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S/MOT/SMCW6151/A/23/07/99 1W240030
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EXTERNALLY BYPASSED THREE PHASE INDUCTION MOTOR SOLID-STATE REDUCED VOLTAGE STARTER (SOFTSTARTER) WITH SOFTSTOP FEATURE
celduc relais SMCV can be employed everywhere using a costly and relatively big variable speed controller is not required (pumps, fans, compressors, conveyors, ). Its six thyristor structure working like a full wave phase angle controller (both positive and negative cycles are controlled), allows to reduce efficiently the induction motor starting current as well as the motor starting torque. This motor starting current reduction allows to optimize the mains grid as well as its protections and avoid having voltage fluctuations leading to ambient light variations also called "flicker". Built to help the user to get his assembly in compliance with the European directives and standards, this product easy fits in the existing application without any modification of the wiring field configuration. Thus, the SMCV can easily replace an electromechanical star-delta starter without changing the motor coupling! In a project including a three phase induction motor it can be implemented like a usual three phase electromechanical contactor. Furthermore, its ability to be installed inside the delta wiring allows this device to drive 1.73 times more current than a standard on line softstarter, The SMCV also have diagnostic and self-test functions to inform people involved in the machine maintenance and to reduce the cost and the delay to restart the production.
SMCW6151
Externally Bypassed 3 Phase Induction Motor Softstarter 200 - 480VAC ->15kW (Y) ->26kW (D)
MAIN CHARACTERISTICS Max. Motor Power @40C IAC53b @40C Phase With External Bypass With Ext. Bypass to Mains Status Input Star (Y) Delta (D) Phase Frequency Outputs Max. EN60947-4-2 Voltage 400VAC 230VAC 400VAC 230VAC 200 to 10 to 24V / 1A 15kW 8.6kW 26kW 15kW 30A 22.5A 40 to 65Hz 480VAC 24VDC AC/DC BENEFIT FOR MOTOR STARTING DIRECT ON LINE (DOL) STARTING STAR (Y)
Mechanical part stress: - noise - Maintenance costs High inrush current: - Motor and mains protections oversized - Risk of flicker
Softstarting: - Noise reduction - Maintenance cost reduction No more high inrush current: - Motor and mains protections optimization - No more harmonic or flicker problems
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DESCRIPTION
Three phase mains connections
Supply
Fig. 2
LEDs
Option switches
1L1
3L2
Controls
+
5 4
1L1
Ctrl Byp.
NPN Start Kick SoftStop Byp.
Status outputs
Time(s)
0,5 0.25 0 64 32 1
3 2 1
2T1
4T2
6T3
Diag.
Initial Torque
Made in France
2T1
4T2
6T3
Settings
Motor connections
1,2 Diagnostic Output Closed NO (AC or DC) Time Increasing voltage ramp duration Ts= 0 up to 64s
DESCRIPTION OF THE CONNECTIONS 2,3 4,6 5,6 Bypass Output Closed NO (AC or DC) Control Input High (PNP) or Low (NPN) Yes (4+ / 6-) Urgent stop Input Open Yes (5+ / 6-)
1L1, 3L2, 5L3 Three phase mains (Obligatory) Input Since 3x200VAC NO (AC) NPN / START Softstarter type of control option PNP, NPN or since the mains presence
2T1, 4T2, 6T3 Motor supply (Obligatory) Output 100ms after control NO (AC) Kick Motor shaft breakaway 0 up to 100ms depending on ts
DESCRIPTION OF THE SETTINGS AND OPTIONS Initial Torque Soft-stop Byp. Min. voltage Decreasing Bypass presence applied to the voltage ramp diagnostic motor at start duration (Do not remove) 0 up to 100 % 0, 1/2, 1 or 2 x ts up to 64s max. : 0xts -
Possibilities
: PNP Proceeding : 0.5xts : NPN : ts : Mains : 2xts Fig. 3 DESCRIPTION OF THE DIFFERENT SETTING PARAMETERS
Urg. Stop
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Visualization Supply Line Load
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DESCRIPTION OF THE DIAGNOSTIC INFORMATION IN NORMAL OPERATION Status Outputs Motor Cause probable Byp. Diag. Stopped Stopped Starting Running to nominal speed Decelerating No mains or device not correctly wired Mains voltage and phases OK, Motor detected, No control Mains voltage and phases OK, Motor detected, Control detected and beginning of the softstarting ramp Mains voltage and phases OK, Motor detected, Control detected and end of the softstarting ramp Mains voltage and phases OK, Motor detected, No control and beginning of the softstopping ramp
DIAGNOSTICS IN CASE OF FAILURE Visualization Supply Line Load Status Outputs Byp. Diag. Stopped Mains voltage too low Phase(s) missing, Mains frequency out of range, Too much interference Phase(s) missing Load missing, Short-circuited thyristor Bypass missing Check the phases 3L2 and 5L3 Motor Possible Cause Solution
Check the phases Check the phases Check the motor connections and the solid state switches Check the bypass connections Check if the connection between 5 and 6 of the control terminal block is correctly done. Check as well if the load current is sufficient. Disconnect the softstarter from the mains for a while Remove the control for a while
Stopped
Stopped
Microcontroller malfunction A problem occurred on the mains (no voltage or a phase missing, ) then disappeared but the control voltage was applied A problem occurred on the load (temporary disconnection,) then disappeared but the control voltage was applied LEGEND
Stopped
Stopped
Off
Green
Red
Flashing off/green
Flashing Off/red
4-
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Fig. 6 STATUS OUTPUT UTILIZATION
CONTROL INPUTS AND STATUS OUTPUTS Fig. 4 HIGH SIDE CONTROL (PNP) Fig. 5 LOW SIDE CONTROL (NPN)
ELECTRICAL CHARACTERISTICS OF THE STARTING AND STOPPING INPUTS VALUES CHARACTERISTICS LABELS (Given at 20C ambient unless otherwise specified) Input Ctrl Urg. Stop Immediately stop the Controlling the device Function device High side control Low side control Opening the Control Type (PNP) (NPN) connection to zero volt (Depending on the option switches) 4&6 4&6 5&6 Concerned Terminals Control Voltage Range 10->24VDC Uc (according to EN60947-4-2) 8.5V Min. Control Voltage Ucmin. 2.5VDC 1.5VDC Max. Voltage Drop Ut Ucmax=28VDC Utmax=28VDC Utmax=6VDC Max. Input Voltage -Ucmax=28VDC -Utmax=28VDC -Utmax=6VDC Max. Reverse Voltage Uc<1VDC Ut>2.5VDC Ut>1.5VDC Release Voltage Control Current Current To Switch Ic Ict 5->19mADC 50->100ADC 20mADC
REMARKS
CHARACTERISTICS Output Concerned Terminals Function Nom. Operating Voltage Operating Voltage Range Non-repetitive Max. Peak Voltage Protection Against Overvoltage Min. Load Current Max. Permanent Current Overload Current Protection Against Short-Circuits On-state Resistance Off-state Resistance Off-state Capacitance Turn-on Time Turn-off Time
STATUS OUTPUT CHARACTERISTICS VALUES LABELS (Given at 20C ambient unless otherwise specified) Diag. Byp. 1&2 2&3 Indicates the end of the Environment problem starting period and can be detection or faulty device used to control a bypass indication electromechanical contactor 24VAC/DC Usan 0->28VAC/DC Usa 60V Usapmax Yes 25V size 7 varistors integrated Ibymin Ipbmin Iby/Ipb Ibyp/Ipbp 0 1A AC/DC 2.4A AC/DC No Ron Roff Coff Toff Ton 500m 100M 130pF 0.5ms 2ms
REMARKS
See curve fig. 8 page 5 @100ms 10% of the cycle See curve fig. 9 page 5 See curve fig. 10 page 5
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Fig. 7
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CONTROL
CHARACTERISTIC CURVES OF THE CONTROLLING INPUTS AND STATUS OUTPUTS Control Input Current/Voltage Characteristic Curve Giving Max. Output Status Current Fig. 8 In PNP Mode (High Side Control) Versus Ambient Temperature
Fig. 9
Fig. 10
Curve Giving The Max. Number Of Overload Pulses Regarding Their Duration For The Overvoltage Protection Of The Status Outputs
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REMARKS See internal diagram fig. 1 page 2
INTERNAL SUPPLY ELECTRICAL CHARACTERISTICS VALUES LABELS (Given at 20C ambient unless otherwise specified) 3L2 & 5L3 200->480VAC Ue 1mA typical Is 40-65Hz f 100ms tm POWER SIDE CHARACTERISTICS VALUES LABELS (Given at 40C ambient unless otherwise specified) 1L1, 2T1, 3L2, 4T2, 5L3, 6T3 Pn Pn Pn Pn Uen Ue Uep
CHARACTERISTICS Concerned Terminals Max Power Of The Motor @400VAC Star Wiring (Y) Max Power Of The Motor @230VAC Star Wiring (Y) Max Power Of The Motor @400VAC Delta Wiring (D) Max Power Of The Motor @230VAC Delta Wiring (D) Nom. Operating Voltage Operating Voltage Range Max. Non-repetitive Peak Voltage Integrated Overvoltage Protection AC53a Nom. Current according to EN60947-4-2 (Induction Motor) AC53a Max. Permanent Current With Bypass (Induction Motor) Max. AC1 Permanent Current (Resistive Loads) Non-repetitive Peak Overload Current (1 cycle of 10ms) Fusing Limit Current For Choosing The Protecting Fuses Min. Load Current Max. Leakage Current Power Factor Operating Mains Frequency Range Off-state Dv/Dt Integrated Transient Voltage Protection Max. Current Rising Time Direct Voltage Drop Resistive Part Of The Direct Voltage Drop Threshold Part Of The Direct Voltage Drop Max. Junction Temperature Junction/Plate Thermal Resistance Per Power Element Plate/Heatsink Thermal Resistance Vertically Mounted Heatsink Thermal Resistance Heatsink Thermal Time Constant
REMARKS
15kW (With an external bypass 8.6kW (With an external bypass 26kW (With an external bypass 15kW (With an external bypass
230VAC & 400VAC 200->480VAC 1200V
Yes 510V size 14 varistors Ie (AC53a) Ie (AC53a) Ith (AC1) ITSM I2t Iemin Ilk Pf F dv/dt 22.5A
See curves fig. 16 & 17 page 7 Hard conditions See curve fig. 15 page 7 Normal conditions See curve fig. 15 page 7 E.g. softstarting lamps See Curve fig. 14 page 7 @10ms @400VAC50Hz
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Fig. 13
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CHARACTERISTIC CURVES OF THE POWER ELEMENTS Overload Current Characteristic Fig. 14 Electrical Label Description Regarding Overload Duration
ITSM 2000 (A) 1800 (Peak Values) 1600 1400 1200 1000 800 600 400 200 0 0.01 0.10
10.00
Fig. 15
Number Of Allowed Switching In Order Not To Exceed The Max. Thermal Characteristics
Nb 1000
Min. on or off-state time = (3600/Nb)-Starting time (s) Max. Number Nb Of Starting Per Hour Regularly Distributed Within One Hour For Iac53b=30A @40C Ambient Temperature Max. Number Nb Of Starting Per Hour Regularly Distributed Within One Hour For Iac53b=30A @20C Ambient Temperature
100
Max. Number Nb Of Starting Per Hour Regularly Distributed Within One Hour For Iac53b=22.5A @40C Ambient Temperature (EN60947-4-2)
10
1 0.10
10.00
100.00
Fig. 16
Fig. 17
Curve Giving The Max. Number Of Overload Pulses Regarding Their Duration For The Overvoltage Protection Of The Power Elements
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REMARKS
INPUT/OUTPUT ISOLATION CHARACTERISTIC VALUES LABELS (Given at 20C ambient unless otherwise specified) 4kV Uimp 2.5kV Uied 4kV Uimp 4kV Uimp 1G Rio <8pF Cio CLIMATIC OPERATING ENVIRONMENT VALUES LABELS (Given at 20C ambient unless otherwise specified) -40->+100C Tstg Tamb -40->+90C Tc 100C According to I.E.C. 68 parts 2 & 3 According to I.E.C. 68 parts 2 & 30
CHARACTERISTICS Storage Ambient Temperature Ambient Operating Temperature Max. Heatsink Temperature Wet Heat Resistance (continuous) Wet Heat Resistance (cyclical)
REMARKS
CONNEXIONS AND REQUIRED TOOLS ON THE CONTROLSIDE VALUES CHARACTERISTICS LABELS (Given at 20C ambient unless otherwise specified) Screwed Connections 0.8 x 2mm Screwdriver Wire Cross Section Min. And Max. Tightening Torque CONNEXIONS AND REQUIRED TOOLS ON THE POWER SIDE VALUES LABELS (Given at 20C ambient unless otherwise specified) Screwed Posidriv 2 or 0.8 x 5.5mm 1,5->6mm2 (10mm2 without ferrule) 1.8->3N.m 2 2.5mm2
REMARKS
REMARKS
Min. And Max. Tightening Torque Possible Number Of Connected Wires For The Max. Cross Section
CHARACTERISTICS AND REQUIRED TOOLS FOR THE SETTINGS VALUES CHARACTERISTICS LABELS (Given at 20C ambient unless otherwise specified) "Time" and "Initial Torque" Option Switches Setting Screwdriver 10 2 for each switch Number Of Positions Changing Position >1.5N.cm +/- 50% >3N.cm +/- 50% Required Torque 36 0 Angle Between Each Position MISCELLANEOUS CHARACTERISTICS VALUES LABELS (Given at 20C ambient unless otherwise specified) UL94V0 Omega DIN rail (DIN50022) or screwed Low audible vibration during the softstarting and softstopping periods 600g
REMARKS
REMARKS
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Fig. 18
S/MOT/SMCW6151/A/23/07/99 1W240030
DIMENSIONS
AC-53a Ie
30 A U imp 4000V
IEC947-4-2 EN 60947-4-2
Ue
celduc France
200-480 V 40/65HZ
74
SMCW6151
1L1
3L2
110
SoftStop Byp.
Byp. Diag.
Initial Torque
2T1
Time(s)
0,5 0.25 0 64 32 1
2T1
4T2
6T3
83
CHARACTERISTICS
CHARACTERISTICS OF THE THERMAL PROTECTION VALUES LABELS (Given at 20C ambient unless otherwise specified)
76
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1L1
REMARKS
CHARACTERISTICS
CHARACTERISTICS OF THE FAN VALUES LABELS (Given at 20C ambient unless otherwise specified)
REMARKS
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REMARKS No state changing or destruction No state changing or destruction No state changing or destruction No state changing or destruction
IMMUNITY LEVEL WITHIN ELECTROMAGNETIC COMPATIBILITY (E.M.C.) VALUES CHARACTERISTICS LABELS (Given at 20C ambient unless otherwise specified) Electrostatic discharges EN 61000-4-2 EN 61000-4-3 EN 61000-4-4 EN 61000-4-5 EN 61000-4-11 8kV in the air 4kV contact 10V/m 2kV direct coupling on the power side 2kV clamped coupling on the input side 1kV direct coupling differential mode (Input and output sides) 2kV direct coupling common mode (Input and output sides)
EMISSION LEVEL WITHIN ELECTROMAGNETIC COMPATIBILITY (E.M.C.) VALUES CHARACTERISTICS LABELS (Given at 20C ambient unless otherwise specified) In compliance with the standards for industrial field Conducted Disturbances EN55011 In compliance with the standards for domestic field with an external bypass contactor <30dbV for the frequency range 30->230MHz Radiated Disturbances EN55011 <37dbV for the frequency range 230->1000MHz The conducted or radiated disturbances generated by solid state relays depend on the wiring and load configuration. The test method recommended by the European standards and concerning electromagnetic compatibility leading to results far from reality, we decided to advise our customer in order to adapt their filtering scheme to their application. The European standard EN60947-4-2 requires the measurement to be done at full on state (end of the softstarting Remarks Concerning Filtering period). Therefore, our products are below the industrial field required levels on inductive load like the induction motor and no additional filter is needed. The starting period that may last several minutes generates enough interference to disturb sensitive devices located near the softstarter. If any, please contact us so that we can help you to choose the right filter. LOW VOLTAGE DIRECTIVE CHARACTERISTICS Standard Protection Level Protection For Direct Touch LABELS VALUES (Given at 20C ambient unless otherwise specified) EN60947-4-2 2L0 According to V.D.E. 160 part 100 : Back hand and finger safety APPROVALS CHARACTERISTICS CE Marking c UL US VDE 0805 LABELS EN 60947-4-2 UL508 EN60950 VALUES (Given at 20C ambient unless otherwise specified) Yes Pending Pending
REMARKS
REMARKS
IP
REMARKS
Office environment
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S/MOT/SMCW6151/A/23/07/99 1W240030
IMPORTANT
DANGER!
The installation of this product must be done by qualified people, informed about electric hazards (electrocution risks linked to the voltage levels in the circuit). Any intervention on the installation must be operated the circuit disconnected from the electric grid by an electromechanical mean insuring a sufficient galvanic isolation. The device concerned by this document is composed of silicon based solid state switches. They never ensure a safe function when they are not controlled (Important leakage current and untimely closing). Therefore, we advise you to use an electromechanical device in series with the softstarter, which can ensure a safe operation in the disconnected circuit. The emergency stop must not be done by the softstarter. It must be done by an electromechanical with sufficient current breaking possibility. In order to operate in the circuit in safe condition, the control part of the softstarter will have to be disconnected from the control or auxiliary supplies as well.
ATTENTION
1-
The SMCV does not correctly operate on three phase mains with the motor neutral connected to the neutral of the mains. If any, please contact us.
The overload relay must be adapted to the motor. Please take care not to make short-circuits while installing the by-pass contactor or the backward wires for delta wiring.
23-
4- The control voltage will have to be held sufficiently to allow the by-pass to close. Take care not to remove the by-pass checking option "byp.".
5In case of fast softstarting and softstopping controls without waiting for the end of the ramps, the motor may heat up. Please contact your motor supplier to choose an adapted model. ENVIRONMENT OF THE SOFTSTARTER LABELS DESCRIPTION FERRAZ 14 x 51 am 50/500V To be determine by the user Moeller Z00-24 class 10A To be determine by the user KM1 A1/A2 TC 30A AC1 15VAmax. / 15W max. Not available Comply with the characteristics given in general information
DEVICES On Line Fuses (Hard conditions according to EN60947-4-2) On Line Fuses (Normal conditions) Overload Relay (Hard conditions according to EN60947-4-2) Overload Relay (Normal conditions) Breaking Capability Of The By-pass Contactor By-pass Contactor Coil Thermal Protection Wiring / Settings
REMARKS
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Fig. 20
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Fig. 21
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OTHER LOAD POSSIBILITIES Softstarting Incandescent Or Infrared Lamps Softstarting Three Phase Loaded Transformers (AC1 Current) (Please consult us)
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Fig. 22
MOUNTING Mounting Precautions : The heatsink fins must be mounted vertically to ensure a good thermal convection. A minimum space must be left free around the assembly. 20mm mini. 20mm mini.
Fig. 24
Mounting
Removing
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ADVISES FOR THE SETTINGS ATTENTION Obtaining a particular starting time value is only a consequence of the motor torque reduction and can not be guaranteed or easily repeatable. The rotary switch Time (s) setting values only give the duration of the voltage ramp applied to the motor but not necessarily its starting time. The main SMCV function is to obtain a motor torque reduction to take care of the motor load and the electric grid. The motor starting time is only a consequence and completely depends on the motor itself, its load and the settings done by the user. The SMCV can not break a motor driving a load that has much inertia. The user can only obtain a stop time equal or longer than a simple disconnection from the electric grid. Using the softstop feature can only be justified when the motor load tends to break the motor (pumps, ) or when the products treated by the machine need to be stop slowly (conveyors,). In the case of load with high inertia, the softstop feature can help to reduce slowly the magnetic field inside the motor to avoid long time overvoltage in the circuit. Setting Examples Long Starting Time For lamps, Advise Settings Direct On Line Starting (DOL) Transformers, For Testing The Motor Starting (On a motor, it may hum)
or
et
et
Loads With Increasing Torque Like N2 And Increasing Power Like N Load Examples Advised Time Setting Fans Centrifugal Pumps Torque Curve Depending on the user starting time requirement Advised Torque Setting Adjusted to avoid the motor to hum Softstop of the starting time (Magnetic field reduction)
Loads With Decreasing Torque Like 1/N And Constant Power Load Examples Winding material around a shaft (cable, paper, metal, textile, plastic, ) Chip disposal Torque Curve Advised Time Setting
Maximum (64s)
Advised Torque Setting Depending on the user starting current requirement Softstop of the starting time (Magnetic field reduction)
N
Loads with Constant Torque And Power Increasing Like N Load Examples Advised Time Setting Conveyors, cranes, constant volume pumps, Torque Curve
N
Loads Increasing Like N And Constant Power Load Examples Advised Time Setting Machine tools, Rolling mills, Torque Curve Depending on the user starting current requirement Softstop Depending on the user stopping smoothness requirement Depending on the user starting time requirement Advised Torque Setting Adjusted to avoid the motor to hum Softstop Depending on the user stopping smoothness requirement
Maximum (64s)
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