Fairford Synergy SGY-101 User manual

1
synergy
™
Quick Start Guide
Type le A kW at 400V UL.FLA A HPat 440-
480V
SGY-101 17 7.5 17 10
SGY-103 22 11 21 15
SGY-105 29 15 27 20
SGY-107 35 18.5 34 25
SGY-109 41 22 40 30
SGY-111 55 30 52 40
SGY-113 66 37 65 50
SGY-115 80 45 77 60
SGY-117 100 55 96 75
Ie AC-53a:3.5-17:90-5

2
Redefining Motor Control
As the original pioneers of soft start technology Fairford Electronics Ltd have been
at the forefront of motor control innovation since the 1970’s. A major designer and
manufacturer of soft start motor control solutions Fairford have manufactured and
supplied over 1 million products into the market place and are recognised as the
reference point for many control solution providers worldwide.
In 2009 we started to recognise the need for a new technology that bridged the
gap between Drive technology and Soft start. This started the development process
for synergy™, a new form of motor control that met the needs of those requiring
functionality of a drive in a fixed speed application. Three years and 1000’s of man
hours later we have achieved our goal and met the needs of an ever increasing
market.
Focusing on the key aspects of a drive such as energy saving and communications
as well incorporating original features of a soft start including internal bypass and
cost, we took this base design and enhanced it even further. With size and cabinet
capacity becoming an ever increasing focus we developed the world’s smallest
power to size ratio motor controller. In addition, synergy™ utilises Fairford’s globally
renowned Automatic setup feature which allows the user to programme the unit
to each individual application using a simple 4 button process. Not only that but in
order to keep pace with the modern technology and a fast growing market it removes
buttons and uses touch screen technology to bring the user interface to even greater
management levels.
With built in SCR failure protection as standard, and full motor overload protection as
well as full data logging, field serviceable and upgradeable software and extensive
input/output programmability synergy™ meets all of the key design criteria.
More importantly it redefines motor control solutions as we have previously known it.

3
A
A
25mm (1”) 25mm (1”)
75mm (3”) 75mm (3”)
SECTION A-A
Environment - installation
Enclosure Ventilation
When fitting synergy into a cabinet, ventilation must be provided if the heat output of
the unit is greater than the cabinet will dissipate. Use the following formula to
determine the fan requirement. An allowance has been incorporated into the formula
so that the figure for Q is the air delivery in the fan suppliers data.
The maximum power dissipation occurs when energy saving.
Heat dissipated can be approximated with the formula:-
Watts (synergy) = ½x Synergy current rating x 3
Q = volume of air (cubic meters per hour-m3/h)
Wt = Heat produced by the unit and all other heat sources within the enclosure (Watts)
Tmax = Maximum permissible temperature within the enclosure
(50°c for a fully rated synergy)
Tamb = Temperature of the air entering the enclosure (°c)
If you prefer to work in CFM, substitute °F for °C. Q is now in CFM
Q = 4xWt
(tmax - tamb)
278mm (11”)
95mm (3¾”)
60mm
(2⁄”)
176mm (6 ⁄”)
260mm (10¼”)
25mm (1”)
278mm (11”)
95mm (3¾”)
60mm
(2⁄”)
176mm (6 ⁄”)
260mm (10¼”)
Dimensions Fitting
Weight = 3.5kg

4
Wiring connection
Description Default Program-
mable Required rating
group 1 relay
common
relay N/C fault yes 230Vac 1A AC15,
30VDC 0.5 Resistive
relay N/O fault yes 230Vac 1A AC15,
30VDC 0.5 Resistive
group 2 relay
common
relay N/O run yes 230Vac 1A AC15,
30VDC 0.5 Resistance
relay N/O TOR yes 230Vac 1A AC15,
30VDC 0.5 Resistance
analog output 0-10V yes 0 to 10V 10mA /
4-20mA
analog 0V 0V
analog input 0-10V Yes 24Vdc 50mA
0V input 0V
24V input 24Vdc + 10%-15%
Required rating Program
mable Default Description
Group 1 input
common
24VDC or 110VA or
230VAC +10% -15% yes start/stop opto-coupled
input
24VDC or 110VA or
230VAC +10% -15% yes opto-coupled
input
group 2 input
common
24VDC or 110VA or
230VAC +10% -15% yes opto-coupled
input
N/C
3 x PTC in series
(130°C) OFF thermistor
3 x PTC in series
(130°C) OFF thermistor
N/C
110Vac / 230Vac
+10% -15% control supply
110Vac / 230Vac
+10% -15% control suppy
*24VDC Specification 24VDC 60W Residual ripple 100mV Spikes/switching Peaks 240mV Turn On/Off response No overshoot of V out Overvoltage voltage protection output voltage must be clamped to V30VDC
D1C0M D1-1I D1-2I D2C0M D2-1I Not Used PTC+ PTC-
110-230
Vac
Not Used
11 12 24 33 34 44
A0
AC0M
0Vdc
24Vdc
AI
N
L

5
24VDC control supply and
digital input programming
Digital
input
programming
In Delta
24VDC D1 - 1I = Start
D1 - 2I = Stop
D2 - 1I = Reset
0VDC
3 Wire Control Diagram
110/230V AC control supply
and digital input programming
Please note: Power factor correction capacitors must not be positioned on the output of all power circuits
In Line
!
LD1-2ID1-1I D2-1I 33
N D2COM
D1COM 34
K1
!
24
VDC D1-2ID1-1I D2-1I 33
0VDC D2COMD1COM 34
K1
!
LD1-2ID1-1I D2-1I 33
N D2COMD1COM 34
K1
!
24
VDC D1-2I
D1-1I D2-1I 33
0VDC D2COM
D1COM 34
K1
110/230V AC
N
Wiring connection
Induction
Motor
U1
U2
V2 W2
V1 W1
Induction
Motor
Terml Fwd Rev
T1 U1 U1
T2 V1 V1
T3 W1 W1
L1 W2 W2
L2 U2 V2
L3 V2 U2
K1 - Main contactor or
circuit breaker isolation
and protection switch gear
(provided by the customer)
K1 - Main contactor and
protection switch gear
(provided by the customer)
For this configuration
applying the equation.
synergy™ ie =
ie (motor)/
Allows lower current
rating synergy than
the motor.
When In Delta
configuration is used a
line contactor controlled
by synergy MUST be
used with the In Delta
Firing Mode selected in
the advanced menu.
3

6
Programmes
1.
3.
5.
7.
6.
8.
2.
4.
Please note;
Only appears if
application with a
trip class higher
than 10 is selected

7
Rating table
Type ie IEC
kW
UL,
FLA
HP
230v 400v 200v 208v 220-
240
440-
480
SGY-101 17 17 4 7.5 17 3 5 5 10
SGY-103 22 22 5.5 11 21 5 5 5 15
SGY-105 29 29 7.5 15 27 7.5 7.5 10 20
SGY-107 35 35 7.5 18.5 34 10 10 10 25
SGY-109 41 41 11 22 40 10 10 10 30
SGY-111 55 55 15 30 52 15 15 15 40
SGY-113 66 66 18.5 37 65 20 20 20 50
SGY-115 80 80 22 45 77 25 25 30 60
SGY-117 100 100 30 55 96 30 30 30 75
• Rated operational powers in kW according to IEC 60072-1(primary series)
corresponding to IEC current rating optimised for 400V
• Rated operational powers in hp according to UL508 corresponding to FLA current
rating(optimised for 440-480v)
• The IEC, Ie rating will apply for EN 60947-4-2, AC-53a:3.5-17:90-5
• The UL minimum FLA ratings will apply for UL temperature rise testing, as limited
by UL components specs at 50°c ambient.
• The rated operation current Ie as specified in rating index, is determined by highest
current at 400V or 440-480V (IEC or UL)

8
Technical information

1
10
100
1000
1 1.5 2 2.5 3 3.5 4 4.5
Trip time ( seconds )
Multiple of Motor FLA
Motor overload 'cold' trip curves
(20°C ambient)
Class10 Class20 Class30
* Please note: When the overload has tripped there is a forced
cooling time to allow the overload to recover before the next start.

9
Technical information/Standards
Rated operational voltages Ue230Vac to 480Vac
Rated operational current IeSee model ratings table below
Rating index Ie: AC-53a:3.5-17: 90-5
Rated frequency/frequencies 45 to 65Hz
Rated duty Uninterrupted
Form designation Form 1 Internally bypassed
Rated insulation voltage Ui480V
Rated impulse withstand
voltage Uimp
Main circuit 4kV
Control supply circuit 2.5kV
IP code
Main circuit IP00 (IP 20 optional)
Supply and control circuit IP 20
Pollution degree 2
Rated conditional short-circuit current and type
of co-ordination with associated short circuit
protective device
Type 1 co-ordination. See model ratings table below
for rated conditional short-circuit current and required
current rating and characteristics of the associated
SCPD
Rated control circuit voltage
(programmable)
Uc24Vdc, 110Vac or 230Vac
Rated control supply voltage Us24Vdc, 110Vac or 230Vac
Relay specication AC-15 230Vac, 1A
DC-13 30Vdc, 0.7A
EMC Emission levels EN 55011 Class A
EMC Immunity levels IEC 61000-4-2 8kV/air discharge or 4kV/contact discharge
IEC 61000-4-3 10 V/m
IEC 61000-4-4 2kV/5kHz (main power and ports)
1kV/5kHz (signal ports)
IEC 61000-4-5 2kV line-to-ground
1kV line-to-line
IEC 61000-4-6 10V
IEC 61000-4-11 0%Ue for 0.5 cycle
0%Ue for 1 cycle
40%Ue for 10/12 cycles
70%Ue for 25/30 cycles
80%Ue for 250/300 cycles

10
Standards
Please note for higher temperatures and altitudes contact your supplier.
Correctly selected semi-conductor fuses can provide additional protection against
damage to the synergy™ unit (This is sometimes referred to as type 2
co-ordination). The following semi-conductor fuses have been calculated to
provide increased protection.
Type designation (eg. SGY-101-4-01) SGY
101
SGY
103
SGY
105
SGY
107
SGY
109
SGY
111
SGY
113
SGY
115
SGY
117
Rated operational
current
IeA17 22 29 35 41 55 66 80 100
Rated conditional
short circuit current
IqkA 5 5 5 5 5 5 5 10 10
Semiconductor
fuse (class aR)
for protection of
thyristors
Mersen 6.9
URD 30
A80A 80A 125A 125A 160A 200A 200A 250A 315A
Bussmann
170M31_
170M32_
A
80A 80A 125A 125A 160A 200A 200A 250A 315A
Class J time-delay Maximum
rating
A30 40 50 60 70 100 125 150 175
UL listed inverse-time
circuit breaker
Maximum
rating
A60 60 60 80 60 150 150 250 300
Wire sizes and
torques
Main
terminals
mm22.5 - 70 Nm 9
Cu STR only 75C
AWG 12-2/0 lb-in 80
Control
terminals
mm20.2-1.5 Nm 0.5
AWG 24-16 lb-in 4.5
Protective Earth
(PE)
M6
Nm 8
70
Lb-in
Terminal wiring
Models ratings table
-20°c (-4°f) to 50°c (122°f) above 50°c de-rate by 2% per degree to a
maximum of 60°c (140°f).
Maximum altitude above sea level 1000m (3281ft) above 1000m de rate
by 1% per 100m (328ft) to a maximum altitude of 2000m (6562ft).

11
Notes

Electric current! Danger to life!
Only skilled or instructed persons may carry out the following operations.
Lebensgefahr durch Strom!
Nur Elektrofachkräfte und elektrotechnisch unterwiesene Personen dürfen die im Folgenden
beschriebenen Arbeiten ausführen.
Tension électrique dangereuse!
Seules les personnes qualiées et averties doivent exécuter les travaux ci-après.
¡Corriente eléctrica! ¡Peligro de muerte!
El trabajo a continuación descrito debe ser realizado por personas cualicadas y advertidas.
Tensione elettrica: Pericolo di morte!
Solo persone abilitate e qualicate possono eseguire le operazioni di seguito riportate.
 触电危险！
只允许专业人员和受过专业训练的人员进行下列工作。
Электрический ток! Опасно для жизни!
Только специалисты или проинструктированные лица могут выполнять
следующие операции.
Levensgevaar door elektrische stroom!
Uitsluitelijk deskundigen in elektriciteit en elektrotechnisch geinstrueerde personen is het
toegestaan, de navolgend beschrevene werkzaamheden uit te voeren.
Livsfare på grund af elektrisk strøm!
Kun uddannede el-installatører og personer der e instruerede i elektrotekniske arbejdsopgaver,
må udføre de nedenfor anførte arbejder.
Προσοχή, κίνδυνος ηλεκτροπληξίας!
Οι εργασίες που αναφέρονται στη συνέχεια θα πρέπει να εκτελούνται μόνο από
ηλεκτρολόγους και ηλεκτροτεχνίτες.
Perigo de vida devido a corrente eléctrica!
Apenas electricistas e pessoas com formação electrotécnica podem executar os trabalhos que a
seguir se descrevem.
Livsfara genom elektrisk ström!
Endast utbildade elektriker och personer som undervisats i elektroteknik får utföra de arbeten
som beskrivs nedan.
Hengenvaarallinen jännite!
Vain pätevät sähköasentajat ja opastusta saaneet henkilöt saavat suorittaa
seuraavat työt.
Nebezpečí úrazu elektrickým proudem!
Níže uvedené práce smějí provádět pouze osoby s elektrotechnickým vzděláním.
Eluohtlik! Elektrilöögioht!
Järgnevalt kirjeldatud töid tohib teostada ainult elektriala spetsialist vői
elektrotehnilise instrueerimise läbinud personal.
Életveszély az elektromos áram révén!
Csak elektromos szakemberek és elektrotechnikában képzett személyek végezhetik
el a következőkben leírt munkákat.
Elektriskā strāva apdraud dzīvību!
Tālāk aprakstītos darbus drīkst veikt tikai elektrospeciālisti un darbam ar
elektrotehniskām iekārtām instruētās personas!
Pavojus gyvybei dėl elektros srovės!
Tik elektrikai ir elektrotechnikos specialistai gali atlikti žemiau aprašytus darbus.
Porażenie prądem elektrycznym stanowi zagrożenie dla życia!
Opisane poniżej prace mogą przeprowadzać tylko wykwalikowani elektrycy oraz
osoby odpowiednio poinstruowane w zakresie elektrotechniki.
Življenjska nevarnost zaradi električnega toka!
Spodaj opisana dela smejo izvajati samo elektrostrokovnjaki in elektrotehnično
poučene osebe.
Nebezpečenstvo ohrozenia života elektrickým prúdom!
Práce, ktoré sú nižšie opísané, smú vykonávat’ iba elektroodborníci a osoby s
elektrotechnickým vzdelaním.
Опасност за живота от електрически ток!
Операциите, описани в следващите раздели, могат да се извършват само от
специалисти-електротехници и инструктиран електротехнически персонал.
Atenţie! Pericol electric!
Toate lucrările descrise trebuie efectuate numai de personal de specialitate calicat şi
de persoane cu cunoştiinţe profunde în electrotehnică.
synergy
™
Quick Start Guide
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[email protected]
www.fairford.com
Ref: syn1_QSG_06.13(V1)