Zener SMARTSTART 6V400 User Manual

User’s Manual:
SMARTSTART
6000 Series
Models:
6R15 – 6R830
6V400 – 6V630
®
Contents ……..
Introduction
Receiving
Handling & Storage
Handling on Installation
Software
2
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2
2
2
2
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3
3
The Smarstart® 6000
(General Warning)
Soft Starter Operation
‘SMART-TORQ’ Torque Control
3
Installation
Read & familiarise yourself with the warnings
detailed on Page 1 of the manual before
proceeding.
(High Voltage Warning)
Read all operating instructions before
installing, wiring, operating, servicing or
inspecting the Smartstart®. Ensure that the
instruction manual is made available to the
final user of the product as well as all
personnel involved in any aspect of
installation, adjustment or maintenance.
Mechanical Installation
Heat Dissipation & ventilation
Mechanical Dimensions
Power Wiring - General
Semiconductor Fuses
Power Wiring – 15A-80A
Power Terminals – 100A and above
Power Terminals – 100A and above
Power Terminals – 6 wire & CT relocation
Control Wiring
Programming
Local Control Panel
Menu Map
4
4
5
6
6
7
8
9
10-12
13
14
Input/Output functionality
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14
15
16
17
17
18
21
22
23
23
25
25
26
Fault Diagnosis
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27
Specifications
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28
Thermal Protection
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29
Unit ratings
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30
Shipping/Packaging Details
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31
Options
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32
SMART-TORQ
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34
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35
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36-38
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39
1. Setup menu – Display
2. Setup menu – Motor
3. Setup menu – Control
4. Setup menu – Protection
5. Setup menu – Inputs
6. Setup menu – Outputs
7. Setup menu – Resets
8. Setup menu – Advanced
9. Setup menu – Commands
10. Setup menu – Starter Diag
Appendix A –
Typical start parameters
Appendix B –
Application Diagrams
Set up Record Sheet
Technical Manual: Smartstart® 6000
4
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IMI0042 rev D
IMPORTANT – Read this first !!
Read all operating instructions before installing, wiring, operating, servicing or inspecting the Smartstart®.
Ensure that the instruction manual is made available to the final user of the product as well as all personnel
involved in any aspect of installation, adjustment or maintenance.
Your Smartstart® must be applied and installed by a suitably qualified and experienced electrical tradesperson in
accordance with this manual, good engineering practice and all local rules and regulations.
There are hazardous voltages inside the Smartstart® whenever it is connected to an electrical supply.
The Smartstart® contains high energy circuits that may be hazardous. Do not operate with the covers removed or the
doors of the enclosure in which it is installed open. Do not touch the terminals of the Smartstart® or any associated
motor and wiring when it is energised, even if the Smartstart® and motor are stopped. Electric shock may result.
Do not modify this equipment electrically, mechanically or otherwise. Modification may create safety hazards as well as
voiding the UL listing of models so listed.
The Smartstart® is designed to drive an appropriately rated and otherwise suitable 3 phase induction motor. It is not
suitable for single phase motors or other types of motor or non-motor load. Use with inappropriate load types may
create a safety hazard.
Where the Smartstart® is used as a component part of another product, it is the purchaser's responsibility to ensure
that the final product meets all of the necessary safety, EMC, regulatory, operational and other requirements for that
product. Requirements for the purchaser's final product may be substantially different to the requirements for standalone inverters.
The Smartstart® is intended for use only in fixed wiring applications. It is not intended for use on a flexible supply
cable.
Mount the Smartstart® on a vertical, incombustible surface such as metal or masonry. Do not place combustible or
flammable material near the Smartstart®. Failure to observe these precautions may create a fire hazard
The Smartstart® is manufactured under strict quality control arrangements, however additional and independent safety
equipment must be installed if the application is such that failure of the product may result in personal injury or
property damage.
Ensure the Smartstart® is applied in a manner that does not adversely affect the proper operation of other equipment
or systems, particularly those that have a safety function.
Install emergency stop circuitry that removes power from the Smartstart® and does not depend on any feature of the
product for proper and safe operation.
The Smartstart® has features that may be used to cause an automatic restart in certain circumstances. The overall
application (machine etc) must be designed such that automatic restart is not hazardous.
Do not install this equipment in locations where mechanical damage to the enclosure is possible. In particular, consider
vehicles, vandalism and attack by insects or animals. Severe equipment damage and safety hazards may result.
Technical Manual: Smartstart® 6000
IMI0042 rev D
Page 1
Introduction
Receiving:
Inspect the Smartstart® for any shipping damage. If any
damage is found, report it to the carrier immediately.
Remove cover of starter and visually check for damage.
Do not attempt to operate the Smartstart® if any
obvious damage exists or suspect damage has occurred.
After the initial inspection, the Smartstart® can be
repacked and stored in a clean, dry location until it is
required for use.
Handling & Storage:
To ensure the starter is protected before installation,
handle and store the equipment in its packaging.
DO NOT store this equipment in an area where the
ambient temperature will fall below -20ºC or rise above
70ºC. DO NOT store this equipment in areas that are
subject to condensation or corrosive atmosphere. Proper
storage is necessary to ensure satisfactory startup and
performance.
Handling on Installation:
Use handling points where provided to lift larger
units.
The Smartstart® 6000 range comprises 3 sizes with
various weights and dimensions.
An appropriate handling device must be used with large
starters. ‘Handling points’ have been provided to aid
lifting.
The precautions described below must be followed:
Software:
This manual applies to the Smartstart® 6000 series
software revision R0.96K. The Software revision can be
viewed on the ‘Dash Board’ (Display) of the Smartstart.
DO NOT handle the starter by the power
terminals/busbar.
Technical Manual: Smartstart® 6000
IMI0042 rev D
Page 2
Introduction
®
Zener ‘SMART-TORQ ’ Torque Control
Feature
®
Smartstart 6000
Basic Soft Starter Operation
®
The Zener Smartstart is a reduced voltage controller
designed for starting standard 3 Phase induction motors.
The unit is solid state, using a microprocessor to control
inverse parallel (back to back) pairs of SCR’s.
An SCR/thyrisor is a semiconductor device that latches
when triggered. Once triggered it allows current to flow
in one direction only and turns off at zero current.
The firing angle of the SCR’s are controlled to achieve
the desired acceleration of the motor.
The Zener Smartstart® 6000 incorporates a closed loop
torque control system to provide better control over
starting & stopping 3 phase induction motors.
Conventional voltage ramp control systems typically
produce low torque at low speeds. When starting &
stopping variable torque loads (e.g Pumps) this can
results in a very rapid acceleration or deceleration with a
non linear change in motor speed.
The Smarstart® 6000 series overcomes these issues by
regulating the torque in the motor to match the load
type during the acceleration & deceleration. This
essentially allows a constant torque to be produced in
the motor. The continual monitoring of the motor
characteristics during the ramp also allows
instantaneous adjustment of the starter output to allow
for changes in load conditions.
The ‘SMART-TORQ®’ control system provides smooth
starting & stopping, allowing ramp profiling to produce a
linear acceleration and deceleration of the motor speed.
There are many benefits with variable torque loads such
a pumps and fans by achieving a linear ramp profile and
greater control over deceleration. With pump
applications this provides better control to minimise
water hammer problems.
SMART-TORQ Benefits include:
Soft Starters provide the following benefits:
1. Reduced stresses and wear on the mechanics
of the system
2. Reduced starting currents
3. Minimise voltage dips on the supply
4. Lowered Peak demand charges
5. Eliminate belt slippage on fans
6. Smooth acceleration of motor / load
1. A true linear acceleration of the load and motor
for all load types.
2. Reduced peak inrush starting currents.
3. Reduced stresses and wear on the mechanics of
the system
4. Ramp profiling to better match type of load such
as variable torque loads. Better control of
pumps and fans, without rapid initial ramp but
linear ramp.
5. Reduced heating in motor at low speeds.
6. No instability due to changing power factor.
Closed loop system to monitor and react to
changing power factor.
7. No instability due to slot ripple in 3 wire and 6
wire operation.
8. Better control of deceleration through closed
loop torque control system.
The Smartstart® also offers user access to ramp profiling
parameters to fine tune the Torque Control System to
achieve more application specific performance
requirements. See Page 34 for more information.
Technical Manual: Smartstart® 6000
IMI0042 rev D
Page 3
Installation - Mechanical
Mechanical Installation
Heat Dissipation
The Smartstart® should be installed by qualified
electrical personnel only. The following should be
considered when installing the Smartstart.
The Smartstart® is cooled by temperature controlled
internal fans. Installing a bypass contactor will reduce
the heat dissipated and the ventilation required. Soft
Starters generally dissipate approximately 4.5watts per
Amp when operated without a bypass contactor.
Mount in a vibration free environment.
Mount vertically and away from heat radiating
sources.
Do not mount in direct sunlight or on hot surfaces.
Mount in a suitable enclosure for the environment
in which it is to operate, the total heat dissipation
must be considered.
Do not drill holes into the Smartstart® enclosure.
Do not allow metal shavings or any other
conductive material to enter the enclosure or
damage may result.
The heat dissipated can be calculated by;
Continuous Duty:
P = (FLC x 4.5)
Bypass Duty:
P = (FLC x SC x 4.5 x t x N) / 3600
Where;
> 20mm
P
= Power dissipated in Watts
FLC = Nameplate FLC of Motor
SC = Average starting current
expressed per unit of FLC
t
= Starting time
N = Number of starts per hour
> 75mm
> 75mm
> 75mm
When installing the Smartstart® in an enclosure or
switch board it is necessary to consider the heat
dissipated and then the ventilation required.
The following formula’s will assist in determining
whether ventilation is required and how much.
Ventilated Enclosure:
> 75mm
V = (3.1 x P) / T
Where; V = Airflow required in m3/hour
P = Power dissipated in Watts
T = Temperature differential in °C
(inside – outside)
Non Ventilated Enclosure:
A = P / ( T x k)
Where; A = Exposed surface area of cabinet
in m2
P = Power dissipated in Watts
T = Temperature differential in °C
(inside – outside)
k = Heat transmission constant
(5 for Painted metal)
Technical Manual: Smartstart® 6000
IMI0042 rev D
Page 4
Installation - Mechanical
Dimensions
(All Dimensions in mm)
Model:
Chassis
A
B
C
D
Depth
6R015B2
6R030B2
6R060B2
6R080B2
B2
B2
B3
B3
335
335
440
440
162
162
162
162
315
315
420
420
111
111
111
111
172
172
172
172
Model:
Chassis
A
B
C
D
Depth
6R10000
6R19000
6R22000
A2
A2
A2
430
430
430
248
248
248
400
400
400
216
216
216
232
232
232
Model:
Chassis
A
B
C
D
Depth
6R36000
6R58000
6R83000
A3
A3
A3
670
670
670
375
375
375
640
640
640
159
159
159
285
285
285
Mounting Holes:
Mounting Holes:
Mounting Holes:
Technical Manual: Smartstart® 6000
IMI0042 rev D
Page 5
Installation - Power Wiring
Power Wiring
Motor Protection:
The Zener SS6000 is installed between the mains
and cable to the motor. If a mains or isolation
contactor is used it is best controlled by the SS6000
‘Line relay’.
The Smartstart 6000 provides advanced motor
protection with user selectable overload classes,
over & under current protection, phase imbalance
and thermistor protection. It is important that the
power wiring is followed correctly to ensure proper
protection and starter performance.
Refer to page 18 and 28 for more details regarding
motor protection.
Semiconductor Fuses
Semiconductor fuses are recommended for all
electronic soft starters to provide protection of the
thyristors in the event of an output short circuit.
Semiconductor fuses are strongly recommended for
applications such as submersible pumps.
Semiconductor fuses are optional with all models.
•
For smaller models (15 – 80Amp) fuse kits
are available.
3Wire / 6wire: The standard connection of an
electronic soft starter is 3 wire. An alternative
connection is 6 wire or inside delta connection. This
is commonly used when replacing a star/delta type
motor starter.
Bypass / Continuous: The Smartstart® can
operate with or without a bypass contactor. Some
models include an integral bypass contactor. The
bypass contactor reduces the heat dissipation of
the soft starter as the semiconductors are bypassed
after the ramp time.
Select cables & install in compliance
with local regulations
Technical Manual: Smartstart® 6000
Refer to instruction sheet for more details
and dimensions.
•
For larger models semiconductor fuse kits
are available.
•
Refer to page 33 for more details on semiconductor fuses.
IMI0042 rev D
Page 6
Installation - Power Terminals
(up to 80Amp)
3 Wire with integral Bypass
Only Models;
6R015B2
6R030B2
6R060B2
6R080B2
Power Terminations
Model:
6R015B2
6R030B2
6R060B2
6R080B2
Earth
Max cable size
Tightening
Torque
6 / 10mm2
6 / 10mm2
35mm2
35mm2
M6 stud
1.5 – 1.8 Nm
1.5 – 1.8 Nm
3.2 – 3.7 Nm
3.2 – 3.7 Nm
-
Semiconductor Fuse kit (Optional)
Model:
Description
Part No.
6R015B2
6R030B2
6R060B2
6R080B2
-
Fuse Kit to suit 15A
Fuse Kit to suit 30A
Fuse Kit to suit 60A
Fuse Kit to suit 80A
Fuse Kit Cover
TQ00020
TQ00021
TQ00022
TQ00023
TQ00024
Refer to instruction sheet for more details and
dimensions.
Semiconductor Fuse Replacement
Model:
Description
Part No.
6R015B2
6R030B2
6R060B2
6R080B2
Semiconductor Fuse
Semiconductor Fuse
Semiconductor Fuse
Semiconductor Fuse
TF
TF
TF
TF
Refer to page 13
For Control Wiring
Technical Manual: Smartstart® 6000
IMI0042 rev D
Page 7
Installation - Power Terminals
(100A model and above)
Chassis A2:
Power Terminations
Model:
Chassis
Busbar Hole
Bolt Size
Earth Stud
6R10000
6R19000
6R22000
6R36000
6R58000
6R83000
6V40000
6V63000
A2
A2
A2
A3
A3
A3
A3
A4
1x 8.5mm
1x 8.5mm
1x 8.5mm
2x 10.4mm
2x 10.4mm
2x 10.4mm
2x 10.4mm
2x 10.4mm
M8
M8
M8
M10
M10
M10
M10
M10
M8
M8
M8
M8
M8
M8
M8
M8
(All soft starters include a bolt kit)
Semiconductor Fuse kit (Optional)
Model:
Description
Part No.
6R10000
6R19000
6R22000
6R36000
6R58000
6R83000
Fuse Kit to suit 6R100
Fuse Kit to suit 6R190
Fuse Kit to suit 6R220
Fuse Kit to suit 6R360
Fuse Kit to suit 6R580
Fuse Kit to suit 6R830
TQ00025
TQ00026
TQ00027
TQ00028
TQ00029
TQ00030
Chassis A3:
Semiconductor Fuse Replacement
Model:
Description
Part No.
6R10000
Semiconductor Fuse
(200A)
Semiconductor Fuse
(400A)
Semiconductor Fuse
(400A)
Semiconductor Fuse
(630A)
Semiconductor Fuse
(500A)
Semiconductor Fuse
(700A)
TF
6R19000
6R22000
6R36000
6R58000
6R83000
Qty per
Starter
TF
TF
TF
TF
TF
Technical Manual: Smartstart® 6000
IMI0042 rev D
Page 8
Installation - Power Wiring
(100A model and above)
3 Wire Continuous
3 Wire Bypass
(Without Bypass Contactor)
NOTE: The SS6000 must have the appropriate rating
to operate without a bypass contactor.
Refer to page 13
For Control Wiring
Refer to page 13
For Control Wiring
Technical Manual: Smartstart® 6000
IMI0042 rev D
Page 9
Installation - Power Wiring
(100A model and above)
Using 6 wire Configuration
The Smartstart 6000 can be configured to operate in 6
wire mode. 6 wire mode may be the preferred method
due to:
The following illustrates the difference between 3 wire & 6
wire connection:
1. Possible reduction in the size of starter
required, saving on space and /or cost.
2. Wiring may already be present if a start/delta
type starter was previously used.
3. Reduced motor cable size.
The major advantage is that the current in the SCR
is 58% less than it would be for the same motor
connected in 3 wire. The diagram below illustrates
how the motor is connected in 6 wire, also known
as inside delta.
Current Monitoring & Torque Control:
For the torque control to operate correctly the C.T’s
need to monitor the ‘line’ current and not the ‘Phase’
currents. For this reason the C.T’s normally supplied
internally, need to be relocated external to the soft
starter.
It is critical that the C.T’s be installed in the correct
phase and in the correct direction. Page 12 provides
instructions as to where the C.T’s are to be located.
Refer to page 12
For details on correctly installing
external C.T’s
Technical Manual: Smartstart® 6000
IMI0042 rev D
Page 10
Installation - Power Wiring
(100A model and above)
SS6000 : 6 wire Bypass
SS6000 : 6 wire Continuous
Refer to page 13
For Control Wiring
Refer to page 13
For Control Wiring
Refer to page 12
For details on correctly
installing external C.T’s
Refer to page 12
For details on correctly
installing external C.T’s
Technical Manual: Smartstart® 6000
IMI0042 rev D
Page 11
Installation - Power Wiring
(100A model and above)
Relocating the Internal Current
Transformers for 6 wire operation.
If the C.T’s are not installed correctly the SS6000
will display a fault or a ‘C.T Phase error’.
The SS6000 comes standard with internal Current
Transformers (C.T’s) for monitoring the current
during acceleration, deceleration and when in
bypass.
It is important that the SS6000 be wired in a
manner to ensure the C.T’s are always monitoring
the motor current. For this reason 9 terminals are
provided. This is important to ensure continual
protection of the soft starter, the motor and the
load. The correct installation of the C.T’s is crucial
for optimum performance of the SS6000 torque
control system. In some situations such as 6 wire
operation, it may be necessary to relocate the
C.T’s external to the SS6000. For 6 wire operation
the C.T’s are to be installed on the incoming line
supply cables so that the line current is monitored
(not the phase currents).
The SS6000 can be purchased with C.T’s external
by ordering ‘ prepared for 6 wire’;
Part no.
TF60015
TF60016
Description:
Prepare for 6 wire: 6R100-220
Prepare for 6 wire: 6R360-830
Check for correct installation
Installation of external C.T’s
If a CT phase error occurs the problem may be
identify under the menu ‘Starter Diagnosis’. ‘+L1 /
+L3’ should be displayed.
When relocating the C.T’s external to the soft
starter it is important to ensure the following:
1. C.T’s are installed on L1 & L3
2. C.T’s are installed in correct direction
P1 label = line side
3. C.T’s are terminated with correct phasing.
S1 = Red
S2 = Black
> If L2 is displayed move the CT from L2 phase.
> If a “-“ is displayed, the direction of the
corresponding CT needs to be reversed.
Refer to page 25 for menu location
The C.T’s supplied with the SS6000 has a label
which shows the correct phase and direction.
Technical Manual: Smartstart® 6000
IMI0042 rev D
Page 12
Control Wiring
Control Wiring Overview
Refer To page 36-38 for
further guidance to wiring for
different applications
Typical Configuration of Control Terminals
Technical Manual: Smartstart® 6000
IMI0042 rev D
Page 13
Programming
Local Control Panel / Remote Console
The local control panel consists of 5 push buttons and
a plain English display to simplify programming.
Increase the value or change selection.
Navigate up through menu / submenus.
‘Decel’
The Smartstart® is decelerating the motor. Ramp time
completed (%) & Motor Current (A) is displayed.
The Menu Map (Dash Board)
ENTER
Decrease the value or change selection.
Navigate down through menu / submenus.
SMARTSTART 6000
6R030
r1.XX
Main Menu
Esc
Allows access to menu, submenus & saves
the parameter entered.
Ready
Escapes from current menu position
without saving.
100A
80%
140 SCR % Thermal
121 Mtr Capacity
Note 2.:
The bargraph Variable can
be changed. See menu
item ‘Bargraph var’.
415v
1-2-3
Note 3.:
User Access to the menu
may be resticted. See
menu item ‘D01 Menu
Access’.
Manual reset of a trip (if enabled).
Operating Status Indication
Status / Fault displayed in
Plain English
Off
Supply Voltage and
Motor Current
0A
Bar Graph to provide
visual indication
50Hz
90% Torq
90% Pwr
0%
Bargraph Value
Default ‘Motor current %’
‘Off’
The Smartstart® has control power applied but not
enabled.
Note 1.:
The default screen can be
changed. See menu item
‘D02 Default Screen’.
100A
56kW
0.9PF
56kW
Volt Imbal
415
415
0%
415V
Curr Imbal
100
100
0%
100A
‘Standby’
The Smartstart® has been enabled to start and the run
relay energized to bring in the line contactor (if
installed). The Smartstart® will initiate a start
immediately 3 phase supply is applied. Supply Voltage
is displayed.
0 Starts
0 Trip
‘Accel’
The Smartstart® is accelerating the motor. Ramp time
completed (%) & Motor Current (A) displayed
0.8 RunHrs
400kw.Hrs
‘At Speed’
The motor is at full speed, the accel time period may
not be complete. Ramp time completed (%) & Motor
Current (A) is displayed.
Last Trip
‘Run Bypass or Cont.’ The ramp time is complete
and the bypass contactor operated or SCR’s are in full
conduction. Motor Current (A) is displayed.
This symbol identifies the parameters for quick
setup.
Technical Manual: Smartstart® 6000
IMI0042 rev D
Page 14
Programming
Menu Map Overview
Set Up Menu
The ‘Dash Board’
ENTER
ENTER
SMARTSTART 6000
6R030
r1.XX
ESC
Setup Menu
1 Display
ESC
ENTER
Ready
100A
Setup Menu
2 Motor
ESC
D01 Menu Access
D02 Default Screen
D03 Bargraph Variable
D04 Bargraph FS
M01 Motor Amps
M02 Motor Volts
M03 Motor PF
M04 Motor Wiring
80%
ENTER
Setup Menu
3 Control
ESC
C01 Run Mode
C02 Current Limit
C10 Accel Ramp
C11 Accel Time
C12 Start Torque
C13 Final Torque
C20 Decel Ramp
C21 Decel Time
C22 Release Torque
ENTER
Setup Menu
4 Protection
ESC
ENTER
Setup Menu
5 Inputs
ESC
ENTER
Setup Menu
6 Outputs
ESC
ENTER
Setup Menu
7 Resets
ESC
I10 D igIn 1 Mode
I11 D igIn 1 Variable
I12 D igIn 1 Delay
I20 D igIn 2 Mode
I21 D igIn 2 Variable
I22 D igIn 2 Delay
Q10 Relay 1 Mode
Q11 Relay 1 Variable
Q20 Relay 2 Mode
Q21 Relay 2 Variable
Q30 Relay 3 Mode
Q31 Relay 3 Variable
Q40 Relay 4 Mode
Q41 Relay 4 Variable
Q50 AN Out 1 Mode
Q51 AN Out 1 Variable
Q52 AN Out 1 FS
R01 Manual Reset
R02 Power Reset
R03 Start Reset
ENTER
Setup Menu
8 Advanced
ESC
ENTER
Setup Menu
9 Commands
ESC
ENTER
Setup Menu
10 Starter Diag
ESC
1 Reset Trips
2 Clear mtr OL
3 Clear Counters
4 Clear meters
5 Reset Configuration
P01 Motor Overload
P02 Motor Over Temp
P03 Phase Rotation
P10 Accel OverTime
P20 Voltage Imbalance Alarm
P21 Volt Imbal Alarm
P22 Volt Imbal Level
P23 Volt Imbal Delay
P30 Current Imbalance Alarm
P31 Current Imbal Alarm
P32 Current Imbal Level
P33 Current Imbal Delay
P40 Undercurrent alarm
P41 Under Current Alarm
P42 Under Current Level
P43 Under Current Delay
P50 Over Current Alarm
P51 Over Current Alarm
P52 Over Current Level
P53 Over Current Delay
P60 UnderTorque Alarm
P61 Under Torque Alarm
P62 Under Torque Level
P63 Under Torque Delay
P70 OverTorque Alarm
P71 Over Torque Alarm
P72 Over Torque Level
P73 Over Torque Delay
A10 Kick Start
A11 Kick Time
A12 Lick Level
A20 Accel method
A21 Accel Profile
A22 Accel Control
A30 Decel method
A30 Decel Profile
A31 Decel Control
A41 Motor OL Reset
A42 Str OT Reset
A51 Motor Stator
A61 Try Tiny Motor
S1 Digital Inputs
S2 Thermistor Resistance
S3 Check Motor Wiring
S4 Check CT1/CT2
Technical Manual: Smartstart® 6000
IMI0042 rev D
Page 15
Programming
Menu Navigation
Setup Menu
Note: to change any parameters the SS6000 must be
disabled. Remove the link in the Enable input (term.
14) or the external enable circuit.
D01 Menu Access:
Sets the desired user access to menu
The Main Menu
Off
0V
1 Display
Selection: Disabled; Setup; Read only
Default:
Setup
To save changes
To exit without saving
Dashboard screen (1 of 8)
0%
Esc
Enter
Setup Menu
1 Display
Setup Menu
2 Motor
If the menu access is disabled a user access code
is required to access the menu. The access code
is 1470.
Refer to Page 16
MENU ACCESS
Refer to Page 17
Read Only
3 sec
Setup Menu
3 Control
Refer to Page 17
* Press <Enter> for
3 seconds.
LOGIN CODE
> 1470
Setup Menu
4 Protection
Refer to Page 18
Setup Menu
5 Inputs
Refer to Page 21
Setup Menu
6 Outputs
Refer to Page 22
Selection:
Overview; Thermal; Electrical; Power;
Volt imbal; Curr imbal; Counters;
meters
Default: Overview
To save changes
To exit without saving
D03 Bargraph Var.:
Sets the bargraph variable to monitor & Display.
Setup Menu
7 Resets
Refer to Page 23
Setup Menu
8 Advanced
Refer to Page 23
Setup Menu
9 Commands
Refer to Page 25
Setup Menu
10 Starter Diag
D02 Default Screen:
The default screen is the dashboard screen that
the Soft Starter will return to - on power up, exit
or time-out from the menu.
Selection:
Mtr current; Mtr Torque;
Mtr Thermal; SCR Thermal; Active
Power; Power Factor
Default:
Mtr Current
To save changes
To exit without saving
D04 Bargraph FS.:
Adjust the full scale of the bar graph meter as a
percentage.
Selection: 100;120;150;200;300;400;600
Default:
300%
To save changes
To exit without saving
Refer to Page 25
Technical Manual: Smartstart® 6000
IMI0042 rev D
Page 16
Programming
Setup Menu
2 Motor
M01 Motor Amps:
Adjust to the value of motor full load current
(FLC) indicated on the motor rating plate, even if
connected in 6 wire (inside delta).
C02 Current Limit:
The current limit is expressed as a percentage of
the entered motor Amps (FLC). This current limit
setting operates during the ramp time only and
will over-ride the torque settings. Reducing the
current limit will limit the torque available to the
motor and load. If set too low it may prevent the
motor from accelerating or reaching full speed.
Range:
40% to maximum unit rating
Default:
Maximum rating of unit
To save changes
To exit without saving
M02 Motor Volts:
Adjust the value to the motor nameplate voltage.
Range:
199 – 481V
Default:
415V
To save changes
To exit without saving
Range:
150 to 450% FLC
Default:
450%
To save changes
To exit without saving
Appendix A – Page 35 provides a guide to starting
parameters for various load types.
C10 Accel Ramp:
C10 Accel Ramp
10s
30%
130%
Accel Time
M03 Motor PF:
Adjust to the value to the motor Power Factor as
indicated on the motor rating plate.
Start Torque
Final Torque
Range:
0.60 – 0.98
Default:
0.90
To save changes
To exit without saving
To enter submenu to modify
To exit sub menu
C11 Accel Time:
Adjust this to vary the time taken to ramp the
voltage to full supply voltage or the torque to
reach the ‘finish torque’. The accel time will
affect the actual current during starting – the
faster the rate of acceleration the higher the
start current.
M04 Motor Wiring: (select models only)
Select the wiring configuration of the soft starter.
Range:
3 Wire; Std 6 Wire; Alt 6 Wire
Default:
3 Wire
To save changes
To exit without saving
Range:
1 to 60 seconds
Default: 10 s
To save changes
To exit without saving
Setup Menu
C12 Start Torque:
The initial torque provided when a start is
initiated. Adjust to the lowest setting which
allows the motor to turn on a start command.
This is entered as a percentage of nominal
Torque (FLT). This setting will be dependent on
the torque required by the load.
3 Control
C01 Run Mode:
Set to the configuration of the Smartstart 6000.
Range:
Bypass; Continuous
Default: Bypass
To save changes
To exit without saving
Range:
15% to 200%
Default: 30%
To save changes
To exit without saving
Technical Manual: Smartstart® 6000
IMI0042 rev D
Page 17
Programming
C13 Final Torque: (torque control only)
This sets the torque provided at the end of the
acceleration period. This is entered as a
percentage of nominal Torque (FLT).
Range:
15 to 200%
Default: 130%
To save changes
To exit without saving
C20 Decel Ramp:
C20 Decel Ramp
0
%
Start Torque
Setup Menu
4 Protection
P01 Mtr Overload:
The Smartstart 6000 continuously monitors the
motor current (even in bypass) and calculates the
temperature rise of the motor. The tripping curves
are based on the protection classes as defined by
IEC60947-4-2. Refer to page 29 for more details
on overload class curves. Select the overload
protection class suitable for the motor & load
combination. This protection is type R1, thus will
not reset the thermal capacity when power is
removed or motor is stopped. This prevents the
motor from restarting if the motor is too hot.
Final Torque
Range:
2;10a;10;15;20;25;30;disabled
Default:
10
To save changes
To exit without saving
To enter submenu to modify
To exit sub menu
The overload setting must be selected according
to the motor manufacturers recommendations.
C21 Decel Time:
The time taken to decelerate the motor to the
‘release torque setting’.
Range:
0 to 120 seconds
Default: 0 s
To save changes
To exit without saving
C22 Release Torq:
The Smartstart 6000 will decelerate the motor at
the ‘decel time’ rate until the torque reaches the
release torque value entered. This is entered as
a percentage of nominal Torque (FLT).
P02 Mtr OverTemp:
Provides overload protection of the motor by
monitoring the actual motor temperature. A
thermistor or NC switch can be connected directly
to terminals 20 and 21. This will operate in
conjunction with P02 Mtr Therm OL.
Range:
Thermistor; NC switch; disabled
Default:
NC switch
To save changes
To exit without saving
Range:
0 to 100%
Default: 2%
To save changes
To exit without saving
In pump applications the deceleration provided by the
Smartstart 6000 will reduce problems with water
hammer with greater control of the motor torque &
speed. The Smartstart 6000 has advanced settings to
customise the control of the motor during acceleration
and deceleration. Refer to Menu ‘Advanced Controls’
on page 25 for more details.
PTC type:
i. Trip resistance 3000 ohms
ii. Reset 1650 ohms
iii. Thermistor Fault <20ohms
P03 Ph Rotation:
Selectable phase sequence protection to inhibit
motor operation if a prohibited phase sequence is
detected such as reverse operation. Ideal for
pumping applications.
Range:
Ignore; 1-2-3; 3-2-1;
Default:
Ignore
To save changes
To exit without saving
Technical Manual: Smartstart® 6000
IMI0042 rev D
Page 18
Programming
P22 Volt Imbal Level:
Adjust to set the voltage imbalance threshold, as
a percentage of the average phase voltage.
P10 Acc Overtime :
P10 Accel OverTime
Trip
120s
Range:
5 – 25%
Default: 25%
To save changes
To exit without saving
Trip/off
OverTime Delay
P23 Volt Imbal Delay:
Adjust to set a delay for the voltage imbalance
trip.
To enter submenu to modify
To exit sub menu
Range:
0– 5 seconds
Default: 5 s
To save changes
To exit without saving
P11 Overtime Alarm:
Protection against the start time exceeding the
preset acceleration or ramp time.
Range:
off; trip
Default: off
To save changes
To exit without saving
P30 Curr Imbal:
P30 Curr Imbal
Trip
P12 Overtime Del:
The time exceeding the set ramp time before a
trip on Accel overtime occurs.
25%
10s
Status
Level
Delay
Range:
5 – 300 secs
Default: 120s
To save changes
To exit without saving
To enter submenu to modify
To exit sub menu
P31 Curr Imbal Alarm:
Protection against a current imbalance.
P20 Volt Imbal :
P20 Volt Imbal
Trip
25%
Range:
off; trip
Default: trip
To save changes
To exit without saving
5s
Status
Level
P32 Curr Imbal Level:
Set the current imbalance threshold, as a
percentage of the average phase current.
Delay
To enter submenu to modify
To exit sub menu
Range:
5 – 25%
Default: 25%
To save changes
To exit without saving
P21 Volt Imbal Alarm:
Provide protection against a supply voltage
imbalance.
P33 Curr Imbal Delay:
Set a delay for the current imbalance trip.
Range:
off; trip
Default: trip
To save changes
To exit without saving
Range:
0 – 10 seconds
Default: 10s
To save changes
To exit without saving
Technical Manual: Smartstart® 6000
IMI0042 rev D
Page 19
Programming
P40 Undercurrent:
P51 Overcurrent Alarm:
Provide protection against over current. This
protection is not active during the accel & decel
period.
P40 Undercurrent
Trip
5%
5s
Status
Range:
off; trip
Default: off
To save changes
To exit without saving
Level
Delay
To enter submenu to modify
To exit sub menu
P52 Overcurrent Level:
Adjust to the desired trip threshold, as a
percentage (%) of the Motor Amps.
P41 Undercurrent Alarm:
Protection against under current. This protection
is not active during accel & decel period.
Range:
off; trip
Default: off
To save changes
To exit without saving
Range:
80 – 250%
Default: 100%
To save changes
To exit without saving
Ideal for detecting loss of load or low load
conditions such as belt breakages or blocked
water pipes
P53 Overcurrent Delay:
Adjust to set the time period that the current
must exceed the threshold before a trip occurs.
Range:
0 - 30 seconds
Default: 10 s
To save changes
To exit without saving
P42 Undercurrent Level:
Adjust to the desired trip threshold, as a
percentage (%) of the Motor Amps.
Range:
10 – 100%
Default: 10%
To save changes
To exit without saving
P60 Under Torque:
P60 Under Torque
Trip
P43 Undercurrent Delay:
Adjust to set the time period that the current
must fall below the threshold before a trip
occurs.
10%
10s
Status
Level
Delay
Range:
1-90 seconds
Default: 10 s
To save changes
To exit without saving
To enter submenu to modify
To exit sub menu
P61 Under torque Alarm:
P50 Overcurrent:
Provide protection against under-torque. This
protection is not active during the accel & decel
period.
P50 Overcurrent
Trip
110%
2s
Status
Range:
off; trip
Default: off
To save changes
To exit without saving
Level
Delay
To enter submenu to modify
To exit sub menu
Technical Manual: Smartstart® 6000
IMI0042 rev D
Page 20
Programming
P62 Under Torque Level:
Adjust to the desired trip threshold, as a
percentage of nominal torque.
P73 Over Torque Delay:
Adjust to set the time period that the torque
must exceed the threshold before a trip occurs.
Range:
10 – 100%
Default: 10%
To save changes
To exit without saving
Range:
0 - 30 seconds
Default: 10 s
To save changes
To exit without saving
P63 Under Torque Delay:
Adjust to set the time period that the torque
must fall below the threshold before a trip
occurs.
Range:
1 - 90 seconds
Default: 10 s
To save changes
To exit without saving
Setup Menu
5 Inputs
I10 DigIn 1 Mode
Activates digital input 1.
Range:
Enable; Invert; Disable
Default:
Enable
To save changes
To exit without saving
P70 Over Torque (Electronic Shear Pin):
P70 Over Torque
Trip
100%
5s
Status
I11 DigIn 1 Variable
Set the functionality of digital input 1.
Level
Range:
ESO; Remote trip; Remote reset
Default: Remote Reset
To save changes
To exit without saving
Delay
Electronic Shear Pin or protection against over
torque. This protection is not active during the
accel & decel period.
I12 DigIn 1 Delay
Set the delay that the digital input needs to be
active for the Soft starter to respond.
To enter submenu to modify
To exit sub menu
P71 Over Torque Alarm:
Provide protection against excess torque. This
protection is not active during the accel & decel
period.
Range:
0.0 – 30.0 seconds
Default: 3.0
To save changes
To exit without saving
I20 DigIn 2 Mode
Activates digital input 2.
Range:
off; trip
Default: off
To save changes
To exit without saving
P72 Over Torque Level:
Adjust to the desired trip threshold, as a
percentage of nominal torque.
Range:
Enable; Invert; Disable
Default:
Disable
To save changes
To exit without saving
I21 DigIn 2 Variable
Set the functionality of digital input 2.
Range:
ESO; Remote trip; Remote reset
Default: Disabled
To save changes
To exit without saving
Range:
80 – 250%
Default: 100%
To save changes
To exit without saving
Technical Manual: Smartstart® 6000
IMI0042 rev D
Page 21
Programming
I22 DigIn 2 Delay
Set the delay that the digital input needs to be
active for the Soft starter to respond.
Q31 Relay 3 Variable
Set the functionality of Relay 3.
Range:
See table on page 26
Default:
Motor On
To save changes
To exit without saving
Range:
0.0 – 30.0 seconds
Default: To save changes
To exit without saving
Q40 Relay 4 Mode
Activates Relay 4.
Range:
Enable; Invert; Disable
Default:
Enable
To save changes
To exit without saving
Setup Menu
6 Outputs
Q10 Relay 1 Mode
Activates Relay 1.
Range:
Enable; Invert; Disable
Default:
Enable
To save changes
To exit without saving
Q11 Relay 1 Variable
Set the functionality of Relay 1.
Range:
See table on page 26
Default:
Line Ctrl
To save changes
To exit without saving
Q41 Relay 4 Variable
Set the functionality of Relay 4.
Range:
See table on page 26
Default:
Trip Alarm
To save changes
To exit without saving
Q50 An Out 1 Mode
Activate and set the signal type for Analogue
Output 1.
Range:
Disabled ; 0-10v; 0-5v; 0-20mA;
4-20mA
Default:
Disabled
To save changes
To exit without saving
Q20 Relay 2 Mode
Activates Relay 2.
Range:
Enable; Invert; Disable
Default:
Enable
To save changes
To exit without saving
Q51 An Out 1 Variable
Set the functionality of Analogue Output 1.
Range:
See table on page 26
Default:
Current
To save changes
To exit without saving
Q21 Relay 2 Variable
Set the functionality of Relay 2.
Range:
See table on page 26
Default:
Bypass Ctrl
To save changes
To exit without saving
Q52 An Out 1 FS (Full Scale)
Set the full scale of the Analogue output signal.
Range:
50 – 500%
Default:
200%
To save changes
To exit without saving
Q30 Relay 3 Mode
Activates Relay 3.
Range:
Enable; Invert; Disable
Default:
Enable
To save changes
To exit without saving
Example:
Technical Manual: Smartstart® 6000
20mA = 400% Current
20mA = 200% Torque
IMI0042 rev D
Page 22
Programming
Set to the time of the kick
Setup Menu
Range:
0.0 – 2.0 seconds
Default: 0.0 (Disabled)
To save changes
To exit without saving
7 Resets
R01 Manual Reset
Activate or de-activate the manual reset ie. The
reset on the local console.
A12 Kick Level
Set the level of kick as a percentage % of
Locked Rotor Current.
Range:
Enable; Disable
Default:
Disable
To save changes
To exit without saving
Range:
50 – 100%
Default: 70%
To save changes
To exit without saving
R02 Power Reset
Activate or de-activate reset on removal of control
supply.
A20 Accel Method
Range:
Enable; Disable
Default:
Enable
To save changes
To exit without saving
A20 Accel Method
Squared
Torque
Accel Profile
R03 Start Reset
Activate or de-activate reset on a start command.
Accel Control
The acceleration method allows adjustment of the
aceleration profile and acceleration control. This
provides advanced control of the motor during the
ramp time to better match the type of load or
application.
Range:
Enable; Disable
Default:
Disabled
To save changes
To exit without saving
See Appendix A on Page 34-35 for more details.
Setup Menu
To enter submenu to modify
To exit sub menu
8 Advanced
A10 Kick Start
A21 Accel Profile
Select the type of acceleration profile to match
the type of load or application.
A10 Kick Start
0.2s
70%
Example: Pump/Fan = Squared
Kick Time
Range:
Linear, Squared
Default: Squared
To save changes
To exit without saving
Kick Level
Set to provide a kick during starting. This provides
an adjustable torque boost to the motor when a
start is initiated. This will also result in a higher
start current during the kick duration.
A22 Accel Control
Select the type of Acceleration control to suit the
load or application. Torque Control will provide
greater control of motor acceleration.
When a kick time of 0.0 seconds is selected
‘Disabled’ will be displayed.
Range:
Torque; Voltage
Default: Torque
To save changes
To exit without saving
To enter submenu to modify
To exit sub menu
A11 Kick Time
Technical Manual: Smartstart® 6000
IMI0042 rev D
Page 23
Programming
A30 Decel Method
A30 Decel Method
Linear
Torque
A42 Str OT Reset
Enter the level for the Starter over temperature
protection to allow a reset.
Range:
40 – 90° C
Default: 60° C
To save changes
To exit without saving
Decel Profile
Decel Control
The deceleration method allows adjustment of the
deceration profile and acceleration control of the
Soft Starter. This provides advanced control of the
motor during the ramp down time to better match
the type of load or application. This is especially
useful in resolving water hammer related
problems.
A51 Motor Stator
Enter Details of the Motor Stator.
See Appendix A on Page 34-35 for more details.
A61 Try Tiny Motor
Allows a test of the starter using a small test
motor or motor smaller than the starter is rated.
To save changes
To exit without saving
Range:
1.5 – 5.0%
Default: 3.0%
To save changes
To exit without saving
Range:
Enable/Disable
Default: Disable
To save changes
To exit without saving
A31 Decel Profile
Select the type of deceleration profile to match
the type of load or application.
Range:
Linear; Squared
Default: Linear
To save changes
To exit without saving
The soft starter will trip on motor loss if motor
current falls below 12% of the entered FLC. This
creates a problem for workshop testing or fault
finding. If ‘Try Tiny Motor’ is enabled a start is
allowed which ignores this protection. When the
control supply is removed this automatically resets
to ’disabled’.
A32 Decel Control
Select the type of deceleration control to suit the
load or application. Torque control will provide
greater control over the deceleration / stopping
of a motor under load.
Range:
Torque; Voltage
Default: Linear
To save changes
To exit without saving
A41 Motor Mtr OL Reset
Enter the level for the Motor over load protection
to allow a reset.
Range:
10 – 100%
Default: 90
To save changes
To exit without saving
Technical Manual: Smartstart® 6000
IMI0042 rev D
Page 24
Programming
Setup Menu
Setup Menu
10 Starter Diag
9 Commands
To clear/reset any of the following a confirmation
code is required:
1
2
3
4
5
11
12
13
Reset Trip
Clr Mtr OL
Clr Counters
Clr Meters
Reset Config
Clr Stress
Clr All Data
Factory Reset
This menu provides indication of inputs and wiring
checks.
Each Relay can also be forced on and the Analogue
output set for 100%.
S1 Digital In:
S1 Digital In
EN=0
D1=0
D2=0
Enable Input
Digital 1 Input
Digital 2 Input
The Confirmation Code is: 1470
0 = No control signal present
1 = Control signal present
S2 Thermistor In:
Displays thermistor resistance in Kohms.
The trip resistance is 3000Ohms and a short circuit is
detected when <20Ohms.
S3 Chk Motor Wirirng:
Displays detected motor wiring.
Example: ‘ Correct
Mtr 3 wire ‘
S4 Chk CT1/CT2
Displays detected CT connection.
Example: ‘Correct
Technical Manual: Smartstart® 6000
+L1 / +L3’
IMI0042 rev D
Page 25
Programming
Table 1: Output Relay Functionality
Table 2: Analogue Output Functionality
Relay Function
Selection:
Description
Line Ctrl
Control for Line Contactor
Bypass Ctrl
Analogue Output
Selection:
Description
Control for Bypass Contactor
Mtr Torque
Estimated torque produced in
motor
Accel Ramp
Starter in acceleration ramp
mode
Mtr Thermal
Estimated Motor temperature of
over load
Decel Ramp
Starter in deceleration ramp
mode
SCR thermal
SCR temperature
Ramping
Starter in Ramp Mode
Active power
Power consumed kW
Up to Speed
motor is up to speed
Power Factor
Power Factor
Motor On
Motor is running
Mtr Current
Motor Current
Trip Alarm
A trip alarm is active
Test (100%)
Maximum output
Bypass FLT
Bypass contactor failed
Freq Error
Supply frequency range
exceeded
Mtr Loss
Output phase(s) Open
circuit/motor isolated
Remote Trip
Remote trip active
SCR OL Trip
SCR reached overload level
Mtr OL Trip
Motor reached overload level
Mtr OT Trip
Motor thermistor/switch trip
active
Ph Rotation
Rotation trip active
Remote Trip
Remote trip active
Over time
Over time trip active
Volt Imbal
Voltage Imbalance trip active
Curr Imbal
Current imbalance trip active
Under Current
Under current trip active
Over Current
Over Current trip active
Under Torque
Under Torque trip active
Over Torque
Over Torque trip active
Warning Alarm
A warning alarm is active
Test (ON)
Turns relay on
Technical Manual: Smartstart® 6000
IMI0042 rev D
Page 26
Fault Diagnosis
Message:
Problem:
01 PSU LOW VOLT
Control Supply Voltage low
02 LINE FREQ
Line supply frequency out of range
03 LINE PH FLT
3 Phase supply problem, open phase
04 LINE PH DIR
Line Phase sequence in wrong direction –
User Selectable, see page 18
05 MTR 3/6 WIRE
Wiring detected different to motor wiring
setting.
06 MOTOR PH FLT
Motor phase did not conduct on start,
motor not connected, open motor phase
or problem with motor. Incorrect CT
phasing and/or insufficient motor current.
07 CT PHASING
Incorrect CT phasing and/or
insufficient motor current.
10 START FAILED
Motor did not start
12 OUTPUT FAULT
SCR feedback lost, motor wiring or SCR
fault.
13 MOTOR LOSS
Motor current lost in all 3 phases
14 BYPASS FAULT
Fault with Bypass Contactor detected
15 BP POLE FLT
3 Phase/pole fault
20 STR OVERCURR
Starter instantaneous over current
21 STR OVERTEMP
Starter heatsink over temperature
22 STR TEMP FLT
Starter heatsink temperature sensor
fault
23 STR OVERLOAD
Starter thermal overload
24 MOTOR STALL
Motor Stalled, current after start >300%
for 3 seconds.
25 VOLT IMBAL
Voltage imbalance as per user setting.
See page 19
26 CURR IMBAL
Current imbalance as per user setting. See
page 19
30 MTR OVERLOAD
Motor thermal overload trip as per user
setting. See page 18
31 MTR OVERTEMP
Motor over temperature from
thermistor input. See page 18
32 MTR TEMP FLT
Motor thermistor sensor fault detected.
See page 18
33 MTR OVERCURR
Over current trip as per user setting.
See page 20
34 MTR UNDERCURR
Under current trip as per user setting. See
page 20
35 MTR OVERTORQ
Over torque trip as per user setting.
See page 21
36 MTR UNDERTORQ
Under torque trip as per user setting. See
page 20
40 REMOTE TRIP
Trip initiated from external source. Remote
input on Digital input 1 or 2. See page 21
41 ACC OVERTIME
Acceleration time has exceeded set time
as per user setting. See page 19
Technical Manual: Smartstart® 6000
IMI0042 rev D
Page 27
Specifications
Input Voltage:
6R series:
220 to 460Vac
6R15-80: 380Vac to 415Vac
Thermistor:
Input Frequency:
50 / 60Hz +/- 3Hz,
Auto detecting
Control Supply:
24Vdc (+15%, -15%)
24VDC Power Supply (min. requirements):
Power Supply O/P:
24VDC Regulated
Peak power requirements:
6R15-30:
1.5 Amps (36W)
6R60-80:
2 Amps (48W)
6R100–220:
3.0Amps (72W)
6R300–880:
4.0 Amps (96W)
These ratings allow for peak current requirements of
internal fans
Configurations:
Duty:
Light Duty:
Standard Duty:
Severe Duty:
SCR PIV:
SCR configuration:
Dv/dt suppression:
Over Voltage:
Rated Insulation:
EMC
Current Feedback
Control
Standards Compliance
Environment:
Enclosure protection:
Operating Temp.
Cooling:
Maximum Altitude:
Operating position:
Maximum ambient
Pollution:
Inputs:
Digital Inputs:
Function :
3 wire & 6 wire
Bypass or Continuous
6R15 to 6R80 have integral Bypass
Contactor.
300% for 15 secs; 10start/hr
300% for 40secs; 10start/hr
400% for 10 secs;10start/hr
450 for 20 secs; 5start/hr
300% for 60 secs; 5start/hr
Minimum 1400V
Full-wave
RC snubber networks
MOV
2Kv
Class A (to AS61800 – C-tick)
Current transformer in circuit
at all times.
Torque controlled Ramp or
voltage ramp, with current limit
override
AS31800 C-tick; AS3947.4.2,
IEC60947-4-2
IP00 – IP20
0 to 55°C
(derate by 1% / °C >40°C)
Temperature controlled forced
ventilated
1000m without derating
Vertical
Thermistor or NC switch
PTC type, Trip Resistance 3000Ohms,
<20ohms detected as Short Circuit.
Outputs:
Digital Output:
Contact Rating:
4 Programmable Relays
5A 250Vac; 5A 30VDC
Analogue Output:
Signal:
1x Programmable Output
0-10V, 0-5V, 4-20mA
Communications: Modbus RS485 with Ethernet Option
(Available in later revision)
Protection:
Motor Overload
SCR Over temp.
SCR protection:
Under Current
Over Current
Under Torque:
Over Torque:
Motor Stalled
Current limit
Starter Overload
O/P Short Circuit
Voltage imbalance
Current Imbalance
Bypass failure
SCR fault
Acc over time
Phase reversal
Motor Loss
CT fault
Adjustable; Class 10, 10A, 20, 25, 30
type R1, total memory function
Heat sink temperature
Currrent & thermal modelling
Adjustable level and trip time
Adjustable level and trip time
Adjustable level and trip time
Adjustable level and trip time
300% for 3 seconds (run mode only)
Adjustable
Current & thermal modelling
Semiconductor fuses (optional)
Input voltage imbalance
Input & output current imbalance
No bypass after ramp time or during
run mode
Open or Short circuit SCR
Accel time exceeds set time
Phase rotation inhibit
Motor or output open cct
Fault with CT’s
Human Interface Module (HIM):
Type:
Local or remote mountable (IP66)
Display:
Backlit LCD (Blue) , English
Menu:
Coded & English
Menu Protected:
Selectable user access code
Cable type:
Ribbon or Cat-5
Essential Services Over-ride (ESO):
Selectable Digital input with 24Vdc logic.
Battery:
Type:
CR1220
Degree 3 conforming to
IEC947-4-2
24Vdc logic
2x Programmable inputs
1x Enable Input
Technical Manual: Smartstart® 6000
IMI0042 rev D
Page 28
Thermal Protection
Starter Thermal Protection:
Motor thermal Protection
Thermal protection of the soft starter is provided by a
temperature sensor located on the heatsink and by
calculating the temperature of the thyristor junction
with sophisticated modeling of the specific devices
used. Fans are powered by 24VDC supply and
thermally controlled when the heatsink temperature
exceeds 40°C and whist the motor is ramping.
Cold Curves
SS6000 Motor Thermal Over load Cur ves - Cold
10000.000
Motor thermal Protection
The SS6000 provides thermal protection of the motor
by providing a thermistor input and also a
programmable motor overload protection feature.
Class 30 Cold
Trip Time (s)
The starter continuously monitors the current and
calculates the temperature rise of the motor based on
the motor data provided. The standard IEC60947-4-2
defines the protection classes giving the starting
capacities of the motor (warm or cold) without thermal
trips.
1000.000
Class 20 Cold
100.000
Class 10 Cold
Class 10A Cold
Class 2 Cold
10.000
The thermal protection displayed by the starter
corresponds to the thermal time constant:
• An overload trip will occur and stop the motor, if
the motor exceeds the critical temperature rise
threshold of 125%
1.000
0
1
2
3
4
5
6
7
8
X FLC
• This feature has a memory function based on the
thermal capacity and may not allow a start if
the temperature rise is too high.
Hot Curves
SS6000 Motor Thermal Overload Curves - Warm
• The thermal state continues to calculate even
when the starter is off and powered down.
Simply by turning power off and back on will
not reset the thermal state.
1000.000
100.000
Motor thermistor Protection
Class 30 Warm
Trip Time (s)
The SS6000 provides an input for a thermistor or
normally closed switch. Thermistor / PTC probes
integrated in the motor to measure its temperature
can be connected to the thermistor input terminals.
Class 20 Warm
10.000
Class 10 Warm
Class 10A War m
Class 2 War m
This input has a trip resistance of 3000ohms and a
resistance of 20ohms or less will be detected as a
short circuit.
1.000
Alternatively, a normally closed thermal switch may be
used which open circuits at a specific temperature.
0.100
0
1
2
3
4
5
6
7
8
X FLC
Technical Manual: Smartstart® 6000
IMI0042 rev D
Page 29
Unit ratings
The following tables provide the maximum motor FLC that should be used on each SS6000 model for specific
starting & operating duties.
15A – 80A with Integral Bypass Contactor (380 - 415V)
Light Duty:
Standard
Duty:
Severe Duty:
Model
Chassis
Dimensions (mm)
15A
15A
15A
6R015B2
B2
335h 162w 174d
30A
25A
20A
6R030B2
B2
335h 162w 174d
60A
54A
44A
6R060B2
B3
440h 162w 174d
80A
70A
56A
6R080B2
B3
440h 162w 174d
220 -460V 3 Wire Bypass
Light Duty:
Standard Duty:
Severe Duty:
Model
Chassis
Dimensions (mm)
105
92
82
6R10000
A2
430h 248w 232d
193
170
151
6R19000
A2
430h 248w 232d
221
193
172
6R22000
A2
430h 248w 232d
367
321
285
6R36000
A3
670h 375w 285d
586
513
456
6R58000
A3
670h 375w 285d
830
806
716
6R83000
A3
670h 375w 285d
220 -460V 3 Wire Continuous
Light Duty:
Standard Duty:
Severe Duty:
Model
Chassis
Dimensions (mm)
100
88
78
6R10000
A2
430h 248w 232d
178
157
141
6R19000
A2
430h 248w 232d
203
179
161
6R22000
A2
430h 248w 232d
341
302
270
6R36000
A3
670h 375w 285d
534
473
425
6R58000
A3
670h 375w 285d
796
710
641
6R83000
A3
670h 375w 285d
220 -460V 6 Wire Bypass (inside Delta Connection)
Light Duty:
Standard Duty:
Severe
Duty:
Model
Chassis
Dimensions
(mm)
180
159
140
6R10000
A2
430h 248w 232d
330
290
260
6R19000
A2
430h 248w 232d
380
330
295
6R22000
A2
430h 248w 232d
635
555
490
6R36000
A3
670h 375w 285d
1015
888
789
6R58000
A3
670h 375w 285d
1435
1395
1240
6R83000
A3
670h 375w 285d
Technical Manual: Smartstart® 6000
IMI0042 rev D
Page 30
Unit ratings
220 -460V 6 Wire Continuous (Inside Delta Connection)
Light Duty:
Standard Duty:
Severe
Duty:
Model
Chassis
Dimensions (mm)
173
152
135
6R10000
A2
430h 248w 232d
308
270
240
6R19000
A2
430h 248w 232d
350
310
275
6R22000
A2
430h 248w 232d
590
520
465
6R36000
A3
670h 375w 285d
920
815
735
6R58000
A3
670h 375w 285d
1378
1225
1110
6R83000
A3
670h 375w 285d
Note:
1.
2.
The above ratings are based on a 40Degree Ambient. Ratings up to 60degC are available.
The bypass contactor is not included unless stated otherwise.
Shipping/Packaging Details
Part No.
Dimensions
(mm)
Weight
(kg)
6R015B2
380 x 220 x 248
6
6R030B2
380 x 220 x 248
6
6R060B2
488 x 220 x 248
7
6R080B2
488 x 220 x 248
7
6R10000
480 x305 x 290
18
6R19000
480 x 305 x 290
18
6R22000
480 x 305 x 290
18
6R36000
770 x 470 x 430
68
6R58000
770 x 470 x 430
68
6R83000
770 x 470 x 430
68
Technical Manual: Smartstart® 6000
IMI0042 rev D
Page 31
SS6000 Options
24vdc Power Supplies
Part Number
Description
Comments
TQ60001
24Vdc Power Supply, 36W, 1.5 Amps
Power Supply to suit 6R15 to 6R30
TQ60002
24Vdc Power Supply, 48W, 2.0 Amps
Power Supply to suit 6R60 to 6R80
TQ60003
24Vdc Power Supply, 72W, 3.0 Amps
Power Supply to suit 6R100 to 6R220
TQ60004
24Vdc Power Supply, 96W, 4.0 Amps
Power Supply to suit 6R360 to 6R830
Remote Console Option (H.I.M): Ribbon Cable
Part Number
Description
Comments
TQ60006
Remote Console (IP66) - loose
Available for all models
TF60006
Remote Console (IP66) - fitted
Available for all models
TQ60007
Remote Console (IP66) Cable per 2m
Available for all models
TQ60008
Remote Console (IP66) Cable per 3m
Available for all models
TQ60009
Remote Console (IP66) Cable per 5m
Available for all models
TQ60010
Remote Console (IP66) Cable per m
Available for all models
TF60007
Remote Console (IP66) Cable per 2m – fitted
Available for all models
TF60008
Remote Console (IP66) Cable per 3m – fitted
Available for all models
TF60009
Remote Console (IP66) Cable per 5m – fitted
Available for all models
TF60010
Remote Console (IP66) Cable per m – fitted
Available for all models
Remote SMART Console Option (H.I.M): Cat-5 Cable
Part Number
Description
Comments
TQ60011
Remote Console (IP66) - loose
Available for all models
TF60011
Remote Console (IP66) - fitted
Available for all models
TQ60012
Remote Console (IP66) Cable per m (Max 10m)
Available for all models
TF60012
Remote Console (IP66) Cable per m (Max 10m) - fitted
Available for all models
Technical Manual: Smartstart® 6000
IMI0042 rev D
Page 32
SS6000 Options
Option Boards
SS6000 Model
Description
Part Number:
All
Option Card : Data Logger & SD port
TQ60005
All
Option Card : Data Logger & SD port - fitted
TF60005
All
Communications: Ethernet Modbus TCP Port & Data Logger
TQ60032
All
Communications: Ethernet Modbus TCP Port + Data Logger - fitted
TF60032
(All models come standard with Modbus RS485)
Other Options
SS6000 Model
Description
Part Number:
6R100 – 6R220
Prepared for 6 wire
TF60015
6R360 – 6R830
Prepared for 6 wire
TF60016
Semiconductor Fuse Kits
SS6000 Model
Description
Part Number:
6R015B2
Semiconductor Fuse Kit to suit 6R15
TQ60020
6R030B2
Semiconductor Fuse Kit to suit 6R30
TQ60021
6R060B2
Semiconductor Fuse Kit to suit 6R60
TQ60022
6R080B2
Semiconductor Fuse Kit to suit 6R80
TQ60023
6R15-6R80
Semiconductor Fuse Kit Cover
TQ60024
6R10000
Semiconductor Fuse Kit to suit 6R100
TQ60025
6R19000
Semiconductor Fuse Kit to suit 6R190
TQ60026
6R22000
Semiconductor Fuse Kit to suit 6R220
TQ60027
6R36000
Semiconductor Fuse Kit to suit 6R360
TQ60028
6R58000
Semiconductor Fuse Kit to suit 6R580
TQ60029
6R83000
Semiconductor Fuse Kit to suit 6R830
TQ60030
Technical Manual: Smartstart® 6000
Replacement Fuse:
IMI0042 rev D
Page 33
Appendix A
ZENER SMART-TORQ
Torque Control System
There are several methods available to soft start a motor. The more
traditional methods are Direct-on-line, Star/Delta, Auto transformer and
Primary resistance starters. The more sophisticated methods also provide a
soft stop and include Soft Starters and Variable Speed drives (VSD’s). VSD’s
can provide a better soft start with significantly lower starting currents and
many other benefits including energy savings. However, a Soft Starter may
provide a more economical solution to motor starting over the life of the
motor.
Soft Starters provide the following benefits:
1.
Reduced stresses and wear on the mechanics of the system
2.
Reduced starting currents
3.
Minimise voltage dips on the supply
4.
Lowered Peak demand charges
5.
Eliminate belt slippage on fans
6.
Smooth acceleration of motor / load
The rate of acceleration is dependent on the additional torque
(Acceleration Torque) available in the motor.
Thus, we can achieve a constant or linear rate of Acceleration by providing
‘constant’ acceleration torque to the motor.
Since the torque required by the load may not be linear, the torque delivered
by the soft starter must match that of the load. To achieve this, the torque
developed in the motor must be the sum of the ‘acceleration torque’ and the
load torque at a spec ific speed.
Below illustrates the constant acceleration torque applied for different load
types;
1) Constant Torque type Load (eg. Conveyor)
Torque
The conventional voltage ramp Soft Starter is a reduced voltage starter and is
similar to the traditional methods mentioned above. The problem with
voltage ramp soft starters is a non linear acceleration of the motor. This is
very noticeable on a pump type load where there is much higher acceleration
torque available at the beginning of the start. The diagram below shows the
variation in acceleration torque available for both a Direct on line (full
voltage) and the voltage ramp type soft start.
Total Torque
Acceleration
Torque
Speed
DOL (full Voltage)
Torque
Load Torque
100%
2) Variable Torque type Load (eg. Pump/Fan)
LRT
FLT
(100%)
Total Torque
Load Torque
Acceleration
Torque
Torque
Load Torque
Voltage Ramp
Torque
Speed
Acceleration
Torque
100%
‘SMART-TORQ®’ is a Torque Control System developed by Zener to overcome
this problem with greater control over the acceleration torque in the motor.
The torque is controlled in a manner which suits the type of load to achieve a
linear acceleration in motor shaft speed. This control system is also active
during the deceleration phase, providing a soft stop where the motor
decelerates at a constant rate. This can be used to overcome water hammer
problems associated with the c losing or slamming of check valves.
ZENER SMART-TORQ Key Benefits:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
A true linear acceleration of the load and motor for variable &
constant torque loads.
Reduced stresses and wear on the mechanics of the system
Ramp profiling to better match type of load such as variable
torque loads. Better control of pumps and fans.
Torque Control available in Accel & Decel Modes and 3wire or
6wire motor configuration.
Eliminate water hammer problems.
Reduced peak current draw, especially at motor pull-in/pull-out
operating points.
Reduced heating in motor at low speeds.
No instability due to changing power factor. Closed loop system
to monitor and react to changing power factor.
No instability due to slot ripple in 3 wire and 6 wire operation.
Better control of deceleration through closed loop torque control
system.
No external speed sensor required to produce superior
performance
Technical Manual: Smartstart® 6000
Speed
100%
How is this achieved ?
The SMARTSTART® 6000 continually monitors start variables such as motor
current, voltage and power factor to determine the input electrical power.
From the motor parameters, the IR & magnetic losses are used to calculate
the Air Gap Power (ie. the power transmitted to the motor shaft). With an
instantaneous value of shaft power the instantaneous torque can be
determined. With this information we can vary the thyristor conduction to
achieve the desired torque. The torque is varied to follow a spec ific curve,
based on the initial torque setting, the final torque setting and the profile
selected. The end result is equal acceleration torque over the ramp period to
provide a linear acceleration in motor shaft speed. The profile is user
adjustable allowing for non-linear torques if required to other or unusual
types of loads.
Summary.
The ‘SMART-TORQ®’ Torque Control System provides smoother starting &
stopping, allowing ramp profiling to produce a linear acceleration and
deceleration of the motor speed. There are many benefits with variable
torque loads such a pumps. A linear acceleration and deceleration provides
better control to eliminate water hammer problems. The SMARTSTART® 6000
combines this superior torque control system with a robust design to suit all
types of loads and applications. All models inc lude substantial heatsink mass
with temperature controlled force ventilation to accommodate the more
severe (heavy) duty applications.
IMI0042 rev D
Page 34
Appendix A
Indicative parameters for different load types
1. Pump (3 wire/Bypass with No Soft Stop)
Factory defaults are intended for general
pumping/fan application with no Soft Stop. Enter
motor parameters as per motor nameplate.
2. Submersible Pump
(3 wire/Bypass with No Soft Stop)
Factory defaults are intended for general pumping
application with no Soft Stop. The acceleration
time needs to be reduced to 3secs or as per
pump/motor manufacturers recommendations.
Enter motor parameters as per motor nameplate.
Ref
C11
M01
M02
M03
Page
17
17
17
17
Parameter
Accel time
Motor Amps
Motor Volts
Motor PF
Setting (factory Default)
3sec
(10s)
‘Namplate Motor FLC’
‘Namplate Motor Volts’
‘Namplate Motor PF’
5. Conveyor: (3 wire/Bypass)
Factory defaults are preset for a variable torque
load. The Torque settings will need to be adjusted
for a constant torque type load. Enter motor
parameters as per motor nameplate.
Ref
C12
C13
A21
P01
M01
M02
M03
Page
17
18
23
18
17
17
17
Parameter
Start Torque
Final Torque
Accel profile
Motor Overload
Motor Amps
Motor Volts
Motor PF
Setting (factory Default)
150%
(30%)
150%
(130%)
Linear
(Squared)
Class 20
(10)
‘Namplate Motor FLC’
‘Namplate Motor Volts’
‘Namplate Motor PF’
6. Compressor: (3 wire/Bypass)
Factory defaults are preset for a variable torque
load. The Torque settings will need to be adjusted
for a constant torque type load. Enter motor
parameters as per motor nameplate.
3. Pump :(3 wire/Bypass with Soft Stop)
Factory defaults are intended for general pumping
application with no Soft Stop. Enter motor
parameters as per motor nameplate. Adjust the
‘Release Torque’ and ‘Decel time’ to achieve the
required soft stop.
Ref
C21
C22
M01
M02
M03
Page
18
18
17
17
17
Parameter
Decel time
Release Torque
Motor Amps
Motor Volts
Motor PF
Setting (factory Default)
*15sec
(0s)
*2%
(2%)
‘Namplate Motor FLC’
‘Namplate Motor Volts’
‘Namplate Motor PF’
4. Fan :(3 wire/Bypass)
Factory defaults are intended for general pumping
application which is similar to that required for a
fan. However, the Accel time may need to be
increased to allow for longer ramp times of high
inertia fans. The Motor Overload Class may also
need to be increased with the extended ramp of
high inertia fans. Enter motor parameters as per
motor nameplate.
Ref
C11
P01
M01
M02
M03
Page
17
18
17
17
17
Parameter
Accel time
Motor Overload
Motor Amps
Motor Volts
Motor PF
Ref
C12
C13
A21
P01
M01
M02
M03
Page
17
18
23
18
17
17
17
Parameter
Start Torque
Final Torque
Accel profile
Motor Overload
Motor Amps
Motor Volts
Motor PF
Setting (factory Default)
60%
(30%)
130%
(130%)
Linear
(Squared)
Class 20
(10)
‘Namplate Motor FLC’
‘Namplate Motor Volts’
‘Namplate Motor PF’
7. Suggested Protection Settings
Below are suggested settings to provide additional
protection of the motor and load. These are
general settings and should be further tuned to
suit the application and load conditions.
Ref
P01
P02
P03
P10
P20
P30
P41
P70
Page
18
18
18
19
19
19
20
21
Parameter
Motor Overload
Motor O/Temp
Phase Rotation
Accel O/Time
Volt Imbal.
Current Imbal.
Under Current
Over Torque
Setting (factory Default)
Class 10a/10/20
(10)
Thermistor
(Disabled)
1-2-3
(Disabled)
Trip / 5s
(Disabled)
Trip / 25% / 5s
(Default)
Trip / 25% / 10s
(Default)
Trip / 50% / 10s
(Disabled)
Trip / 110% / 10 s (Disabled)
Setting (factory Default)
15+
(10s)
Class 10 /Class 20
(10)
‘Namplate Motor FLC’
‘Namplate Motor Volts’
‘Namplate Motor PF’
Technical Manual: Smartstart® 6000
IMI0042 rev D
Page 35
Appendix B
Application Diagrams
General Purpose
Technical Manual: Smartstart® 6000
IMI0042 rev D
Page 36
Appendix B
Application Diagrams
Typical Water & Sewerage Pumping
Technical Manual: Smartstart® 6000
IMI0042 rev D
Page 37
Appendix B
Application Diagrams
Irrigation Pump
Technical Manual: Smartstart® 6000
IMI0042 rev D
Page 38
DESIGNATOR:
Menu Map / Set up Record Sheet
Main menu
1 Display
2 Motor
3 Control
Sub menu Level 1
Sub menu Level 2
_______________
Software Revision: ___________
Default
D02 Default Screen
Overview
D03 Bargraph Var.
Mtr Current
D04 Bargraph FS
300%
M01 Motor Amps
Unit Rating
M02 Motor Volts
415V
M03 Motor PF
0.9
M04 Motor Wiring
3 Wire
C01 Run mode
Bypass
C02 Current Limit
450%
Setting
C10 Accel Ramp
C11 Accel Time
10
C12 Start Torque
C13 Final Torque
30%
C21 Decel Time
0
C22 Release Torque
2%
100%
C20 Decel Ramp
4 Protection
P01 Mtr Overload
Class 10
P02 Mtr Over Temp
Disabled
P03 Ph Rotation
P10 Acc OverTime
P20 Volt Imbal Alarm
P30 Curr Imbal Alarm
P40 Undercurrent Alarm
P50 Overcurrent Alarm
P60 Under Torque Alarm
P70 Over Torque Alarm
Ignore
P11 Overtime Alarm
Off
P12 OverTime Delay
120s
P21 Volt Imbal Alarm
trip
P22 Volt Imbal Level
25%
P23 Volt Imbal Delay
5s
P31 Curr Imbal Alarm
trip
P32 Curr Imbal Level
25%
P33 Curr Imbal Delay
10
P41 Undercurrent Alarm
off
P42 Undercurrent Level
10%
P43 Undercurrent Delay
10s
P51 Overcurrent Alarm
off
P52 Overcurrent Level
100%
P53 Overcurrent Delay
10s
P61 Under Torque Alarm
off
P62 Under Torque Level
10%
P63 Under Torque Delay
10
P71 Over Torque Alarm
off
P72 Over Torque Level
100%
P73 Over Torque Delay
10s
Technical Manual: Smartstart® 6000
IMI0042 rev D
Page 39
DESIGNATOR:
Menu Map / Set up Record Sheet
Main menu
Sub menu Level 1
5 Inputs
I10 DigIn 1 Mode
Default
I11 DigIn 1 Variable
Remote Reset
I12 DigIn 1 Delay
3.0s
Disable
I21 DigIn 2 Variable
-
I22 DigIn 2 Delay
-
Q10 Relay 1 Mode
Enable
Q11 Relay 1 Variable
Q21 Relay 2 Variable
Bypass Ctl
Enable
Q31 Relay 3 Variable
Q40 Relay 4 Mode
Motor On
Enable
Q31 Relay 4 Variable
Trip
Q51 An Out 1 Variable
Current
Q52 An Out 1 FS
200%
Q50 An Out 1 Mode
Disabled
R01 Manual Reset
Disabled
R02 Power Reset
Enabled
R03 Start Reset
Disabled
A10 Kick Start
A20 Accel Method
A30 Decel Method
9 Commands
Line Ctl
Enable
Q30 Relay 3 Mode
8 Advanced
Setting
Enable
Q20 Relay 2 Mode
7 Resets
Software Revision: ___________
Sub menu Level 2
I20 DigIn 2 Mode
6 Outputs
_______________
A11 Kick Time
0.0s
A12 Kick Level
70%
A21 Accel Profile
Square
A22 Accel Control
Torque
A31 Decel profile
Linear
A32 Decel Control
Torque
A41 Motor OL Reset
90%
A42 Str OT Reset
60DegC
A51 Motor Stator
3.00%
1 Reset Trip
2 Clr Mtr OL
3 Clr Counters
4 Clr Meters
5 Reset Config
10 Starter Diag
S1 Digital In
S2 Thermistor Resitance
S3 Chk Motor Wiring
S4 Chk CT1/CT2
Technical Manual: Smartstart® 6000
IMI0042 rev D
Page 40