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:
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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
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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)
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MountingHoles:
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MountingHoles:
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MountingHoles:
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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’.
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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.

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Selectcables&installincompliancewith
localregulations
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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.

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

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‐
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SemiconductorFusekit(Optional) 

RefertoPage43forselection.



SemiconductorFuseReplacement

RefertoPage43forreplacementfuses.
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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.