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Automation Direct Stellar SR55 Series, User Manual

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Stellar

®

 SR55 Series Soft Starter User Manual – 1st Ed, Rev F – 09/18/2019

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Table of Contents

Chapter 1:  Mechanical Installation  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �   1–1

User Manual Overview  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �   1–2

Overview of this Publication  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  � 1–2
Who Should Read This Manual �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  � 1–2
Supplemental Publications  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  � 1–2
Technical Support  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  � 1–2
Special Symbols  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  � 1–2

Mechanical Installation  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �   1–3

Mounting�  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  � 1–3
Requirements for an Enclosure �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  � 1–3
Enclosure Ventilation  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  � 1–3
Mechanical Specifications�  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  � 1–4
Dimensions�  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  �  � 1–4

Summary of Contents for Stellar SR55 Series

Page 1: ...Stellar SR55 Soft Starter User Manual SR55_UMW First Edition Revision F...

Page 2: ...Stellar SR55 Series Soft Starter User Manual 1st Ed Rev F 09 18 2019 BLANK PAGE...

Page 3: ...or resale as on line control equipment in hazardous environments requiring fail safe performance such as in the operation of nuclear facilities aircraft navigation or communication systems air traffi...

Page 4: ...ns des environnements dangereux n cessitant une s curit absolue par exemple l exploitation d installations nucl aires les syst mes de navigation a rienne ou de communication le contr le de la circulat...

Page 5: ...uit and is not designed to provide isolation For this reason isolation device s must be installed in the power supply circuit in accordance with the applicable wiring and safety regulations Warning AC...

Page 6: ...Page W 4 Stellar SR55 Series Soft Starter User Manual 1st Ed Rev F 09 18 2019 BLANK PAGE...

Page 7: ...Parameter descriptions P8 7 P9 1 P13 1 P14 0 P15 19 Parameter examples P12 1 P13 1 Trip codes 601 1501 Fail Safe codes C h 5 Modbus RTU comm note C h 6 RJ45 R12 adapter pin out Cooling fan running con...

Page 8: ...Page H 2 Stellar SR55 Series Soft Starter User Manual 1st Ed Rev F 09 18 2019 BLANK PAGE...

Page 9: ...User Manual Overview 1 2 Overview of this Publication 1 2 Who Should Read This Manual 1 2 Supplemental Publications 1 2 Technical Support 1 2 Special Symbols 1 2 Mechanical Installation 1 3 Mounting...

Page 10: ...rameters 3 14 Parameter Details 3 15 Parameters Not Configurable Through Touchscreen Menu 3 15 Parameters in Sequence and Grouped by Touchscreen Navigation 3 20 Auto Setup Menu of Parameters 3 20 Adva...

Page 11: ...on SR55 CM ENETIP and SR55 CM MODTCP 5 7 SR55 Configuration 5 7 IP Address Configuration 5 7 Communication Module Front Panel Indicator Lights 5 8 Modbus TCP Network Communications 5 8 EtherNet IP Net...

Page 12: ...2 High Efficiency Motors B 4 B 1 13 EU Compliance with the EMC Directive B 4 B 1 14 Fuses B 4 B 2 Rules for Specific Applications B 5 B 2 1 In Delta Operation B 5 B 2 2 High Inertia Loads B 5 B 2 4 Re...

Page 13: ...urchasing Implications of Meeting an EMC Standard C 3 C 7 Basic EMC Considerations C 4 C 7 1 Immunity C 4 C 7 2 Emissions C 4 C 7 3 Emissions Harmonics C 4 C 7 4 Emissions Radio Frequency RF C 4 C 7 5...

Page 14: ...TOC 6 Stellar SR55 Series Soft Starter User Manual 1st Ed Rev F 09 18 2019 Table of Contents BLANK PAGE...

Page 15: ...s Chapter 1 Mechanical Installation 1 1 User Manual Overview 1 2 Overview of this Publication 1 2 Who Should Read This Manual 1 2 Supplemental Publications 1 2 Technical Support 1 2 Special Symbols 1...

Page 16: ...179 within the U S 303 397 7956 international www global ihs com Technical Support By Telephone 770 844 4200 Mon Fri 9 00 a m 6 00 p m E T On the Web www automationdirect com Our technical support gro...

Page 17: ...e distances around soft starters as specified in the tables shown with the dimension drawings Means to effect proper air flow through the enclosure and maintain temperature and humidity within the ran...

Page 18: ...inuous Humidity max 85 non condensing not exceeding 50 40 C 104 F Maximum Altitude 1 000m 3281ft above 1000m derate by 1 of SR55 Ie per 100m 328ft to a maximum altitude of 2 000m 6562ft Environmental...

Page 19: ...Left 1 6 in 40mm Right Front 1in 25mm NOTE The addition of optional finger guards to size 1 and size 2 SR55 soft starters adds approximately 14mm 0 5in to the vertical dimension but does NOT change t...

Page 20: ...Page 1 6 Stellar SR55 Series Soft Starter User Manual 1st Ed Rev F 09 18 2019 Chapter 1 Mechanical Installation BLANK PAGE...

Page 21: ...ter 2 Electrical Installation 2 1 Safety Warning 2 2 Agency Approvals 2 2 Technical Information and Standards 2 2 Electrical Specifications 2 3 Circuit Protection 2 4 Short Circuit Protection 2 4 Moto...

Page 22: ...on and Standards Rated Operational Voltages Ue 200VAC to 480VAC Rated Operational Current Ie See Electrical Specifications table Rating Index SR55 017 to 180 Ie AC 53a 3 5 17 90 5 SR55 242 to 477 Ie A...

Page 23: ...1A resistive 1 AO 0 10VDC 10mA max or 4 20mA Start Time Setting Range 1 to 300 seconds Start Voltage Setting Range 10 to 100 Stop Time Setting Range 0 to 300 seconds Model SR55 124 SR55 156 SR55 180 S...

Page 24: ...sen 6 9 URD 31xx Bussmann 170M40xx Bussmann 170M41xx Bussmann 170M42xx SIBA 20 61xx Mersen 6 9 URD 33xx Bussmann 170M60xx Bussmann 170M61xx Bussmann 170M62xx SIBA 20 63xx Rating A 400 550 550 700 800...

Page 25: ...LA Motor overload cold trip curves 20 C ambient Wire Sizes and Torques SR55 Wire Sizes and Torques Terminal Models Wire Size Torque mm2 AWG N m lb in Main Terminals Cu STR 75 C Only Terminal SR55 017...

Page 26: ...sistive 3 x PTC in series 130 C OFF thermistor analog output 0 10V yes 0 to 10V 10mA 4 20mA 3 x PTC in series 130 C OFF thermistor analog 0V 0V signal ground analog input 0 10V yes 0 to 10V 10mA 4 20m...

Page 27: ...herNet IP comm module slot RJ45 port future use For wire size and torque requirements refer to the Wire Sizes and Torques section of this chapter For suitable short circuit protection devices SCPDs re...

Page 28: ...D2 1I Reset Power factor correction capacitors must not be positioned between the soft starter and the motor or there is a risk of damaging the thyristors due to current peaks User Programmable Contro...

Page 29: ...1COM N or 0VDC K2 2 T1 4 T2 6 T3 1L1 3 L2 5 L3 Reversing Wiring Diagram Item K1 K2 K1A K1B SR55 These are the major components of the system Local wiring regulations should be observed Note the use of...

Page 30: ...Page 2 10 Stellar SR55 Series Soft Starter User Manual 1st Ed Rev F 09 18 2019 Chapter 2 Electrical Installation BLANK PAGE...

Page 31: ...Summary of Parameters Not Configurable Through Touchscreen Menu 3 6 Summary of Parameters for Auto Setup 3 6 Summary of Parameters for Individual Parameter Setup 3 7 Block Transfer Parameters 3 14 Pa...

Page 32: ...imply touch the on screen buttons to enter data or to scroll through the SR55 setup menu using the intuitive Up Dn BACK and NEXT buttons as necessary From the home Menu screen select either Auto Setup...

Page 33: ...ompressor Centrifugal Agitator Heavy Compressor Reciprocating Select Your Application OK Back Next Compressor Reciprocating Centrifugal Select Your Application Warning Selected Application Will Enable...

Page 34: ...2 7 Compressor Scroll 35 10 7 0 10 3 5 25 15 1 0 1 0 1 0 0 0 0 0 0 8 2 8 Ball mill 40 10 10 0 20 5 5 25 5 1 0 1 0 1 0 0 0 0 0 0 8 2 9 Centrifuge 40 10 10 0 30 2 5 300 5 1 0 1 0 1 0 0 0 0 0 0 8 2 10 B...

Page 35: ...30 Pump Positive displacement Reciprocating 10 10 10 60 20 3 5 25 15 1 0 0 0 1 1 1 0 0 1 0 2 25 31 Pump Positive displacement Rotary 10 10 10 60 20 3 5 25 15 1 0 0 0 1 1 1 0 0 1 0 2 25 32 Pump Jack 4...

Page 36: ...37760 9380 OFF P0 9 Current Limit OFF ON Read 37824 93C0 OFF P0 10 iERS Active OFF ON Read 38080 94C0 OFF P0 12 I O Status Register 0 to 255 Read 62016 F240 OFF Block Transfer detailed info starts pa...

Page 37: ...50 P2 9 Automatic End Start 2 toggle OFF ON R W 19904 4DC0 OFF P2 10 Automatic End Start 3 toggle OFF ON R W 20032 4E40 OFF P2 11 Rate End Start 3 0 to 100 R W 768 0300 50 P3 Start Settings detailed i...

Page 38: ...setting is OFF beginning in firmware version 59 35 P7 detailed info page 3 21 P7 0 Control Method Local Touch Screen User Programmable Two Wire Control Three Wire Control Modbus Network R W 59392 E80...

Page 39: ...tion same as DI1 function selections R W 10945 2AC1 OFF P10 4 Digital Input 2 D1 2I High Input 1 Sets Value toggle OFF ON R W 11266 2C02 ON P10 5 Digital Input 3 D2 1I Select Function same as DI1 func...

Page 40: ...0 7D00 n a P15 1 Phase Rotation L1 L2 L3 or L1 L3 L2 Read 32064 7D40 L1 L2 L3 P15 2 I1 A 0 to 10 000 Read 33536 8300 0 P15 3 I2 A 0 to 10 000 Read 33538 8302 0 P15 4 I3 A 0 to 10 000 Read 33540 8304 0...

Page 41: ...re Last Overload 8 Read 38488 9658 P16 9 Event Time Last Peak Start Current Last Temperature Last Overload 9 Read 38491 965B P16 event times are associated with parameters P18 P20 and P21 and the time...

Page 42: ...t Temperature 1 C 20 C to 80 C Read 39681 9B01 ambient P20 2 Last Temperature 2 C 20 C to 80 C Read 39682 9B02 ambient P20 3 Last Temperature 3 C 20 C to 80 C Read 39683 9B03 ambient P20 4 Last Temper...

Page 43: ...80 P26 0 Modbus Network Address 1 to 32 R W 16000 3E80 1 P26 1 Modbus Network Baud Rate Baud 9 600 19 200 38 400 57 600 115 200 R W 16064 3EC0 19 200 P26 2 Modbus Network Parity none odd even R W 161...

Page 44: ...95 R W 17664 4500 OFF Transfer 2 P0 21 17601 44C1 OFF Data 2 P0 41 17666 4502 OFF Transfer 3 P0 22 17602 44C2 OFF Data 3 P0 42 17668 4504 OFF Transfer 4 P0 23 17603 44C3 OFF Data 4 P0 43 17670 4506 OF...

Page 45: ...d Reg Type Description Read Write If set to On this parameter will hold the Start Ramp even if Current Irms is less than the Current Limit Level To map to digital input refer to P10 2 P10 4 P10 6 Rang...

Page 46: ...With Digital Outputs P0 4 Ready Hold Reg Type Description Read Only STATUS INDICATION Ready To map to Digital Output refer to P11 0 P11 2 P11 4 P11 6 Range Modbus Decimal Value Default decimal Off The...

Page 47: ...has been stopped On Indicates that the motor is running and is being actively controlled by the SR55 0 1 Off 0 Modbus Address Modbus Format 37632 9300 hex 16 bit unsigned Touchscreen Menu Path none P0...

Page 48: ...saving mode has been disabled either internally or via iERS On Indicates that the SR55 is operating in the iERS energy saving Mode 0 1 Off 0 Modbus Address Modbus Format 38080 94C0 hex 16 bit unsigned...

Page 49: ...it unsigned Touchscreen Menu Path none P0 40 P0 55 Block Transfer Data Locations Hold Reg Type Description Read Write Data locations for data block transfer For details please refer to Block Transfer...

Page 50: ...c value that correlates the trip time with overload level Select Trip class according to application requirements The trip time depends on the selected Trip Class the duration of the overload and the...

Page 51: ...hree Wire Control Modbus Network 0 1 2 3 4 Local 0 Modbus Address Modbus Format 59392 E800 hex 16 bit unsigned Touchscreen Menu Path Home Auto Setup Control Method also Home Advanced Control Method al...

Page 52: ...ess Modbus Format 19840 4D80 hex 16 bit unsigned Touchscreen Menu Path Home Advanced Automatic Settings Automatic Pedestal P2 1 Automatic Ramp Hold Reg Type Description Read Write Automatically contro...

Page 53: ...0 linear scale 1 0 006104 0 100 0 16384 x 0 006104 Modbus dec value EX Modbus value of 2900 17 7016 50 Modbus Address Modbus Format 20608 5080 hex 16 bit unsigned Touchscreen Menu Path Home Advanced A...

Page 54: ...djusts the response of the Automatic smoothing Increase to provide a greater smoothing effect if there are torque fluctuations that occur during the soft stop When set to zero the smoothing is effecti...

Page 55: ...vide a greater smoothing effect if torque fluctuations occur during the soft start When set to zero the smoothing is effectively disabled Range Modbus Decimal Value Default 0 100 linear scale 1 0 0061...

Page 56: ...t Time 0 1 On 1 Modbus Address Modbus Format 53790 D21E hex 16 bit unsigned Touchscreen Menu Path Home Advanced Start Settings Start Current Limit Trip also Home Advanced Trip Settings Start Current L...

Page 57: ...Format 7040 1B80 hex 16 bit unsigned Touchscreen Menu Path Home Advanced Start Settings Kick Start Time also Home Advanced Start Settings Kick Start Kick Start Time P3 7 Kick Start Pedestal Type Descr...

Page 58: ...e motor crawls at the end of the soft stop Decrease if greater soft stop effect is required at end of ramp Range Modbus Decimal Value Default 10 40 linear scale 1 0 006104 10 40 1638 6553 x 0 006104 M...

Page 59: ...Level P4 4 Stop Current Limit Time Type Description Read Write The maximum time allowed for the current limit If the current limit is still active at the end of this period the SR55 will either trip...

Page 60: ...urrent On The SR55 will trip when lower than expected current draw occurs This trip is constrained by the Low Current Trip Level and the Low Current Trip Time This feature is not active during soft st...

Page 61: ...5 linear scale 1 1mA 450 I SR55 Modbus Address Modbus Format 27584 6BC0 hex 16 bit unsigned Touchscreen Menu Path Home Advanced Motor Protection Shearpin Settings Shearpin Trip Current P5 7 Shearpin T...

Page 62: ...s the intelligent Energy Recovery System feature iERS Range Modbus Decimal Value Default decimal Off The feature is disabled and the motor operates at full voltage On The voltage to the motor will be...

Page 63: ...Level Type Description Read Write Determines the maximum energy saving potential Reduce if the application shows signs of instability The amount of energy that can be saved may fall as the iERS Level...

Page 64: ...een Menu Path Home Advanced iERS Fixed Voltage Advanced Control Method Parameter P7 0 Control Method Hold Reg Type Description Read Write Local Touch Screen Control using the button on the keypad Digi...

Page 65: ...nsitivity P8 1 Cover Open Trip Hold Reg Type Description Read Write For safety purposes the SR55 has the ability to trip if the front cover is open Range Modbus Decimal Value Default decimal Off The S...

Page 66: ...rite This can be used to detect if the motor is running lightly loaded Range Modbus Decimal Value Default decimal Off The SR55 will continue to operate regardless of motor current On The SR55 will tri...

Page 67: ...ecimal Value Default decimal Off The SR55 will continue to operate On The SR55 will trip if the motor thermistor exceeds its response temperature or the PTC input is open circuit 4k 0 1 Off 0 Modbus A...

Page 68: ...fected On The SR55 will trip if the internal current sensors fail or the current measured falls to a very low level 0 1 Off 0 Modbus Address Modbus Format 53775 D20F hex 16 bit unsigned Touchscreen Me...

Page 69: ...luctuations If the torque fluctuations get too bad then the SR55 may trip this could cause issues with the restart With Shut Down Trips turned on if the torque fluctuations are experienced the SR55 wi...

Page 70: ...s to turn on properly 0 1 On 1 Modbus Address Modbus Format 53781 D215 hex 16 bit unsigned Touchscreen Menu Path Home Advanced Trip Settings Sensing Fault Trip P8 19 Thermal Sensor Trip Hold Reg Type...

Page 71: ...unsigned Touchscreen Menu Path Home Advanced Trip Settings Keypad Trip P8 23 Logging Trip Hold Reg Type Description Read Write Detects if the logging to the internal SD card has failed to operate norm...

Page 72: ...uration Changes phase rotation L1 L2 L3 to L1 L3 L2 For Legacy Delta Mode to be activated Firing Mode must be set to In Delta Range Modbus Decimal Value Default decimal Off Operates normally Refer to...

Page 73: ...re set for No Function Selected P10 3 0 and High Input Sets Value P10 4 1 which are the default settings for this input D1 2I 1 Sets Control Method to 2 Wire Hand D1 2I 0 Sets Control Method to Modbus...

Page 74: ...ng the terminals function defined in I O menu Two Wire Control Control using terminals functions fixed as shown on screen Three Wire Control Control using terminals functions fixed as shown on screen...

Page 75: ...t Function Settings on page 3 46 Off 0 Modbus Address Modbus Format 10945 2AC1 hex 16 bit unsigned Touchscreen Menu Path Home I O Digital Inputs Digital Input 2 D1 2I Select Function P10 4 Digital Inp...

Page 76: ...t x x Select Function I O parameters 10944 10946 Settings Modbus Decimal Value Description Off 0 No function selected Start Stop 280 Off Stops or Soft Stops the SR55 On Starts the SR55 Freeze Ramp 285...

Page 77: ...on is activated the output is open 0 1 On 1 Modbus Address Modbus Format 11904 2E80 hex 16 bit unsigned Touchscreen Menu Path Home I O Digital Outputs Digital Output 1 N C 12 High Output 1 When Value...

Page 78: ...the output is closed 0 1 On 1 Modbus Address Modbus Format 11908 2E84 hex 16 bit unsigned Touchscreen Menu Path Home I O Digital Outputs Digital Output 3 N O 34 High Output 1 When Value P11 6 Digital...

Page 79: ...the SR55 is enabled and ready for a start Remains on when Running Error 583 STATUS INDICATION Error Off The SR55 is fault free On Indicates that SR55 has detected a fault and has shut down The fault...

Page 80: ...6 bit unsigned Touchscreen Menu Path Home I O Analog Inputs Select Function Analog Input Examples of P12 1 Analog Input Fuction Selections AI Function Settings Modbus Dec Value Example Current Limit S...

Page 81: ...I O Analog Outputs Analog Output Type P13 1 Analog Output Select Function Hold Reg Type Description Read Write Allows the Analog Output to be mapped to different functions The output will change in p...

Page 82: ...bus value of 5250 32 05 0 Modbus Address Modbus Format 9088 2380 hex 16 bit unsigned Touchscreen Menu Path Home I O Analog Outputs Scaling Level I O PTC Motor Thermistor Trip Parameter P14 0 PTC Motor...

Page 83: ...e of the incoming supply Range Modbus Decimal Value Default decimal RYB L1 L2 L3 RBY L1 L3 L2 0 1 L1 L2 L3 0 Modbus Address Modbus Format 32064 7D40 hex 16 bit unsigned Touchscreen Menu Path Home Moni...

Page 84: ...32 bit unsigned Touchscreen Menu Path Home Monitor Current Irms P15 6 Vrms Approx Type Description Read Only The RMS 3 phase supply voltage This is the average of the 3 phases This value is used for p...

Page 85: ...1VA Apparent Power kVA Value 1000 0 kVA Modbus Address Modbus Format 34816 34817 8800 8801 hex 32 bit unsigned Touchscreen Menu Path Home Monitor Apparent Power S P15 10 Reactive Power Q Type Descript...

Page 86: ...eFreq 25 9 0 Modbus Address Modbus Format 23040 5A00 hex 16 bit unsigned Touchscreen Menu Path Home Monitor BackStop P15 14 Delay Max Type Description Read Only The maximum possible delay for iERS sav...

Page 87: ...current in Amps at which the iERS is enabled or disabled The iERS function is active when the motor current is less than the Start Saving Level When the iERS function is disabled internal bypass rela...

Page 88: ...splayed should be less than 100 and the SR55 trips when value 400 4k open circuit 1023 The value will increase rapidly when the motor thermistors approach their nominal temperature If thermistors are...

Page 89: ...tes Touchscreen Menu Path Home Log Start Current Temperature Overload Last Peak Start Current Last Temperature Last Overload P16 1 Event Time Last Peak Start Current Last Temperature Last Overload 1 H...

Page 90: ...st Overload 3 P16 4 Event Time Last Peak Start Current Last Temperature Last Overload 4 Holding Register Type Description Read Only Displays the event time 4 Range Modbus Decimal Value Default hh mm s...

Page 91: ...st Overload 6 P16 7 Event Time Last Peak Start Current Last Temperature Last Overload 7 Holding Register Type Description Read Only Displays the event time 7 Range Modbus Decimal Value Default hh mm s...

Page 92: ...rload 9 Log Trip Log Event Times Parameters P17 0 Last Trip Type Description Read Only Displays the last Fault trip Refer to Trip Code Descriptions in this chapter Range Modbus Decimal Value Default T...

Page 93: ...Trip Log Last Trip 2 P17 3 Last Trip 3 Type Description Read Only Displays the last Fault trip 3 Refer to Trip Code Descriptions in this chapter Range Modbus Decimal Value Default Trip 0 65 535 Trip...

Page 94: ...Trip Log Last Trip 5 P17 6 Last Trip 6 Type Description Read Only Displays the last Fault trip 6 Refer to Trip Code Descriptions in this chapter Range Modbus Decimal Value Default Trip 0 65 535 Trip...

Page 95: ...ath Home Log Trip Log Last Trip 8 P17 9 Last Trip 9 Type Description Read Only Displays the last Fault trip 9 Refer to Trip Code Descriptions in this chapter Range Modbus Decimal Value Default Trip 0...

Page 96: ...nge Modbus Decimal Value Default 0A 10 000A linear scale 1 1mA Current A Value 1000 0A Modbus Address Modbus Format 38404 38405 9604 9605 hex 32 bit unsigned Touchscreen Menu Path Home Log Start Curre...

Page 97: ...nge Modbus Decimal Value Default 0A 10 000A linear scale 1 1mA Current A Value 1000 0A Modbus Address Modbus Format 38412 38413 960C 960D hex 32 bit unsigned Touchscreen Menu Path Home Log Start Curre...

Page 98: ...stop Range Modbus Decimal Value Default Peak Current 0A 10 000A Peak Current Time hh mm ss linear scale 1 1mA Current A Value 1000 Time ms since midnight bytes5 4 3 2 and Days since 01 01 1984 bytes1...

Page 99: ...Description Read Only Displays the peak current of the last successful stop 3 Range Modbus Decimal Value Default Peak Current 0A 10 000A Peak Current Time hh mm ss linear scale 1 1mA Current A Value 1...

Page 100: ...cription Read Only Displays the peak current of the last successful stop 6 Range Modbus Decimal Value Default Peak Current 0A 10 000A Peak Current Time hh mm ss linear scale 1 1mA Current A Value 1000...

Page 101: ...Current 8 P19 9 Last Peak Stop Current 9 Type Description Read Only Displays the peak current of the last successful stop 9 Range Modbus Decimal Value Default Peak Current 0A 10 000A Peak Current Time...

Page 102: ...og Last Temperature 1 P20 2 Last Temperature 2 Type Description Read Only Displays the heatsink temperature at the end of the last successful start 2 Range Modbus Decimal Value Default 20 C to 80 C bi...

Page 103: ...og Last Temperature 4 P20 5 Last Temperature 5 Type Description Read Only Displays the heatsink temperature at the end of the last successful start 5 Range Modbus Decimal Value Default 20 C to 80 C bi...

Page 104: ...og Last Temperature 7 P20 8 Last Temperature 8 Type Description Read Only Displays the heatsink temperature at the end of the last successful start 8 Range Modbus Decimal Value Default 20 C to 80 C bi...

Page 105: ...321 9D81 hex 16 bit unsigned Touchscreen Menu Path Home Log Overload Log Last Overload 1 P21 2 Last overload 2 Type Description Read Only Displays the overload level at the end of the last successful...

Page 106: ...x 16 bit unsigned Touchscreen Menu Path Home Log Overload Log Last Overload 6 P21 7 Last overload 7 Type Description Read Only Displays the overload level at the end of the last successful start 7 Ran...

Page 107: ...g Totals Log Number of Starts Log Download Log File Parameter P23 0 Download Log File Type Description Read Write Download the full log file onto the USB flash drive The SR55 logs several parameters d...

Page 108: ...Read Write Allows the time to be changed to local time Range Modbus Decimal Value Default hh mm ss Time ms since midnight bytes5 4 3 2 and Days since 01 01 1984 bytes1 0 GMT Modbus Address Modbus For...

Page 109: ...and stopped The Log and Monitor screens can also still be accessed Range Modbus Decimal Value Default 0 9 per Byte ASCII character 48 57 48 0 57 9 n a Modbus Address Modbus Format 12864 3240 hex Byte...

Page 110: ...Parity Hold Reg Type Description Read Write Sets the serial communications parity bit Also sets the stop bits No parity uses 2 stop bits Odd even parity uses 1 stop bit Range Modbus Decimal Value Def...

Page 111: ...riod To prevent a Communications Trip If enabled a parameter must be written to or read within this time period Range Modbus Decimal Value Default 0ms 60 000ms linear scale 1 1 ms 5000ms Modbus Addres...

Page 112: ...lock is enabled P27 1 About Type Description Read Only Gives the SR55 model number serial number and current firmware versions Range Modbus Decimal Value Default Model number Serial Number Firmware v...

Page 113: ...he on board touchscreen only Range Modbus Decimal Value Default decimal No Yes 0 1 No 0 Modbus Address Modbus Format 62272 F340 Touchscreen Menu Path Home Device Parameters to USB P27 6 Parameters fro...

Page 114: ...ting as expected Check all incoming and outgoing connections 350 357 Thyristor Firing Trip One or more of the internal control thyristors SCRs have failed to turn on properly Delta Firing Mode The SR5...

Page 115: ...nications failure A parameter has not been written to or polled in the time set in the Timeout period under Device Networks If the Communications Trip is disabled the SR55 will not be stopped by the c...

Page 116: ...on between the Main Board and Touchscreen Board has been affected and is unable to recover automatically 2428 The modbus communication has been affected and is unable to recover automatically 2430 The...

Page 117: ...20 consecutive attempts 2602 The event logging function has been unsuccessful for 20 consecutive attempts 2603 The SD card could not be accessed 20 consecutive attempts Fail Safe Trip Codes As part o...

Page 118: ...e flash drive it will be overwritten It is suggested that parameter files be archived in a separate folder with a unique name other than PARAM A new parameter configuration must be configured on the S...

Page 119: ...er Chapter Chapter Table of Contents Chapter 4 Principles of iERS intelligent Energy Recovery System 4 1 Principles of the iERS 4 2 Enabling Intelligent Energy Recovery System iERS 4 2 Principles of i...

Page 120: ...nt changes in motor torque may cause the SR55 soft starter to switch rapidly between the iERS on state and the bypassed state as the motor torque changes If left unchecked such switching may cause pre...

Page 121: ...regardless of the torque demanded by the mechanical load The energy required to support the load torque is determined by the torque demand As load torque increases the rotor slows down a little i e s...

Page 122: ...que If the reduced voltage is correctly chosen the working point at the reduced torque demand becomes the point A By reducing the terminal voltage the motor has in effect been exchanged for one which...

Page 123: ...haracteristics duty cycle supply voltage and the cost of electricity Figure 4 5 1 Energy Savings 40 60 80 100 120 140 160 seconds FLC 100 50 0 Current demand with Energy Saving in operation Magnetizin...

Page 124: ...0 5 8 1 5 1 Examples of estimated energy savings 1 37 5 kW 4 pole motor From Table 1 use the estimated savings figure for the next higher rating i e 55 kW The savings would be approximately 3 5 x 37...

Page 125: ...when the motor is fully loaded the relays will be energized and we will have no losses in the thyristors We will therefore gain maximum saving which is especially beneficial on typical cyclic loading...

Page 126: ...mited by the impedance presented by a de energized motor and the applied voltage Usually expressed as a multiple of motor full load current Kic k start Voltage The percentage of supply voltage applied...

Page 127: ...sage Structure For RTU Mode 5 4 Supported Functions 5 5 Memory Map 5 6 Message Timing 5 6 Network Communications EtherNet IP and Modbus TCP 5 7 Communication Module Overview 5 7 Module Installation SR...

Page 128: ...ional Modbus TCP communication module SR55 CM MODTCP per SR55 soft starter EtherNet IP Network Communications Overview Multiple SR55 soft starters can be networked for configuration and control from a...

Page 129: ...ot connected 5 TXD0 A OUT SG 6 TXD1 B OUT SG Warning To avoid damage to the SR55 or to the RS 485 master do NOT connect to this pin Modbus RTU Connections SR55 xxx SR55 SPLT SR55 xxx SR55 xxx SR55 xxx...

Page 130: ...the master in a defined structure In both messages request and answer the used structure is the same Address Function Code Data and CRC Master request message Address 1 byte Function 1 byte Request Da...

Page 131: ...holding register type block R W limited to 8 registers Function code 03 Modbus Function 03 Transaction Table Query Response Field Hex Byte Field Hex Byte Slave address 01 Slave address 01 Function 03...

Page 132: ...ading or writing equipment parameters from or to the holding registers The data addressing is zero offset such that the parameter Modbus address corresponds to the register number Modbus Address Memor...

Page 133: ...SR55 option module slot per the hardware installation instructions in the Accessories chapter of this user manual Refer to the installation instructions in the Accessories chapter of this user manual...

Page 134: ...ve Red Duplicate IP fatal error Red flashing Connection timeout Module Status LED LED State Description Off No power Green Controlled Run state Green flashing Not configured or idle state Red Major fa...

Page 135: ...he SR55 CM ENETIP Module and is dictated by the EDS file provided by HMS Industrial Networks The EDS describes parameters that can be accessed explicitly in an Acyclic manner Not all of these paramete...

Page 136: ...lder that it was installed to usually the HMS folder in the Start menu In Windows 8 from the home tile screen simply type in ipconfig Typing any text on this screen will open the Search dialog The pro...

Page 137: ...from a specific Network Interface Controller This could be required if there are multiple network cards on the PC Click OK then Scan for SR55 units again Below shows a screen capture of an SR55 077 an...

Page 138: ...wing up in the IPconfig screen check the following That the SR55 MODTCP or SR55 ENETIP module is inserted correctly and MS LED is on or flashing green See module installation instructions in this SR55...

Page 139: ...ing error will be returned If the IPv4 Ethernet address is incorrect the following error will be returned notice that unlike the previous error this error returns Destination host unreachable If Ping...

Page 140: ...value is 21 O T Output Data Size is 4 bytes The Data format for Control is shown in the Output Data Setup screen capture No Configuration data is required To start the SR55 a value of 33 should be pla...

Page 141: ...Chapter 5 Communications Page 5 15 Stellar SR55 Series Soft Starter User Manual 1st Ed Rev F 09 18 2019 EtherNet IP Network Communications continued Output Data Setup...

Page 142: ...Page 5 16 Stellar SR55 Series Soft Starter User Manual 1st Ed Rev F 09 18 2019 Chapter 5 Communications EtherNet IP Network Communications continued Config Data Setup No Config Data...

Page 143: ...the other parameters either require a value of 1 or 0 for SET 16 and will return a value of 0 or 1 on the GET 14 parameters To run the starter a value of 1 must be set in the Network Control parameter...

Page 144: ...Manual 1st Ed Rev F 09 18 2019 Chapter 5 Communications EtherNet IP Network Communications continued Explicit Message Instruction Examples from Productivity Series CPU Example instruction for setting...

Page 145: ...Stellar SR55 Series Soft Starter User Manual 1st Ed Rev F 09 18 2019 EtherNet IP Network Communications continued Example instruction for controlling the Start and Stop of the Motor Productivity CPU...

Page 146: ...SR55 Series Soft Starter User Manual 1st Ed Rev F 09 18 2019 Chapter 5 Communications EtherNet IP Network Communications continued Example instruction for reading back the Fault status of the Starter...

Page 147: ...r User Manual 1st Ed Rev F 09 18 2019 EtherNet IP Network Communications continued Example instruction to reset any faults on the Starter Productivity CPU Drive State Byte Value State Description 1 St...

Page 148: ...Page 5 22 Stellar SR55 Series Soft Starter User Manual 1st Ed Rev F 09 18 2019 Chapter 5 Communications BLANK PAGE...

Page 149: ...ter Chapter Chapter Table of Contents Chapter 6 Accessories 6 1 Optional Accessories 6 2 Finger Guards 6 2 Remote Touchscreen 6 3 RJ45 to RJ12 Adapter 6 5 Serial Modbus Communication Splitter 6 5 Comm...

Page 150: ...al for size 2 Stellar SR55 series soft starter power terminals Provides IP20 protection rating Package of 2 124 thru 180 SR55 KPD REM Touchscreen optional remote for Stellar SR55 series soft starters...

Page 151: ...screen allows remote monitoring configuration and control of SR55 soft starters Since the touchscreen is a master RS 485 device it can control multiple SR55 soft starters Includes a 3m 9 8ft Cat5e cab...

Page 152: ...it is connected to by displaying the starter s node address and serial number EX address 01 and serial number A0167805 Fig 1 Fig 2 Fig 3 How to use the remote touchscreen The remote touchscreen s con...

Page 153: ...ugs directly into the RJ12 port on top of the SR55 and provides a receptacle for a communication cable with an RJ45 connector Serial Modbus Communication Splitter SR55 SPLT With front cover on With fr...

Page 154: ...ort connects to the starter using a standard RJ45 Ethernet patch cord and an SR55 RJ45 RJ12 adapter The RJ45 port on the left connects to the next splitter on the network If this is the last splitter...

Page 155: ...and Parameters Chapter 3 and Communications Chapter 5 of this user manual for detailed parameter and EtherNet IP network communications information Refer to the installation instructions in the follo...

Page 156: ...nt safety information and warnings contained in this SR55 User Manual Instructional Video https www youtube com watch v ybqj_hwGrm8 Written Instructions 1 Ensure that all power is removed from the SR5...

Page 157: ...ly Fig 5a not seated Fig 5b seated properly Fig 6 Fig 6 view is from a disassembled SR55 for reference only 6 This is caused by the two plastic clips on the bottom side of the module shown in fig 7 an...

Page 158: ...3 butt splice terminals If replacement terminals are needed they can be purchased from a third party distributor PN UY2 MFG 3M 2 SR55 FAN 6 12VDC fans fit SR55 156 and SR55 180 soft starters Some ear...

Page 159: ...d The replacement fan kit SR55 FAN 6 includes a 12VDC fan and a resistor for use in the 24VDC starters as described below For early model SR55 156 and SR55 180 soft starters one of the original fans m...

Page 160: ...t starter 1 Unscrew existing fan s 2 Cut wires close to fan s Instructions for Fan Replacement Method 1 3 Fit black wires from new fan and SR55 into connector included 4 Push connector shut with plier...

Page 161: ...oft starters as described below NOTE Refer to the Cooling Fan Replacement Method Selection Flowchart on page 6 11 to determine which replacement method and instructions to use for your soft starter Im...

Page 162: ...into connector Replacement fan 7 Select the Red wires as shown below and place into connector Push shut with pliers 8 Place and crimp the two remining wires 1 Red wire and 1 Black wire into the final...

Page 163: ...SR55 414 and SR55 477 models 1 Remove 4 screws from lower end molding 2 Slide lower end molding off of busbars Instructions for Fan Replacement Method 3 Only for SR55 FAN 8 SR55 414 SR55 477 Soft Star...

Page 164: ...stalled on the SR55 soft starters Touchscreen Replacement Installation Instructions 1 Carefully remove the outer bevel casing around the LCD display 2 Remove the two plastic rivets below the LCD displ...

Page 165: ...ement screen FFC cable in socket making sure that it is correctly seated Push the gray part down to lock 7 Once the socket is locked with the FFC cable firmly connected gently place the board back in...

Page 166: ...Page 6 18 Stellar SR55 Series Soft Starter User Manual 1st Ed Rev F 09 18 2019 Chapter 6 Accessories BLANK PAGE...

Page 167: ...e A 1 Stellar SR55 Series Soft Starter User Manual 1st Ed Rev F 09 18 2019 Updating Firmware A A A Appendix Appendix Appendix Table of Contents Appendix A Updating Firmware A 1 Updating SR55 Firmware...

Page 168: ...pdating the firmware of an SR55 soft starter 1 Obtain a USB flash drive and ensure that it has been formatted to FAT32 ADC part number USB FLASH is a 4GB SanDisk USB flash drive that has been verified...

Page 169: ...Starter User Manual 1st Ed Rev F 09 18 2019 5 Double click on the new directory and inside you will see all of the boot loading files Select all of these files and copy them onto the route directory...

Page 170: ...t the USB flash drive which contains the new issue of the boot load firmware into the USB connector on the SR55 The flash drive is shown in red above the touchscreen If using the remote touchscreen yo...

Page 171: ...loading bar will appear which shows the update process has begun 10 Wait for approximately one minute for the updating firmware screen to be displayed This screen shows the progress of the firmware b...

Page 172: ...Page A 6 Stellar SR55 Series Soft Starter User Manual 1st Ed Rev F 09 18 2019 Appendix A Updating Firmware BLANK PAGE...

Page 173: ...Enclosures B 3 B 1 11 Efficiency B 4 B 1 12 High Efficiency Motors B 4 B 1 13 EU Compliance with the EMC Directive B 4 B 1 14 Fuses B 4 B 2 Rules for Specific Applications B 5 B 2 1 In Delta Operatio...

Page 174: ...ts load from standstill to full speed and to maintain full speed efficiently at all torque levels up to the design full load torque Most modern three phase induction motors have characteristics that a...

Page 175: ...al electrically operated brake internally connected to the motor input terminals can only be soft started when the brake is re connected to the supply through its own contactor Do NOT soft start the b...

Page 176: ...13 EU Compliance with the EMC Directive When considering the use or fitting of any Soft Starter users and installers in European countries must comply with the EMC Directive 2004 108 EC The manufactur...

Page 177: ...e involved then an analysis of the starting characteristics should be made This requires accurate data about the motor and the load Complete motor data Current Voltage Power Speed Rotor Inertia Speed...

Page 178: ...rger size or one with a high starting torque characteristic before a soft starter can be employed B 2 12 Overhauling Loads Certain applications can overspeed the motor as part of normal operation Powe...

Page 179: ...ertical lowering unloaded 10 40 Conveyor vertical lowering loaded 10 25 Crusher not rock unloaded 25 75 Can be high inertia Drilling machine unloaded 10 Fan axial flow propeller 20 40 Feeder screw 100...

Page 180: ...B 3 2 The Induction Motor In order to appreciate the benefits of using an electronic controller it is important to have some understanding of the characteristics and limitations of the induction moto...

Page 181: ...Each load coupled to an induction motor has its own speed torque curve Pull Out Torque MK TORQUE Pull up Torque Full Load Torque FLT MN Synchronous speed 0 SPEED S Torque Speed Curve Coupled Load Lock...

Page 182: ...otor by techniques such as double cage or deep bar design and this usually is the motor characteristic chosen for lifting and hoisting applications Figure B 3 2 4 Torque Speed Curve High Starting Torq...

Page 183: ...figuration from an initial wye connection to a delta connection as the motor accelerates The change over or transition point is controlled by the time switch and is usually arranged to be approximatel...

Page 184: ...s such as auto transformer starting popular in North America primary reactance starting etc are employed to a greater or lesser extent to compensate for some of the disadvantages of each type of start...

Page 185: ...affinity laws will allow the inverter drive to show very considerable energy savings over virtually all other methods of control through varying the speed of the motor in response to changes in load...

Page 186: ...one phase while the other two are directly connected Owing to the variable quality and performance of many so called inverters and soft starters available to the unsuspecting purchaser international s...

Page 187: ...by the impedance presented by a de energized motor and the applied voltage Usually expressed as a multiple of motor full load current Kic k start Voltage The percentage of supply voltage applied befor...

Page 188: ...Page B 16 Stellar SR55 Series Soft Starter User Manual 1st Ed Rev F 09 18 2019 Appendix B Soft Starter Application Considerations BLANK PAGE...

Page 189: ...Within the EU C 2 C 3 Mandatory Requirements Within the EU C 2 C 4 Guidance for Installation Personnel and System Designers C 2 C 5 EMC Basic Criteria C 3 C 6 Purchasing Implications of Meeting an EMC...

Page 190: ...ournal of the EC will list this standard as EN 60947 4 2 The SR55 has been type tested in accordance with the test procedures and levels laid down in the product standard C 3 Mandatory Requirements Wi...

Page 191: ...alth care applications directly connected to a public low voltage network Generally industrial installations require higher immunity levels and permit higher levels of conducted and radiated emissions...

Page 192: ...circuits are configured as a fully controlled regulators W3C Only non triplen integer multiples of the third harmonic odd harmonic frequencies are created starting with and diminishing rapidly from t...

Page 193: ...ons Certain industries particularly continuous process industries employ distribution systems that operate either with a ground connection through a high impedance or without a ground at all These sys...

Page 194: ...e cross coupling between cables Shield any cables carrying sensitive signals The digital control inputs to a SR55 are opto isolated and do not normally require buffering e g through a small relay or s...

Page 195: ...D D D Appendix Appendix Appendix Table of Contents Appendix D Sizing an SR55 Soft Starter D 1 SR55 Soft Starter Selection Steps D 2 SR55 Soft Starter Overload Trip D 3 SR55 Index Ratings D 3 Standard...

Page 196: ...quired Trip Class motor HP and connection type SR55 Soft Starters Selection Table per IEC 60947 4 1 2009 Table G 1 Motor Size Soft Starter Size In Line Connection In Delta Connection Application Trip...

Page 197: ...C 53a X Tx F S SR55 017 to SR55 180 17 to 195 AC 53a 3 5 17 90 5 SR55 242 to SR55 477 242 to 500 AC 53a 3 5 17 90 3 Index ratings AC 53a and AC 53b are specified by IEC standard 60947 4 2 IEC Index Ra...

Page 198: ...itted for up to 17 seconds only The Duty Cycle is expressed by two symbols F and S which describe the duty and also set the time that must be allowed for cooling F is the ratio of the on load period t...

Page 199: ...he starts hour is given below in Figure 2 and the two examples that follow This assumes that the SR55 is still operating at the same duty F as given in Figure 1 Figure 2 SR55 Starts Hour Deration Dera...

Page 200: ...onfiguration 1 Set Application Auto Setup 2 Set Motor Current to 80A Auto Setup 3 Warm Trip Time will be reduced to Trip Class 10 value 320A for 13s Example 2 SR55 Selection and Configuration Step SR5...

Page 201: ...Stellar SR55 Series Soft Starter User Manual 1st Ed Rev F 09 18 2019 BLANK PAGE...

Page 202: ...Stellar SR55 Series Soft Starter User Manual 1st Ed Rev F 09 18 2019...

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