TECO-Westinghouse SA7 Instruction Manual

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A U TO M ATION STA RT E R
SA7
INSTRUCTION MANUAL
REV 11/03
P/N: 027-2063
November 2003
© Copyright TECO-Westinghouse Motor Company 2003
TECO-Westinghouse Motor Company retains the right to change specifications and illustrations
in the text, without prior notification. The contents of this document may not be copied without the
explicit permission of TECO-Westinghouse Motor Company.

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Summary of Contents for TECO-Westinghouse SA7

  • Page 1 November 2003 © Copyright TECO-Westinghouse Motor Company 2003 TECO-Westinghouse Motor Company retains the right to change specifications and illustrations in the text, without prior notification. The contents of this document may not be copied without the explicit permission of TECO-Westinghouse Motor Company.
  • Page 2 The soft s tarter contains a number of components demanding special treatment, as for example thyristors. The cir- cuit board contain small amounts of tin and lead. Legal requirements for disposal and recycling of these materials must be complied with. ' 2003 TECO-Westinghouse Motor Company...
  • Page 3: Table Of Contents

    I n s ta l l a t i o n o f t h e s o ft s ta r t e r i n a c a b i n e t ......28 ' 2003 TECO-Westinghouse Motor Company...
  • Page 4 ........67 ' 2003 TECO-Westinghouse Motor Company...
  • Page 5 F i g . 11 Hole pattern for SA7-017 to SA7-250 ....... .29 Fig.
  • Page 6: F I G

    ...........45 Fig. 31 Current transformer position when Bypass SA7-017 to SA7-250... .46 Fig.
  • Page 7: General Information

    For all enquiries and spare pa r ts orders, please quote the correct name of the device and serial number to ensure that your inquiry or order is dealt with correctly and swift l y. ' 2003 TECO-Westinghouse Motor Company...
  • Page 8: How To Use The Instruction Manual

    Check on receipt: Check that the goods are complete as listed on the delivery note, see type no. etc. on the rating plate. I s t h e packaging damaged? ' 2003 TECO-Westinghouse Motor Company...
  • Page 9 Pack the device so that it is shock-resista n t . Intermediate storage A ft e r d e l i v e r y o r a fter it has been dismounted, the device can be stored before further use in a dry room. ' 2003 TECO-Westinghouse Motor Company...
  • Page 10: Description

    . The typical settings to optimize a voltage ramp are: Initial voltage, ramp time, dual ramp time. Current (A) Time 03-F116 Figure 2: Vo l tage Control ' 2003 TECO-Westinghouse Motor Company...
  • Page 11: Current Control

    For an example, to stop a pump with an unlinear ramp will give water hammer. S o ft s tarters which doesn t monitor the torque, will start and stop too fast if the load is lighter than the setting of current or ramp time. Current (A) Time Figure 4: Torque Control ' 2002 TECO-Westinghouse Motor Company...
  • Page 12: As6 Control Methods

    SA7 control methods SA7 Soft St arters control all three phases supplied to the motor. It manages all the 3 possible starting methods where the closed loop Torque control is the most eff i c i e n t w a y o f s tarting and stopping motors.
  • Page 13: How To Get Started

    Check that the motor and supply voltage corresponds to values on the soft s ta r t e r s r a t i n g p l a t e . Ensure the installation complies with the appropriate local regulations. 1 ) The menu 006 must be put to 02 for start/stop command from terminal strip. ' 2003 TECO-Westinghouse Motor Company...
  • Page 14: Main Functions/Applications

    1 7 6 4 A m ps Default: Nominal current soft s ta r t e r Default: 1764 rpm Range: 25% - 150% of St a r t e r A m ps Range: 500-3600 rpm ' 2003 TECO-Westinghouse Motor Company...
  • Page 15: Setting Of The Start And Stop Ramps

    F F i f o n l y s o ft s ta r t r e q u i r e s . Set ramp up time at start (1-60 sec). ENTER8 to confirm new value. NEXTg , PREV f to change menu. ' 2003 TECO-Westinghouse Motor Company...
  • Page 16: Setting The Start Command

    Set the display to menu 005. Now the Motor current can be viewed on the display. 0 0 5 RMS current read-out 0 . 0 Default: Range: 0.0-9999 Amp. NOTE! The menu 005 can be selected at any time when the motor is running. ' 2003 TECO-Westinghouse Motor Company...
  • Page 17: St A R T I N G

    St art the motor by pressing the STA RT/STOP key on the keyboard or through the remote control, PCB terminal 11 , 12 and 13 and the motor then sta r ts s o ft l y. Current (A) Time 03-F116 Figure 6: Example of start ramp with main function voltage ramp. ' 2003 TECO-Westinghouse Motor Company...
  • Page 18: Application And Function Selection

    Main function Torque ramp start (menu 25) will give the best results . Stop function Dynamic Brake (menu 36, selection 1) can be used. As well as the Slow Speed at start and stop (menu 38-40) can be used for better start and stop performance. ' 2003 TECO-Westinghouse Motor Company...
  • Page 19: The Application Functions List

    36:=1 or 2 Sander 25:=1 36:=1 or 2 * Softstart can be packaged with standalone full wave DC injection brake for heavy loads or faster stopping. Ta b l e 1 : Application Rating List ' 2003 TECO-Westinghouse Motor Company...
  • Page 20 Problem This column describes possible problems that are familiar for this kind of application. Solution SA7 Gives the possible solution for the problem using one the SA7 function. Menus Gives the menu numbers and selection for the SA7 function. 25;=1", means: program selection 1 in menu 25.
  • Page 21: Table 2 Application Function List

    SA7 Instruction Manual APPLICATION & FUNCTIONS Appl i cat i on/ Pr obl em Sol ut i on SA7 M enus Dut y Too fast start and stops MSF Pump application with following start / stop PU M P features...
  • Page 22: Function And Combination Matrix

    Torque control start / stop (menu 025) Voltage ramp with current limit (menu 020) Current limit start (menu 021) Pump control (menu 022) Analog input (menu 023) Direct on line start (menu 024) Table 3: Combination matrix ' 2003 TECO-Westinghouse Motor Company...
  • Page 23: Special Condition

    Small motor or low load The minimum load current for the soft s tarter is 10% of the rated current of the soft s ta r t e r. Example SA7-60, rated current = 60 A. Min. Current 6 A. Please note that this is min. load current and not min. rated motor current.
  • Page 24: St Arting With Counter Clockwise Rotating Loads

    However if this alarm is not used (factory default), it is also possible to have the phase reversal contactors in the i n p u t o f t h e s o ft s ta r t e r. ' 2003 TECO-Westinghouse Motor Company...
  • Page 25: Operation Of The Soft Sta Rter

    0 3 Step down voltage at sto p (%) 0 4 Stop ramp 1 ( sec.) 0 5 Current readout 0 6 Cont rol mode 0 7 Extended functions ST ART STO P PREV V NEXT ENTER RESET 03-F28 Figure 7: PPU unit ' 2003 TECO-Westinghouse Motor Company...
  • Page 26: Led Display

    Run at F1&F4 alarm 101-102 Nominal motor parameters 041-046 Machine protection 089-099 Relay K1&K2 functions 051-052 Main supply protection 081-088 Analogue output 054-056 Motor protection 057-058 Digital input 071-075 Parameter set 03-F30 Figure 9: Menu structure ' 2003 TECO-Westinghouse Motor Company...
  • Page 27: The Keys

    The message -Loc w i l l d i s p l a y i f t r y i n g t o s e t a parameter or operate the soft s tarter in locked mode. Default: The key lock status can be read out in menu 221. Range: no, yes Keyboard is not locked Y E S Keyboard is locked ' 2003 TECO-Westinghouse Motor Company...
  • Page 28: Overview Of Soft S Tarter Operation And Parameter Set-Up

    NOTE! When installing the soft starter, make sure it does not come into contact with live components. The heat generated must be dispersed via the cooling fins to prevent damage to the thyristors (free circulation of air). ' 2003 TECO-Westinghouse Motor Company...
  • Page 29: Hole Pattern For Sa7-017 To Sa7-250

    03-F07 Figure 10: SA7 Dimensions SA7-017 to SA7-250 208,50 03-F122 Figure 12: Hole pattern for SA7-170 to SA7-250 with Figure 11: Hole pattern for SA7-17 to SA7-250 upper mounting bracket instead of DIN-rail (backside view) ' 2003 TECO-Westinghouse Motor Company...
  • Page 30: Table 7 Sa7-017 To Sa7-250

    208.5 5.5 / M5 -250 Table 7: SA7-017 to SA7-250 M i ni m um f r ee space ( m m ) Ti ght eni ng t or que f or bol t ( N m ) D i m ensi on C onnect i on...
  • Page 31: Connections

    01 02 PE 69 70 75 76 77 78 71-72 73-74 03-F54_1 Figure 13: Connection of SA7-017 to SA7-085 Connection of AS6-017 to AS6-085 Device connections Protective earth, (PE), Mains supply, Motor Motor power supply T 1 , T 2 , T3...
  • Page 32: F I G

    01 02 03 75 76 77 78 69 70 71-72 73-74 03-F55_1 Figure 14: Connection of SA7-110 to SA7-145 Connection of SA7-110 to SA7-145 Device connections Protective earth, (PE), Mains supply, Motor Motor power supply T 1 , T 2 , T3...
  • Page 33: F I G

    69 70 75 76 77 78 79 71-72 73-74 03-F104 Figure 15: Connection of SA7-170 to SA7-250 Connection of SA7-170 to SA7-250 Device connections Protective earth, (PE), Mains supply, Motor Motor power supply T 1 , T 2 , T3...
  • Page 34: Connection And Setting On The Pcb Control Card

    Connection of L3 or T3 phase (AS6-017 -AS6-250) Current transformer input, cable S2 (brown) Common connection for temrinal 75 and 76 Fan connection 24 VDC 0 VDC Fan connection *Internal connection, no customer use Table 9: PCB Terminals ' 2003 TECO-Westinghouse Motor Company...
  • Page 35: Minimum Wiring

    NOTE! If local regulations say that a mains contactor should be used, the K1 then controls it. Always pro- vide short circuit protection in the form of a circuit breaker or properly rated time delay fuses. ' 2003 TECO-Westinghouse Motor Company...
  • Page 36: W Iring Examples

    Figure 18: Analog input control, parameter set selection, analogue output PTC Sensor in Motor Motor Overtemp Alarms if resistance exceeds 2.4k , resets when resistance drops below 2.2k Figure 19: Motor overtemp protection via PTC sensor ' 2003 TECO-Westinghouse Motor Company...
  • Page 37: Functional Description Set-Up Menu

    FUNCTIONAL DESCRIPTION SET-UP M E N U This chapter describes all the parameters and functions in numerical order as they appear in the SA7. Table 10 gives an overview of the menus, see also Chapter 12. page 75 (set-up menu list).
  • Page 38: Ramp Up/Down Parameters

    0.0-9999 A m p Range: 1-60 sec Read-out of the RMS motor current Set Ramp up time at sta r t . NOTE! This is the same read-out as function 201, see § 7.28, page 64. ' 2003 TECO-Westinghouse Motor Company...
  • Page 39: St Art/Stop/Reset Command

    . A reset can be given both when the motor is running and when the motor is stopped. A reset from the Start / Reset keyboard will not start or stop the motor. ' 2003 TECO-Westinghouse Motor Company...
  • Page 40: Menu Expansion Setting

    The settings are carried out by beginning with the set- Stop ramp 2 disabled tings in menus 001-004 and 007-008 and proceed with 1-60 Set the stop ramp 2 time. A dual the following steps : v o l tage ramp is active. ' 2003 TECO-Westinghouse Motor Company...
  • Page 41: Torque Control Parameters

    C u r r e n t l i m i t l e v e l i n Vo l tage ramp mode. NOTE! Only possible when Voltage Ramp mode is enabled. Menus 021-025 must be oFF . Current Voltage ramp Current limit at start 03-F109 Figure 22: Current limit ' 2003 TECO-Westinghouse Motor Company...
  • Page 42: Current Limit

    Pump control disabled. Vo l tage Ramp to continue. Note that the current will rise uncontrolled if enabled. the operation continues (see § 7.24.2, page 62). 150-500 Pump control application is enabled. ' 2003 TECO-Westinghouse Motor Company...
  • Page 43: Analogue Input Control (Main Function)

    0-20mA c o n t r o l s i g n a l . Analogue input is set for 2-10V/ 4-20mA c o n t r o l s i g n a l . ' 2003 TECO-Westinghouse Motor Company...
  • Page 44: Torque Control (Main Function)

    End torque at stop Stop Time Start Time Figure 28: Torque control at sta r t / s t o p . Current (A) Speed Time Time 03-F113 03-F114 Figure 29: Current and speed in torque control. ' 2003 TECO-Westinghouse Motor Company...
  • Page 45: Torque Boost

    300 - 700% of In The Torque boost current controller use selected value as the motor current reference. NOTE! Check whether the motor can accelerate the load with "Torque booster", without any harmful mechanical stress. ' 2003 TECO-Westinghouse Motor Company...
  • Page 46: F I G

    1 and 3 with PI towards the line. Blue to Blue to terminal 75 terminal 76 LOAD 03-F56 Figure 31: Current transformer position when Bypass SA7-017 to SA7-250. CONTROL POWER NOTE: CT'S LOCATED EXTERNALLY TO MONITOR 2 WIRE 3 WIRE START...
  • Page 47: Power Factor Control

    NOTE! For several start/stops it is recommend to In both methods the SA7 detects when the motor is use the PTC input. s ta n d i n g s t i l l , s o r o tating in wrong direction is avoided.
  • Page 48: F I G

    Default: Figure 32: Braking time Range: 1 , 2 Dynamic vector brake, active Soft brake active BL BR BL BR CONTROL POWER 2 WIRE 3 WIRE START START STOP Figure 33: Soft brake wiring example ' 2003 TECO-Westinghouse Motor Company...
  • Page 49: Slow Speed And Jog Functions

    Speed at St o p t i m e . This time will now be the absolute maximum time for Slow Speed to be active a fter a stop command, in case the external signal will not appear. Default: Range: 10-100 Select the magnitude of the slow speed torque. ' 2003 TECO-Westinghouse Motor Company...
  • Page 50: Slow Speed During A Selected Time

    Figure 35: Slow speed at start/stop during a selected time The Slow speed torque (menu 37) and the DC-Brake a fter Slow speed (menu 40, § 7.15.4, page 50) can be selected if needed. ' 2003 TECO-Westinghouse Motor Company...
  • Page 51: Motor Data S E T T I N G

    Default: Nominal soft s tarter current Nominal motor power 0 4 3 Default: Nominal soft s tarter power Nominal motor speed 0 4 4 1 4 5 0 Default: in rpm nsoft Range: 500-3600 rpm ' 2003 TECO-Westinghouse Motor Company...
  • Page 52: Programmable Relay K1 And K2

    K1 is set for Operation . K 1 i s s e t f o r F u l l Vo l tage . K1 is set for Power pre-alarm . No function K1 is set for Run . ' 2003 TECO-Westinghouse Motor Company...
  • Page 53: Analogue Output

    2 . Set the parameter on menu 54. Analogue output 0 5 4 o F F Default: Range: oFF, 1 , 2 Analogue output is disabled. Analogue output is set to 0-10V/0-20mA Analogue output is set to 0-10V/4-20mA ' 2003 TECO-Westinghouse Motor Company...
  • Page 54: D I G I Tal Input Selection

    1 - 4 N o d i g i ta l i n p u t c o n t r o l Rotation sensor for brake functions Slow speed function Jog forward command Job reverse command ' 2003 TECO-Westinghouse Motor Company...
  • Page 55: Parameter Set

    061 (Parameter set) can be changed. A l l o t h e r parameters are not allowed to change. It is possible to change parameter set at stop and at full v o l tage running. ' 2003 TECO-Westinghouse Motor Company...
  • Page 56: Motor Protection, Overload (F2 Alarm)

    This means still generate an alarm if it is not selected that the motor can be overheated. oFF. Overload time sec Current (x I Figure 43: The thermal curve ' 2003 TECO-Westinghouse Motor Company...
  • Page 57: Mains Protection

    Response delay over volt- 0 8 4 i n g age alarm o F F Default: Range: oFF, 1-60 sec Overvoltage alarm is disabled 1-60 Set the response delay time for over v o l tage alarm F9. ' 2003 TECO-Westinghouse Motor Company...
  • Page 58: Application Protection (Load Monitor)

    - Any reversal of phase sequence will Power min alarm limit [098]: 0.85xP actual cause alarm F16. NOTE! The actual phase sequence can be A successful auto set shows a message Set for 3 s and viewed in menu 87. ' 2003 TECO-Westinghouse Motor Company...
  • Page 59: Pre-Alarm

    0 9 5 0.1-25.0 Sets the response delay of the Max delay Alarm level. o F F Default: Range: oFF, 0.1-25.0 sec Max Pre-Alarm is disabled. 0.1-25.0 Sets the response delay of the Max Pre-Alarm level. ' 2003 TECO-Westinghouse Motor Company...
  • Page 60 F7-alarm occurs after the response delay time. The Auto set function in menu 089, aff e c t this limit if the alarm is set oFF in menu 099. T h i s i s category 1 alarm. ' 2003 TECO-Westinghouse Motor Company...
  • Page 61 SA7 Instruction Manual S E T-UP M E N U Figure 44: Load monitor alarm functions ' 2003 TECO-Westinghouse Motor Company...
  • Page 62: Resume Alarms

    6s ramp time. - Reset the alarm with either ENTER/RESET key or by giving a stop command. ' 2003 TECO-Westinghouse Motor Company...
  • Page 63: Automatic Return Menu

    Default: Range: 1-247 This parameter will select the unit address. Serial comm baudrate 1 1 2 9 . 6 Default: 9 . 6 Range: 2.4, 4.8, 9.6, 19.2,38.4 kBaud This parameter will select the baudrate. ' 2003 TECO-Westinghouse Motor Company...
  • Page 64: Reset To Factory Setting [199]

    011 to menu Range: 0.000-2000MWh 199. Vi e w t h e t o tal power consumption. RMS current 2 0 1 0 . 0 Default: Range: 0.0 - 9999Amp Read-out of the RMs motor current. ' 2003 TECO-Westinghouse Motor Company...
  • Page 65 RMS current in phase L1 2 1 1 0 . 0 Main voltage L2-L3 2 1 6 Default: Range: 0.0 - 9999Amp View the current in phase L1. Default: Range: 0-720V View main voltage L2-L3. ' 2003 TECO-Westinghouse Motor Company...
  • Page 66: Keyboard Lock

    Press key NEXT or PREV to reach the alarm list in menus 901-915 (menu 007 has to be ON). Alarm 9 0 1 Default: Range: F1-F6 View actual alarm. ' 2003 TECO-Westinghouse Motor Company...
  • Page 67: Protection And Alarm

    Automatic reset when a stop command is given. Manual reset during run. When the reset occurs, the alarm relay output K3 is deactivated, the alarm indication on the display disappear and the original menu shows. ' 2003 TECO-Westinghouse Motor Company...
  • Page 68: Alarm Overview

    Serial communication broken will not stop operation. Contact broken = 2. Cat 3. Run from keyboard if necessary. Run with auto reset. Phase reversal Cat 1. Stop with manual Incorrect phase order on main voltage input. alarm. reset. ' 2003 TECO-Westinghouse Motor Company...
  • Page 69: Troubleshooting

    If the fault is not found, reset the alarm and inspect the alarm list. If alarm F12 is found, a thyristor is probably Open motor contact, cable or shorted. (Motor terminal open) motor winding. Make a restart. If alarm F14 appears immediately, contact Saftronics Technical Support. ' 2003 TECO-Westinghouse Motor Company...
  • Page 70 - System address (menu 111). (Serial Communication broken. - Baudrate (menu 113). broken) - Parity (menu 113). If the fault is not found run the motor with keyboard control if urgent, see also manual f ' 2003 TECO-Westinghouse Motor Company...
  • Page 71 Some menus include only read 35, read-out menus has '---' in the factory setting out values and not parameters. column. Unlock keyboard by pressing thekeys 'NEXT' and -Loc Keyboard is locked. 'ENTER' for at least 3 sec. ' 2003 TECO-Westinghouse Motor Company...
  • Page 72: Maintenance

    Check that the cooling fan/s permit free air flow. Clean any external air filters if necessary. In the event of fault or if a fault cannot be cured by using the fault-tracing table in chapter 9. page 69. ' 2003 TECO-Westinghouse Motor Company...
  • Page 73: Options

    / d a ta sheet are available. (03-F62) Figure 48: Shows an example of the External PPU aft e r i t h a s b e e n b u i l t i n ' 2003 TECO-Westinghouse Motor Company...
  • Page 74: Set-Up Menu List

    25-300% of P in kW 1 - 4 in kW nsoft nsoft Nominal speed 500-3600 rpm 1 - 4 in rpm nsoft Nominal power factor 0.50-1.00 1 - 4 0.86 Nominal frequency 50, 60 Hz ----- ' 2003 TECO-Westinghouse Motor Company...
  • Page 75 1 - 4 Job forward enable oFF, on 1 - 4 Job reverse enable oFF, on 1 - 4 Automatic return menu oFF, 1-999 ---- Serial comm. unit address 1-247 ---- Serial comm. baudrate 2.4-38.4 kBaud ---- ' 2003 TECO-Westinghouse Motor Company...
  • Page 76 I n s o ft Nominal current soft s ta r t e r. (SA7 rated current) Pnsoft Nominal power soft s ta r t e r. (SA7 HP at selected voltage) Nnsoft Nominal speed soft s ta r t e r.
  • Page 77: Index

    C u r r e n t l i m i t ......41 I n i t i a l v o l tage at start ramp 2 ....40 ' 2003 TECO-Westinghouse Motor Company...
  • Page 78 ........58 ' 2003 TECO-Westinghouse Motor Company...
  • Page 79 ......51 PPU unit .......25 ' 2003 TECO-Westinghouse Motor Company...
  • Page 80 ......23 Under voltage ......58, 68 ' 2003 TECO-Westinghouse Motor Company...
  • Page 81 ......35 W iring example ......36 ' 2003 TECO-Westinghouse Motor Company...

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