Zener SMARTSTART 6000 User manual

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ZENERVARIDRIVESOLUTIONS
ZENERSMARTSTART®6000
SoftStarterInstructionManual
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InstructionManual:Smartstart®6000IMI0042revK
Contents
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Introduction  2
Receiving………2
Handling&Storage………2
HandlingonInstallation………2
Software………2
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TheSmartstart®60003
SoftStarterOperation………3
‘SMART‐TORQ’TorqueControl………3
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Installation4
MechanicalInstallation………4
HeatDissipation&ventilation………4
MechanicalDimensions………5
PowerWiring‐General………6
SemiconductorFuses………6
PowerWiring–15A‐80A………7
PowerTerminals–100Aandabove………8
PowerTerminals–6wire&CTrelocation………10
ControlWiring………13
Communications………15
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Programming16
LocalControlPanel/Display………16
TripLog/Resetting………18
MenuMap………19
1Setupmenu–Display(D01‐D20)………20
2Setupmenu–Motor(M01–M04)………21
3Setupmenu–Control(C01‐C22)………21
4Setupmenu–Protection(P01‐P73)………23
5Setupmenu–Reset(R01‐R13)………26
6Setupmenu–Input(X10‐X22)………27
7Setupmenu–Output(Y10‐Y52)………27
8Setupmenu–Advanced(A10‐A61)………29
9Setupmenu–Network(N01‐N20)………31
10Setupmenu–Commands ………32
11Setupmenu–StarterDiagram………32
12Setupmenu–NetworkDiagram………33
Relayfunctions,I/Ofunctions,
Alarm&TripMessages……...34‐36
BrakefailProtection………37
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Specifications………38
ThermalProtection………39
Unitratings………40
Shipping/PackagingDetails………41
Options………42
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Appendix–
A–Smart‐Torque/Typicalstartparameters………44
B‐ApplicationDiagrams………46
C–RemoteConsoleInstructions……..49
D–DataLoggerOptionBoard…….50
E–6WireusinginternalCT’s…….52
SetupRecordSheet………53
Read&familiariseyourselfwiththewarnings
detailedonPage1ofthemanualbefore
proceeding.
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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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Thissymbolidentifiestheessentialparametersfo
r
quicksetup.
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(High Voltage Warnin
g
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(General Warning)

IMPORTANT – Read this first !!
InstructionManual:Smartstart®6000IMI0042revK
Page1
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Readalloperatinginstructionsbeforeinstalling,wiring,operating,servicingorinspectingtheSmartstart®6000.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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YourSmartstart®6000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.
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TherearehazardousvoltagesinsidetheSmartstart®6000wheneveritisconnectedtoanelectricalsupply.
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TheSmartstart®6000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®6000oranyassociated
motorandwiringwhenitisenergised,eveniftheSmartstart®6000andmotorarestopped.Electricshockmayresult.
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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.
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TheSmartstart®6000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.
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WheretheSmartstart®6000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stand‐
aloneinverters.
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TheSmartstart®6000isintendedforuseonlyinfixedwiringapplications.Itisnotintendedforuseonaflexiblesupply
cable.
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MounttheSmartstart®6000onavertical,incombustiblesurfacesuchasmetalormasonry.Donotplacecombustibleor
flammablematerialneartheSmartstart®6000.Failuretoobservetheseprecautionsmaycreateafirehazard
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TheSmartstart®6000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.
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EnsuretheSmartstart®6000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.
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InstallemergencystopcircuitrythatremovespowerfromtheSmartstart®6000anddoesnotdependonanyfeatureofthe
productforproperandsafeoperation.
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TheSmartstart®6000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.
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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.
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TheSmartstart®6000offersanEssentialServicesOver‐ride(ESO)modeofoperation.Thismodeofoperationintentionally
ignoressomemotorandstarterprotection.Asaresulttheequipmentmayoperateoutsideitsthermalratingandvoid
anywarranty.

Introduction
InstructionManual:Smartstart®6000IMI0042revK
Page2
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Receiving:
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InspecttheSmartstart®6000foranyshippingdamage.Ifany
damageisfound,reportittothecarrierimmediately.
Removecoverofstarterandvisuallycheckfordamage.
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DonotattempttooperatetheSmartstart®6000ifany
obviousdamageexistsorsuspectdamagehasoccurred.
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Aftertheinitialinspection,theSmartstart®6000canbe
repackedandstoredinaclean,drylocationuntilitis
requiredforuse.
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Handling&Storage:
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Toensurethestarterisprotectedbeforeinstallation,
handleandstoretheequipmentinitspackaging.
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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.
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HandlingonInstallation:
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TheSmartstart®6000rangecomprises5sizeswithvarious
weightsanddimensions.
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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:
DONOThandlethestarterbythepower
terminals/busbar.
Usehandlingpointswhereprovidedto
liftlargerunits.
Software:
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ThismanualappliestotheSmartstart®6000series
softwarerevisionV1.31.TheSoftwarerevisioncanbe
viewedonthe‘DashBoard’(Display)oftheStarter.
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TheSmartstart6000
InstructionManual:Smartstart®6000IMI0042revK
Page3
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BasicSoftStarterOperation
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TheZenerSmartstart®6000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.
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AnSCR/thyristor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.
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ThefiringangleoftheSCR’sarecontrolledtoachievethe
desiredaccelerationofthemotor.
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SoftStartersprovidethefollowingbenefits:
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1. Reducedstressesandwearonthe
mechanicsofthesystem
2. Reducedstartingcurrents
3. Minimizevoltagedipsonthesupply
4. LoweredPeakdemandcharges
5. Eliminatebeltslippageonfans
6. Smoothaccelerationofmotor/load
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SMART‐TORQ®TorqueControl
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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.
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TheSmartstart®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.
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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
aspumpsandfans)byachievingalinearrampprofileand
greatercontroloverdeceleration.Withpump
applicationsthisprovidesbettercontroltominimize
waterhammerproblems.
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SMART‐TORQBenefitsinclude:
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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.
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TheSmartstart®6000offersuseraccesstorampprofiling
parameterstofinetunetheTorqueControlSystemto
achievemoreapplicationspecificperformance
requirements.SeePage44formoreinformation.

Installation‐Mechanical

TechnicalManual:Smartstart®6000IMI0042revK
Page4
MechanicalInstallation

TheSmartstart®6000shouldbeinstalledbyqualified
electricalpersonnelonly.Thefollowingshouldbe
consideredwheninstalling.

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®6000
enclosure.
Donotallowmetalshavingsoranyother
conductivematerialtoentertheenclosureor
damagemayresult.

Clearancesforairflow:






















Models:6R15/30/60/80Only:
BelowillustratestheclearancestoallowaccesstoPortsif
fitted;
i) RemoteConsole(RJConnection)
ii) SDCardSlot
iii) EthernetPort













HeatDissipation

TheSmartstart®6000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.

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;

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

WheninstallingtheSmartstart®6000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:

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(m2)
P=PowerdissipatedinWatts
T=Temperaturedifferential(°C)
(inside–outside)
k=Heattransmissionconstant
(5forPaintedmetal)

> 75mm
> 75mm
> 20mm
> 75mm
> 75mm

Installation‐Mechanical

TechnicalManual:Smartstart
®
6000IMI0042revK
Page5
Dimensions
(AllDimensionsinmm)









MountingHoles:





















MountingHoles:



















MountingHoles:

























































Model:ChassisABC D Depth
6R005B2B2335162315 111 174
6R015B2B2335162315 111 174
6R030B2B2335162315 111 174
6R060B2B3440162420 111 174
6R080B2B3440162420 111 174
Model:ChassisA BC D Depth
 
6R10000A2430248400 216 244
6R19000A2430248400 216 244
6R22000A2430248400 216 244

6V09000A2+430248+55400 216 244
Model:ChassisABC D Depth
 
6R36000A3670375640 159 285
6R58000A3670375640 159 285
6R83000A3670375640 159 285
 
6V20000A3+670375640 159 305
6V40000A3+670375640 159 305
 

Installation‐PowerWiring

TechnicalManual:Smartstart
®
6000IMI0042revK
Page6

PowerWiring

TheZenerSmartstart®6000isinstalledbetweenthe
mainsandcabletothemotor.Ifamainsorisolation
contactorisuseditisbestcontrolledbythestarters
‘Linerelay’.





























3Wireor6wire:Thestandardconnectionofan
electronicsoftstartertoamotor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®6000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








MotorProtection:

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23‐26and39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.

Forlargermodelssemiconductorfusekitsare
availablewhichmounttothe‘Line’Busbar.

Refertopage43formoredetailsonsemi‐
conductorfuses.











Installation‐PowerTerminals
(upto80Amp)

TechnicalManual:Smartstart
®
6000IMI0042revK
Page7

3WirewithintegralBypass

OnlyModels;6R015B2&6R005B2
6R030B2
6R060B2
6R080B2


PowerTerminations

Model:MaxcablesizeTightening
Torque
6R005B26mm21.5–1.8Nm
6R015B26mm21.5–1.8Nm
6R030B26mm21.5–1.8Nm
6R060B235mm23.2–3.7Nm
6R080B235mm23.2–3.7Nm
EarthM6stud‐
















SemiconductorFusekit(Optional) 

RefertoPage43forselection.



SemiconductorFuseReplacement

RefertoPage43forreplacementfuses.































































Refer to page 13-14
For Control Wiring
(1) OptionalFastActingSemiconductorFusesselectedtosuitthe
SCRdevicesused.
(2) LineContactorcontrolledbytheSoftStarter.
(seeControlwiringonPage13&14andapplicationdrawings
onPage46‐48)
(3) Models6R5to6R80includeanintegralBypassContactor.With
thesemodelsanexternalbypasscontactorisnotrequired.

Installation‐PowerTerminals
(100Amodelandabove)

TechnicalManual:Smartstart
®
6000IMI0042revK
Page8


PowerTerminations
















(Allsoftstartersincludeaboltkit)









































ChassisA2:




























ChassisA3:






























SemiconductorFusekit(Optional)
FusekitincludesFusesandadditionalbusbar

Model:DescriptionPartNo.
 
6R10000FuseKittosuit6R100TQ60025
6R19000FuseKittosuit6R190TQ60026
6R22000FuseKittosuit6R220TQ60027
6R36000FuseKittosuit6R360TQ60028
6R58000FuseKittosuit6R580TQ60029
6R83000FuseKittosuit6R830TQ60030
SemiconductorFuseReplacement
Model:DescriptionPartNo. Qtyper
Starter
 
6R10000SemiconductorFuse(200A)TF22200 3
6R19000SemiconductorFuse(400A)TF22400 3
6R22000SemiconductorFuse(400A)TF22400 3
6R36000SemiconductorFuse(630A)TF23630 3
6R58000SemiconductorFuse(500A)TF23500 6
6R83000SemiconductorFuse(700A)TF23700 6
Model:ChassisBusbarHoleBoltSize EarthStud
 
6R10000A21x8.5mmM8 M8
6R19000A21x10.4mmM10 M8
6R22000A21x10.4mmM10 M8
6V09000A2+1x8.5mmM8 M8
6R36000A32x10.4mmM10 M8
6R58000A32x10.4mmM10 M8
6R83000A32x10.4mmM10 M8
6V20000A32x10.4mmM10 M8
6V40000A32x10.4mmM10 M8
6V60000A42x10.4mmM10 M8

Installation‐PowerWiring
(100Amodelandabove)

TechnicalManual:Smartstart
®
6000IMI0042revK
Page9
3WireBypass















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
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











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
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
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









3WireContinuous
(WithoutBypassContactor)

NOTE:TheSS6000musthavetheappropriateratingto
operatewithoutabypasscontactor.



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
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
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

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
Refertopage13&14
ForControlWiring
Refertopage13&14
ForControlWiring
(1) OptionalFastActingSemiconductorFusesselectedtosuitthe
SCRdevicesused.
(2) LineContactorcontrolledbytheSoftStarter.
(seeControlwiringonPage13&14andapplication
drawingsonPage46‐48)
(3) BypassContactorcontrolledbytheSoftStarter.
(seeControlwiringonPage13&14andapplication
drawin
g
sonPa
g
e46‐48
)

(1) OptionalFastActingSemiconductorFusesselectedto
suittheSCRdevicesused.
(2) LineContactorcontrolledbytheSoftStarter.
(seeControlwiringonPage13&14andapplication
drawingsonPage46‐48)


Installation‐PowerWiring
(100Amodelandabove)

TechnicalManual:Smartstart
®
6000IMI0042revK
Page10
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:

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.


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
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

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



Thefollowingillustratesthedifferencebetween3wire&6
wireconnection:
















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

InsomecasestheCT’scanbeinternal
.
RefertoAppendixEonpage52for
details

Installation‐PowerWiring
(100Amodelandabove)

TechnicalManual:Smartstart
®
6000IMI0042revK
Page11
Standard6wireBypass





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Standard6wireContinuous

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Refertopage13&14
ForControlWiring
Refertopage13&14
ForControlWiring
Refertopage12
Fordetailsoncorrectlyinstallin
g
externalC.T’s
Refertopage12
Fordetailsoncorrectlyinstallin
g
externalC.T’s
(1) OptionalFastActingSemiconductorFusesselectedtosuittheSCR
devicesused.
(2) LineContactorcontrolledbytheSoftStarter.
(seeControlwiringonPage13&14andapplicationdrawingson
Page46‐48)
(3) BypassContactorcontrolledbytheSoftStarter.
(seeControlwiringonPage13&14andapplicationdrawingson
Pa
g
e46‐48
)

(1) OptionalFastActingSemiconductorFusesselectedto
suittheSCRdevicesused.
(2) LineContactorcontrolledbytheSoftStarter.
(seeControlwiringonPage13&14andapplication
drawingsonPage46‐48)


Installation‐PowerWiring
(100Amodelandabove)

TechnicalManual:Smartstart
®
6000IMI0042revK
Page12
RelocatingtheInternalCurrent
Transformersfor6wireoperation.

TheSmartstart®6000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Smartstart®6000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torquecontrolsystem.
In6wireoperation,itisnecessarytorelocatetheC.T’s
externaltothestarter.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Smartstart®6000mustbepurchasedwithC.T’s
externalbyordering‘preparedfor6wire’;

Partno.Description:
TF60015Preparefor6wire:6R100‐220
TF60016Preparefor6wire:6R360‐830

NOTE:6WireusingInternalCT’s 
InsomecasestheCT’smayremaininternal.Thisissubject
totheMotorFLCandtheSoftStarterRating.Referto
AppendixEPage52formoredetails.


InstallationofexternalC.T’s
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

TheC.T’ssuppliedwiththeSmartstart®6000hasa
labelwhichshowsthecorrectphaseanddirection.

IftheC.T’sarenotinstalledcorrectlythestarterwill
displayafaultora‘C.TPhaseerror’.









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

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
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
Programming:

Programthestarterfor3wireor6wireoperation.The
selectionavailablefor6wireis‘Standard6wire’or
‘alternate6wire’,dependingonthewiring
configurationused.Thewiringinthismanualisdrawn
forStandard6wire.Refertopage21:parameter‘M04
MotorWiring’.

Energisethe3Phasesupplytothestarterwithout
attemptingastart.Lookfora“W05MOTORWIRING”
warningandcheckthe“MTRWIRINGCHK”is
‘CORRECT’inthediagnosticmenu.

Checkforcorrectinstallation

TheCorrectCTconnectioncanbecheckedafterthe
firstmotorstart.ACTphaseerrormaybeidentified
underthemenu‘StarterDiagnosis’.‘+L1/+L3’should
bedisplayed.

>IfL2isdisplayedmovetheCTfromL2phase.

>Ifa“‐“signisdisplayed,thedirectionofthe
correspondingCTneedstobereversed.

IncorrectCTinstallationwillresultina“W07CT
PHASING”warningandaffecttheoptimumstartingof
themotor.


ControlWiring

TechnicalManual:Smartstart
®
6000IMI0042revK
Page13
+
-
TypicalConfigurationofControlTerminals.









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




ReferTopage45‐47forguidance
towiringfordifferent
applications
Refer to page 14 for alternative
start/stop control wiring.

ControlWiring

TechnicalManual:Smartstart®6000IMI0042revK
Page14
Default/StandardControl:

1. StandardPower‐upStart(noSoftStop)











2. StandardRun/Stopusingenableinput
(SoftStart/SoftStoporCoast)
C20DecelRamp :0.0forcoast
:Adjustforsoftstop(>0)

Ifenableislefton,power‐upstartwillbesupported











3. StandardRun/stopusingbuilt‐in24hourcycletimer
Start/stopbyinternaltimer.Seepage28fordetails










Alternativeconfigurationavailable:

1. 3wireStart/Stop
A53StartLogic :‘edgesensed’
X10DigIn1:Enabled
X11DigIn1Variable:Start(latching)
X11DigIn1Delay:0.0sec

UseenableorDIGin2forstop:
X20DigIn2:Invert
X21DigIn2Variable:Stop
X22DigIn2Delay:0.0sec
C20DecelRamp :0.0forcoast
:Adjustforsoftstop(>0)












2. DelayedSoftStartand/orSoftStop
MultiplepumpcontrolsystemsorprestartwarningA
X10DigIn1:Enabled
X11DigIn1Variable:Start(latching)
X11DigIn1Delay:Adjusttosuit(0‐300seconds)
X20DigIn2:Invert
X21DigIn2Variable:Stop
X22DigIn2Delay:Adjusttosuit(0‐300seconds)
(AdjustAccelandDeceltosuitapplication)












ControlSupply
24VDC12/13
ENABLE14
DIGIn115
DIGIn216
RUN/STOP
ControlSupply
24VDC12/13
ENABLE14
DIGIn115
DIGIn216ControlSupply
24VDC12/13
ENABLE14
DIGIn115
DIGIn216START
STOP
ControlSupply
24VDC12/13
ENABLE14
DIGIn115
DIGIn216
START
STOP
ControlSupply
24VDC12/13
ENABLE14
Relay3or4
‘TIMERRELAY’

NetworkConnections

TechnicalManual:Smartstart®6000IMI0042revK
Page15
ModbusRS485

TheSmartstart®6000comesstandardwithModbusRS485
serialcommunications.TypicalwiringforRS485shown
below.

















Thefollowingprecautionswillhelpminimizetheriskof
networkfailure:

Usetwistedpairshieldedcommunicationscable
Eachlengthofcableshouldhaveitsshieldconnected
togroundatoneendonly(recommendedatthe
computerorcontrollerend)
Itisrecommendedtousetwotwistedpairs,onepair
forcircuit‘common’,andanotherpairforbalanced
datalines.











The‘common’circuitmustbeconnectedtoall
devicesonthebusandconnecteddirectlyto
protectiveground(atonepointonly,typicallynear
themasterdevice).‘Screen’terminalprovidesalocal
protectiveground.(Eg.Forcableshield)

Toreducenetworknoiseplacealineterminatornear
eachofthetwoendsofthebus.A120Ohmresistor
isrecommendedforbothlineterminators.A
capacitor(1nf)inserieswiththeresistormayalso
improveperformance.












Linepolarization(450–650Ohmspull‐upandpull
down)isalsorecommended,typicallyin/nearthe
masterdevice.
Avoidlayingcommunicationscablesadjacentto
powercables.
Ifpossiblecommunicationscablesshouldcrosspower
cablesatrightangletoeachother.
Upto64nodes(equipment)maybeconnectedtothe
samenetworkwithoutanRS485repeater.



ModbusEthernetTCP

AnEthernetoptioncardisavailablewhichprovidesan
Ethernetsocket.WhentheEthernetcardisfittedthe
RS485connectionwillnotoperate.

























AcomprehensiveNetworkGuideisavailableonour
website:www.zener.com.auorcontactusformore
details.

PLC/
Computeror
RS232/485
converter
A

B

Com
A

B

Com
A

B

Com
A

B

Com
ZENERSS6000
ZENERSS6000
ZENERSS6000
120Ohm
A
B


Com
Com
A
B


Com
Com
PLC/
Computer
ZENERSS6000ZENERSS6000
ETHERNETHUB

Programming
TechnicalManual:Smartstart®6000IMI0042revK
Page16
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.

Decreasethevalueorchangeselection.
Navigatedownthroughmenu/submenus.

Allowsaccesstomenu,submenus&
savestheparameterentered.

Escapesfromcurrentmenuposition
withoutsaving.

Manualresetofatrip(ifenabled).This
alsotakesyoudirecttothetriplog.
TheDASHBOARD

TheSmartstart®6000providesacomprehensive
displayofoperatingvariables,statusandalarms.The
screenscanbescrolledthroughusingtheUP/DOWN
pushbuttons.TheseDASHBOARDscreensarealso
accessibleevenwhenthemenulockoutisenabled.
Anyofthesescreensmayalsobeconfiguredasthe
defaultscreenonpower‐up.
DefaultScreen:














TheDashBoard



Off ## % #V
#%
StatusdisplayedinPlain
EnglishSeepage17for
moredetails
SupplyVoltageor
MotorCurrent
BarGraphValue
Default‘Motorcurrent%’.
SeeD03Page20
BarGraphtoprovidevisual
indication.SeeD04Page20

InterlockorWarning
messagesdisplayed
ENTER
11 : 44 : 43 Net*
19 AUG 2013 Idle
% Thermal 100 STR
Capacity 100 MTR
415v 50Hz 100A
1-2-3 56kW
56 kW % Pwr
0.9 PF % Trq
Volt Imbal 0%
415 415 415V
Curr Imbal 0%
100 100 100A
0 Starts
0 Trip
0.8 Hrs
400 kWh
TRIP LOG [ENTER]
T00 NO TRIP ALM
Esc Main Menu
Off 100A
80%
Note1.:
Thedefaultscreencanbe
changed.Seemenuitem‘D02
DefaultScreen’.

Note2.:
ThebargraphVariablecanbe
changed.Seemenuitem‘Bar
graphVar’.

Note3.:
UserAccesstothemenumay
berestricted.Seemenuitem
‘D01MenuAccess’.



NetworkStatusIndication:
Thetime&Clockscreenalso
displaysthenetworkstatus.

Net*‐Indicatesrateof
Networktransactions
Off‐Networkisdisabled
Idle‐NoActivity
Down‐NetworkDown
Live‐Networkisactive,but
notreceiving
ERR!‐Communicationerror
messagecorrupt
BAD!‐Invalidrequest
RxOK‐Requestprocessed
normally
Ctrl‐Controlvianetworkis
enabledandonline.


SMARTSTART 6000
6R030 V1.32
Thissymbolidentifiesthe
parametersforquicksetup.
The‘!’symbolisdisplayedinthetoprightcornerof
thedisplaywhenthestarterhasoperatedinESO
modeandthestarterhasbeen‘stressed’.Thiscan
onlyberesetbyZenerElectricandmayvoidany
productwarranty
%oftotalaccelerationor
ramptime

Programming
TechnicalManual:Smartstart®6000IMI0042revK
Page17
OperatingStatusIndication





‘Off’:TheSmartstart®6000hascontrolpowerapplied
butnotenabledandnolinesupply.
‘Standby’:TheSmartstart®6000hasbeenenabledto
startandtherunrelayenergizedtobringintheline
contactor(ifinstalled).TheSmartstart®6000will
initiateastartimmediately3phasesupplyisapplied.
‘Ready’:Linesupplyonbutnorenabled.
‘ACCEL##%’:TheSmartstart®6000isacceleratingthe
motor.Ramptimecompleted(%)&MotorCurrent(A)
displayed.
‘AtSpeed##%’:Themotorisatfullspeed,theaccel
timeperiodmaynotbecomplete.Ramptime
completed(%)&MotorCurrent(A)isdisplayed.
‘RunBypassorRunCont.’:Theramptimeiscomplete
andthebypasscontactoroperatedorSCR’sareinfull
conduction.MotorCurrent(A)isdisplayed.
‘DECEL##%’:TheSmartstart®6000isdeceleratingthe
motor.Ramptimecompleted(%)&MotorCurrent(A)
displayed
‘StartReq’:Enabled,butstartdelayed/postponeddue
tocoolingorstarttimerdelay.
‘KickStart’:Kickstartisactive.
‘MotorOff’:Briefmessageasmotordefluxesor
Pendingmotorlosstrip.
‘Tripped’:Systemhastripped.(NotseeninAutoretart)
‘Cooling’:Startertoohottostartorduring“Minimum
offtime”.
‘Shutdown’:PSUundervoltagedetected
(SMARTSTARTshuttingdown).
‘Brownout’:SustainedPSUundervoltagecondition
(supplyproblem/fault).
‘ARPending’:Systemtrippedbutwaitingforauto
restart.
‘ARLockout’:FinaltripafterallARattempts
exhausted.

Warnings,AlarmsandMessages:

TheSmartstart®6000hasbeendesignedtoprovidethe
userwithacomprehensivedisplayofitsoperating
status.MessagesinplainEnglishareflashedacrossthe
screen(ifenabled)toalerttheuserofitscurrent
status,anywarnings,tripsorpendingactions.The
codewillhaveaprefixofT(trip),W(Warning)orI
(Interlock).

Example1:Ifautorestartisselecteditwillflash:
‘ARPENDING’,thenumberofrestartsandtime
beforearestart.

Example2:Ifthemotororstarterhasreacheda
thermalstatewherecannotrestartitwillflash:
‘PENDING,I30MTROVERLOAD’

‘FLASHALERTS’(TopLineofDisplay)
TheSmartstart®6000canbeconfiguredtoFlash
Warning&Alarmmessagesirrespectiveofthe
DASHBOARDscreencurrentlyactive.
See‘D05Warningalarms’onpage21.Thesealerts
include:

PENDING
WARNING
TRIPPED
OVERRIDE
AR#12in1234s
AR#12Anytime
LOCKOUT

Refertotable4onpage34forexplanationofeach.

‘ALARMSandinterlockMessages
TheSmartstart®6000canbeconfiguredtoDisplaythe
TripcodeandDescriptionoverthebargraphonthe
defaultscreen.Interlockmessagescanalsobe
displayed.See‘D06Almoverbar’onpage21.

InterlockMessages
Whenthisfeatureisenabled(ie.D06‐‘AllAlarms’)
interlockmessagesaredisplayedonthe2ndline.Referto
‘D06WarningAlarms’formoreinformation).Interlock
messageshavean‘I’prefix.Eg.‘I70EnableOFF’.These
messagesprovidemoreinformationaboutthecurrent
statusofthestarterandprovidediagnosticstowhythe
motormaynotbeoperating.

Refertopage35&36forexplanationofthesemessages.




ACCEL 50 % 250A
300%
Currentstatus %ofAccelor
Deceltime ActualCurrent
Currentas%ofmotor
FLC.(Programmable)
BarGraphdisplaying
current%