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Related Manuals for Zener SMARTSTART 6000 Series
Summary of Contents for Zener SMARTSTART 6000 Series
- Page 1 User’s Manual: ® SMARTSTART 6000 Series Models: 6R15 – 6R830 6V400 – 6V630...
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Page 3: Table Of Contents
Contents …….. Introduction Receiving ……… Handling & Storage ……… Handling on Installation ……… Software ……… ® The Smarstart 6000 Soft Starter Operation ……… ‘SMART-TORQ’ Torque Control ……… Warning) (General Installation Read & familiarise yourself with the warnings Mechanical Installation ……… detailed on Page 1 of the manual before Heat Dissipation &... - Page 4 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.
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Page 5: Introduction
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. -
Page 6: The Smarstart ® 6000
6000 Zener ‘SMART-TORQ ’ Torque Control Feature Basic Soft Starter Operation ® The Zener Smartstart 6000 incorporates a closed loop ® The Zener Smartstart is a reduced voltage controller torque control system to provide better control over designed for starting standard 3 Phase induction motors. -
Page 7: Installation
Installation - Mechanical Mechanical Installation Heat Dissipation ® ® The Smartstart should be installed by qualified The Smartstart is cooled by temperature controlled electrical personnel only. The following should be internal fans. Installing a bypass contactor will reduce considered when installing the Smartstart. the heat dissipated and the ventilation required. -
Page 8: Mechanical Dimensions
Installation - Mechanical Dimensions (All Dimensions in mm) Model: Chassis Depth 6R015B2 6R030B2 6R060B2 6R080B2 Mounting Holes: Model: Chassis Depth 6R10000 6R19000 6R22000 Mounting Holes: Model: Chassis Depth 6R36000 6R58000 6R83000 Mounting Holes: ® Technical Manual: Smartstart 6000 IMI0042 rev D Page 5... -
Page 9: Power Wiring - General
Installation - Power Wiring Power Wiring Motor Protection: The Zener SS6000 is installed between the mains The Smartstart 6000 provides advanced motor and cable to the motor. If a mains or isolation protection with user selectable overload classes, contactor is used it is best controlled by the SS6000 over &... -
Page 10: Power Wiring - 15A-80A
Installation - Power Terminals (up to 80Amp) 3 Wire with integral Bypass Only Models; 6R015B2 6R030B2 6R060B2 6R080B2 Power Terminations Model: Max cable size Tightening Torque 6R015B2 6 / 10mm 1.5 – 1.8 Nm 6R030B2 6 / 10mm 1.5 – 1.8 Nm 6R060B2 35mm 3.2 –... -
Page 11: Power Terminals - 100A And Above
Installation - Power Terminals (100A model and above) Chassis A2: Power Terminations Model: Chassis Busbar Hole Bolt Size Earth Stud 6R10000 1x 8.5mm 6R19000 1x 8.5mm 6R22000 1x 8.5mm 6R36000 2x 10.4mm 6R58000 2x 10.4mm 6R83000 2x 10.4mm 6V40000 2x 10.4mm 6V63000 2x 10.4mm (All soft starters include a bolt kit) -
Page 12: Power Terminals - 100A And Above
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 ®... -
Page 13: Power Terminals - 6 Wire & Ct Relocation
Installation - Power Wiring (100A model and above) Using 6 wire Configuration The following illustrates the difference between 3 wire & 6 The Smartstart 6000 can be configured to operate in 6 wire connection: wire mode. 6 wire mode may be the preferred method due to: 1. - Page 14 Installation - Power Wiring (100A model and above) SS6000 : 6 wire Bypass SS6000 : 6 wire Continuous Refer to page 13 Refer to page 13 For Control Wiring For Control Wiring Refer to page 12 Refer to page 12 For details on correctly For details on correctly installing external C.T’s...
- Page 15 Installation - Power Wiring (100A model and above) Relocating the Internal Current If the C.T’s are not installed correctly the SS6000 will display a fault or a ‘C.T Phase error’. Transformers for 6 wire operation. The SS6000 comes standard with internal Current Transformers (C.T’s) for monitoring the current during acceleration, deceleration and when in bypass.
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Page 16: Control Wiring
Control Wiring Control Wiring Overview Typical Configuration of Control Terminals ® Technical Manual: Smartstart 6000 IMI0042 rev D Page 13... -
Page 17: Programming
Programming Local Control Panel / Remote Console ‘Decel’ ® The Smartstart is decelerating the motor. Ramp time The local control panel consists of 5 push buttons and completed (%) & Motor Current (A) is displayed. a plain English display to simplify programming. Increase the value or change selection. -
Page 18: Menu Map
Programming Menu Map Overview Set Up Menu The ‘Dash Board’ ENTER D01 Menu Access ENTER Setup Menu D02 Default Screen SMARTSTART 6000 D03 Bargraph Variable 1 Display 6R030 r1.XX D04 Bargraph FS ENTER M01 Motor Amps Setup Menu M02 Motor Volts M03 Motor PF 2 Motor Ready... -
Page 19: Setup Menu - Display
Programming Menu Navigation Setup Menu Note: to change any parameters the SS6000 must be 1 Display disabled. Remove the link in the Enable input (term. 14) or the external enable circuit. D01 Menu Access: The Main Menu Sets the desired user access to menu Selection: Disabled;... -
Page 20: Setup Menu - Motor
Programming Setup Menu C02 Current Limit: The current limit is expressed as a percentage of 2 Motor the entered motor Amps (FLC). This current limit setting operates during the ramp time only and M01 Motor Amps: will over-ride the torque settings. Reducing the Adjust to the value of motor full load current current limit will limit the torque available to the (FLC) indicated on the motor rating plate, even if... -
Page 21: Setup Menu - Protection
Programming C13 Final Torque: (torque control only) Setup Menu This sets the torque provided at the end of the acceleration period. This is entered as a 4 Protection percentage of nominal Torque (FLT). Range: 15 to 200% P01 Mtr Overload: Default: 130% The Smartstart 6000 continuously monitors the... - Page 22 Programming P22 Volt Imbal Level: P10 Acc Overtime : Adjust to set the voltage imbalance threshold, as P10 Accel OverTime a percentage of the average phase voltage. Trip 120s Range: 5 – 25% Default: To save changes Trip/off To exit without saving OverTime Delay P23 Volt Imbal Delay: Adjust to set a delay for the voltage imbalance...
- Page 23 Programming P40 Undercurrent: P51 Overcurrent Alarm: Provide protection against over current. This P40 Undercurrent protection is not active during the accel & decel Trip period. Status Range: off; trip Level Default: Delay To save changes To exit without saving To enter submenu to modify To exit sub menu P52 Overcurrent Level: P41 Undercurrent Alarm:...
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Page 24: Setup Menu - Inputs
Programming P62 Under Torque Level: P73 Over Torque Delay: Adjust to the desired trip threshold, as a Adjust to set the time period that the torque percentage of nominal torque. must exceed the threshold before a trip occurs. Range: 10 – 100% Range: 0 - 30 seconds Default:... -
Page 25: Setup Menu - Outputs
Programming Q31 Relay 3 Variable I22 DigIn 2 Delay Set the functionality of Relay 3. Set the delay that the digital input needs to be Range: See table on page 26 active for the Soft starter to respond. Default: Motor On To save changes Range: 0.0 –... -
Page 26: Setup Menu - Resets
Programming Set to the time of the kick Setup Menu Range: 0.0 – 2.0 seconds 7 Resets Default: 0.0 (Disabled) To save changes To exit without saving R01 Manual Reset Activate or de-activate the manual reset ie. The A12 Kick Level reset on the local console. - Page 27 Programming A30 Decel Method A42 Str OT Reset Enter the level for the Starter over temperature A30 Decel Method protection to allow a reset. Linear Torque Range: 40 – 90° C Default: 60° C To save changes Decel Profile To exit without saving Decel Control The deceleration method allows adjustment of the A51 Motor Stator...
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Page 28: Setup Menu - Commands
Programming Setup Menu Setup Menu 10 Starter Diag 9 Commands This menu provides indication of inputs and wiring To clear/reset any of the following a confirmation checks. code is required: Each Relay can also be forced on and the Analogue Reset Trip output set for 100%. -
Page 29: Input/Output Functionality
Programming Table 1: Output Relay Functionality Table 2: Analogue Output Functionality Relay Function Analogue Output Selection: Description Selection: Description Line Ctrl Control for Line Contactor Estimated torque produced in Bypass Ctrl Control for Bypass Contactor Mtr Torque motor Starter in acceleration ramp Accel Ramp Estimated Motor temperature of mode... -
Page 30: Fault Diagnosis
Fault Diagnosis Message: Problem: 36 MTR UNDERTORQ Under torque trip as per user setting. See page 20 01 PSU LOW VOLT Control Supply Voltage low 40 REMOTE TRIP Trip initiated from external source. Remote input on Digital input 1 or 2. See page 21 02 LINE FREQ Line supply frequency out of range 41 ACC OVERTIME... -
Page 31: Specifications
Specifications Input Voltage: 6R series: 220 to 460Vac 6R15-80: 380Vac to 415Vac Thermistor: Thermistor or NC switch PTC type, Trip Resistance 3000Ohms, Input Frequency: 50 / 60Hz +/- 3Hz, <20ohms detected as Short Circuit. Auto detecting Outputs: Control Supply: 24Vdc (+15%, -15%) Digital Output: 4 Programmable Relays Contact Rating:... -
Page 32: Thermal Protection
Thermal Protection Starter Thermal Protection: Motor thermal Protection Thermal protection of the soft starter is provided by a Cold Curves temperature sensor located on the heatsink and by calculating the temperature of the thyristor junction with sophisticated modeling of the specific devices SS6000 Motor Thermal Over load Cur ves - Cold used. -
Page 33: Unit Ratings
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) Standard Light Duty: Severe Duty: Model Chassis Dimensions (mm) -
Page 34: Shipping/Packaging Details
Unit ratings 220 -460V 6 Wire Continuous (Inside Delta Connection) Severe Light Duty: Standard Duty: Model Chassis Dimensions (mm) Duty: 6R10000 430h 248w 232d 6R19000 430h 248w 232d 6R22000 430h 248w 232d 6R36000 670h 375w 285d 6R58000 670h 375w 285d 1378 1225 1110... -
Page 35: Options
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... - Page 36 SS6000 Options Option Boards SS6000 Model Description Part Number: Option Card : Data Logger & SD port TQ60005 Option Card : Data Logger & SD port - fitted TF60005 Communications: Ethernet Modbus TCP Port & Data Logger TQ60032 Communications: Ethernet Modbus TCP Port + Data Logger - fitted TF60032 (All models come standard with Modbus RS485) Other Options...
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Page 37: Smart-Torq
100% ® ‘SMART-TORQ ’ is a Torque Control System developed by Zener to overcome Speed 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. - Page 38 Appendix A Indicative parameters for different load types 5. Conveyor: (3 wire/Bypass) 1. Pump (3 wire/Bypass with No Soft Stop) Factory defaults are preset for a variable torque Factory defaults are intended for general load. The Torque settings will need to be adjusted pumping/fan application with no Soft Stop.
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Page 39: Appendix B - Application Diagrams
Appendix B Application Diagrams General Purpose ® Technical Manual: Smartstart 6000 IMI0042 rev D Page 36... - Page 40 Appendix B Application Diagrams Typical Water & Sewerage Pumping ® Technical Manual: Smartstart 6000 IMI0042 rev D Page 37...
- Page 41 Appendix B Application Diagrams Irrigation Pump ® Technical Manual: Smartstart 6000 IMI0042 rev D Page 38...
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Page 42: Set Up Record Sheet
DESIGNATOR: _______________ Menu Map / Set up Record Sheet Software Revision: ___________ Main menu Sub menu Level 1 Sub menu Level 2 Default Setting 1 Display D02 Default Screen Overview D03 Bargraph Var. Mtr Current D04 Bargraph FS 300% 2 Motor M01 Motor Amps Unit Rating M02 Motor Volts... - Page 43 DESIGNATOR: _______________ Menu Map / Set up Record Sheet Software Revision: ___________ Main menu Sub menu Level 1 Sub menu Level 2 Default Setting 5 Inputs I10 DigIn 1 Mode Enable I11 DigIn 1 Variable Remote Reset I12 DigIn 1 Delay 3.0s I20 DigIn 2 Mode Disable...
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