys and select the language Selected language; English to Language P20 1 = English Press the key to save the selected option and exit the programming mode Press the key next parameter Press the key programming mode 68 Exit the programming mode. Language P20 1 = English to go to the Delta Inside P150=OFF to enter the Soft-Starter Connection Type to the motor: 0=Inactive = standard 3 wires 1=Active = Delta inside 6 wires Enter the programming mode Delta Inside P150=OFF CHAPTER 5 - START-UP HMI LED DISPLAY HMI LCD DISPLAY ACTION Use the keys and for programming Soft-Starter connection type to motor Press the key to save the selected option and exit the programming mode Press the key parameter Delta Inside P150=OFF Soft-Starter connection type to motor: standard 3 wires (Maintained the already existing value) Exit the programming mode Delta Inside P150=OFF to go to the next Type of Control P202= Volt.Ramp. Press the Key programming mode DESCRIPTION to enter the Selection of the start control type: 0=Voltage ramp 1=Current Limit 2=Pump Control 3=Torque Control 4=Current Ramp Enter the programming mode. Type of Control P20 2= Volt.Ramp. Use the keys and select the start control type to Press the key to save the selected option and exit the programming mode Press the key parameter Type of Control P20 2= Volt.Ramp. Selected start control type: Voltage ramp (Maintained the already existing value) Exit the programming mode Type of Control P20 2= Volt.Ramp. to go to the next Initial start voltage by voltage ramp: (25 to 90)%Un Init. Volt Start P101=30% Press the key to enter programming mode Enter the programming mode. Init. Volt Start P101=30% 69 CHAPTER 5 - START-UP HMI LED DISPLAY HMI LCD DISPLAY ACTION Use the keys and select the initial start voltage to Init. Volt Start P101=35% Press the key to save the selected option and exit the programming mode Press the key parameter Exit the programming mode Start Time Ramp P102=20s Press the key to enter the programming mode Start Time Ramp P102=20s Use the keys and to select the ramp time for the start voltage Start Time Ramp P102=15s Press the key parameter Initial selected voltage: 35% Un (according to load requirements) Init. Volt Start P101=35% to go to the next Press the key to save the selected option and exit the programming mode DESCRIPTION Voltage Ramp Time: (1 to 999)s Enter the programming mode. Selected ramp time for the start voltage: 15s (according load requirements) Exit the programming mode Start Time Ramp P102=15s to go to the next Motor rated voltage (Un): (0 to 999)V Motor Rated Volt P400=380V Press the key programming mode to enter the Enter the programming mode. Motor Rated Volt P400=380V Use the keys and select the motor rated voltage 70 to Motor Rated Volt P400=380V Selected motor rated voltage: 380V (according to the motor data) CHAPTER 5 - START-UP HMI LED DISPLAY HMI LCD DISPLAY ACTION Press the key to save the selected option and exit the programming mode Press the key parameter DESCRIPTION Exit the programming mode Motor Rated Volt P400=380V Motor Rated current (In): (0 to 1500)A to go to the next Motor Rated Cur. P401=20.0A Press the Key programming mode to enter the Enter the programming mode. Motor Rated Cur. P401=20.0A Use the keys and to select the motor rated current Motor Rated Cur. P401=101.0A Press the key to save the selected option and exit the programming mode Selected motor rated current: 101A (according to the motor data) Exit programming mode Motor Rated Cur. P401=101.0A Press the key parameter to go to the next Service Factor P406=1.00 Press the Key programming mode Motor Service Factor (F.S.): 0.00 to 1.50 to enter the Enter the programming mode. Service Factor P406=1.00 Use the keys and to select the motor Service Factor Service Factor P406=1.15 Press the key to save the selected option and exit the programming mode Selected motor Service factor: 1.15 (according to the motor data) Exit programming mode Service Factor P406=1.15 71 CHAPTER 5 - START-UP HMI LED DISPLAY HMI LCD DISPLAY ACTION Press the key parameter to go to the next Ther.Prot.Class P640=Class 30 Press the key programming mode to enter the Thermal motor Protection Class: 0= Inactive 1= Class 5 2= Class 10 4= Class 20 5= Class 25 6= Class 30 7= Class 35 8= Class 40 9= Class 45 Enter the programming mode. Ther.Prot.Class P640=Class 30 Use the keys and to select the thermal motor protection class Press the key to save the selected option and exit the programming mode Press the key parameter DESCRIPTION Thermal motor protection class: 6= Class 30 (According to the motor data) Ther.Prot.Class P640=Class 30 Exit the programming mode Ther.Prot.Class P640=Class 30 to go to the next Soft-Starter is reset Soft-Starter is ready for operation Soft Starter ready Open the input circuit-breaker to disconnect the Soft-Starter SSW-06. NOTE! Repeat the first power-up process: If you want to repeat the first power-up routine, set parameter P204 = 5 (it loads the factory standard default parameters), then follow the first power-up routine; The first power-up routine, as decribed above, automatically sets some parameters automatically to the factory default. For more details, refer to Chapter 6. 72 CHAPTER 5 - START-UP 5.3 START-UP This Section describes the start-up procedure when operating via the Keypad (HMI). Three types of control will be considered: Start-up by Voltage Ramp: The start by voltage ramp is the most used method and its programming and parameter setting is very easy to do. The Soft-Starter SSW-06 applies the voltage to the motor without any feedback of the voltage or current applied to the motor Start-up by Current Limit: The maximum current level is maintained during the start-up and it is set according to the application requirements. This programming is very easy. Start-up by Current Ramp: The maximum current level is also limited during the start-up, however higher or lower start-up current limits can be set. Start-up by Pump Control: Optimized control method, providing the required torque to start/stop hydraulic centrifugal pumps smoothly. Start-up by Torque Control: The Soft-Starter SSW-06 is fitted with a torque control algorithm of high performance and is totally flexible to meet any application requirement during the motor start or stop and its coupled load. The method allows a torque control with 1 setting point, a torque control with 2 setting points and a torque control with 3 setting points. NOTE! Every time the content of the Parameter P202 is changed, the SoftStarter will execute a setting sequence routine according to the selected control type. For more details, refer to Parameter P202 in Chapter 6 and 7. The following sequence is valid for Drive 1 (see item 3.3.1). The SSW-06 Soft-Starter must already be installed and the electronics, fans and power must already be energized, according to chapter 3, with the setting sequence of the initial Start-up complete, as described (Item 5.2). 73 CHAPTER 5 - START-UP 5.3.1 Start -up: Operation via Keypad (HMI) Type of control: Voltage Ramp HMI LED DISPLAY HMI LCD DISPLAY ACTION DESCRIPTION Soft-Starter is ready to be operated Power-up the Soft-Starter Soft Starter ready Press the key . Press the key to find P000. Also the key may be used to find Paramater P000 Press the key programmin mode Parameter Access P000=0 to enter the It enable the access for changing parameter. With setting according to Factory Default [P200 = 1 (Password is active)], you must set P000 = 5 for changing the parameter content. Enter the Programming Mode Parameter Access P000=0 Use the Keys and program the Password value Password value (Factory Default) to Parameter Access P000=5 Press the key to save the selected option and exit the programming mode Exit the programming mode Parameter Access P000=5 Press the key to find P202. Also the key may be used to find Paramater P202 Type of Control P202=Volt. Ramp. Press the Key programming mode to enter the This Parameter defines the Type of Control 0=Voltage Ramp 1=Current Limit 2=Pump Control 3=Torque Control 4=Current Ramp Enter the Programming Mode Type of Control P202=Volt. Ramp. Type of Control selected for the Start-up: Voltage Ramp (maintained the existing value) Use the keys and to select the correct value of the Control Type Type of Control P202=Volt. Ramp. 74 CHAPTER 5 - START-UP ACTION HMI LED DISPLAY HMI LCD DISPLAY Press the key to save the selected option and exit the programming mode DESCRIPTION Exit the programming mode Type of Control P202=Volt. Ramp. Motor Current (A) Press the key and maintain it depressed to find P003 Motor Current P003=0A Press the key This is only a Read Parameter Motor Current P003=0A Press the key Motor Current P003=346A To Stop press the key Motor Current P003=90A To restart press the key SoftStarter ready Motor Current P003=346A Press the key Motor Current P003=90A Motor accelerates and a high value of current is reached. Then the current decreases down to a value required by the load. Motor decelerates until stopping by coast to rest. Time to stop depends on load inertia and friction. Motor accelerates and a high value of current is reached. Then the current decreases up to a value required by the load. 75 CHAPTER 5 - START-UP HMI LED DISPLAY HMI LCD DISPLAY ACTION Press the key again SoftStarter ready SoftStarter ready DESCRIPTION Soft-Starter is now controlled via terminals (REMOTE). Motor decelerates till stopping by the load inertia. Soft-Starter is controlled again via keypad (LOCAL). Motor remains stopped. NOTES! Setting hints and suggestions for all types of controls and their uses can be found in Chapter 7. For start-up through voltage ramp refer to Item 7.1.1. 76 6 CHAPTER DETAILED PARAMETER DESCRIPTION This Chapter describes in detail all Soft-Starter SSW-06 parameters. In order to simplify the explanation, the parameters have been grouped by characteristics and functions: Read Only Parameters Variables that can only be viewed on the display but not changed by the user. Regulation Parameters Programmable values used by the Soft-Starter SSW-06 functions. Configuration Parameters These Parameters define the Soft-Starter SSW-06 characteristics, the functions which to be executed, as well as the input/output functions of the control board. Motor Parameters Motor data that are indicated on the motor nameplate. Special Function Parameters Here are included the parameters related to special functions. Protection Parameters Here are included the parameters related the actuation levels and actuation time of the motor protection Symbols and definitions used in the text below: (1) Indicates that the parameter can only be changed when the Soft-Starter SSW-06 is disabled (motor stopped). (2) Parameters not changed when programmed at Factory Default. (P204=5). 6.1 ACCESS AND READ ONLY PARAMETERS - P000 to P099 Parameter P000 Access Parameter/ Password Value Setting Range [Factory Setting] Unit 0 to 999 [0] - Description / Notes opens This parameter opens the access to change the parameter values. When values are set according to Factory Default [P200 = 1 (Password is active)] to must set P000 = 5 to change parameter values, i. and. the Password value is equal to 5. To change the password to any other value (password 1), proceed as follows: (1) Set P000=5 (current password) and P200= 0 (password inactive). (2) Press the key . (3) Change P200 to 1 (password active). (4) Press the key again: display shows: P000. (5) Press the key again: display shows 5 (last password). (6) Use the keys and to change to the desired password value (password 1). (7) Press the key : display shows P000. From this moment on, the new password becomes active. Thus, to change parameter content P000 one must set to the new password. (Password 1). 77 CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter P001 Soft- Starter SSW-06 Current Range [Factory Setting] Unit 0 to 999.9 [-] 0.1% Description / Notes Indicates Soft-Starter SSW-06 output current as percentage of the rated current of the Soft-Starter (%In of the SSW-06) . Precision of ± 2% for the full scale. (The full scale is 5x ln of the SSW-06). NOTE! When the connection is used inside the delta of the motor (P150=1), the indication of the current value will already be multiplied by 1.73. P002 Motor Current 0 to 999.9 [-] 0.1% Indicates Soft-Starter SSW-06 Output Current as percentage of the motor rated current (%In of the motor). Precision of ± 2% for the full scale. (The full scale is 5x ln of the SSW-06). NOTE! When the connection is used inside the delta of the motor (P150=1), the indication of the current value will already be multiplied by 1.73. P003 Motor Current 0 to 9999.9 [-] 0.1A Indicates the Soft-Starter SSW-06 output current in Ampere (A). Precision of ± 2% for the full scale. (The full scale is 5x ln of the SSW-06). NOTE! When the connection is used inside the delta of the motor (P150=1), the indication of the current value will already be multiplied by 1.73. P004 Line Voltage 0 to 999 [-] 1V Indicates the average True rms voltage of the tree input phases in Volts (V). Accuracy: ± 2V. P005 Line Frequency 0 to 99 [-] 1Hz Indicates the line frequency in Hertz (Hz). Precision of ± 5% of the rated frequency of the supply network. NOTE! Only indicates network frequency when there is a voltage greater than 20V rms in the power supply (R/ 1L1, S/ 3L2 and T/5L3). P006 Soft-Starter SSW-06 Status 78 XXXX [-] - Indicates the actual Soft-Starter SSW-06 status: 0 = “rdy” Soft-Starter is ready to be enabled; 8 = “Sub” Soft-Starter under voltage fault; 9 = “Exx” Soft-Starter fault; 1 = “ruP” Soft-Starter is enabled according to “ramp up”; 2 = “FuLL” Soft-Starter is enabled at “full voltage”; 3 = “PASS“ Soft-Starter is enabled with “By-pass”; 6 = “ECO” Reserved; 4 = “rdo” Soft-Starter is enabled according to “ramp down”; 5 = “br” Soft-Starter is enabled according to “braking”; 6 = “rEv” Soft-Starter is enabled according to “reversing”; 7 = “JOG” Soft-Starter is enabled according to “jog”; 11 = “dly” Soft-Starter awaiting the post “delay” stop time; 12 = “G.di” Soft-Starter with “general disable”. CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter Range [Factory Setting] Unit Description / Notes P007 Soft-Starter SSW-06 Output Voltage 0 to 999 [-] 1V Indicates the average True rms voltage of the tree output phases of the Soft-Starter SSW-06 in Volts (V). Accuracy: ± 2V. P008 Power Factor 0 to 1.00 [-] - Indicates motor power factor. Accuracy:: ± 5%. NOTE! The motor power factor will only be indicated when the current is at 20% of the rated current of the SSW-06. 0.00 (Zero) will be indicated if the current is below 20% of the SSW-06 rated current. P009 Motor Torque 0 to 999.9 [-] 0,1% Indicates the motor torque in percent of the rated motor toque (% Tn of the Motor). The Soft-Starter SSW-06 is fitted with a software for estimating the motor torque by using the same principles contained in Weg Frequency Inverter This high technology software enables indicating the motor torque very close to the effective present torque. Accuracy of ± 10% Tn of the Motor. ATTENTION! Information related to the rated torque of the motor and maximum starting torque of the motor can be found in the manufacturer’s catalogue. NOTE! For the correct torque to be indicated, in P009, all the parameters related to the motor, P400 to P406, must be correctly programmed according to the data informed in the motor name plate. P010 Ouput Power 0 to 6553.5 [-] 0.1kW Indicates the active power as average of the three ouput phases of the Soft-Starter SSW-06 in kilo Watts (kW). NOTE! The output power will only be indicated when the current is greater than 20% of the SSW-06 rated current. 0 (Zero) Will be indicated if the current is lower than 20% of the SSW-06 rated current. P011 Apparent Output Power 0 to 6553.5 [-] 0.1kVA Indicates the apparent power as average of the three ouput phases of the Soft-Starter SSW-06 in kilo Volts Ampere (kVA). 79 CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter P012 Digital Input Status DI1 to DI6 Range [Factory Setting] Unit Description / Notes LCD=1,0 LED=0 to 255 [-] - Indicates on the keypad LCD display the status of the 6 digital inputs of the control board (DI1 to DI6). Number 1 stands for Active and Number 0 for Inactive, in the following order: DI1, DI2,...,DI5, DI6. The LED Display shows a decimal value corresponding to the status of the 6 digital inputs, where the status of each bit is considered one bit in the specified sequence: Inactive=0 Active=1 DI1 status is the most significant bit. Example: Dl1 = Active (+24V); Dl2 = Inactive (0V); Dl3 = Inactive (0V); Dl4 = Active (+24V); Dl5 = Inactive (0V); Dl6 = Inactive (0V). It is equivalent to the bit sequence: 10010000 Which corresponds to the decimal number 144. The least significant bits are not displayed. The keypad displays will be as follows: DI1...DI6 Status P012=100100 P013 Digital Outputs RL1 to RL3 Status LCD=1,0 LED=0 to 255 [-] - Indicates on the keypad LCD display the status of the 3 relay outputs of the control board. Number 1 stands for Active and 0 for Inactive, in the following order: RL1, RL2, RL3. The keypad LED display shows the decimal value that corresponds to the status of the 3 digital outputs, where the status of each bit is considered one bit in the specified sequence: Inactive=0 Active=1 RL1 status is the most significant bit. The 5 least significant bits are always ‘0’. Example: RL1=Active; RL2=Inactive; RL3=Active This is equivalent to the binary sequence: 10100000 Which corresponds to the decimal number 160. The least significant bits are not displayed. The Keypad displays will be: RL1...RL3 Status P012=101 80 CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter P014 Last Fault Range [Factory Setting] Unit Description / Notes P015 Second Previous Fault 03 to 77 [-] 03 to 77 [-] - P016 Third Previous Fault 03 to 77 [-] - P017 Fourth Previous Fault 03 to 77 [-] - P023 Software Version X.XX [-] - P030 Current of Phase R 0 to 9999.9 [-] 0.1A P031 Current of Phase S 0 to 9999.9 [-] 0.1A P032 Current of Phase T 0 to 9999.9 [-] 0.1A P033 Line Voltage - R-S 0 to 999 [-] 1V P034 Line Voltage - S-T 0 to 999 [-] 1V P035 Line Voltage - T-R 0 to 999 [-] 1V P042 Time Powered Indicate the code of the last, second, third and fourth previous Faults. Fault Sequence: Exy P014 P015 P016 P017 Indicates the Software Version contained in the microcontroller memory of the control board. Accuracy: ± 2% for full scale (full scale is 5 x In of the SSW-06). NOTE! When the connection is used inside the delta of the motor (P150=1), the indication of the current value will already be multiplied by 1.73. Accuracy: ± 2V. NOTE! The voltage will only be indicated when it reaches a value greater than 15V. Below this value, only 0.00 (zero) will be indicated. LCD: 0 to 65530 Indicates the total number of hours that the Soft-Starter was powered. LED: 0 to 6553h (x10) The LED Display shows the total number of hours that the Soft-Starter was energized divided by 10. [-] This value remains stored even when the Soft-Starter is switched OFF. 1h Example: Indication of 22 hours powered. Time Powered P042=22h 81 CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter P043 Time Enabled Range [Factory Setting] Unit Description / Notes 0 to 6553 [-] 0.1 (<999.9) 1 (<6553) P050 Motor Thermal Protection Status 0 to 250 [-] 1% P085 Status of the Fieldbus Communication Board 0 to 3 [-] - Indicates the total number of hours that the Soft-Starter has run. This value remains stored even when the Soft-Starter is turned OFF. Indicates up to 6553 hours, rolls over to 0000. If P204 is set to 3, P043 is reset to zero. Indication of the state of motor thermal protection in a scale of 0% to 250%. Being 250 the thermal protection functioning point of the motor, indicating an error. The value indicated in this parameter depends on the motor working condition and how long it has been in this condition, for example: stopped, starting or in full operation. The thermal class selected and the rated power of the motor also influence in this parameter. Only a value of approximately 160 can be read if the motor is operating in full load for over 2 hours with a current equal to the rated current plus the service factor (In x F.S. @ 2h). P085 0 1 2 3 Description Off Board inactive Board active and Offline Board active and Online Table 6.1 - Fieldbus communication board status Indicates the status of the Fieldbus communication board. Standard is disabled when board is not inserted. For more details, refer to the Fieldbus Manual for the Soft-Starter SSW-06. 6.2 REGULATION PARAMETERS - P100 to P199 P101 Initial Voltage Used in the control by Voltage Ramp and Pump Controls, P202=0 or 2. 25 to 90 Sets the initial value of the rated voltage (%Un) that will be applied to [ 30 ] the motor according to Figure 6.1. 1% Un of the Motor For more details about the programming and use, see Voltage Ramp and Pump Control in P202. The initial voltage is 0.5s after the Soft-Starter SSW-06 receives the command to start the motor. This is the waiting time for the network isolation contactor to start the power supply. U(V) Start P101 0 P102 0,5s Start Figure 6.1 – Initial time for motor start 82 CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter Range [Factory Setting] Unit Description / Notes NOTE! When another control type is selected, not the Voltage Ramp or Pump Control, the initial voltage will be attenuated due to the limit imposed by the current. P102 Acceleration Ramp Time 1 to 999 [ 20 ] 1s When the Soft-Starter SSW-06 has been programmed to Voltage Ramp Control or Pump Control, this will be the ramp time of the voltage increment as shown in Figure 6.2. U(V) Start 100%Un P101 0 t(s) P102 Enable Voltage Ramp Disable Figure 6.2 – Acceleration ramp by Voltage Ramp When the Soft-Starter SSW-06 has been programmed to Current Limit control, Torque Control or Current Ramp, this time acts as maximum starting time, as a protection against locked rotor. I(A) Start I Limit P110 Rated Current Maximum time 0 P102 Enable Current Limit t(s) Disable Figure 6.3 – Acceleration Ramp by Current Limit NOTE! The time set at P102 is not the exact motor acceleration time, but the voltage ramp time or the maximum start time. The motor acceleration time will depend on the motor and the load characteristics. 83 CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter P103 Voltage Step during Deceleration Range [Factory Setting] Unit Description / Notes 99 to 60 Used in applications with hydraulic pumps. [ 100=Inactive ] Set the rated voltage (%Un), which will be applied to the motor 1% Un of the Motor instantaneously when the Soft-Starter SSW-06 receives the ramp deceleration command. For more details about programming and use, refer to Pump Control at P202. NOTE! To enable this function, you must set a deceleration ramp time. P104 Deceleration Ramp Time 1 to 299 [ 0=Inactive ] 1s Used in hydraulic pump applications. Enables and sets the time of the voltage decrement ramp. For more details about programming and use, refer to Pump Control. It can be used as Voltage Ramp control, Pump Control, Current Limit and Current Ramp. NOTE! This function is used to lengthen the normal deceleration time of a load and not to force a shorter time than that imposed by the load. P105 End Deceleration Voltage 30 to 55 [ 30 ] - Used in hydraulic pump applications. Sets the rated voltage (%Un), which will be applied to the motor at the end of the deceleration ramp. For more details about the programming and use, refer to Pump Control. U(V) 100%Un Stop P103 P105 0 P104 t(s) Disable Voltage Ramp Figure 6.4 – Deceleration Ramp by voltage decrement P110 Current Limit 84 150 to 500 Defines the current limit during the motor start as a percentage of [ 300% ] the rated motor current set at P401. 1% In of the Motor When the current limit is reached during the motor start, the Soft-Starter SSW-06 will maintain the current at this limit until the motor reaches the end of the start. When the current limit is not reached, the motor will start immediately. For more information about selection of the Current Limit control, refer to P202. CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter Range [Factory Setting] Unit Description / Notes I(A) Start I Limit P110 Rated Current Maximum Time 0 t(s) P102 Enable Current Limit Disable Figure 6.5 – Fixed starting Current Limit P111 Initial Current by Current Ramp P112 Time for Current Ramp 150 to 500 Used for the control by Current Ramp, P202=4. [ 150 ] Allows a current limit ramp to be programmed to help in the starting 1% Un of the Motor of loads that have a lower or higher starting torque. The initial value of the current limit is shown by P111, the final value is shown by P110 and the time is shown by P112, according to figure 6.6. 1 to 99 [ 20 ] 1% of P102 Used for the control by Current Ramp, P202=4. It enables programming the time, in percent of P102, for the end Current Ramp. After the time, programmed at P112, has elapsed, it starts operation by Current Limit, given by P110. a) I(A) Start P110 I Limit Rated Current P111 0 t(s) P112 P102 Maximum Time Enable Current Limit Disable 85 CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter Range [Factory Setting] Unit Description / Notes b) I(A) Start P111 I Limit P110 Rated Current 0 t(s) P112 P102 Maximum Time Enable Disable Current Limit Figure 6.6 a) and b) - Current Limit by Current Ramp during Starting P120 (1) Starting Torque Characteristics 1 to 3 [ 1=Constant ] - P120 1 2 3 Starting Torque Profile Constant (1 setting point) Linear (2 setting points) Quadratic (3 setting points) Table 6.2 - Starting Torque Profile It enables choosing which torque limit profile the Soft-Starter SSW-06 will supply to the motor during the start. Three different types of Torque Limit Profile are available allowing the start of any type of load: constant or 1 point, linear or 2 points and quadratic or 3 points. b) a) Tn(%) Tn(%) Start Start P122 Tn Nominal P121 Tn Nominal 0 P202=2 P121 P202=1 t(s) P102 0 t(s) P102 c) Tn(%) Start P122 Tn Nominal P121 P202=3 P123 0 P124 t(s) P102 Figure 6.7 a) to c) - Available Torque Profile during the start 86 CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter Range [Factory Setting] Unit Description / Notes NOTE! Choose the type of torque control, easier to program and set, according to the knowledge about the characteristics of the load. P121 Initial Starting Torque 10 to 400 Enables programming an initial torque limit or a constant during the [ 30 ] start, according to the torque type selected at P120. 1% Tn of the Motor P120 1 (Constant) 2 (Linear) 3 (Quadratic) Action P121 limits the maximum torque during the start. P121 limits the initial torque during the start. P121 limits the initial torque during the start. Table 6.3 - Function of P121 according to P120 For more details about programming and application, refer to Torque Control at P202. P122 End Satrting Torque 10 to 400 It enables programming an end torque limit for the start, when a [ 110 ] linear or quadratic torque linear has been selected at P120. 1% Tn of the Motor P122 1 (Constant) 2 (Linear) 3 (Quadratic) Action P122 Not used P122 limits the end torque during the start. P122 limits the end torque during the start. Table 6.4 - Function of P122 according to P120 For more details about programming and application, refer to Torque Control at P202. P123 Minimum Starting Torque 10 to 400 It enables programming an intermediate torque limit during the start, [ 27 ] when a quadratic torque ha been selected at P120. 1% Tn of the Motor P123 1 (Constant) 2 (Linear) 3 (Quadratic) Action P123 not used P123 not used P123 limits the intermediate torque during the start. Table 6.5 - Function of P123 according to P120 For more details about programming and application, refer to Torque Control at P202. P124 Time for Minimum Starting Torque 1 to 99 [ 20 ] 1% of P102 It enables programming the time for the intermediate torque limit during the start, as a percentage of the maximum time programmed at P102, when a quadratic torque has been set at P120. P124 1 (Constant) 2 (Linear) 3 (Quadratic) Action P124 not used P124 not used P124 time for the intermediate torque limit during the start. Table 6.6 - Function of P124 according to P120 For more details about programming and application, refer to Torque Control at P202. 87 CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter P125 (1) Stopping Torque Characteristics Range [Factory Setting] Unit Description / Notes 1 to 3 [ 1=constant] - P125 1 2 3 Stop torque profile Constant (1 set point) Linear (2 set points) Quadratic (3 set points) Table 6.7 - Stop Torque Characteristics Here you can choose the torque limit profile that the Soft-Starter SSW-06 shall supply to the motor during the start. Three different types of torque profiles are available that permit improving the speed performance during the start process. Tn(%) Tn(%) Stop Tn Nominal Stop Tn Nominal P127 P125=1 P126 P125=2 P126 P126 0 0 t(s) P128 t(s) P128 P104 P104 Tn(%) 100%Tn Tn Nominal P125=3 P127 P126 0 t(s) P128 P104 Figure 6.8 – Available torque profiles for the stop process NOTE! Choose the type of torque control, easier to program and set, according to the knowledge about the characteristics of the load. P126 End Torque for the Stop 10 to 100 Here you can program the end torque limit or constant for the stop, [ 20 ] according to the torque type selected at P125. 1% Tn of the Motor P126 1 (Constant) 2 (Linear) 3 (Quadratic) Action P126 limits the maximum torque during the stop process P126 limits the end torque during the stop process P126 limits the end torque during the stop process Table 6.8 - Function of P126 according to P125 For more details about programming and application, refer to Torque Control at P202. 88 CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter P127 Minimum Stop Torque Range [Factory Setting] Unit Description / Notes 10 to 100 Here you can program the initial torque limit or an intermediate torque [ 50 ] limit for the stop, when a linear torque or a quadratic torque has been 1% Tn of the Motor selected at P125. P127 1 (Constant) 2 (Linear) 3 (Quadratic) Action P127 not used P127 limits the torque when the motor is stopped P127 limits the intermediate torque for the stop Table 6.9 – Function of P127 according to P125 For more details about programming and application, refer to Torque Control at P202. P128 Time for Minimum Stop Torque. 1 to 99 [ 50 ] 1% of P104 Here you can program the time for the intermediate stop torque, as percent of the maximum time programmed at P104, when the quadratic torque has been selected at P125. P128 1 (Constant) 2 (Linear) 3 (Quadratic) Action P128 not used P128 not used (time equal to 0) P128 time for the intermediate torque limit for the stop process. Table 6.10 – Function of P128 according to P125 For more details about programming and application, refer to Torque Control at P202. P130 (1) Pump Control 0 [ 0=Pump ] - This parameter is reserved for future software versions with hydraulic pump control type. The current version has been developed for the control of centrifugal hydraulic pump, considering quadratic motor loads. For more details about the Pump Control, see P202. U(V) Start 100%Un Stop P103 P101 P105 0 P104 P102 Enable Pump Control t(s) Disable Figure 6.9 – Start and Stop by Pump Control P140 (1) External By-pass Contactor 0 or 1 [ 0=Inactive ] - P140 0 (Inactive) 1 (Active) Action Without external By-pass contactor With external By-pass contactor Table 6.11 - External By-pass contactor This function is enabled when the installation of an external By-pass contactor is required that must be connected parallel to Soft-Starter SSW-06. 89 CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter Range [Factory Setting] Unit Description / Notes The models of models from 85A to 820A have an internal By-pass contactor. The models of models from 950A to 1400A do not have an internal By-pass contactor. When P140=1 in the models with an internal By-pass, the internal By-pass will not enable. The external By-pass contactor is used: 1) (Models without internal By-pass) for possibility one external By-pass contactor; 2) (Models with internal By-pass) for instance when a direct start is required in case of an emergency. The internal By-pass contactors do not permit a direct start. These contactors can be enabled only after the motor start has been realized by the thyristors; 3) (Models with internal By-pass) if the motor stalls frequently at By-pass condition. NOTE! See the recommended setup at items 3.3 and 3.3.12 for more Information. P150 (1)(2) Inside Delta Motor Connection 0 or 1 [ 0=Inactive] - P150 Action 0 (Inactive) Soft-Starter SSW-06 with standard motor connection 1 (Active) Soft-Starter SSW-06 inside delta motor connection Table 6.12 - Motor connection type SSW-06 offers two operation modes: Standard Connection or connection inside the Motor Delta Connection. When a Standard Connection is used, the motor is connected in series to the Soft-Starter SSW-06 through three cables. When an Inside Delta Connection is used, the Soft-Starter SSW-06 is connected separately in each winding through six cables. (See item 3.2.5.2). In this type of connection, the current that flows through of the Soft-Starter SSW-06 is only the current of the inside delta motor connection, in other words, 58% of the rated motor current. This characteristic changes the relation between the Soft-Starter SSW-06 nominal currents and those of the motor. In this connection, the SoftStarter can be used with its rated current dimensioned in the following way: - 1.5 times the rated motor current during start; - 1.73 times the rated motor current during full voltage. During the start, the relation is lower due to the characteristics that are common to this type of connection (inside delta) the Thyristors of the Soft-Starter need to lead the same current in a lower time period, increasing with this the losses in the Thyristor during the start. The standard connection requires less output wiring. The Inside Delta Motor Connection requires double wiring, but for short distances, this will be a cheaper option for the Soft-Starter + motor + wiring set. ATTENTION! Do not operate the motor when P150 has not been programmed correctly. Soft-Starter SSW-06 can be seriously damaged when this parameter has not been programmed correctly. 90 CHAPTER 6 - DETAILED PARAMETER DESCRIPTION 6.3 CONFIGURATION PARAMETERS - P200 to P299 Parameter P200 Password Range [Factory Setting] Unit 0 or 1 [1] - Description / Notes P200 0 (inactive) Action This Parameter allows parameter content changing, independent of P000 1 (Active) Change of Parameter content is only possible, when P000 is equal to the password value Table 6.13 - Password With the Factory Setting, the password will be P000=5. To change the Password, see P000. P201 (2) Language Selection 0 to 3 [1=English] - P201 Description 0 Portuguese 1 English 2 Espanish 3 German Table 6.14 - Language selection P202 (1) Type of Control 0 to 4 [ 0=Voltage Ramp ] - P202 Type of Control 0 Voltage Ramp 1 Current Limit 2 Pump Control 3 Torque Control 4 Current Ramp Table 6.15 - Types of control Soft-Starter SSW-06 has five starting control types to better match all application requirements. Start by Voltage Ramp (1): The start by Voltage Ramp is the most used starting method. Its programming and setting is very easy. The Soft-Starter SSW-06 applies the voltage to the motor without voltage or current feedback. This method is used for loads with lower initial torque or quadratic torque. This type of control can be used as initial operating test. Start by Current Limit (2): The maximum current level is maintained during the start and is set according to the application requirements. Its programming and setting is very easy. This method is used for loads with higher initial torque or constant torque. This type of control is used for matching the start process to the limits of the power supply capacity. Start by Current Ramp (3): The maximum current level is limited during the start process, however higher or lower current limits can be set during the start beginning. 91 CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter Range [Factory Setting] Unit Description / Notes It can substitute the kick-start functions for loads with higher initial torques. This type of control is used for loads with lower or higher initial torques. This type of control is used to match the start process to the limits of the power supply capacity. Start by Pump Control (4): This type of control provides the required torque for starting and stopping hydraulic centrifugal pumps smoothly. It has a special algorithm for application in centrifugal pumps, where loads with quadratic torques are present. This special algorithm aims at to minimize pressure “overshoots” in the hydraulic piping, which can result in breakdown or excessive pump wearing. Start by Torque Control: The SSW-06 Soft-Starter has a high performance and totally flexible torque control algorithm to meet the needs of any application, for smoothly starting or stopping the motor and its load. Torque Control with 1 setting point (2): This type of control allows a constant starting torque limitation. Torque Control with 2 setting points (3): This type of control allows the starting torque limitation through linear ramp. Torque Control with 3 setting points (4): This type of control allows the setting of the starting torque limitation at three different points: initial, intermediate and final. It also allows the start of quadratic loads, among others. (1) Very easy to set and program (2) Easy to set and program (3) Set and program, requires knowledge of the load to set and program (4) Set and program, requires extensive knowledge of the load to set and program NOTES! 1) These types of controls are arranged according to the use and programming difficulty level. Thus, we recommend starting with the easier control modes first. 2) Every time the content of P202 is changed, the Soft-Starter will start a sequence routine of minimum settings for each selected type of control. You must run and set all parameters of this sequence (up to the last) when required. Only after all settings have been made can you start the motor. 92 CHAPTER 6 - DETAILED PARAMETER DESCRIPTION P202 Voltage Ramp Current Limit Pump Limit Torque Control Current Ramp P101 P102 P130 P102 P102 P102 P110 P101 P120 P110 P400 P400 P102 Constant Linear Square P111 P401 P401 P103 P121 P121 P121 P112 P406 P406 P104 P122 P122 P400 P640 P640 P105 P123 P401 P400 P124 P406 P401 P610 P611 P620 P406 P640 P104 P125 Constant Linear Square P126 P126 P126 P127 P127 P640 P128 P400 P401 P402 P404 P405 P406 P640 Figure 6.10 – Parameter sequence according to the selected type of control 93 CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter Range [Factory Setting] Unit Description / Notes Torque Control Pump Control Current Ramp START Voltage Ramp Current Limit Current Ramp Pump Control Torque Control Current Limit Voltage Ramp STOP The table below shows the relation between the adopted starting control type and the automatically selected stop control type. X X X X X Table 6.16 – Stop/Start Operation P204 (1) Load/Save Parameter 0 to 11 [0] - Parameters with note (2) indicated are not changed when Factory Settings are loaded through P204 = 5. To load User Parameter 1 (P204=7) and/or User 2 (P204=8) in the operation area of Soft-Starter SSW-06, it is necessary for User Memory 1 and/or User Memory 2 to be been saved previously (P204=10 and/or P204=11). User Memory 1 0 =1 04 2 P =7 04 2 P Current Parameter of Soft-Starter SSW-06 P204=5 Factory Setting (WEG Standard) P2 04 =1 1 P2 04 =8 User Memory 2 Figure 6.11 - Parameter Transfer 94 CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter Range [Factory Setting] Unit Description / Notes P204 Action 0, 1, 2, Not used: 4, 6, 9 No action 3 Reset P043: Resets Running Time 5 Loads Factory Default: Loads current Soft-Starter parameter with factory setting 7 Loads User 1: Loads current Soft-Starter parameter with the values stored in Memory 1. 8 Loads User 2: Loads current Soft-Starter parameter with the values stored in Memory 2. 10 Save User 1: Transfer the current parameter contents of the Soft-Starter to memory 1 11 Save User 2: Transfer the current parameter contents of the Soft-Starter to memory 2 Table 6.17 - Action of loading/saving parameters NOTE! Parameter loading/saving will be executed only after parameter setting and after the key has been pressed . P205 Display Default Selection 0 to 7 [2] - This Parameter selects which parameter listed below will be displayed after the Soft-Starter has been powered-up: P205 1 2 3 4 5 6 7 Status P001 (Motor current % In of the Soft-Starter) P002 (Motor current % In of the Motor) P003 (Motor current (A)) P004 (Supply Line Voltage) P005 (Supply Line Frequency) P006 (Soft-Starter Status) P007 (Output Voltage) Table 6.18 - Options displays default P206 Auto-Reset Time 0 to 600 [ 0=Inactive ] 1s In the event of a fault trip, except for E10, E15, E24, E28, E29, E30, E31, E41, E62, E63, E67, E70, E71, E72, E75, E76 and E77, the Soft-Starter SSW-06 can initiate an automatic reset after the time given by P206 is elapsed. If P206 2 Auto-Reset does not occur. If after Auto-Reset the same fault is repeated three times consecutively, the Auto-Reset function will be disabled. A fault is considered consecutive if it happens again within 30 seconds after Auto-Reset. Thus if an error occurs four times consecutively, it will be displayed permanently (and the Soft-Starter will be disabled). 95 CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter P215 (1) Copy Function (HMI) Range [Factory Setting] Unit 0 to 2 [ 0=Off ] - Description / Notes The copy function is used to transfer the content of the parameters from one Soft-Starter SSW-06 to another. The Soft-Starters must be of the same type (voltage/current) and the same software version must be installed. P215 Action 0 Off 1 Copy Explanation - SSW HMI Transfers the current parameter contents from the Soft-Starter and from Users 1/2 to the non volatile (HMI) keypad memory (EEPROM). The current Soft-Starter parameters are not changed. 2 Paste Transfers the contents of the non-volatile (HMI) keypad HMI SSW memory (EEPROM) to the current Soft-Starter SSW-06 parameters and to user 1 or 2 memories. Table 6.19 - Copy function Procedures: 1. Connect the Keypad to the Soft-Starter SSW-06 from which the parameters will be copied (Soft-Starter A); 2. Set P215=1 (copy) for transferring the parameter from the Soft-Starter A to the HMI. Press the key . While copy function is being executed, the display will show COPY. P215 resets automatically to 0 (Inactive) after the transfer has been completed. 3. Disconnect the keypad (HMI)from the Soft-Starter SSW-06. 4. Connect the same Keypad to the Soft-Starter SSW-06 to which the parameters should be transferred (Soft-Starter B). 5. Set P215=2 (paste) for transferring the content from the non-volatile keypad memory (EEPROM containing the parameter of the Soft-Starter A) to the Soft-Starter B. Press the key . While the keypad is executing the copy function, the display shows COPY. When P215 returns to 0, the parameter transfer has been concluded. Now Soft-Starters A and B have the same parameter content. Please remember: If Soft-Starters A and B command different motors, please check the motor parameters of Soft-Starter B. For copying the parameter contents from Soft-Starter A to other Soft-Starter, repeat procedures 4 and 5 above. Soft-Starter A Parameters Soft-Starter B Parameters SSW HMI (copy) P215=1 Press. HMI SSW(paste) P215=2 Press. EEPROM EEPROM HMI HMI Figure 6.12 - Parameter Copying from “Soft-Starter A” to “Soft-Starter B” 96 CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter Range [Factory Setting] Unit Description / Notes The Keypad (HMI) can not be operated while it is executing the read or write procedures. NOTES! 1) If the Keypad (HMI) has saved parameters of a “different version” than that installed in Soft-Starter SSW-06 to which it is trying to copy the parameters, the operation will not be executed and Soft-Starter SSW-06 will display error E10 (Error: Copy Function not permitted). “Different Version” are those that are different in “x” or “y”, supposing that the numbering of Software Versions is described as Vx.yz. 2) This function changes all SSW-06 parameters to the new values. P218 LCD Display Contrast Adjustment P220 (1) LOCAL/REMOTE Source Selection 0 to 150 [ 127 ] - It allows the adjustment of the LCD Display contrast, as a function of the viewing angle. Increase/decrease the parameter content untill the best contrast is obtained. 0 to 8 [2] - Defines the command source that will select between the LOCAL / REMOTE selection condition. P220 Local/Remote Selection Default Condition 0 Always Local Condition - 1 Always Remote Condition - 2 Key of the Keypad (HMI) Local 3 Key of the Keypad (HMI) Remote 4 Digital Inputs DI4 ... DI6 (P266 ... P268) 5 Serial Communication Local 6 Serial Communication Remote 7 Fieldbus Communication Local 8 Fieldbus Communication Remote Table 6.20 - LOCAL/REMOTE Selection Default condition = when Soft-Starter SSW-06 is powered-up (start-up) In the factory default setting, the key of the Keypad (HMI) will select Local or Remote Mode. When powered up, the Soft-Starter SSW-06 starts in Local mode. P229 (1) Command Selection -Local Condition 0 to 3 [ 0=HMI ] - Defines the origin of the Soft-Starter SSW-06 enable/disable commands. P229/P230 0 1 P230 (1) Command Selection -Remote Condition 0 to 3 [ 0=Terminals ] - Origin of the Commands Keypad keys (HMI) Digital Input DIx 2 Serial Communication 3 Fieldbus Communication (DevideNet or Profibus DP) Table 6.21 - Command Selection 97 CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter P231 (1) FWD/REV Selection Range [Factory Setting] Unit 0 to 2 [ 0=Inactive ] - Description / Notes P231 Action 0 Inactive 1 By Contactor 2 JOG Only Table 6.22 - FWD/REV selection “By Contactor” This option enables the possibility of changing the direction of rotation via contactors connected at the input power supply. The new method implemented in the Soft-Starter SSW-06 allows the use of only two contactors to change the motor direction of rotation and isolate the power supply at the same time. Possibility of changing the direction of rotation with inside delta motor connection. When the motor is stopped the contactors are opened. When the motor is enabled the specific contactor is enabled. U(V) Start 100%Un Disable FWD/REV - K2 Closed 0 FWD/REV - K1 Closed P630 t(s) Enable Start 100%Un Figura 6.13 – Troca do sentido de giro via contator NOTES! 1. Set P277=1 (FWQ/REV-K1) and P278=1 (FWQ/REV-K2) before connecting the power supply. 2. The method used to start the motor to a new direction of rotation will be the same as the one set to start the motor at the first time. 3. The motor will start again only after the time set at P630 (time delay after starting). 4. See the recommended setup at items 3.3 and 3.3.8. 98 CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter Range [Factory Setting] Unit Description / Notes “JOG Only” This option allows the slow speed with Jog in both forward and reverse directions without auxiliary contactors connected at the input power supply. See more information and the notes at the P510 and P511 parameters. U(V) P102 P511 0 t(s) P511 P102 Figure 6.14 - Motor direction of rotation with “Jog only” P251 AO1 Output Function (0 to 10)V 0 to 10 [ 0=Not used ] - Check possible options in table 6.24 and Figure 6.15. For the values shown in Table 6.24, P252=1000 and AO1=10V. P252 AO1 Analog Output gain 0.000 to 9.999 [ 1.000 ] - Sets the gain of the analog output AO1. For P252=1.000 the value of output AO1 is set according to the description in Figure 6.15. P253 AO2 Analog Ouput Function (0 to 20)mA or (4 to 20)mA 0 to 10 [ 0=Not Used ] - Check the possible options in Table 6.24 and Figure 6.15. For the values shown in Table 6.24, P253=2, P254=1000 and AO2=20mA. P254 AO2 Analog Output Gain 0.000 to 9.999 [ 1.000 ] 0.001 Sets the gain of the analog output AO2. For P254=1.000 the value of output AO2 é is set according to the description in Figure 6.15. P255 AO2 Analog Output Type (0 to 20)mA or (4 to 20)mA 0 or 1 [ 0=0-20mA ] - It selects the signal type of the current analog output AO2. P255 Output type 0 (0 to 20)mA 1 (4 to 20)mA Table 6.23 - AO2 signal type For transforming the current analog output AO2 to a voltage output of 0 to 10V, connect a resistor of 500 ± 1% 0.5W in parallel with the output signal a resistor of 500 ± 1% 0.5W. Remember when the output type is selected to 4 to 20mA, this will be the total range of the signal output. 0% of the signal = 4mA and 100% of the signal = 20mA. 99 CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter Range [Factory Setting] Unit Description / Notes P251/P253 Function of the Analog Output Full Scale when 0 Not used - 1 Current in % In of the SSW 5 x P295 2 Input Voltage in %Un of the SSW 1.5 x P296(max.) 3 Motor Voltage in % Un of the SSW 1.5 x P296(max.) 4 Power Factor P008 = 1.00 5 Thermal Protection P050 = 250% 6 Power in W 1.5 x 3 x P295 x P296(max.) x P008 7 Power in VA 1.5 x 3 x P295 x P296(max.) 8 Torque in %Tn of the Motor P009 = 100% 9 Fieldbus 16383 (3FFFh) 10 Serial 16383 (3FFFh) Table 6.24 - Functions of the Analog Outputs P251 P253 Current (%In of the SSW) Input Voltage (%Un of the SSW) Output Voltage (%Un of the SSW) Power Factor Motor Thermal Protection Gain AO1 AO2 P252, P254 Power (W) Power (VA) Torque (% In Motor) Fieldbus Serial Figure 6.15 - Block diagram of the Analog Outputs Scale of the Analog Output indications: - Full scale =10V: for Output AO1. - Full scale =20mA for Output AO2. P264 (1) Digital Input DI2 Function P265 (1) Digital Input DI3 Function P266 (1) Digital Input DI4 Function 100 0 to 2 Check the available options in Table 6.25. [ 2=Error Reset ] The states of the digital inputs can be monitored in parameter P012. “Enable/Disable” = Closed/Open Digital Input DI1 respectively. No 0 to 2 specific Parameter need to be programmed for this function. Only [ 0=Not used ] programming of the Enable/Disable command for the digital input is required. . “Start/Stop” = When P264=1 (Start/Stop at three wires) is 0 to 6 programmed, the digital input DI1 and DI2 become automatically: [ 0=Not used ] DI1=Start and DI2=Stop. Use pulsing switches. - CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter P267 (1) Digital Input DI5 Function P268 (1) Digital Input DI6 Function Range [Factory Setting] Unit Description / Notes 0 to 6 “Local/Remote” = Digital Input is open/closed respectively. Do not [ 0=Not used ] program more than one digital input for this function. “Error Reset” = Resets the errors when the digital input is closed. Use only pulsing switch. When the input remains closed, the error 0 to 7 reset will not act. [ 0=Not used ] “No External Error” = No External Error will be present when the digital input is closed. “General Enabling/General Disabling” = Closed/Open to the digital input, respectively. This function allows the motor to start when it is in general enabling and to stop without a deceleration ramp when given the general disabling command. There is no need to program General Enabling to start the motor via digital input. If the general enabling is programmed via digital input, this must be closed to allow the motor to start, even if the commands are not via digital inputs. “Motor Thermistor” = The DI6 digital input is associated to the input of the motor thermistor (PTC). If you want to used the DI6 as a normal digital input, you must program the Parameter P268 to the desired function and you must connect in series to the input a resistor with its resistance between 270W and 1600W, as shown below: X1: X1: 12 12 Contact PTC DI6 (P268=7) + tº 13 R=(270 to 1600) DI6 (P268) 13 Figure 6.16 - PTC connection diagram or Digital Input “Rotation Direction” = Digital input open K1 “on” and K2 “off”, digital input closed K1 = “off” and K2 “on” (item 3.3.8). This enables the change control of the rotation direction through digital input. Do not program more than one digital input for this function “Jog” = It is possible to enable the slow speed with Jog via Digital Input when it is closed. Use a push-botton only. If more than one digital input was programmed for this function, any one which is closed enables the Jog. “Brake Off” = It is possible to disable the braking methods when the digital input is open, for extra safety, for monitory the real motor standstill and disable the braking immediately. If more than one digital input is programmed for this function, any one which is opened disables the braking immediately. 101 CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter Range [Factory Setting] Unit Description / Notess DIx Parameter Function Not used Enable/Disable or Start Stop (Three wires) General Enable FWD/VER REV Local/Remote No external Error JOG Brake Off Error Reset Motor Thermistor DI1 P264 (DI2) P265 (DI3) P266 (DI4) P267 (DI5) P268 (DI6) - 0 0 0 0 0 - - - - - - 1 2 - 1 2 - 1 2 3 4 5 6 - 1 2 3 4 5 6 - 1 2 3 4 5 6 7 Table 6.25 - Functions of the Digital Inputs P277 (1) RL1 Relay Output Function 0 to 9 [ 1=in Operation ] - P278 (1) RL2 Relay Output Function 0 to 9 [ 2=at Full Voltage ] - (1) P279 RL3 Relay Output Function 102 0 to 9 [ 6=No Fault ] - Check the available options in Table 6.26. The status of the digital outputs can be monitored in the Parameter P013. The digital output will be enabled when the function which has been programmed for the digital output is true. 18 19 RL1 20 21 RL2 22 23 24 RL3 X1C Figure 6.17 - Status of the relay digital outputs when disabled. “Not used” = the digital outputs are disabled. “In Operation” = the output will be enabled instantly with the Soft-Starter SSW-06 Enable command, and will only be disabled when the Soft-Starter SSW-06 receives the command Disable, or when the end of the deceleration ramp is reached, if programmed. “Full Voltage” = the output will be enabled when the Soft-Starter SSW-06 reaches 100% Un and it will be disabled when the Soft-Starter SSW-06 receives the command Disable. “External By-pass” = its operation is similar to the “Full Voltage” operation, but it must be applied only when the use of an external By-pass contactor is required. See P140 and the recommended setup at items 3.3 and 3.3.12. “FWD/REV-K1” = This operation is similar to the “In Operation”, but it must be enabled with forward motor direction of rotation. See P231 and the recommended setup at items 3.3 and 3.3.8. “FWD/REV-K2” = This operation is similar to the “In Operation”, but it must be enabled with reverse motor direction of rotation. See P231 and the recommended setup at items 3.3 and 3.3.8. “DC-Braking” = The output will be enabled during the DC-Braking is active. See P500 and the recommended setup at items 3.3 and 3.3.11. The output will be enabled when DC-Braking is active. See P500 and the recommended set-up at items 3.3 and 3.3.11. CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter Range [Factory Setting] Unit Description / Notes “No Fault” = the output is enabled without error. i. and., if the SoftStarter SSW-06 is not disabled due to any error. “Fault” = the output is enabled with error. i. and., if the Soft-Starter SSW-06 is disabled due to any error. RLx Parameter P277 Function (RL1) Not used 0 In Operation 1 At full Voltage 2 External By-pass 3 FWD/REV-K1 4 FWD/REV-K2 DC-Braking 5 No Fault 6 Fault 7 Fieldbus 8 Serial 9 P278 P279 (RL2) (RL3) 0 0 1 1 2 2 3 3 4 5 5 6 6 7 7 8 8 9 9 Table 6.26 - Functions of the Relay Outputs P295 (1) (2) Rated Current 0 to 20 [ According to the rated current of the Soft-Starter SSW-06 ] - P295 0 1 2 3 4 5 6 Rated Current 10A 16A 23A 30A 45A 60A 85A P295 7 8 9 10 11 12 13 Rated Current 130A 170A 205A 255A 312A 365A 412A P295 14 15 16 17 18 19 20 Rated Current 480A 604A 670A 820A 950A 1100A 1400A Table 6.27 – Rated current configuration ATTENTION! Always Program this parameter with a current that matches exactly the current of the model of your Soft-Starter SSW-06. Error in programmingthis parameter maydamage your Soft-Starter SSW-06 exactly. P296 (1) (2) Rated Voltage 0 or 1 [ According to the rated voltage of the Soft-Starter SSW-06 ] - P296 0 1 Voltage Range 220/575V 575/890V Table 6.28 - Voltage range ATTENTION! Program always this parameter with a voltage that matches exactly the voltage of the model of your Soft-Starter SSW-06. 103 CHAPTER 6 - DETAILED PARAMETER DESCRIPTION 6.4 - SERIAL COMMUNICATION PARAMETERS – P300 to P399 Parameter P308 (1)(2) Soft-Starter address on the Serial Communication Network P309 (1)(2) Fieldbus Communication Board Enabling Range [Factory Setting] Unit Description / Notes 1 to 247 [1] 1 Defines the Soft-Starter SSW-06 address on the serial Modbus-RTU communication network. For more information, refer to the Serial Communication Manual for the Soft-Starter SSW-06. 0 to 6 [ 0=Inactive ] - P309 0 1 2 3 4 5 6 Action Inactive Profibus-DP (1 Input and 1 Output) Profibus-DP (4 Inputs and 4 Outputs) Profibus-DP (7 Inputs and 7 Outputs) DeviceNet (1 Input and 1 Output) DeviceNet (4 Inputs and 4 Outputs) DeviceNet (7 Inputs and 7 Outputs) Table 6.29 - Fieldbus Communication Protocol Type Enables and defines the protocol type of the Fieldbus Communication Board. For more information, refer to the Fieldbus Communication Manual for the Soft-Starter SSW-06. NOTE! Without a Fieldbus Communication Board, this parameter must remain at 0 (not used). P312 (1)(2) Protocol Type and Transfer Rate of the Serial Communication. 1 to 9 [ 1=Modbus-RTU (9600bps, no parity) ] - P312 1 2 3 4 5 6 7 8 9 Action Modbus-RTU (9600bps, no parity) Modbus-RTU (9600bps, odd parity) Modbus-RTU (9600bps, even parity) Modbus-RTU (19200bps, no parity) Modbus-RTU (19200bps, odd parity) Modbus-RTU (19200bps, even parity) Modbus-RTU (38400bps, no parity) Modbus-RTU (38400bps, odd parity) Modbus-RTU (38400bps, even parity) Table 6.30 - Serial Communication Protocol Type Defines the protocol standards of the serial Modbus-RTU communication protocol. For more information, refer to Serial Communication Manual for the Soft-Starter SSW-06. P313 Serial and Fieldbus Communication Error Actions (E28, E29 and E30) 0 to 3 [ 0=Off ] - P313 0 1 2 3 Action Off Disable General Disable Changes to Local Table 6.31 - Error action of the Serials and Fieldbus Communication 104 CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter Range [Factory Setting] Unit Description / Notes Defines the action to be adopted when some errors relating to the Serial or Fieldbus Communication occur. For more information refer to the Serial Communication Manual and/ or to the Fieldbus Communication Manual for the Soft-Starter SSW-06. NOTE! When Serial Communication or Fieldbus Communication is not used, this parameter must remain at 0 (not used). P314 (1) Timeout Time for Serial Communication Telegram Reception 0 to 999 [ 0=not used ] 1s Allows time programming for the fault detection during the serial Modbus-RTU communication. So you can adopt an action when, for instance, the communication with the master of the Modbus-RTU network is lost. For more information, refer to the Soft-Starter SSW-06 Fieldbus Communication Manual. NOTE! This parameter must remain at 0 (not used), when the serial communication is not being used. P315 (1) Read Parameter via Fieldbus 1 0 to 999 [0] 1 This parameter allows selecting the number of the first parameter to be selected, which content will be sent from the Soft-Starter SSW-06 to the Master of the Fieldbus network. For more details, refer to the Soft-Starter SSW-06 Fieldbus Communication Manual. P316 (1) Read Parameter via Fieldbus 2 0 to 999 [0] 1 This parameter allows selecting the number of the second parameter to be selected, which content will be sent from the Soft-Starter SSW-06 to the Master of the Fieldbus network. For more details, refer to the Soft-Starter SSW-06 Fieldbus Communication Manual. P317 (1) Read Parameter via Fieldbus 3 0 to 999 [0] 1 This parameter allows selecting the number of the third parameter to be selected, which content will be sent from the Soft-Starter SSW-06 to the Master of the Fieldbus network. For more details, refer to the Soft-Starter SSW-06 Fieldbus Communication Manual. 105 CHAPTER 6 - DETAILED PARAMETER DESCRIPTION 6.5 MOTOR PARAMETERS - P400 to P499 Parameter Range [Factory Setting] Unit Description / Notes P400 (1) Motor Rated Voltage 0 to 999 [ 380 ] 1V Set this parameter value according to the motor nameplate and the connection diagram in the terminal box. The motor protection is based on the content of this parameter. P401 (1) Motor Rated Current 0.0 to 1500 [ 20.0 ] 0.1A Set this parameter value according to the motor nameplate. The motor protection against current and the current limit are based on this parameter content. NOTES! 1) To ensure that these protections operate correctly, the motor rated current must not be lower than 30% of the rated current of the Soft-Starter SSW-06. 2) The use of motors that operate with load duties lower than 50% their rated loads are not recommended. 3) Program the rated current of the motor according to the power supply voltage. P402 (1) Motor Rated Speed 400 to 3600 [ 1780 ] 1 rpm Set the motor speed according to the motor nameplate data. The motor speed must be the same as indicated on the motor nameplate, already considering its slip. P404 (1) Motor Rated Power 0.1 to 2650 [ 75 ] 0.1kW Set the motor power according to the motor nameplate data. If the power is in CV or HP, multiply the value by 0,74kW. P405 (1) Motor Power Factor 0 to 1.00 [ 0.89 ] 0.01 Set the Motor Power Factor according to the motor nameplate data. P406 (1) Service Factor 0 to 1.50 [ 1.00 ] 0.01 Set the Service Factor according to the motor nameplate. The current protections are based on the content of this parameter. 106 CHAPTER 6 - DETAILED PARAMETER DESCRIPTION 6.6 SPECIAL FUNCTION PARAMETERS - P500 to P599 Parameter P500 (1) Braking Methods Range [Factory Setting] Unit Description / Notes 0 to 3 P500 [ 0=Inactive ] 0 1 2 3 Action Inactive Reverse Braking Optimal Braking DC-Braking Table 6.32 - Braking Methods selection There are three braking methods implemented in the Soft-Starter SSW-06. These braking methods should be used only when fast stop is necessary. stops are necessary. Braking Torque DC-Braking Reverse Braking Optimal Braking Nominal Speed P501 Stopped Disable Figure 6.18 - Braking Torque “Reverse Braking” This is an efficient method to stop very high inertia loads. The motor will stop via AC level voltage in reverse direction until near 20% of the nominal speed when a Optimal Braking is applied to stop the motor. The motor will stop via AC level voltage in reverse direction until close to 20% of the rated speed, when Optimal Braking is applied to stop the motor. The Reverse Braking AC level and Optimal Braking are set in P502. Two contactors are needed. It is compatible with the Soft-Starter SSW-06 inside delta motor connection, except for two and eight pole motors. 107 CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter Range [Factory Setting] Unit Description / Notes U(V) Start 100%Un P501 FWD/REV-K2 Closed 0 FWD/REV-K1 Closed Enable 1s t(s) Disable P502 Start Figura 6.19 - Reverse Braking NOTES! 1. The contactors must be the same model and withstand the motor starting current. For security use auxiliary contact to avoid the contactors to close at the same time. For security, use an auxiliary contact to avoid contactors closing at the same time. 2. Use a digital input set to the “Braking Off” option to avoid starting the motor again in the wrong direction. 3. Por segurança uma entrada digital programada como “Sem frenagem”, para possibilitar a utilização de um sensor de parada no motor que desabilite a frenagem imediatamente, evitando que o motor gire em sentido contrário. 4. The Soft-Starter SSW-06 protects the motor while the Reverse Braking AC level is applied. 5. See the parameters: P266, P267, P268, P277, P278, P500, P501, P502, and P503 and see the recommended setup set-up at 3.3 and 3.3.9. “Optimal Braking” This is an efficient method to stop loads. The direct current is only applied when it will go to produce braking effect. when it produces a braking effect. No contactor needed. It’s compatible with the inside delta motor connection. U(V) Start 100%Un P502 0 1s Enable P501 Disable Figura 6.20 - Optimal Braking 108 t(s) CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter Range [Factory Setting] Unit Description / Notes NOTES! 1. Use the digital input set to "General Enable" to stop the motor without braking. 2. Use one digital input set to Braking Off, for extra safety, for monitory the real motor standstill and disables the braking immediately. 3. For high inertia loads it is recommended to use PTC motor input. 4. It is not recommended the use of Optimal Braking with two and eight pole motors. 5. See the parameters: P266, P267, P268, P500, P501, P502, and P503 and see the recommended setup set-up at items 3.3 and 3.3.10 “DC-Braking” This is an old and efficient method to stop very high inertia loads. The direct current is applied all the time until the motor stops. One contactor is needed to short-circuit two outputs output lines U and V. The necessary current to stop the motor is very high and continuously applied. It is not compatible with the Soft-Starter SSW-06 inside delta motor connection. U(V) Start 100%Un P502 0 Rotation direction K1 closed Enable 1s P501 DC-Brake RLX Closed t(s) Disable Figura 6.21 - DC-Braking NOTES! 1. Use the digital input set to General Enable to stop the motor without braking. 2. Use one digital input set to Braking Off, for extra safety, for monitoring the real motor standstill and disables the braking immediately. 3. It is recommended using a PTC motor input. Using a PTC motor input is recommended 4. See the parameters: P266, P267, P268, P277, P278, P279, P500, P501, P502, and P503 and see the recommended setup set-up at items 3.3 and 3.3.11. 109 CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter P501 Braking Time Range [Factory Setting] Unit Description / Notes 1 to 299 [ 10 ] 1s P501 sets the maximum time that the braking voltage is applied. ATTENTION! 1. This is the main protection of all braking methods. Set it according to the application, since the Soft-Starter SSW-06 and the motor can withstand the settings. 2. The parameters: P001, P002, P003, P008, P009, P010 and P011 are set to zero during Optimal Braking and DC-Braking. 3. The current protections do not work with a DC current because the current transformers saturate with DC current. 4. The Soft-Starter SSW-06 does not protect the motor while it is performing braking. while it is braking. P502 Braking Voltage Level 30 to 70 [ 30 ] % P502 sets the braking voltage level. It is based on the AC line voltage converted to DC voltage. This parameter also sets the level of the AC Reverse Braking. ATTENTION! 1. Be careful with this voltage level. Set it according to the application since the Soft-Starter SSW-06 and the motor can withstand the settings. 2. Start with low voltage levels and increase it according to the necessity. increase them according 3. The current protections do not work with a DC current because the current transformers saturate with DC current. 4. The Soft-Starter SSW-06 does not protect the motor while it is performing the braking. while it is braking. 5. To measure this current during the braking methods you need a special current meters with hall effect transformers. P503 Braking End Detection 0 to 1 [ 0=Inactive ] - P503 0 1 Description Inactive Automatic Table 6.33 - Braking End Detection This parameter set sets the automatic detection of the motor standstill. NOTES! 1. This function does not work with two and eight pole motors. 2. This function does not work with inside delta motor connections. 3. The motor standstill detection can vary with the motor temperature. 4. Always use the braking time as the main protection. 110 CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter P510 (1) Jog Range [Factory Setting] Unit Description / Notes 0 to 1 [ 0=Inactive ] - P510 0 1 Action Inactive Active Table 6.34 - Jog selection This parameter enables the fixed slow speed with Jog. Slow speed with Jog forward foreward direction is about 1/7 of the full speed. Slow speed with Jog reverse direction is about 1/11 of the nominal speed rated. P510 0 Inactive) 1 (Active) P231 0 (Inactive) 1 (Active) 1 (By Contactor) 1 (Active) 2 (JOG Only) Action without Jog allows the slow speed with Jog only in forward direction. allows the slow speed with Jog in the same direction of the power supply and the auxiliary contactors connected at the input power supply, changing the motor direction of rotation. allows the slow speed with Jog in both forward and reverse directions without contactors. Table 6.35 - Jog and motor direction of rotation P511 Jog Level 10 to 100 [ 10 ] 1% This parameter set sets the level of the torque torque level of the slow speed with Jog. This parameter sets the slow speed torque level with Jog. ATTENTION! 1. Be careful with this torque level. Set it according to the application since the Soft-Starter SSW-06 and the motor can withstand the settings. 2. The motor can be enabled during a short period of time with Jog. Connect a push-botton to a digital input to enable the Jog. 3. The P102 parameter is the limit of time protection to the Jog protection of the. If this time was exceed the fault E62 will actuate. If this time is exceeded, fault E62 will appear. The P102 parameter is the time limit protection of the Jog. If this time is exceeded, fault E62 will appear. 4. The parameters: P001, P002, P003, P008, P009, P010 and P011 are set to zero during the Jog Function. 5. The current protections do not work with the Jog current because the current transformers saturate with the low Jog frequency. 6. Soft-Starter SSW-06 does not protect the motor during a Jog without the use of a PRC sensor on the motor. 7. To correctly measure the currents during the Jog, it is necessary to use hall effect transformers. 111 CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter P520 (1) Torque Pulse at Start P521 Pulse Time at Start P522 Pulse Level of the Starting Voltage P523 Pulse Level of the Starting Current Range [Factory Setting] Unit Description / Notes 0 or 1 [ 0=Inactive ] 0.1 to 2 [ 0.1 ] 0.1s 70 to 90 [ 70 ] 1 %Un of the motor 300 to 700 [ 500 ] 1 %In of the motor Soft-Starter SSW-06 allows for the use of a torque pulse during the starting process for loads that have high resistance during the starting process. Enabled through P520=1. The duration of this pulse may be adjusted at P521. This pulse will be applied according to the type of control selected at P202: - Voltage ramp: the voltage level may be set at P522. - Current limit: the current level may be set at P523. - Current Ramp: with adjustable current level. NOTES! 1) Use this function only for specific applications, when so required. 2) This function is not required for the Torque Control. U(V) Start 100%Un P522 P101 0 P521 Enable I(A) P102 t(s) Voltage Ramp Disable Start P523 P110 I Limit I Nominal 0 112 P102 P521 Enable Current Limit t(s) Disable CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter Range [Factory Setting] Unit Description / Notes I(A) Start P523 P110 I Limit I Rated Current P111 0 P112 P521 t(s) P102 Maximum Time Enable Disable Current Ramp Figure 6.22 - Actuation Levels of the Starting Torque Pulse. 6.7 PROTECTIONS PARAMETERS - P600 to P699 P600 (1) Intermediate Undervoltage P601 (1) Time of Immediate Undervoltage P602 (1) Intermediate Overvoltage P603 (1) Time of Immediate Overvoltage The under and overvoltage are setting as percentage of the motor 0 to 30 rated voltage (P400). [ 20 ] 1 %Un of the Motor P600 sets the minimum voltage level at which the motor can operate without problems. This protection function acts when the line voltage drops to a value lower than the set and is present during a time equal 1 to 99 to or longer than those set at P601. If this condition is present, the [1] Soft-Starter is disabled and an Undervoltage Error is displayed. 1s P602 sets the maximum overvoltage level that the motor allows, during the time that has been set at P603. If this time is exceeded, the 0 to 20 Soft-Starter is disabled and an Overvoltage Error is displayed. [ 15 ] 1 %Un of the Motor NOTE! These functions are active the entire time the motor is running. 1 to 99 [1] U(V) 1s Actuation Region Running Nominal P602 Deceleration ramp P600 0 t(s) Enable U(V) P602 Disable U (V) Fault Action Fault Action Over Voltage Nominal Nominal P600 Under Voltage t0 P601 t1(s) t0 P603 t1(s) Figura 6.23 - Actuation Levels in case of Undervoltage and Overvoltage 113 CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter P604 (1) Voltage Unbalance between Phases P605 (1) Voltage Unbalance Between Phases Time Range [Factory Setting] Unit Description / Notes 0 to 30 Time of Voltage Unbalance between phases is set as a percentage of [ 15 ] the motor rated current (P400). 1%Un of the Motor P604 sets the maximum voltage difference between the three line phases at which the motor can operate without problems, during the 0 to 99 time set at P605. If these values are exceeded, the Soft-Starter is [1] switched Off and the Voltage Unbalance error is displayed. 1s These settings also activate the phase fault protection during the starting process and during the operation at full voltage. NOTE! This function is active always when motor is running. P610 (1) Immediate Undercurrent P611 (1) Immediate Undercurrent Time P612 (1) Immediate Overcurrent P613 (1) Immediate Overcurrent Time 0 to 99 The Undercurrent and the overcurrent are set as percentage of the [ 20 ] motor rated current (P401). 1%In of the motor P610 sets the minimum current level at which the motor can operate without problems. This protection function acts when the motor current 1 to 99 drops below the value and during a time equal or longer than those [ 0=Inactive ] set at P611. If these values are exceeded, the Soft-Starter is switched 1s Off and the Undercurrent Error is displayed. This function is generally used in applications with hydraulic pump which can not be operated without a load. 0 to 99 P612 sets the maximum overcurrent levels that the motor or Soft[ 20 ] Starter allows during the time set at P613, after which the Soft-Starter 1%In of the motor is switched Off and the Overcurrent Error is displayed. NOTE! These Functions are only active after the motor start and after full voltage operation has been reached. 1 to 99 [ 0=Inactive ] 1s I(A) Actuation Region Start P612 Nominal P610 0 t(s) Enable Disable I(A) I(A) Fault Action Fault Action Over Current P612 Nominal Nominal P610 Under Current t P611 t(s) t P613 Figure 6.24 - Actuation Levels for Overcurrent and Undercurrent 114 t(s) CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter P614 (1) Current Imbalance between Phases P615 (1) Current Imbalance between Phases Times Range [Factory Setting] Unit Description / Notes 0 to 30 The current unbalance values are set as percentage of the motor rated [ 15 ] current (P401). 1 %In of the motor P614 sets the maximum current difference between the three motor phases at which the motor can operate without problems, during the time set at P615. If these values are exceeded, the Soft-Starter is 0 to 99 switched Off and the Current Unbalance error is displayed. [ 0=Inactive ] These settings also activate the phase fault protection during the 1s starting process and during the operation at full voltage. NOTE! This function is actuated only after motor start and after full voltage operation has been reached. P616 (1) Undercurrent before Internal By-pass Closing 0 or 1 [ 1=Active ] - This function, when enabled, ensures protection against undercurrent before By-pass closing, i. and., preventing By-pass closing in case of any supply line fault of any thyristor fault. When this function is disabled, the motor can be started with rated current lower than 10% of the rated Soft-Starter current. NOTE! This function can be disabled only when motors with low currents are tested. P617 (1) Motor Overcurrent Before Internal By-pass Closing 0 or 1 [ 1=Active ] - When this function is enabled it ensures protection against locked rotor at the end of the start, i. and., it preventing that the By-pass closes when an overcurrent two times the rated motor current is detected. NOTE! Disable this function only when the motor can withstand loads with higher currents. P620 (1) RST Phase Sequence P630 Interval of Time after Stop 0 or 1 [ 0=Inactive ] The function of this parameter is to protect loads that can be run only in one direction of rotational. When this function is enabled, only the phase sequence R/1L1, S/3L2, T/5L3 is permitted.. When this function is enabled, the phase sequence is detected every time the motor is powered-up. The function is very useful for driving of driving hydraulic pumps which can be operated only in one direction of rotation. 2 to 999 [2] 2s This function limits the minimum time interval between a new start after the motor has been switched Off. 115 CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter Range [Factory Setting] Unit Description / Notes Un P104=0 t P630=10s Un P104=6s P630=10s Figure 6.25 - Operation via HMI Un t and P104=0 P630=10s Un . t P104=6s P630=10s t Figure 6.26 - Operation via three-wire digital inputs (DI1 and DI2). Un P104=0 P630=10s t P104=6s Un P630=10s Figure 6.27 - Operation via digital input (DI1) 116 t CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter Range [Factory Setting] Unit Description / Notes NOTE! The start command will be executed only after the time interval programmed at P630 has elapsed. NOTES! 1) The time interval starts to be counted at the moment when the motor switch Off command is given, indifferently if a deceleration ramp has been programmed or no. 2) This function is only active when the time interval, which has been set at P630, is longer than the time set at P104 for the deceleration process, if programmed. 3) If the control board supply is removed, or if the microcontroller is reset, no time counting occurs. P640 (1) Motor Protection Thermal Class 0 to 9 [ 6=30 ] 1 P640 0 1 2 3 4 5 6 7 8 9 Action Inactive Class 5 Class 10 Class 15 Class 20 Class 25 Class 30 Class 35 Class 40 Class 45 Table 6.36 - Thermal Classes Soft-Starter SSW-06 has a rigid thermal protection that is efficient and totally programmable for the protection of your motor. All SoftStarter SSW-06 models are fitted with this protection device. When activated, error E05 (overload) will be displayed and the motor will be switched off. This thermal protection has curves that simulate the motor heating and cooling. The calculation is executed by a complex Software, that estimates the motor temperature through True RMS current supplied to the motor. The actuation curves of the Thermal Protection are based on IEC 60947-4-2 standard. The heating and cooling curves are based on WEG's extensive experience with motor development. These curves adopt WEG threephase IP55 standard motors. They also consider if the motor is cooled or not when driven. The cooling time of the thermal image depends on the motor power, which means that each power will have different cooling time. When reduction of this cooling time is required, you can use P641. The estimated motor temperature is saved in non-volatile memory every time the power supply of the control board is switched off. Thus, when the control board is switched on again, the last value saved will return. 117 CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter Range [Factory Setting] Unit Description / Notes Time t(s) 1000 100 Class Class Class Class Class Class Class 10 45 40 35 30 25 20 15 Class 10 1 1x 1x 2x 2x 3x 3x 5x 4x 5x 4x 6x 6x 7x 7x 8x Class 5 Current x In 9x 8x F.S.=1 9x 10x F.S.=1,15 Figure 6.28 – Thermal Protection Classes for cold motor Class 40 30 20 10 3xIn 135s 101.2s 67.5s 33.7s 5xIn 48.1s 36.1s 24s 12s 7xIn 24.5s 18.3s 12.2s 6.1s Table 6.37 – Thermal Protection Class Times for cold motor with S.F.=1.0 Class 40 30 20 10 3xIn 180.2s 135.1s 90.1s 45.1s 5xIn 63.6s 47.7s 31.8s 15.9s 7xIn 32.4s 24.3s 16.2s 8.1s Table 6.38 – Thermal Protection Class Times for cold motor with S.F.=1.15. 118 CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter Range [Factory Setting] Unit Description / Notes Time t(s) 1000 100 10 Class Class Class Class Class Class Class Class 1 45 40 35 30 25 20 15 10 Class 5 0,1 1x 2x 3x 4x 5x 6x 7x 8x Current x In 9x Figure 6.29 – Thermal Protection Classes for hot motor with 100% In Class 40 30 20 10 3xIn 47.2s 35.4s 23.6s 11.8s 5xIn 16.8s 12.6s 8.4s 4.2s 7xIn 8.5s 6.4s 4.2s 2.1s Table 6.39 - Thermal Protection Time for hot motor Current in % of In of the Motor 0%(cold) 20% 40% 60% 80% 100% (rated load) Factor 1 0,87 0,74 0,61 0,48 0,35 Table 6.40 - Multiplication Factor of the Cold Thermal Classes Time to obtain Hot Thermal Class Times 119 CHAPTER 6 - DETAILED PARAMETER DESCRIPTION Parameter Range [Factory Setting] Unit Description / Notes NOTE! As there are several Thermal Protection Classes, you must program that Thermal Protection Class that best meets you application and protects the motor during its allowed duty. NOTE! The SSW-06 Soft-Starter thermal class times are an evolution of the previous WEG soft-starters, therefore the times are different than those of the SSW-03 and SSW-04. The class to be adopted must be in accordance with the SSW-06 graphs. NOTE! When using a motor with a PTC thermal sensor or thermostat entirely connected to the SSW-06 Soft-Starter, there is no need to enable the Thermal Classes, therefore set P640=0. P641 (1) Auto Reset of the Thermal Memory 1 to 600 [ 0=Inactive ] 1s Sets the time for the auto-reset of the thermal image of the motor. This function can be used for applications that require several starts per hour or those with short intervals of time between starting and stopping the motor. The motor cooling curves are based on many years of experience of WEG developing motors. They adopt the Standard IP55 Three Phase Motors with temperature elevation of 60K as a standard. They also consider if the motor is cooling when switched on or not. The thermal image cooling time depends on the power of the motor, in other words, for each power there is a different cooling time. The thermal image can also be reset if parameter P640=0 is programmed returning to the desired Thermal Class afterwards. Motor On Off t Actuation Level E05 whithout reset Motor t On Off t Actuation Level E05 auto-reset Time with reset t Figure 6.30 - Auto-reset of the thermal memory NOTE! Please consider that when using this function, the life time useful life of the motor winding can be reduced. 120 CHAPTER 7 APPLICATIONS AND PROGRAMMING This Chapter is useful for setting and programming the start control type according to the application. 7.1 APPLICATIONS AND PROGRAMMING ATTENTION! Important information about each start control type. ATTENTION! For correct parameter setting you must consider the load data and use WEG Sizing Software, available at WEG Site (http://www.weg.net). If this site can not be accessed, you can follow some practical concepts described below: Although, if you cannot use it, a few practical principles are described in this chapter. I/In C/Cn I/In C/Cn Current Torque Cn Cn Current In In Torque 25 0 50 75 100% rpm 0 25 50 75 100% rpm Figure 7.1 – Characteristic torque and current curve in a direct on-line start and by Voltage Ramp I/In C/Cn I/In C/Cn Torque Current Current Cn Cn Torque In In 0 25 50 75 100% rpm 0 25 50 75 100% rpm Figure 7.2 – Characteristic torque and current curves during a start with current Limit and Torque Control Below are some suggested characteristic curves showing the current and starting toque behavior by considering some load and control types: 121 CHAPTER 7 - APPLICATIONS AND PROGRAMMING Load Type Alternative Pumps Load Type Load Type Screw Compressors 3 Point Torque control Conveyor Control Type 3 Point Torque control Current Limit + K.Starter Axial Fans Current Limit Current Ramp 2 Point Torque control 3 Point Torque control 3 Point Torque control Current Limit + K.Starter Extruders Vertical Sand Mills Wood Peeler Centrifugal Fans Exhaust Current Limit Current Ramp 3 Point Torque control Current Limit + K.Starter Piston Vacuum Pump Piston Compressors Centrifugal Pumps Vane Vacuum Pump Pump Control 2 Point Torque control 3 Point Torque control Constant Torque Control Crushers Wood Peeler Submersible Centrifugal Pumps Current Limit Current Ramp 3 Point Torque control Ball Mill – Ceramics Centrifuges Hammer Mills Current Limit 2 Point Torque control Barley – Starch Processing Wood Chipper Current Ramp + K.Starter Current Limit + K.Starter Mixers Current Limit Current Ramp Current Ramp + K.Starter Current Limit + K.Starter Cellulose Refiners Voltage Ramp Table 7.1 – Typical characteristics of staring torque curves of some load types with suggested types of control 122 CHAPTER 7 - APPLICATIONS AND PROGRAMMING 7.1.1 Starting by Voltage Ramp (P202=0) Voltage Ramp P101 P102 1) Set initial voltage, P101. Set initially to a low value; 2) When load is applied to the motor, set P101 to a value that allows motor running smoothly since the begin of its enabled; 3) Set P102 to the time required for the motor start. Set firstly short time, 10 to 15 seconds, after try to find the most suitable starting condition for your load. P400 P401 U(V) Start 100%Un P406 P640 P101 0 P102 Enable Voltage Ramp t(s) Disable Figure 7.3 – Starting by Voltage Ramp NOTES! 1) Vibrations can occur during the load start, when long starting times have been set, or motor is starting without load. In this case, decrease the starting time; 2) If errors are detected during the motor start, check all connections of the Soft-Starter to the power line, the motor connections, the voltage levels of the power line, the fuses, circuit-breakers and disconnecting switches. 123 CHAPTER 7 - APPLICATIONS AND PROGRAMMING 7.1.2 Starting by Current Limit (P202=1) Current Limit P102 P110 P400 1) To start the motor with a current limit you must apply a load to the motor. No-load tests can be done by voltage ramp; 2) Set P102 to the time required for the load start. At first set short times, 20 to 25s. This time will be used as the locked rotor time, when the motor is unable to start; 3) Set P110 with Current Limit by considering its electrical installation and ensuring sufficient torque for the motor start. Initially you can set firstly 2x to 3x the rated motor current (In of the motor). P401 P406 I(A) Start P640 I Limit P110 I Nominal Maximum Time 0 P102 Enable Limit Current t(s) Disable Figure 7.4 – Starting by constant current limit NOTES! 1) If the current limit is not reached during the starting, the motor will start immediately. 2) P401 must be set according to the motor current; 3) Current Limits that are too low result in torques that are too low for the motor start. Always maintain the motor running after it has been enabled; 4) For loads requiring a higher initial starting torque, you can use the kick start function, P520, or the current ramp method; 5) If errors are detected during the motor start, check all connections of the Soft-Starter to the power line, the motor connections, the voltage levels of the power line, the fuses, circuit-breakers and disconnecting switches. 124 CHAPTER 7 - APPLICATIONS AND PROGRAMMING 7.1.3 Starting by Current Ramp (P202=4) Current Ramp P102 P110 P111 P112 P400 P401 P406 1) For starting the motor with current ramp you must apply load on the motor. No-load tests can be done by voltage ramp; 2) Use this function to help starting loads that require an higher initial torque , as compressors and belt conveyors; 3) When such a load is started with fixed current limit, you can note that the motor requires some time to start the load and then it speeds up quickly; 4) As solution we recommend to set an initial current limit to overcome the load start and then programming a current limit that enables the load acceleration till the start end. In this way you certainly will ensure a smooth start; 5) Set P111 to the current value required to start the motor; 6) Set P112 initially to 2s, i. and., to 10% of P102(20s) = 2s and then increase it gradually; 7) The motor must run as soon as it is enabled; 8) Set P110 with current limit that maintains the motor accelerating. I(A) P640 Start P111 P110 0 I Limit I Nominal P112 P102 Maximum Time Enable Current Ramp t(s) Disable Figure 7.5 – Starting with current ramp and initial higher current NOTES! 1) If the current limit is not reached during the starting, the will motor starts immediately. 2) P401 setting must be according to current of the used motor; 3) Alow Current Limit results in too low torque for the motor start. Always maintain the motor always running after it has been enabled; 4) If errors are detected during the motor start, check all connections of the Soft-Starter to the power line, the motor connections, the voltage levels of the power line, the fuses, circuit-breakers and disconnecting switches. 125 CHAPTER 7 - APPLICATIONS AND PROGRAMMING 7.1.4 Starting by Current Ramp (P202=4) Current Ramp P102 P110 P111 P112 P400 P401 P406 1) To start the motor with current ramp you must apply load on the motor. No-load tests can be done by voltage ramp; 2) Use this function to help starting loads that require a lower initial torque, as fans and blowers; 3) When such a load is started with fixed current limit, you can note that the motor starts the load and then it speeds up; 4) As solution we recommend setting a lower initial current to only run the load and the increase the current limit gradually until the end of the start. In this way you will certainly ensure a smooth start; 5) Set P111 to the current value required to put the motor in movement only; 6) Set P112 initially to 75% of P102(20s) = 15s and then increase it gradually; 7) The motor must run as soon as it is enabled; 8) Set P110 with current limit that maintains the motor accelerating; 9) The motor must accelerate till the start end. I(A) P640 Start P110 I Limit I Nominal P111 0 P112 P102 Maximum Time Enable Current Ramp t(s) Disable Figure 7.6 – Starting with current ramp and initial lower current NOTES! 1) If the current limit is not reached during the starting, the motor will start immediately. 2) P401 must be according to current of the used motor; 3) Current Limits that are too high result in torques that are too low for the motor start. Always maintain the motor running after it has been enabled; 4) If errors are detected during the motor start, check all connections of the Soft-Starter to the power line, the motor connections, the voltage levels of the power line, the fuses, circuit-breakers and disconnecting switches. 126 CHAPTER 7 - APPLICATIONS AND PROGRAMMING 7.1.5 Starting with Pump Control (P202=2) Pump Control P130 P101 1) To start with pump control a load is necessary. Tests without a load can be done with voltage ramp; 2) The parameter setting depends mainly of the types of hydraulic installations. Thus we recommend to optimizing factory settings, if possible. 3) Check if the motor rotation direction is an indicated on the pump frame. If not, connect the phase sequence as indicated at P620; P102 P103 P104 P105 P400 Figure 7.7 – Direction of rotation of a hydraulic centrifugal pump P401 P610 P611 P620 P406 P640 4) Set the initial voltage - P101 – so the motor starts smoothly as soon as it is enabled. 5) Set the acceleration time according to its application, i. and., that the motor is able to start the load smoothly, but the required acceleration is not exceeded. If acceleration times are set too long, this may result in vibration of harmful motor overheating; 6) To check the correct starting process, always use a manometer in the hydraulic installation. Pressure increase should not result in sudden oscillations. Thus the pressure increase should be as linear as possible; U(V) 100%Un Start P101 0 P102 Enable Pump Control Figure 7.8 – Manometer showing pressure increase 7) Program the voltage step during the deceleration process only when no pressure drop is detected at the deceleration begin. With this deceleration voltage step you can improve the pressure drop during the deceleration process; 8) Set the deceleration time according to the application, i. and., ensuring that the pump stops smoothly within the expected limits. The set of excessively long times may result in vibrations or harmful motor overheating; 127 CHAPTER 7 - APPLICATIONS AND PROGRAMMING Pump Control U(V) 100%Un Stop P130 P103 P101 P105 P102 0 P104 t(s) Disable P103 Figure 7.9 – Manometer showing the pressure drop P104 P105 P400 P401 9) Generally, the current increases at the end of the deceleration ramp and in this case the motor requires more torque to achieve a smooth water flow stop. When the motor has already stopped, but is still enabled, the current will increase too much. To prevent this condition, set P105 to a value that as soon it stoop it is also disabled; 10)Set P610 and P611 to current and time levels that prevent the hydraulic pump from running without a load. P610 P611 U(V) Start 100%Un Stop P620 P103 P406 P101 P105 P640 0 P102 Enable Pump Control P104 t(s) Disable Figure 7.10 – Start with pump control NOTES! 1) P400 and P401 must be set according to the line voltage and the rated current of the used motor used; 2) If the hydraulic piping is not fitted with manometer, the hydraulic rams can be noted at the pressure relief valves; 3) Please consider, that sudden line voltage drops results in motor torque drops. Thus, ensure that the power supply line characteristics are within the characteristics required for motor operation; 4) If errors are detected during the motor start, check all connections of the Soft-Starter to the power line, the motor connections, the voltage levels of the power line, the fuses, circuit-breakers and disconnecting switches. 128 CHAPTER 7 - APPLICATIONS AND PROGRAMMING 7.1.6 Starting with Torque Control (P202=3) Torque Control P102 1) The torque control of the Soft-Starter SSW-06 demonstrates excellent performance during motor and load starts; 2) This control is available in a form to facilitate and to adjust the type of control to the type of load; 3) See below some recommendations on how to program and set this type of control. NOTES! P120 Constant Linear Quadratic P121 P121 P121 P122 P122 P123 P124 P104 1) To start with pump control a load is necessary. Tests without a load can be done with voltage ramp. 2) If the torque limits are not reached during the start, the motor will start immediately. 3) Only use the control type and/or torque control type you are able to set. Always select the control type that is easier to set, considering the load characteristics; 4) When heavy loads are started, always select the start by current limit. In this way you can set the energy consumption during the start by considering the power line capacity; 5) All motor parameters must be set according to the motor nameplate, P400 to P406; P125 Constant Linear Quadratic P126 P126 P126 P127 P127 6) Torque limits that are too low do not supply enough torque to start the motor; 7) Low torque limits are also very sensitive to motor temperature oscillations, for instance when load is started with cold or hot motor; P128 P400 P401 P402 P404 P405 P406 P640 8) Low torque limits are also very sensitive to load changes, for instance, oils, greases and relief valves have different resistant torques in relation to the motor start when they are hot or cold; 9) Always maintain motor running after is has been enabled, indifferent if it has been started cold or hot; 10)The motor manufacturer supplies the maximum torque developed by the motor, during the starting or at full load. The Soft-Starters can only limit these this data; 11) If errors are detected during the motor start, check all connections of the Soft-Starter to the power line, the motor connections, the voltage levels of the power line, the fuses, circuit-breakers and disconnecting switches. 129 CHAPTER 7 - APPLICATIONS AND PROGRAMMING 7.1.6.1 Loads with constant torque (P202=3 and P120=1 point) Torque Control 1) Set P121 as percent of the rated motor torque, necessary for the motor + load during running process; 2) Set P102 to the time required for the motor start. Firstly program short times: 10 to 15s; 3) With the torque control you can start the load smoothly within short starting times due to the linearity of the start speed ramp. P400 Tn(%) Speed P102 Start P401 P120 =1 P402 P121 Tn Nominal Load Torque P121 P404 P104 =0 P405 0 t(s) P102 Maximum Time Enable Torque Control Disable P406 P640 7.1.6.2 Loads with initial high torque (P202=3 and P120=3 points) Torque Control P400 P102 P401 P120 =3 Figure7.11 – Start with constant torque control - 1 point 1) Through this function you can achieve a smooth and linear starting ramp. This function is very useful for driving belt conveyors; 2) Through the load curve you can set a starting torque 10% to 20% higher than the load torque for each one of the points P121, P123, P122 and the times at P102 and P124; 3) For the first start you can use a speed measuring instrument, thus ensuring the desired acceleration or the desired speed curve; 4) If no load curves are available, you can apply a similar method as the current ramp method. Also the torque limit, P120=1, can be used for executing the first start-ups and afterward changing to this function. P402 P121 P404 Tn(%) Speed Start P122 P405 P123 P121 P122 P123 Tn Nominal Load Torque P406 P124 P640 P104 =0 0 P124 t(s) P102 Maximum Time Enable Torque Control Disable Figure 7.12 – Starting with quadratic torque control, 3 points, with higher initial load 130 CHAPTER 7 - APPLICATIONS AND PROGRAMMING 7.1.6.3 Loads with constant torque and S speed curve (P202=3 and P120=3 points) Torque Control P400 P102 P401 P120 =3 1) Through the load curve you can set the torque 10% to 20% higher than the load torque for the initial and the end points, P121 and P122, are 30% to 40% higher than load torque for the middle point P123; 2) Maintain P124 between 45% to 55% and set P102 according to the starting time; 3) For the first start you can use a speed measuring instrument, thus ensuring the desired acceleration or the desired speed curve; 4) If no load curve is available, but you are sure that the torque is constant, you can use the torque limit, P120=1 for executing the first start-ups and changing to this function afterwards. P402 Tn(%) P121 Speed P404 Start P122 P405 P122 Tn Nominal Load Torque P123 P123 P121 P406 P124 0 P640 P104 t(s) P124 P102 Maximum Time =0 Torque Control Enable Disable Figure 7.13 – Starting with quadratic torque control, 3 points, with constant load 7.1.6.4 Loads with quadratic torque and S speed curve (P202=3 and P120=2 points) Torque Control P400 P102 P401 P120 =2 1) Through the linear torque ramp you can obtain a speed curve very similar to a S-curve with quadratic load, but not very steep; 2) Through the load curve you can set the torque 10% to 20% higher than the load torque for the initial point P121, and 20% to 30% than the load torque for the end point, P122; 3) If no load curves are available, proceed as follows: 3.1) Set P121 to the required torque to run the motor + load; 3.2) Set P122 to 110% to 130% of the rated motor torque; 3.3) First set P102 firstly to low values, 10s to 15s and then increase these values. Tn(%) P402 Speed Start P122 P121 Tn Nominal P404 P122 P104 P405 P121 P406 0 Load Torque =0 P640 P102 Maximum Time Enable Torque Control t(s) Disable Figure 7.14 – Starting with linear torque control, 2 points, quadratic load 131 CHAPTER 7 - APPLICATIONS AND PROGRAMMING 7.1.6.5 Loads with quadratic torque and linear speed curve (P202=3 and P120=3 points) Torque Control 1) Through a steep quadratic load you can set an intermediate point for improving the linearity of the start speed curve; 2) Through the load curve you can set the torque 20% to 30% higher than the load torque for all points P121, P123 and P122 and set P124 as a percent of the time for the intermediate point 3) If no load curves are available, set it initially with a linear torque, P120=2 points, and afterward set the intermediate time and torque. P400 Tn(%) P102 P401 P120 Speed P122 Start =3 Tn Nominal P402 P123 P121 P404 Load Torque P121 P122 0 P405 P123 P124 t(s) P102 Maximum Time P406 P124 Enable Disable Torque Control P640 P104 =0 Figure 7.15 - Starting with quadratic torque control, 3 points, quadratic load 7.1.6.6 Loads with quadratic torque and higher initial torque (P202=3 and P120=3 points) Torque Control 1) With a very steep quadratic load, very high initial torque, you can set an intermediate point for improving the linearity of the start speed curve; 2) Through the load curve you can set the torque 20% to 30% higher than the load torque for all points P121, P123 and P122 and set P124 as a percent of the time for the intermediate point; 3) If no load curves are available, set it initially with linear torque, P120=2 points, and afterward set the intermediate time and torque. P400 Tn(%) P102 Speed P401 P120 Start P122 =3 Tn Nominal P402 P121 P404 P121 P123 Load Torque P122 P405 P123 P406 P124 0 P124 P102 Maximum Time Enable Torque Control t(s) Disable P640 P104 =0 Figure 7.16 - Starting with quadratic torque control, 3 points, quadratic load with higher initial torque 132 CHAPTER 7 - APPLICATIONS AND PROGRAMMING 7.1.6.7 Hydraulic pump load type (P202=3) Torque Control Torque Control P102 P102 P120 =2 P120 P121 P121 P122 P122 P104 0 P123 P125 =1 P124 =3 Starting (P120=2 or P120=3): 1) Before any setting, carefully read carefully the steps described in Starting with Pump Control, item 7.1.5; 2) If the pump control does not meet your requirements our if a control with better performance is desired, use the torque control; 3) With a linear torque ramp you can obtain a speed curve very similar to the S-Curve with quadratic loads, as centrifugal pumps; 4) Through the load curve you can set the torque 10% to 20% higher than the load torque for the initial point P121, and 20% to 30% higher than the load torque for the end point, P122; 5) Even when the load curve is used, we recommend executing a setting at the application field. For this, proceed as follows: 5.1) Set P121 to the torque required for the running pump; 5.2) Set P122 to 110% to 130% of the rated motor torque; 5.3) Set P102 initially to lower values, 10s to 15s, then increase this setting. Speed Tn(%) P126 P104 Start 0 P122 Tn Nominal P125 =1 Load Torque P121 0 P126 P102 Maximum Time Enable Torque Control Figure 7.17 – Manometer showing the pressure increase, linear torque 6) If the load has a higher initial torque, could be used the quadratic torque (P120=3 points); Tn(%) Speed P122 Start Tn Nominal P121 P123 Load Torque 0 P124 P102 Maximum Time Enable Torque Control Figure 7.18 – Manometer showing the pressure increase, quadratic torque 7) The main purpose of the two above mentioned cases is maintaining the pressure ramp as linear as possible, increasing it gradually; 8) As already described in the pump control, the use of a measuring instrument is required for measuring this pressure and so obtaining the best setting; 133 CHAPTER 7 - APPLICATIONS AND PROGRAMMING Torque Control P400 P102 P401 P120 =2 P402 P121 P404 P122 Stopping (P1240 and P125=1): 1) In most applications only the constant toque control can be used for pump stopping, 1 point=constant; 2) This method is used for water columns that are not very high; 3) Set P126 initially to the same value of P121, provided it is correct; 4) Set P126 in such a way that at the end of the pump stopping process the motor is not still enabled; 5) As soon as the pump is disabled, a gradual pressure drop should be noted without significant pressure oscillation, mainly at the end of the stop, when the retaining valve is closed. P405 P104 0 P406 P125 Tn(%) Speed Start P122 =1 Tn Nominal P640 P126 Load Torque P121 P126 P127 0 P102 Maximum Time P128 t(s) P104 Enable Torque Control Disable Figure 7.19 – Hydraulic pump stopping with constant torque, 1 point Torque Control P400 P102 P401 P120 =2 P402 P121 Stopping (P1240 and P125=2): 1) Linear deceleration torque, 2 points=linear; 2) Applied to high water columns; 3) At first you can set P126 for 10% to 15% lower than the value of P121, provided this value is correct; 4) Set P127 so that when the beginning of the stopping process, the pressure decreases gradually and no sudden pressure oscillation occurs; 5) Set P126 so that at the end of the pump stopping process the motor is not still enabled. P404 Tn(%) P122 Speed Start P405 P122 P104 0 Tn Nominal P127 P406 P125 =2 P121 Load Torque P640 P126 P126 0 P102 Maximum Time P128 P104 t(s) P127 Enable Torque Control Disable Figure 7.20 – Hydraulic pump stopping with linear torque, 2 points 134 CHAPTER 7 - APPLICATIONS AND PROGRAMMING Controle de Torque P400 P102 P401 P120 =2 P402 P121 P404 P122 P405 P104 0 P406 P125 =3 Stopping (P1240 and P125=3): 1) Quadratic deceleration torque, 3 points=quadratic; 2) Applied to high water columns with high pressures; 3) This control is used when it is difficult to achieve a gradual pressure drop without sudden pressure oscillations, mainly at the start of the stopping process; 4) The best way to perform this is to use the load curve as a base and set the 3 points 10% to 15% lower; 5) Set P128 initially to 50%; 6) Set P127 so that at the beginning of the stopping process, the pressure decreases gradually and no sudden pressure oscillation occurs; 7) Set P126 so that at the end of the pump stopping process the motor is not still enabled. P640 P126 Tn(%) Speed Start P122 P127 Tn Nominal Load Torque P128 P121 0 P127 P102 Maximum Time Enable P126 P128 P104 Torque Control t(s) Disable Figure 7.21 – Hydraulic pump stopping with quadratic torque, 3 points 8) If the load shows a higher initial torque, then use the quadratic torque control (P120=3 points). %Tn Speed Tn Nominal P127 0 P126 P128 t(s) P104 Disable Figure 7.22 – Manometer showing the pressure drop, torque control NOTES! 1) The main purpose of the torque control types applied to the stopping process is to maintain the drop in the pressure ramp as linear as possible, decreasing the pressure gradually and thus preventing sudden pressure oscillation, at the beginning, middle and at the end of the stopping process; 2) As already described in the pump control, the use of a measuring instrument is required to measure the pressure and obtain the best setting; 3) Remember: constant torque control is suitable for the greatest number of applications and its use is very easy. 135 CHAPTER 7 - APPLICATIONS AND PROGRAMMING 7.2 PORTECTIONS AND PROGRAMMING 7.2.1 Thermal Classes 7.2.1.1 Suggestions about thermal class setting 1) Initially start from the standard thermal class, sometimes, but without heating the motor excessively. 2) Determine the correct starting time. Find an average of the current through the P002 during the starting time. One can find a current average for any kind of starting control. For example: When an 80A motor is started by voltage ramp, the current at P002 starts at 100A and increases to 300A and after 20s drops to the rated current. (100A+300A)/2 = 200A 200A/80A = 2.5 x In of the motor then: 2.5 x In @ 20s. U(V) 100%Un Start 300A P101 Current in P002 100A 0 t(s) P102 20s Enable Voltage Ramp Figure 7.23 – Typical current curve when started by voltage ramp 3) Use this time to find the minimum class necessary to start a cold motor according to the descriptions of the P640 in chapter 6; t(s) Cold F.S.=1 20s 15 10 5 0 2.5 x In of the Motor xln Figure 7.24 – Determining the minimum thermal class with cold motor Thus the minimum required thermal class for starting the motor is the Class 10. The Class 5 requires a shorter time for this current. This Thermal Class allows motor cold start. 136 CHAPTER 7 - APPLICATIONS AND PROGRAMMING 4) To determine the thermal class for starting the motor at running condition (hot), the motor thermal class must be known. For this we must determine the allowed locked rotor time. NOTE! To program the Thermal Class that your motor will withstand, the allowed locked rotor time must be available. For this data, please refer to the manufacturer catalog. With the blocked rotor time we can find the maximum thermal class that will protect the motor for hot starter, according to the descriptions of the P640; For example: 6,6 x In @ 6s t(s) Hot 6.6s 40 35 30 0 6.6 x In of the Motor xln Figure 7.25 – Determining the maximum thermal classes through the hot starting curves Thus, the maximum thermal class that will protect the motor is Class 35, Class 40 has too long a time for this current. This thermal class allows the motor to start at running condition (hot), in other words, it can be started in any condition. NOTE! Please consider that this protection adopts WEG standard three-phase IP55 motor as a standard. Thus, if your motor is different, do not program the maximum allowed thermal class, but program the thermal class near the minimum thermal class required for the start. 7.2.1.2 Example on how to program the Thermal Class Motor Data: Power: 50 HP Voltage: 380V Rated current (In): 71A Service Factor (S. F.): 1.00 Ip/In : 6.6 Locked rotor time:12s at hot Speed = 1770 rpm Data about the motor + load Starting: Starting by Voltage Ramp, average starting current: 3 x the rated motor current during 25s (3 x In @ 25s). 1) In the chart, at cold at P640, we can find the minimum required Thermal Class that allows motor start with reduced voltage: For 3 x In @ 25s, we select the closest higher one: Class 10. 137 CHAPTER 7 - APPLICATIONS AND PROGRAMMING 2) In the chart, at hot in P640, we can find the maximum Thermal Class that the motor will withstand due to the locked rotor time at hot: For 6.6 x In @ 12s, we select the closest lower Class: Class 40. Now it is known that Thermal Class 10 allows one start and Thermal Class 40 is the upper limit. Thus you must select a Thermal Class between these two Thermal Classes by considering the number of start per hour and the time interval between motor On-Off procedures. The closer to Class 10 you select, more protected will be your motor, less starts per hour are allowed and longer time intervals between motor On-Off procedures are required. The closer to Class 40 you select, nearer the upper motor limit you will be, thus more starts per hour are allowed and shorter time intervals between motor On-Off procedures can be used. 7.2.1.3 Time reduction when changing from cold starting to hot starting To determine the activation times of the hot Thermal Classes, i. and., when the motor is running at rated load with current lower than or equal to 100% of the Nominal Current, use the multiplier factor shown in Table 6.34 at P640, as a percentage of the current that the motor is absorbing when running continuously. For example: A motor is running with 80% In and then is switched Off. It is switched On again immediately. The starting current is 3xIn @ 25s. The selected Thermal Class, in the table 6.22, is the Class 10 with 33,7s @ 3xIn. As shown in table 6.33, the correction factor for 80% In is 0.48. The final activation time will be: 0.48 x 33.7s = 16.2s, i. and., the time is reduced at cold start from 33.7s to 16.2s at hot start. Thus, a new motor is not allowed before the thermal motor image decreases, i.and., cools down. 7.2.1.4 Service Factor When the Service factor (S.F.) is different from 1.00, but its use is required, you can find in the chart, cold, the points for the S.F. = 1.15 and a table for S.F. = 1.15. If you want to know the thermal protection activation time for other Service Factor (S.F.), displace the line xIn proportionally to the left. t(s) Cold 25 20 0 2x 3x 4x F.S.=1.15 15 xIn of the Motor F.F.=1.25 Figure 7.26 – Using the S.F. to find new times 138 CHAPTER 8 DIAGNOSTICS AND TROUBLESHOOTING This Chapter helps the user to identify and correct possible faults that can occur during the Soft-Starter SSW-06 operation. This Chapter also provides instructions about periodical inspections and cleaning requirements. 8.1 FAULTS AND POSSIBLE CAUSES When most of the errors are detected, the motor is switched off and the error is shown on the display as EXY, XY being the error code. For the SSW-06 Soft-Starter to return to normal operation after an error, it is necessary to reset it. This can generally be done in the following ways. It can be reset as follows: Disconnecting and reapplying AC power (power-on reset); Pressing the of the keypad (HMI) - (manual reset); Automatic reset through P206 setting (auto-reset); Via digital input: DI2 (P264 = 2) or DI3 (P265 = 2) or DI4 (P266 = 6) or DI5 (P267 = 6) or DI6 (P268 = 6). The table below shows the reset details for each possible cause. FAULT E03 Undervoltage at Power Section during Operation Phase Loss or Voltage Unbalance in the Power Section during Operation Phase Loss in the Power at the Start DESCRIPTION OF THEACTUATION When the voltage between phases is lower than the programmed value during the programmed time. The motor rated voltage is used as a reference. When the voltage between phases is lower or higher during the programmed time, or when phase loss has been detected. The other two motor phases are used as reference. POSSIBLE CAUSES Power supply is lower than programmed at P400 and P600. The value programmed at P604 and P605 exceeds the limits permitted for the application. Voltage drop during start. Phase loss in the power supply. Input transformers have been undersized. Actuation problems with input contactor. Fuses at input are open. Bad contact in the power supply connections. Wrong motor connection. RESET Power-on Manual Reset Auto-reset DIx Power-on Manual Reset Auto-reset DIx Power-on Manual Reset Auto-reset DIx When there is no voltage synchronization pulse at the start. E04 Soft-Starter Overtemperature When the thermostats of the heat sink act. Panel with unsuitable cooling. Not permitted Start cycles. E05 Motor Overload When the times given by the curves of the programmed thermal classes exceed the programmed values. Not permitted Start cycles. Thermal classes are programmed lower than permitted by the motor duty. Off/On intervals shorter than required for the motor cooling. The value of the thermal protection saved when switching off return when switched on again. E06 External Fault When the digital input programmed to No External Fault opens. DI4...DI6 wiring is open or not connected to +24V. Power-on X1 connector of the CCS6 control board is Manual Reset disconnected. Auto-reset DIx E10 Error in the Copy Function When the Keypad (HMI) has been loaded with parameters of different version as the switch. A bid to copy the HMI parameter to the Soft-Starter with different Software version. E15 Motor not connected When there is no current synchronism pulse at the initial start. Bad contact of the motor connections. Thyristors or internal By-pass relays are short-circuited. Power-on Manual Reset Auto-reset DIx Power-on Manual Reset DIx E16 Overvoltage When the voltage between phases is higher than the programmed on during the programmed time. As reference is used the rated line voltage. Power supply is higher than programmed at P400, P602 and P603. Transformer tap selected with too high voltage. Capacitive power supply with too low inductive load. Power-on Manual Reset Auto-reset DIx Table 8.1 - Detailed Fault Description 139 CHAPTER 8 - DIAGNOSTICS AND TROUBLESHOOTING FAULT E24 Programming Error DESCRIPTION OF THEACTUATION When the setting of an incompatible parameter has been programmed. POSSIBLE CAUSES Setting attempt of an incompatible parameter. See Table 4.2. RESET Automatic Reset after fault correction E28 Timeout error in the telegram of the serial communication When the Soft-Starter does not receive telegrams from the master during a time longer than has been programmed at P314. The Timeout programmed at P314 is longer than the time programmed between the telegrams sent by the network master. The master does not send telegrams cyclically, program P314=0. When the serial communication is not used, program P314=0. For more information, please refer to the Soft-Starter SSW-06 serial communication manual. Automatic Reset after fault correction E29 Communication error Fieldbus inactive When the Fieldbus communication board is Communication error between the Fieldbus active and Communication with the Master is Network Master and the Soft-Starter inactive. SSW-06.Master configuration problem. Communication cables are not installed correctly. When the Fieldbus communication board is not being used, program P309=0. For more details, please refer to the Fieldbus communication manual of the Soft-Starter SSW-06. Automatic Reset after fault correction E30 Communication board error Fieldbus inactive Soft-Starter could not be accessed the Fieldbus communication board during the initialization or during the operation. Power-on Automatic Reset after fault correction E31 Keypad (IHM) Connection Fault When the electrical connection between the Bad contact in the Keypad (HMI) connection. Keypad (HMI) and the switch has been Electrical noise (electromagnetic interference). interrupted. E32 When the DI6 digital input is programmed to Motor Overtemperature the motor PTC input and the detector acts. (DI6 = PTC) E41 Self-Diagnosis fault during power-on E62 Too long time for the current or torque limit during the start E63 Locked Rotor at the start end Data exchange problems between the Soft-Starter SSW-06 and the Fieldbus communication board. Wrong configuration of the Fieldbus communication board, programmed at P309. Board connection problem. When the Fieldbus communication board is not being used, program P309=0. For more details, please refer to the Fieldbus communication manual of the Soft-Starter SSW-06. Excessive load on the shaft. Load cycle too high (large number of starts and stops per minute). Ambient temperature too high. Bad contact or short-circuit (resistance <100) in the wiring from motor thermistor to X1 terminal of the CCS6 board. P268 is wrong. Stalled motor, locked motor. Power-on Manual Reset Auto-reset DIx When the conversion of the input current is Bad electric contact in the current transformer cables Power-on out of allowed range: 2,5V ±3%. or control board connection cables. Manual Reset A thyristor or contactor in short-circuit. DIx Problems in the control board. When the start time due to start with current Time programmed at P102 is shorter than required. Power-on Manual Reset limit, current ramp or torque control is longer The programmed current limit at P110 is too low. DIx than the time set at P102. The programmed current limit at any point of current ramp is too low. The programmed torque limit at any point of the torque control is too low. Stalled motor, locked rotor. When at the end of the acceleration ramp the current is not lower than 2x the motor rated current (P401x2) before closing of the internal By-pass relay. The motor rated current that has been programmed Power-on Manual Reset at P401 is wrong. DIx The time programmed at P102 is shorter than the required to start the motor by voltage ramp. The transformer that supplies the motor may be saturated and requires too much time to recover from the starting current. Stalled motor or locked rotor. For special motor that support this working condition you can set P617=0. Table 8.1 (Cont.) - Detailed Fault Description 140 Automatic Reset after fault correction CHAPTER 8 - DIAGNOSTICS AND TROUBLESHOOTING FAULT E65 Motor Undercurrent at full voltage operation DESCRIPTION OF THEACTUATION When the current is lower than the programmed during the programmed time. Motor rated current is used as reference. POSSIBLE CAUSES The percent value programmed as maximum acceptable undercurrent limit (P610) is lower than required for the motor and its application. In applications with hydraulic pumps which ay be operated without load. RESET Power-on Manual Reset Auto-reset DIx E66 Motor Overcurrent at full voltage operation When the current is higher than the programmed during the programmed time. The rated motor current is used as reference. The percent value programmed as maximum acceptable overcurrent limit (P612) is lower than required for the motor and its application. Motor with instantaneous overload. Stalled motor or locked rotor. Power-on Manual ResetAutoreset DIx E67 Wrong phase sequence at start begin When the signal interruption sequence of the synchronism do not follows the R/1L1, S/3L2, T/5L3 sequence. Parameter P620 has been programmed without need. Wrong phase sequence. This can be changed in another point of the power supply line. Power-on Manual Reset DIx E70 Undervoltage at the Electronics supply When the supply of the control board power Phase loss in the control board supply. supply is lower than 93,5Vac. Bad contact in the control board supply. Fuse in control board supply is open, glass fuse 5x20mm 2A with delayed action. Power-on Manual Reset DIx When any problem with the contacts of the Bad contact of the internal or extenal By-pass relay Power-on E71 Internal By-pass relay By-pass relay, internal or external, has been supply. Manual Reset contact is open Bad contact of the internal or extenal By-pass relay DIx detected at full voltage after start. due to any overload. an overload P140=1 without external By-pass relay connected. E72 Overcurrent before By-pass closing When at the end of the acceleration ramp the current is not lower than 2x the rated current of the Soft-Starter (P295x2) before closing of the internal By-pass relay. Rated Soft-Starter current has been wrong programmed at P295. The time programmed at P102 is shorter than required for the motor start by voltage ramp. Motor rated current is higher than allowed for the Soft-Starter. Stalled motor or locked rotor. Power-on Manual Reset DIx E74 Current unbalance When the current of one of the phases is lower or higher during the programmed time. The other motor phases are used as reference. Value programmed at P614 and P615 is out of range and not allowed for this application. Voltage drop in one or more phases of the power supply. Phase loss in the power supply. Input transformers have been undersized. Input fuses are open. Bad contact of the power supply connections or connections to the motor. Power-on Manual Reset Auto-reset DIx E75 Line frequency out of range When the frequency is lower or higher than When the Soft-Starter + motor are being supplied the limits from 42,5 to 69Hz during more than by a generator that is unable to drive the motor at 0.5s. rated load or is unable to start the motor. Power-on Manual Reset DIx E76 Undercurrent before By-pass closing When at the end of the acceleration ramp the current is lower than 0,1x the rated current of the Soft-Starter (P295x0,1) before closing of the internal By-pass relay. E77 By-pass relay contact is closed When the contact of the By-pass relay, internal Bad contact of the internal or external By-pass relay Power-on Manual Reset or external, will not opened. due to any overload. an overload. Short Circuit in the contact of the internal or external DIx By-pass relay due to any overload. an overload. Short Circuit in parallel with the contact of By-pass: thyristor in short circuit, external short circuit. Power supply fault or thyristor fault before Bypass Power-on Manual Reset closing. DIx The rated Soft-Starter current has been wrong programmed at P295. Rated motor current is lower than the minima current (P295x0.3). For tests you can set P616=0. Table 8.1 (Cont.) - Detailed Fault Description 141 CHAPTER 8 - DIAGNOSTICS AND TROUBLESHOOTING NOTES! When E04 message is displayed (Soft-Starter overtemperature), wait a few minutes for it to cool down before it can be reset. When E05 message is displayed (motor overload) or E30 (motor overtemperature), wait a few minutes for it to cool down the motor slightly before the Soft-Starter can be reset. NOTES! Fault Actuation Forms: E24: - Indicates the code in the LED display and the fault description in the LCD display (see table 4.2 ) - Motor can not be started. - Switches off the relay that has been programmed to "No Error" - Switches on the relay that has been programmed to "With Error" E28, E29 and E30: - Indicates the code in the LED display; - Indicates the code and the fault description in the LCD display; - The actuation form can be configured at P313. E31: - Soft-Starter proceeds operation normally; - No Keypad (HMI) commands are accepted; - Indicates code in the LED display; - Indicates the Code and the Fault description in the LCD display. E41: - Soft-Starter operation is not allowed (motor can not be started); - Indicates code in the LED display; - Indicates the Code and the Fault description in the LCD display. E70: - The last four faults will not be saved in the memory when the power supply is switched off (line disconnection) with stopped motor. OTHER FAULTS: - Relay is switched off when programmed to "No Error"; - Relay is switched on when programmed to "With Error"; - Motor is switched off, when it is enabled; - Indicates the fault code in the LED display; - The LCD display indicates the fault code and the fault description; - Some data is also saved in the EEPROM memory: . The number of the occurred fault (the three previous faults are displaced); . The status of the thermal protection (motor overload); . The status of the time of the running/powering hours. 142 CHAPTER 8 - DIAGNOSTICS AND TROUBLESHOOTING 8.2 TROUBLESHOOTING PROBLEM Motor does not run POINT TO BE CHECKED Incorrect wiring CORRECTIVE ACTION 1. Check the power and control connections. For example the DIx digital inputs programmed for Enabling or External Fault must be connected to +24V. Incorrect programming 1. Check if the parameters are properly programmed for the application; Fault 1. Check if the Soft-Starter is not disabled due to a Fault condition (Refer to table 8.1). Motor does not reach Motor stall rated speed Motor speed varies 2. Increase the torque limit level, if the torque control mode has been selected. Loose Connections (oscillates) Motor speed too low 1. Increase the current limit level, if programmed to current limit. 1. Disable Soft-Starter, switch OFF the power supply and tighten all connections 2. Check if all internal connections are tightened. Motor Nameplate Data 1. Check if the used motor meets the application requirements. Keypad (IHM) connection 1.Check the keypad connections to the Soft-Starter Check the power 1. Rated supply voltage must be following: or too high Display OFF board X1.1, X1.2 and PE Umin = 93.5 Vac Umax= 253 Vac Blown Fuse 1. Replace the fuse of the control board. Jerking during Parameter setting 1. Reduce the time set at P104. pump deceleration of the Soft-Starter Table 8.2 - Troubleshooting of the most frequent problems 8.3 CONTACTING WEG: TELEPHONE / FAX / E-MAIL NOTE! When contacting WEG for service or technical assistance, please have the following data on hand: Soft-Starter Model: Serial number, manufacturing date and hardware revision, as indicated on the Soft-Starter nameplate (Refer to Section 2.4); Software Version (Refer to Section 2.2); Information about the application and Soft-Starter programming. For further information, training or service please contact the Technical Assistance or Distributor closest to you. 143 CHAPTER 8 - DIAGNOSTICS AND TROUBLESHOOTING DANGER! Always disconnect the main power supply before touching any electrical component associated to the SSW-06 Soft-Starter 8.4 PREVENTIVE MAINTNANCE High voltages can be present even after the power supply has been disconnected. Wait at least 3 minutes for the complete discharge of the power capacitors. Always connect the equipment frame to the protection earth (PE) at the correct point for this. ATTENTION! Electronic boards have components sensitive to electrostatic discharges. Never touch the components or connectors directly. If this is unavoidable, first touch the metallic frame or use a suitable ground strap. Never apply a high voltage test on the Soft-Starter SSW-06! If this is necessary, contact WEG. Do not use Megohmmeter for the Thyristor testing. To avoid operation problems caused by harsh ambient conditions, such as high temperature, moisture, dirt, vibration or premature aging of the components, periodic inspections of the Soft-Starters SSW-06 and installations are recommended. . COMPONENT PROBLEMS CORRECTIVEACTIONS Terminal blocks, connectors Loose screws Tighten them (2) Loose connectors Blowers (1) / Cooling System Blowers are dirty Clean them (2) Abnormal acoustic noise Replace the blower Blower is not running Abnormal vibration Printed circuit boards Dust in the air filters Clean or replace them (4) Dust, oil or moisture accumulation Clean them (2) Smell Replace them Power module/ Dust, oil or moisture accumulation, etc. Clean them (2) power connections Connection screws are loose Tighten them Discoloration Replace it Power resistor (2) Smell Table 8.3 - Periodic Inspections after Start-up Notes: (1) It is recommended to replace the blowers after each 40,000 hours of operation; (2) Check the capacitors every six months. It is recommended to replace them after five years of operation; (3) When the SSW-06 Soft-Starter is stored for a long period of time, it is recommended that it be energized for 1 hour, in each interval of 1 year. (4) Two times per month. 144 CHAPTER 8 - DIAGNOSTICS AND TROUBLESHOOTING 8.4.1 Cleaning Instructions When it is necessary to clean the SSW-06 Soft-Starter, do so according to the following instructions: a) Cooling system: RemoveAC power from the Soft-Starter SSW-06 and wait 3 minutes; Remove all dust from the ventilation openings by using a plastic brush or a soft cloth; Remove dust accumulated on the heat sink fins and from the blower blades with compressed air; b) Electronic Boards: RemoveAC power form the Soft-Starter SSW-06 and wait 3 minutes; Remove all dust from the printed circuit boards by using an antistatic soft brush or remove it with an ionized compressed air gun (example Charges Burtes Ion Gun (non nuclear) reference A6030-6DESCO). If necessary, remove the PCBs from the Soft-Starter SSW-06; Always use a ground strap. 8.5 SPARE PART LIST Name Thyristor Module Disc Thryristor Fan Fuse-Control Keypad (HMI) CCS6 C PS63-00 C PS63-01 CPS64 RC S60 RC S61 Current Transformer By-pass Relay By-pass Contactor RC Snnuber * Item Number Specification 0298.0029 0298.0030 0303.9560 0298.0031 0298.0032 0298.0033 0298.0079 0298.0080 0303.9595 0303.7150 0303.7215 0400.3673 0400.3500 0400.3519 0400.3403 0305.6198 417114250 4160.1765 4160.1767 4160.1822 4160.1804 4160.1768 4160.1793 0307.3020 0307.3021 0307.3022 0307.3023 0307.3024 0307.3025 0307.3026 0307.3066 0307.3067 0307.3068 0307.3069 0307.3070 6434.2307 6434.2408 6434.2418 0304.1197 0304.1198 035511610 Thyristor Module 142A 1600V Thyristor Module 180A 1600V Thyristor Module 250A 1600V Thyristor Module 285A 1600V Disc Thyristor 490 1600V Disc Thyristor 551A 1600V Disc Thyristor 750A 1600V Disc Thyristor 900A 1600V Disc Thyristor 1200A 1600V Disc Thyristor 1800A 1600V Disc Thyristor 2400A 1600V Fan 120x120mm 110V/220V Fan 225x225mm 110V Fan 225x225mm 115V Fan 280x280mm 220V Glass Fuse 2A 250V Man-Mac hine Interface Control Card Source and Power Card Source and Power Card Source and Power Card RC Snuber Card RC Snuber Card TC 425/1,4A-2,8VA –2.5% TC 650/1,24A-4,3VA –2.5% TC 850/1,24A-4,7VA –2.5% TC 1025/1,24A-6,8VA –2.5% TC 1275/1,24A-7,5VA –2.5% TC 1560/1,24A-9,1VA –2.5% TC 1825/1,24A-10VA –2.5% TC 2060/2A-8VA –2.5% TC 2400/2A-10VA –2.5% TC 3020/2A-12VA –2.5% TC 3350/2A-13VA –2.5% TC 4100/2A-12VA –2.5% TC 4750/2A-27VA –2.5% TC 5500/2A-36VA –2.5% TC 7000/2A-46VA –2.5% Relay Latching 100A – 48Vcc Relay Latching 200A – 48Vcc Contactor CWM105DP-SB955 0301.1631 0302.4490 Wire Resistor 25R 50W 10% Polip. Capacitor 0,47F 850V Models (Ampéres) 220-575Vac 85 130 170 205 255 312 365 412 480 604 670 820 950 1100 1400 Units per Soft-Starter 3 3 3 3 6 6 6 6 6 6 6 6 6 6 6 2 2 2 2 2 2 3 3 2 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 2 2 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 a) The 110Vca fan is used in the SSW06XXXXT2257XSH1Z-PL b) The 220Vca fan is used in the SSW06XXXXT2257XSH2Z Table 8.4 - Spare Parts List 145 CHAPTER 9 OPTIONS AND ACCESSORIES This chapter describes the options and accessories that can be used with the Soft-Starter SSW-06. These options and accessories are: 9.1 REMOTE KEYPAD (HMI) AND CABLES The MMI can be assembled either from the Soft-Starter or remotely. If using the remote MMI, the frame KMR-SSW-06 (frame for remote mounting) can be used. The advantage of using the frame is the appearance (esthetic) of the remote MMI. The maximum cable length is 5m (16.40 ft). To acquire cables from WEG, see the following models. Cable Length WEG Part No 1m (3.28ft) 0307.6890 2m (6.56ft) 0307.6881 3m (9.84ft) 0307.6873 5m (16.40ft) 0307.6865 Table 9.1 - Connection cables CAB-HMI SSW-06-X The keypad cable must be installed separately from the power cables, following the same recommendations as for the CCS6 control board (Refer to Section 3.2.8). For assembling, see details in figure 9.2 and 9.3. Figure 9.1 - HMI and remote HMI frame for panel installation NOTE! Due to voltage drop in the Keypad cable, do not use cables longer than 5m (16.40ft). 146 CHAPTER 9 - OPTIONS AND ACCESSORIES 17.5 (0.69) 65 (2.56) 2.4 (0.09) 34.9 (1.37) 15.1 (0.59) 17.4 (0.69) 82.2 (3.24) 103 (4.06) 113 (4.45) 113 (4.45) 5 (0.20) 22.7 (0.89) 4.9 (0.39) 16 (0.63) 65 (2.56) a) Keypad (HMI) Dimensions 4 (2x) (0.16) 18.8 (0.74) Front View Back View Screw M3x8 (2x) Torque 5.5Nm Figure 9.2 - Dimensions in mm (in) and how to install the Keypad directly in the panel b) Dimension of frame with Keypad 21.5 (0.85) 120 (4.72) 91 (0.36) 73 (2.87) 36.5 (1.44) 8.1 (0.32) 45 (1.77) 149 (5.87) 84 (3.31) 5.5 (0.22) 74 (2.31) 94 (3.70) 10 (0.39) 42 (1.65) 4.5 (5x) (0.18) Front View Back View Screw M3x8 (2x) Torque 5.5Nm Figure 9.3 - Dimensions in mm (in) and how to install the Keypad in the panel and frame 147 CHAPTER 9 - OPTIONS AND ACCESSORIES HMI Insert spacer to connect the cable to the Soft-Starter HMI Soft-Starter Soft-Starter 5 1 Max. recommended cable length: 5m (16.40ft) 6 9 DB9 connector - Male 5 1 9 6 DB9 connector - Female Figure 9.4 - Cable for remote keypad connectiion Cable Connection Connection Pins Connection Pins Soft-Starter side Keypad (HMI) side 1 1 2 2 3 3 4 4 8 8 9= SHIELD 9= SHIELD Table 9.2 – Coonection pins (DB9) for cables 5m (16.40ft) (the frame may be or not used) 9.2 RS-485 for the Soft-Starter SSW-06 When the interface RS-485 is used, the master can control several drives connected to the same bus. The protocol Modbus-RTU allows the connection of up to 247 slaves (1 slave per address), provided repeaters are also used along the bus. This interface ensures good noise immunity, allowing maximum cable length of up to 1000 m. There are two ways to make available the interface RS-485 in the Soft-Starter SSW-06: 9.2.1 RS-485 Communication Kit for SSW-06 (KRS-485) WEG Item: 417114255. Converter RS-232 to RS-485 with galvanic isolation. Connected inside the product (on the connector XC8 of the control board CCS6). For more details, please refer to the Serial Communication of the Soft-starter SSW-06. Figure 9.5 – Optional board RS-485 for the SSW-06 148 CHAPTER 9 - OPTIONS AND ACCESSORIES 9.2.2 Optional Module MIW-02 WEG Item: 417100543. Converter RS-232 to RS-485 with galvanic isolation. Module outside the product, connected to the interface RS-232 of the SSW-06. For more details, please refer to the MIW-02 Manual. Figure 9.6 – Optional module MIW-02 9.3 FIELDBUS COMMUNICATION KITS To enable the Soft-Starter SSW-06 for the Profibus DP or DeviceNet communication, the use of a communication board required. This communication board is available as optional kit. Two protocols are available for the Soft-Starter SSW-06: 9.3.1 Fieldbus DeviceNet Communication Kit for SSW-06 (KFB-DN) WEG Item: 417114253. The communication protocol DeviceNet has been developed with the purpose to provide a fast, cyclic and deterministic communication between the masters and slaves. For more details, please refer to the Fieldbus Communication Manual. Figure 9.7 – Board of the optional DeviceNet Kit 149 CHAPTER 9 - OPTIONS AND ACCESSORIES 9.3.2 Fieldbus Profibus DP communication kit for SSW-06 (KFB-PD) WEG Item: 417114252. The ProfibusDP communication protocol is used for interconnecting controllers and industrial equipment, such as sensors, valves, drives, bar code readers, frequency inverters, panels and operation interfaces. For more details, please refer to the Fieldbus Communication Manual. Figure 9.8 – Board of the optional Profibus DP kit 150 CHAPTER 10 TECHNICAL SPECIFICATIONS This Chapter describes the technical specifications (electrical and mechanical) of the Soft-Starters SSW-06. 10.1 CURRENTS AND RATINGS ACCORDING TO UL508 55ºC SSW-06 Model 55ºC Rated Rated Current Current 3xIn @ 30s 4.5xIn @ 30s 220/230V 380/400V 440/460V 575V A A hp kW hp kW hp kW hp kW SSW-06.0085 85 57 30 22 50 37 60 45 75 55 SSW-06.0130 130 87 50 37 75 55 100 75 125 90 SSW-06.0170 170 113 60 45 100 75 125 90 150 110 SSW-06.0205 205 137 75 55 100 75 150 110 200 150 SSW-06.255 255 170 100 75 150 110 200 150 250 185 SSW-06.0312 312 208 125 90 175 130 250 185 300 220 SSW-06.0365 365 243 150 110 200 150 300 220 350 260 SSW-06.0412 412 275 150 112 250 185 350 260 450 330 SSW-06.0480 480 320 200 150 300 225 400 300 500 370 SSW-06.0604 604 403 250 185 350 260 500 370 600 450 SSW-06.0670 670 447 250 185 400 300 550 410 650 485 SSW-06.0820 820 547 300 225 500 370 600 450 750 550 SSW-06.0950(1) 950 633 350 260 600 450 700 525 850 630 (1) 1100 733 450 330 700 525 800 600 1000 750 SSW-06.1400(1) 1400 933 500 370 900 670 1050 775 1350 1000 SSW-06.1100 (1) Power valid for room temperature of 40ºC. Table 10.1 - Powers and currents for standard connection with three cables according to UL508 (Room temperature of 55ºC) 55ºC SSW-06 Model 55ºC Rated Rated Current Current 3xIn @ 25s 4.5xIn @ 25s 220/230V 380/400V 575V 440/460V A A hp kW hp kW hp kW hp kW SSW-06.0085 147 98 50 37 75 55 100 75 150 110 SSW-06.0130 225 150 75 55 125 90 150 110 200 150 SSW-06.0170 294 196 100 75 150 110 200 150 300 220 SSW-06.0205 355 236 125 90 200 150 250 185 350 260 SSW-06.0255 441 294 150 110 250 185 350 260 450 330 SSW-06.0312 540 360 200 150 300 220 450 330 550 410 SSW-06.0365 631 421 250 185 350 260 500 370 650 475 SSW-06.0412 713 475 250 185 450 330 550 410 750 550 SSW-06.0480 831 554 350 260 550 410 650 485 850 630 SSW-06.0604 1046 697 450 330 700 525 800 600 1100 800 SSW-06.0670 1160 773 450 330 850 630 900 670 1200 900 SSW-06.0820 1420 947 550 410 1000 750 1150 820 1500 1200 SSW-06.0950(1) 1645 1096 650 485 1150 820 1350 1000 1750 1290 SSW-06.1100(1) 1905 1270 800 600 1350 1000 1600 1175 2000 1475 SSW-06.1400(1) 2424 1616 1000 750 1750 1290 200 1475 2500 1850 (1) Power valid for room temperature of 40ºC. Table 10.2 – Powers and currents for connection inside the motor delta with six cables according to UL508 (Room Temperature of 55ºC) 151 CHAPTER 10 - TECHNICAL SPECIFICATIONS NOTE! Maximum ratings indicated in tables 10.1 and 10.3 are based on 3 x SSW-06 Soft-Starter Rated Current during 30s and 10 starts per hour (3xInSSW@30s). 10.2 CURRENTS AND RATINGS FOR IP55, IV POLE WEG MOTOR 55ºC SSW-06 Model 55ºC Rated Rated Current Current 3xIn @ 30s 4.5xIn @ 30s 380/400V 440/460V kW hp kW hp 60 45 60 45 75 220/230V kW hp kW 55 75 55 125 90 125 90 150 110 150 110 200 150 200 150 250 185 250 185 185 300 220 300 225 225 350 260 350 260 260 440 315 450 330 500 370 500 370 370 600 450 650 485 410 650 485 750 550 525 800 600 850 630 670 1050 775 900 A A SSW-06.0085 85 57 30 22 SSW-06.0130 130 87 50 37 75 55 100 75 SSW-06.0170 170 113 60 45 125 90 125 90 SSW-06.0205 205 137 75 55 150 110 150 110 SSW-06.0255 255 170 100 75 175 132 200 150 SSW-06.0312 312 208 125 90 200 150 250 SSW-06.0365 365 243 150 110 250 185 300 SSW-06.0412 412 275 150 110 300 220 350 SSW-06.0480 480 320 200 150 350 260 400 300 SSW-06.0604 604 403 250 185 450 330 500 SSW-06.0670 670 447 250 185 500 370 550 SSW-06.0820 820 547 350 260 550 410 700 SSW-06.0950(1) 950 633 400 300 750 550 (1) 1100 733 450 330 800 SSW-06.1400(1) 1400 933 550 410 1000 SSW-06.1100 hp 575V 525V kW hp 800 600 600 900 670 1100 810 1200 750 1200 900 1400 1050 1500 1100 900 (1) Power valid for room temperature of 40ºC. Table 10.3 - Powers and currents for standard connection with three cables according to WEG motors 55ºC SSW-06 Model 55ºC Rated Rated Current Current 3xIn @ 25s 4.5xIn @ 25s A A hp 380/400V 440/460V kW hp kW hp 220/230V 525V kW hp 575V kW hp kW SSW-06.0085 147 98 60 45 100 75 125 90 125 90 150 110 SSW-06.0130 225 150 75 55 150 110 175 132 200 150 250 185 SSW-06.0170 294 196 125 90 200 150 200 150 250 185 300 220 SSW-06.0205 355 236 150 110 250 185 300 220 300 220 350 260 SSW-06.0255 441 294 175 130 300 220 350 260 400 300 450 330 SSW-06.0312 540 360 200 150 350 260 450 330 500 370 550 410 SSW-06.0365 631 421 250 185 450 330 500 370 600 450 650 485 SSW-06.0412 713 475 250 185 500 370 600 450 700 525 800 600 SSW-06.0480 831 554 350 260 600 450 700 525 800 600 900 670 SSW-06.0604 1046 697 450 330 750 550 850 630 1050 775 1150 820 SSW-06.0670 1160 773 500 370 850 630 950 700 1150 820 1250 920 SSW-06.0820 1420 947 600 450 1000 750 1200 900 1400 1050 1550 1140 SSW-06.0950(1) 1645 1096 700 520 1200 900 1400 1030 1650 1200 1800 1325 SSW-06.1100(1) 1905 1270 800 600 1400 1030 1600 1175 1900 1400 2100 1550 SSW-06.1400(1) 2424 1616 1050 775 1750 1290 2000 1475 2450 1800 2650 1950 (1) Power valid for room temperature of 40ºC. Table 10.4 - Powers and currents for connection inside the motor delta with six cables according to WEG motors (Room Temperature of 55ºC) 152 CHAPTER 10 - TECHNICAL SPECIFICATIONS NOTE! Maximum ratings indicated on the tables 10.2 and 10.4 are based on 3 x SSW-06 Soft-Starter Rated Current during 25s and 10 starters per hour (3xInSSW@ 25s). 10.3 POWER DATA Supply Capacity Power voltage AC input (R/1L1, S/3L2, T/5L3) 220V to 575 Vac: (-15% to +10%), or (187 to 632) Vac Frequency 50 to 60Hz (± 10 %), or (45 to 66) Hz Maximum number of starts per hour 10 (1 every 6 minutes) Models 85A to 820A. 5 (1 every 12 minutes) Models 950A to 1400A. 3 x In during 30 s Starting Cycle Thyristors (SCRs) Maximum reverse peak voltage 1600V Overvoltage Category III (UL 508/EN 61010) 10.4 ELECTRONICS/PROGRAMMING DATA Supply Control Voltage 110 to 230 Vac (-15% to +10%), or (94 to 253)Vac Frequency 50 to 60Hz (± 10 %), or (45 to 66)Hz Consumption 280mA Maximum Method Voltage Ramp; Connector X1A (1,2) Control Current Limit; Pump Control; Torque Control; Torque Control; Inputs Digitals 5 isolated digital inputs; Minimum high level: 18Vdc; Maximum low level: 3Vdc; Maximum Voltage: 30Vdc; Input Current: 11mA @ 24Vdc; Programmable functions. Motor Thermistor 1 input for motor thermistor; Input Actuation: 3k9 Release: 1k6; Minimum resistance: 100; PTCB referenced to the DGND through 249resistor. Outputs Analogs 1 analog output, not isolated, (0 to +10)V, RL 10k (maximum load); Resolution: 11bits; Programmable functions. 1 analog output, not isolated,(0 to 20)mA/(4 to 20)mA, RL=500/1%@10V; Resolution: 11bits; Programmable functions. Relay 2 relays with NO-contacts, 240Vac, 1A, programmable functions. 1 relay with NO/NC-contact, 240Vac, 1A, programmable functions. 153 CHAPTER 10 - TECHNICAL SPECIFICATIONS 10.4 ELECTRONICS/PROGRAMMING DATA (cont.) Safety Protections Overcurrent; Undercurrent; Overvoltage; Undervoltage; Phase loss; Reversed phase sequence; Overtemperature of heat sink; Motor overload; External fault; Open By-pass contact (when Soft-Starter is fitted with internal By-pass); Overcurrent before By-pass (when Soft-Starter is fitted with internal By-pass); CPU Error; Keypad (HMI) communication error. Programming error; 8 keys: enable / disable, Increment, Decrement, Direction of Rotation, Jog, Local/ Keypad (HMI) HMI-SSW06 Remote and Programming; LCD-Display, 2 lines x 16 columns and 7 segments 4 digits LED display Led’s for indication of the direction of rotation and indication on the Mode of Operation (LOCAL/REMOTE) Permits access/changing of all parameter; External mounting is possible, cables up to 5m (16.40ft) are available. 154 CHAPTER 10 - TECHNICAL SPECIFICATIONS R 4.7 (4x) (0.12) 37.5 (0.98) 29.5 5.3 (2x) (0.14) 18 (0.47) 44.5 (1.75) 59.5 (2.34) 41.4 (1.09) 21 (0.55) 85.5 (3.37) 17.3 (0.45) 10.5 MECHANICAL DATA (1.16) 51.4 (1.35) 5.3 (2x) (0.14) 15.8 (0.41) 168.3 (6.63) 193.3 (7.61) 22.5 (4x) (0.88) Top View X Air Outlet X 75 (2.95) 224 (9.61) 132 (5.20) 288.5 (11.36) 28.5 (1.12) 370 (14.57) 350 (13.78) 11.5 (0.45) Under View Y Y 52.5 (2.07) Air Inlet Figure 10.1 - 85A and 130A Models 155 CHAPTER 10 - TECHNICAL SPECIFICATIONS 17.3 (0.45) 33 33 33 46.4 (1.30) (1.30) (1.30) (1.83) 41.4 (1.09) 5.3 (2x) (0.14) 22.5 (4x) (0.88) X 150 (5.91) Air Outlet 278 (10.9) 223 (8.78) 337.2 (13.28) 36.5 (1.44) 15.8 (0.41) 440 (17.32) 425 (16.73) 9.1 (0.36) 5.3 (2x) (0.14) Top View X Under View Y 21 (0.55) 37.5 (0.98) R 4.7 (4x) (0.12) 18 (0.47) 221.9 (8.74) 51.4 (1.35) Y 81.5 (3.21) Air Inlet Figure 10.2 - 170A to 205A Models 156 CHAPTER 10 - TECHNICAL SPECIFICATIONS 17.3 (0.45) 33 (1.30) 41.4 (1.09) 33 (1.30) 122.5 (4.82) 33 (1.30) 22.5 (4x) (0.88) 5.3 (2x) (0.14) 15.8 (0.41) Under View Y X 200 (7.87) Air Outlet 369.5 (14.55) 278 (10.94) 440 (13.28) 84.8 (3.34) Top View X 550 (21.65) 527 (20.78) 12.5 (0.49) 5.3 (2x) (0.14) 21 (0.55) 37.5 (0.98) R 4.7 (4x) (0.12) 18 (0.47) 257 51.4 (1.35) Y 145 (5.771) Air Inlet Figure 10.3 - 255A, 312A and 365A Models. 157 CHAPTER 10 - TECHNICAL SPECIFICATIONS 41.4 (1.09) 17.3 (0.45) 33 (1.30) 33 (1.30) 133.8 (5.27) 33 (1.30) 5.3 (2x) (0.14) 22.5 (4x) (0.88) 392.5 (11.52) 51.4 (1.35) 21 (0.55) 15.8 (0.41) Under View Y X 84.8 (3.34) Air Outlet 540 (21.26) 200 (7.87) 347.3 (13.67) 650 (25.59) 627.5 (24.70) 12.5 (0.49) (0.14) Top View X 540 (21.26) 5.3 (2x) 18 (0.47) 37.5 (0.98) R 4.7 (4x) (0.12) Y 145 (5.71) Air Inlet Figura 10.4 - Models de 412A, 480A and 604A 158 CHAPTER 10 - TECHNICAL SPECIFICATIONS 41.4 (1.09) 17.3 (0.45) 33 (1.30) 33 (1.30) 218.6 (8.61) 33 (1.30) 5.3 (2x) (0.14) 22.5 (4x) (0.88) 302.4 (11.91) 51.4 (1.35) 5.3 (2x) 15.8 (0.41) 21 (0.55) 18 (0.47) 37.5 (0.98) R 4.7 (4x) (0.12) Under View Y (0.14) 350 (13.78) 540 (21.26) 357.3 (14.07) 685 (31.30) 95 (3.74) Air Outlet 795 (31.30) 775 (30.51) 12.5 (0.49) X Top View X Y 204.3 (8.04) Air Inlet Figura 10.5 - 670A and 820A Models 159 CHAPTER 10 - TECHNICAL SPECIFICATIONS 33 (1.30) 33 (1.30) 33 (1.30) 22.5 (4x) (0.88) 288 (11.33) 229 (9.00) Under View Y 568 (22.37) 400 (15.75) Air Outlet 347.3 (13.65) 754 (29.68) 84.1 (3.31) Top View X 845 (33.27) 810 (31.89) 25 (0.98) X Y 30 (1.18) 148 (5.83) 202 (7.96) Air Inlet Figura 10.6 - 950A Models 160 CHAPTER 10 - TECHNICAL SPECIFICATIONS 33 (1.30) 33 (1.30) 33 (1.30) 22.5 (4x) (0.88) 288 (11.33) 229 (9.00) Under View Y Top View X 22 (0.87) X 93 (3.64) 250 (9.84) 250 (9.84) Air Outlet Air Outlet 1034 (40.70) 1147 (45.16) Air Outlet 1110 (43.70) 432 (17.01) 685 (26.97) Y Y 50 (1.97) 172 (6.78) 252 (9.91) Air Inlet Figura 10.7 - 1100A and 1400A Models 161
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