Eaton S611 User Manual Download

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S611 Soft Starter

MN03902011E—May 2012 www.eaton.com

Communications

Replacement Parts

Description

Catalog Number

Modbus communication adapter without I/O

C441M

Modbus communication adapter with 120 Vac I/O

C441N

Modbus communication adapter with 24 Vdc I/O

C441P

DeviceNet communication adapter with 120 Vac I/O

C441K

DeviceNet communication adapter with 24 Vdc I/O

C441L

PROFIBUS communication adapter with 120 Vac I/O

C441S

PROFIBUS communication adapter with 24 Vdc I/O

C441Q

Ethernet IP/Modbus TCP communication adapter with 120 Vac I/O

C441R

Ethernet IP/Modbus TCP communication adapter with 24 Vdc I/O

C441T

Communication adapter

C440-COM-ADP

Description

Part Number

User interface

S611-KEYPAD

User interface communication cable—0.25m (0.82 ft)

D77E-QPIP25

Control board assembly—52A standard

S611-PCB-052S

Control board assembly—65A standard

S611-PCB-065S

Control board assembly—77A standard

S611-PCB-077S

Control board assembly—99A standard

S611-PCB-099S

Control board assembly—125A standard

S611-PCB-125S

Control board assembly—156A standard

S611-PCB-156S

Control board assembly—180A standard

S611-PCB-180S

Control board assembly—242A standard

S611-PCB-242S

Control board assembly—302A standard

S611-PCB-302S

Control board assembly—361A standard

S611-PCB-361S

Control board assembly—414A standard

S611-PCB-414S

Control board assembly—52A pump

S611-PCB-052P

Control board assembly—65A pump

S611-PCB-065P

Control board assembly—77A pump

S611-PCB-077P

Control board assembly—99A pump

S611-PCB-099P

Control board assembly—125A pump

S611-PCB-125P

Control board assembly—156A pump

S611-PCB-156P

Control board assembly—180A pump

S611-PCB-180P

Control board assembly—242A pump

S611-PCB-242P

Control board assembly—302A pump

S611-PCB-302P

Control board assembly—361A pump

S611-PCB-361P

Control board assembly—414A pump

S611-PCB-414P

Frame A/B CT

S611-CT-AB

Frame C/D CT

S611-CT-CD

Frame E/F CT

S611-CT-EF

Contactor assembly—52–180A

C25DNY172

Contactor assembly—242–414A

C25DNY173

www.comoso.com

Summary of Contents for S611

Page 1: ...S611 Soft Starter User Manual Effective May 2012 Supersedes August 2011 www comoso com...

Page 2: ...www comoso com...

Page 3: ...RCHANTABILITY OTHER THAN THOSE SPECIFICALLY SET OUT IN ANY EXISTING CONTRACT BETWEEN THE PARTIES ANY SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF EATON THE CONTENTS OF THIS DOCUMENT SHALL NOT BECOME...

Page 4: ...E 386 2273 8 00 a m 6 00 p m EST FAX 800 752 8602 After Hours Emergency 800 543 7038 6 00 p m 8 00 a m EST If you are in the U S or Canada and have OI or PLC questions you can take advantage of our to...

Page 5: ...eral 5 Unpacking 5 Storage 5 Shipping 5 INSTALLATION Mounting 6 Dimensions 6 Current Transformer Installation 8 Lug Installation Mechanical 8 Power Wiring 8 Control Wiring Inputs 10 FUNCTIONAL DESCRIP...

Page 6: ...ES Power Ratings 56 Power Losses 58 APPENDIX D MOTOR APPLICATION CONSIDERATIONS Line and Load Power Wiring Cross Reference Tables 59 APPENDIX E SPECIAL FUNCTION OPTION Pump Control Option 64 APPENDIX...

Page 7: ...4 120 Vac Control 16 24 Vdc Control 16 Line Connected Soft Starter SCRs 17 Ramp Start 18 Current Limit 19 Soft Stop 19 User Interface Module UI 22 Start Command Troubleshooting Flowchart 30 Local Cont...

Page 8: ...lt Codes 27 S611 Does Not START 30 S611 Stopped or Faulted 31 Optional Accessory Kits 37 Communications 38 Replacement Parts 38 Operation Mode Standard 39 Operation Mode Pump Option 40 Protection Mode...

Page 9: ...y Duty 500 FLA for 30 Seconds 125 Continuous 57 Severe Duty 600 FLA for 30 Seconds 125 Continuous 57 Maximum Power Loss 58 Mechanical Terminals 59 Compression Terminals Ilsco 59 Compression Terminals...

Page 10: ...nance Be sure equipment is properly grounded Wear safety glasses whenever working on electronic controllers or rotating machinery Warnings and Cautions CAUTION Unit may weigh up to 102 pounds Use suit...

Page 11: ...procedures in this manual before you attempt to set up or operate the equipment WARNING Do not work on energized equipment unless absolutely required If the troubleshooting procedure requires equipmen...

Page 12: ...S611 Soft Starter x S611 Soft Starter MN03902011E May 2012 www eaton com www comoso com...

Page 13: ...ort B adds excessive height to the S611 the adapter may be mounted to the side of the S611 and wired to comms port A using an L Adapter in combination with the Eaton brand communication adapters PROFI...

Page 14: ...IEC 61000 4 4 2 kV 5 kHz rep 2 min intervals 1 2 50 uS 8 20 uS surges IEC61000 4 5 2 kV line to earth 1 kV line to line 1 minute intervals Terminal connections 4 kV line to earth 2 kV line to line 1 m...

Page 15: ...o 414A units Vibration resistance Non operating 3g up to 242A units 2g on 302A to 414A units Operating 1g for all units Unit Weight Lbs kg Product Size Inches mm Catalog Number Length Width Height 24...

Page 16: ...pting rating not less than 65 000 rms symmetrical amperes 480 volts maximum Frame Size Fuses Circuit Breaker Voltage V SCCR Rating A A RK5 K5 J Eaton FDC thermal magnetic 600 10k B RK5 K5 J Eaton FDC...

Page 17: ...y Retain the packaging materials for carrier to review Verify that the unit s catalog number and options match those stated on the order purchase form CAUTION Unit may weigh up to 102 pounds Use suita...

Page 18: ...the S611 Slotted and or round holes may be used as long as two holes top and two holes bottom four total are used minimum To mount the unit use all the hardware specified in the table below Required M...

Page 19: ...and F Frame 8 57 217 6 5 20 132 0 2 76 70 0 2 76 70 0 21 01 533 6 18 30 464 7 4 33 110 0 3 15 80 0 3 15 80 0 0 39 10 0 8 Places 3 54 90 0 11 58 294 2 9 50 241 3 6 81 172 9 5 00 127 0 6 10 155 0 5 00 1...

Page 20: ...e on the output of the S611 soft starter unless a means to turn off the soft starter when disconnect switch is open is used Opening disconnect while the soft starter is operating may cause a malfuncti...

Page 21: ...orque and prevent excessive side loads being placed on the supports Line and Load Power Wiring Notes Additional lug information may be found in Appendix D Each lug kit consists of three lugs Two kits...

Page 22: ...result in severe damage to the controller Control Wiring Terminal Blocks CAUTION Only apply 120 Vac 50 60 Hz to terminal blocks 1 2 and 3 TB1 TB2 TB3 All control wiring is 22 12 AWG 0 33 2 5 mm2 Do no...

Page 23: ...ed 6A at 120V Network control Network TB3 Enable network control input 120 Vac 50 60 Hz maintained Energize 120 Vac to enable network control of the unit If power is removed from the permissive circui...

Page 24: ...Pushbutton Notes 1 For a single conductor a minimum wire of 14 AWG 2 5 mm2 should be used between the control power transformer and the supply terminals 2 See Using Auxiliary Contacts section if it i...

Page 25: ...13 14 95 96 and 98 3 If an isolation or reversing contactor is used upstream of the S611 Eaton recommends that the operator uses the level sensing option default value of the Start Control Parameter...

Page 26: ...reversing contactor is used upstream of the S611 Eaton recommends that the operator uses the level sensing option default value of the Start Control Parameter Code in the Advanced Parameters Menu Rese...

Page 27: ...urrent needed LO Largest outrush needed TS SI LS LO TS LI Max steady state for the CPT SI Outrush for the CPT LO The voltage on the S611 control power supply and control input terminals must be 120 Va...

Page 28: ...nge of state is recognized The resistor is rated 100 ohms at 0 5W The capacitor is 0 25 F at 250 Vac 120 Vac Control 24 Vdc Signal Control When a relay is used in conjunction with an electronic contro...

Page 29: ...ings Cooling and Power Losses gives the S611 s application ratings for various starting conditions Staying within these specified limits should avoid over temperature trips Control There are four 4 te...

Page 30: ...t a lightly loaded motor takes less torque and thus lower voltage and time to accelerate to full speed For this case the S611 will go into bypass before the ramp reaches full voltage In other words th...

Page 31: ...e or lower are not recommended Current Limit Soft Stop Pump Stop This feature is used for applications that require a controlled extended stop It is designed for high frictional loads that tend to sto...

Page 32: ...etup parameter selections 2 Start If 120 Vac is present at the Permissive terminal momentary application of 120 Vac to the Start terminal will initiate a voltage ramp or current limit start for the S6...

Page 33: ...a power outage without operator intervention CAUTION In the AUTO Reset mode CAUTION must be exercised to assure that any restart occurs in a safe manner Edge Sensing Edge sensing is selected with the...

Page 34: ...vanced Config operation or over the network The unit comes out of the box with default settings that accommodate general induction motor applications that provide very basic motor protection Parameter...

Page 35: ...he key to view past faults When the last fault is exceeded the display will show bOt to indicate the bottom of the list has been reached Press the key to view more recent faults When the most recent f...

Page 36: ...Permissive terminal input 4 For two wire control jumper Permissive and Start terminal inputs together 5 The Permissive and Network inputs must be energized 120 Vac to enable starting of the soft start...

Page 37: ...source is used to power the control circuit to edit parameters connections must be made in compliance with all local state and national electrical codes 2 In the Operation mode set the operating para...

Page 38: ...78 Frame Size C 180 90 180 90 Frame Size D 242 120 242 120 Frame Size E 302 151 302 151 Frame Size E 361 180 5 361 180 5 Frame Size F 414 207 414 207 Motor rated voltage Volts 200 600 480 Start metho...

Page 39: ...s fault log Apply the mains voltage and verify that no fault is present The S611 indicates most faults with a fault code in the alphanumeric display and by illuminating the corresponding mode and Prot...

Page 40: ...case starting conditions Adjust Initial Torque for smooth start without hesitation Rotation should begin within two seconds and the motor should smoothly accelerate to full speed 4 If stall faults oc...

Page 41: ...zed all work must be performed by properly quali ed personnel following appropriate safety practices and precautionary measures We highly recommend that you read this entire section of the manual befo...

Page 42: ...terminal If the Start Control parameter is set to Edge verify that the 120V start signal is transitioned from 0 Vac after a fault trip Network Determine if the S611 can be started locally from TB3 Ve...

Page 43: ...priate corrective action during the various run phases of operation Note If no fault codes are present during an unexpected trip of the soft starter verify that the soft starter did not receive a STOP...

Page 44: ...clear Check basis for Stop command Is Reset mode set to AUTO Possible Transient fault set Reset mode to Manual Check for external device failures Consult Manual to diagnose Fault Code Fault Code repe...

Page 45: ...mes E F Note Cover screw nuts are prevented from rotating but are not retained in place by the pole supports Do not allow hardware to fall into the soft starter 3 Lift top of cover approximately 6 in...

Page 46: ...r Interface cable assembly locking tab is located between connector and the cover Use a small screwdriver to depress locking tab The cable may also be removed after PCB is removed from the cover 2 Rem...

Page 47: ...screw nuts are prevented from rotating but are not retained in place by the pole supports Do not allow hardware to fall into the soft starter 3 Lift top of cover approximately 6 in to gain access to t...

Page 48: ...ll three contactors and the contactor support are removed as an assembly from the baseplate to aid individual contactor replacement See Contactor Connector gure on Page 35 1 Remove coil wires from the...

Page 49: ...late only enough to retain the terminal plate s in position and still allow positioning to aid in installation of the contactor support or contactor support assembly onto the baseplate 4 Install conta...

Page 50: ...d S611 PCB 077S Control board assembly 99A standard S611 PCB 099S Control board assembly 125A standard S611 PCB 125S Control board assembly 156A standard S611 PCB 156S Control board assembly 180A stan...

Page 51: ...77 38 5 77 38 5 Frame Size B 99 48 99 48 Frame Size B 125 62 5 125 62 5 Frame Size C 156 78 156 78 Frame Size C 180 90 180 90 Frame Size D 242 120 242 120 Frame Size E 302 151 302 151 Frame Size E 361...

Page 52: ...242 120 Frame Size E 302 151 302 151 Frame Size E 361 180 5 361 180 5 Frame Size F 414 207 414 207 Motor rated voltage Volts 200 600 480 Start method 0 2 2 0 Voltage ramp 1 Current limit 2 Pump start...

Page 53: ...2 4800 3 9600 4 19200 5 38400 6 57600 7 115200 P 05 Modbus Parity Port B 0 2 0 0 Even 1 stop bit 1 Odd 1 stop bit 2 No parity 2 stop bits 3 Even 2 stop bits 4 Odd 2 stop bits 5 No parity 1 stop bit P...

Page 54: ...seconds P 18 Current Phase Loss Trip Delay 1 20 2 Value in seconds P 19 Under Load Trip Delay 1 60 5 Value in seconds P 20 Under Load Source 0 1 0 0 Trip on low kW 1 Trip on under current P 21 Under...

Page 55: ...10 xx x if Ia 100 xxx if Ia 100 Mode Monitor Units A Phase IA LI L2 Status Ready Down Phase B rms current x xx if Ib 10 xx x if Ib 100 xxx if Ib 100 Mode Monitor Units A Phase IB L2 L3 Status Ready Do...

Page 56: ...by pressing the Mode Cancel button Motor Protection Basic Programming Set Points Message Description tOP Indicates that the top of the fault list has been reached bOt Indicates that the bottom of the...

Page 57: ...ter value using the Mode Cancel button Motor Protection Advanced Programming Set Points Step 1 Press Mode button until Operation mode LED is lit Step 2 Press Up or Down button until Advanced Param P O...

Page 58: ...temp 15 None None F 15 Bypass dropout 16 None None F 16 SCR not firing 17 None None F 17 Shorted SCR 18 None None F 18 Instantaneous SCR overcurrent 19 None None F 19 Motor overload 20 Operation Motor...

Page 59: ...lay starts flashing shows the last fault code and illuminates the corresponding Protection Operation LEDs as appropriate to identify the fault Step 2 Press the Down button to view older fault codes or...

Page 60: ...er Interface Module UI Mode LED Indicators Protection Operation Monitor Units LED Indicators Amps Volts kW User De ned Phase Indicator LED Indicators Average Phase A Phase B Phase C Status LED Indicat...

Page 61: ...e thermal overload is designed to protect the motor from overheating caused by excessive current If the motor is overloaded the current drawn rises and heats the motor The FLA sets the trip threshold...

Page 62: ...2 www eaton com Overload Trip Curves Overload Trip Curves Time Seconds Percent FLA 10000 0 1000 0 100 0 10 0 1 0 0 Class 5 Class 20 Class 10 Class 30 100 200 300 400 500 600 700 800 900 115 Class 20 C...

Page 63: ...current Settings Motor Stall The S611 monitors the maximum rms value of the three phase currents The unit will trip with a motor stall fault if the stall fault is enabled and the maximum rms value exc...

Page 64: ...monitors the maximum rms value of the three phase currents The unit will trip with an SCR overcurrent fault if the stall fault is disabled and the maximum rms value exceeds three times the FLA settin...

Page 65: ...the motor is running Phase loss is an extreme case of current imbalance The unit will trip with a motor phase loss fault if the phase loss trip is enabled the percent imbalance exceeds the trip thresh...

Page 66: ...nitors the minimum rms voltage and checks the value just prior to starting to determine if a fault shall be issued and the start terminated When the bypass contactors are engaged the S611 monitors the...

Page 67: ...on a phase for a number of cycles then the SCR not firing fault is issued Shorted SCR The S611 has detection for shorted SCRs The shorted SCR fault is triggered if the S611 detects current flowing whe...

Page 68: ...5N3S 77 25 25 60 75 S611A077N3S 99 30 30 75 100 S611B099N3S 125 40 40 100 125 S611B125N3S 156 50 60 125 150 S611C156N3S 180 60 60 150 150 S611C180N3S 242 75 75 200 250 S611D242N3S 302 100 100 250 300...

Page 69: ...rrent Amps Horsepower Rating 208V 240V 480V 600V Catalog Number 49 15 15 40 50 S611A052N3S 83 25 30 60 75 S611B099N3S 142 40 60 125 150 S611C156N3S 225 75 75 200 200 S611D242N3S 256 75 100 200 250 S61...

Page 70: ...the losses of another cabinet mounted device to determine the enclosure size and any cooling requirements Maximum Power Loss Frame Size FLA Current Range Power Loss Watts Catalog Number A 26 52A 32 S...

Page 71: ...sco Manufacturer S611A052XXX S611A065XXX S611A077XXX S611B099XXX S611B125XXX S611C156XXX Ilsco TA 2 0 TA 2 0 TA 2 0 TA 300 TA 300 TA 600 Manufacturer S611C180XXX S611D242XXX S611E302XXX S611E361XXX S6...

Page 72: ...2 134 300 kcmil CSWS 300 38 CSWD 300 12 134 CSWD 300 12 134 CSWD 300 12 134 350 kcmil CSWS 350 38 CSWD 350 12 134 CSWD 350 12 134 CSWD 350 12 134 Conductor Size S611A052XXX S611A065XXX S611A077XXX S61...

Page 73: ...A29L4 YA29 2LN YA29 2LN 300 kcmil YA30L24 YA30 2LN YA30 2LN YA30 2LN 350 kcmil YA31L11 YA31 2LN YA31 2LN YA31 2LN Conductor Size S611A052XXX S611A065XXX S611A077XXX S611B099XXX S611B125XXX S611C156XXX...

Page 74: ...11F414XXX 8 AWG 6 AWG 5 AWG 4 AWG 3 AWG BLU 3S3 2 AWG BLU 2S2 1 AWG BLU 1S1 1 0 AWG BLU 1 0S1 BLU 1 0S1 2 0 AWG BLU 2 0S BLU 2 0S 3 0 AWG BLU 3 0S BLU 3 0S BLU 3 0D BLU 3 0D 4 0 AWG BLU 4 0S BLU 4 0S...

Page 75: ...he correct wiring information In this case wire the two windings in parallel The soft starter is then used to control the current applied to the motor An in sight disconnect means should be installed...

Page 76: ...ethod parameter Adjustment All of the adjustments to the S611 soft starter are made as noted in this user manual The major difference between the standard S611 soft starter and one with the pump start...

Page 77: ...sters 23 0x2B 0x0E Read Device Identification Get Device Identity 43 14 Protocol supported ASCII or RTU Electrical signaling RS 485 ANSI TIA EIA 485 two wire Checksum CRC 16 bit 0x8005 or CRC CCITT 0x...

Page 78: ...dbus Registers Pin Number Circuit EIA 485 Name Recommended Wire Color Description 1 Common C C Grey Power supply common 2 D1 B B Yellow Transceiver terminal 1 V1 voltage data V1 VO for binary 1 OFF st...

Page 79: ...The debounce value is set in milliseconds Minimum time is 1 ms Maximum debounce time is 1000 ms 104 R W Field input 2 debounce time 106 R W Field input 3 debounce time 108 R W Field input 4 debounce...

Page 80: ...ps 10 304 R DCI_RMS_CURRENT_IC Amps 10 305 R DCI_RMS_CURRENT_AVG Amps 10 306 R DCI_RMS_VOLTAGE_VAB Volts 307 R DCI_RMS_VOLTAGE_VBC Volts 308 R DCI_RMS_VOLTAGE_VCA Volts 309 R DCI_RMS_VOLTAGE_AVG Volts...

Page 81: ...R SCR Overcurrent 5182 R Contactor Overcurrent 5183 R Communication Fault 5184 R Device Fault 325 R DCI_FAULT_QUEUE 1 326 R DCI_FAULT_QUEUE 2 327 R DCI_FAULT_QUEUE 3 328 R DCI_FAULT_QUEUE 4 329 R DCI...

Page 82: ...5 409 R W DCI_STOP_TIME Seconds 10 0 120 0 no pump stop option 50 with pump stop enabled 410 R W Reserved 411 R W DCI_KICK_START_TIME Seconds 10 0 2 0 412 R W DCI_KICK_START_TORQUE 0 100 0 413 R W DCI...

Page 83: ...31 R W DCI_OVER_VOLTAGE_PERCENT 101 120 110 432 R W DCI_OVER_VOLTAGE_TRIP_DELAY_SECONDS Seconds 1 60 10 433 R W DCI_VOLTAGE_UNBALANCE_PERCENT 1 20 6 434 R W DCI_VOLTAGE_UNBALANCE_TRIP_DELAY Seconds 1...

Page 84: ...TY 0 Even parity 1 stop bit default 1 Odd parity 1 stop bit 2 No parity 2 stop bits 3 Even parity 2 stop bits 4 Odd parity 2 stop bits 5 No parity 1 stop bit 443 R W DCI_COMM_LOSS_TIMEOUT_MILLISECS Mi...

Page 85: ...o open fuses All isolation devices closed Verify continuity of mains power to soft starter Load connected All isolation devices closed Reversing contactors if used in proper position Continuity of cir...

Page 86: ...missive This 120 Vac input must be maintained continuously during RUN START Command enable from terminal block No voltage applied to Network terminals When a 120 Vac signal is applied to the Network t...

Page 87: ...s are selected a motor START command will exist if a 120 Vac signal is present on terminal Start and terminal Permissive and remains energized when the fault condition clears After a transient fault t...

Page 88: ...20 Vac control power and or less than 100 Vac Check terminal block for condition and security Verify 120 Vac at appropriate terminals Verify proper operation and capacity of CTs START command troubles...

Page 89: ...er operation to the S611 If cycling power does not correct the fault condition contact EatonCare for service 8 Voltage Zero Cross Lost Mains voltage lost Phase L1 or L3 lost Load disconnected Restore...

Page 90: ...e to excessive vibration and or shock Reduce levels of vibration and or shock Verify control power and wire size meet specifications Verify that the control power supply meets the 120 Vac voltage and...

Page 91: ...age in the Operation mode is set to the correct value Note Verify that the value in the Under Voltage parameter is set to the correct line voltage and not to a nominal value Under Voltage trip level t...

Page 92: ...for failed motor coupling or pump cavitation Reduce trip threshold Increase trip delay time to ride through transient load changes Note When the bypass contactors are closed the average value of the t...

Page 93: ...trip threshold range is 150 400 of motor FLA Jam trip delay range is 1 20 seconds default is 2 0 seconds 34 Contactor Overcurrent Only active in bypass if the jam fault is disabled Current exceeds the...

Page 94: ...82 S611 Soft Starter MN03902011E May 2012 www eaton com www comoso com...

Page 95: ...www comoso com...

Page 96: ...able efficient and safe power is available when it s needed most With unparalleled knowledge of electrical power management across industries experts at Eaton deliver customized integrated solutions t...

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