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Synergy Series Soft Start User Manual

MAN-SGY-017. Version 01. 27/06/2016

223

SGY-301 to SGY-305 have metal fan guards fitted for safety reasons.
These must be removed before the fans can be taken off. They MUST be refitted using the supplied
push rivets after the fans have been attached.

A5. User Serviceable Items (continued)

fit blue wires from new fan
and Synergy into connector

squeeze with pliers

Repeat with second pair of blue.
Then 2 pairs of red wires

position fans and connectors

Fix new fan(s) to unit

Air flow
direction

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Summary of Contents for synergy

Page 1: ...Innovation in soft start technology synergytm USER MANUAL MAN SGY 017 Version 01...

Page 2: ...Synergy Series Soft Start User Manual MAN SGY 017 Version 01 25 07 2016 2 synergytm userguide Fairford Electronics Ltd Bristow House Gillard Way Ivybridge PL21 9GG UK www fairford com...

Page 3: ...Electrical Control Supply Requirements 21 2 1 3 Access 21 2 1 4 Fuse Protection 21 2 1 5 Safety 21 2 2 Electrical Connections 22 2 2 1 Electrical Supplies 22 2 3 Technical Information and Standards 2...

Page 4: ...4 Summary Parameters for Touchscreen Setup Log Category 44 3 7 5 Summary Parameters forTouchscreenSetup Device Category 46 3 8 Auto Setup Menu 47 3 9 Advanced Menu 49 3 10 Input Output 68 3 11 Monitor...

Page 5: ...rs 125 4 4 3 Profibus DP Module Pinout 126 4 4 4 Profibus DP Control 126 4 5 Anybus Module Installation 128 5 Modbus RTU Parameter Table 130 6 Trip and Fault Codes 169 6 1Trip Code Descriptions 169 6...

Page 6: ...t Stopping 182 8 2 6 Reversing Drives and Plug braking 183 8 2 7 Replacement of Fluid Couplings 183 8 2 8 Two speed Motor Applications 183 8 2 9 Multiple Motor Starting 183 8 2 10 Overhauling Loads 18...

Page 7: ...9 A1 4 Sizing Chart 201 A2 Glossary of Terms 203 A3 Starter View 205 A3 1 Introduction 205 A3 2 Installation 205 A3 3 User Interface 206 A3 4 Parameter Viewer and Editor 207 A3 4 1 Opening Parameter F...

Page 8: ...Synergy Series Soft Start User Manual MAN SGY 017 Version 01 25 07 2016 8 A6 2 Network Connection 227 A6 3 Remote Keypod Operation 229...

Page 9: ...to lightly loaded motors to only allow the motor to consume the exact amount of energy required to maintain the speed at that load When the motor is at full load the internal bypass closes this reduce...

Page 10: ...la terre Masse Indique une borne dont l usage pr vu est d tre connecter conducteur externe pour assurer la protection contre les chocs lectriques en cas de d fauts Caution Statements The examples and...

Page 11: ...en vigueur et il doit avoir un indice de protection minimal It is the responsibility of the installer to provide suitable grounding and branch circuit protection in accordance with local electrical s...

Page 12: ...rt without written permission Enquiries about copyright of Fairford Electronics deliverables should be made to Fairford Electronics Ltd If by permission of the copyright owner any part of this documen...

Page 13: ...ilation must be provided if the heat output of the unit is greater than the cabinet will dissipate Use the following formula to determine the fan requirement An allowance has been incorporated into th...

Page 14: ...Q quantit d air m tre cube par heure m3 h Wt Chaleur produite par l unit et toutes autres sources de chaleur dans l armoire Watts Tmax Temp rature maximale admissible dans l armoire 50 C pour synergy...

Page 15: ...Synergy Series Soft Start User Manual MAN SGY 017 Version 01 25 07 2016 15 1 6 Dimensions 1 Mechanical Installation continued...

Page 16: ...Synergy Series Soft Start User Manual MAN SGY 017 Version 01 25 07 2016 16 1 6 Dimensions continued 1 Mechanical Installation continued...

Page 17: ...Synergy Series Soft Start User Manual MAN SGY 017 Version 01 25 07 2016 17 1 6 Dimensions continued 1 Mechanical Installation continued synergyTM SGY401 to SGY403...

Page 18: ...Synergy Series Soft Start User Manual MAN SGY 017 Version 01 25 07 2016 18 1 6 Dimensions continued 1 Mechanical Installation continued synergyTM SGY501 to SGY505...

Page 19: ...4 F to 140 F continuous Humidity max 85 non condensing not exceeding 50 40 C 104 F Maximum Altitude 1 000m 3281ft above 1000m derate by 1 of synergy Ie per 100m 328ft to a maximum altitude of 2 000m...

Page 20: ...Synergy Series Soft Start User Manual MAN SGY 017 Version 01 25 07 2016 20 Blank Page...

Page 21: ...after gaining access to the electrical connections 2 1 4 Fuse Protection The Mains Supply and the Control Supply each require protection Although all units have electronic overload protection for the...

Page 22: ...Rated Duty Uninterrupted IEC 60947 4 2 Form Designation Form 1 internally bypassed Rated Insulation Voltage Ui 480V Rated Impulse Withstand Voltage Uimp Main circuit 4kV Control supply circuit 2 5 kV...

Page 23: ...ary series corresponding to IEC current rating 2 Rated operational powers in hp according to UL508 corresponding to FLA current rating 3 The IEC Ie rating applies for EN 60947 4 2 max rating index 195...

Page 24: ...00A 1 Suitable For Use On A Circuit Capable Of Delivering Not More Than ___Iq___ rms Symmetrical Amperes 480 Volts Maximum When Protected by Class J time delay Fuses with a Maximum Rating of ___Z1___...

Page 25: ...tection configurable through the user interface Overload trip settings are determined by the Motor Current setting and the Trip Class setting Trip class choices are Class 10 Class 20 and Class 30 The...

Page 26: ...10mm 2 0in x 0 5in SGY505 80mm x 10mm 2 5in x 0 5in Control terminals All models 0 2 1 5mm 2 24 16AWG 0 5 4 5 Protective Earth 1 M6 stud SGY101 4mm 2 12AWG 8 70 Cu only SGY103 to SGY111 6mm 2 10AWG S...

Page 27: ...Synergy Series Soft Start User Manual MAN SGY 017 Version 01 25 07 2016 27 Blank Page...

Page 28: ...n be 110 to 230Vac applied to the N L terminals or 24Vdc applied to the 0Vdc 24V input terminals The correct voltage as specified must only be applied to one of these supply inputs to avoid risk of da...

Page 29: ...ble et les besoins en couple voir la section Informations techniques normes du pr sent guide In Delta For this configuration applying the equation synergy Ie ie motor 3 Allows lower current ratingsyn...

Page 30: ...trol method menu found in the Digital Inputs menu If you would prefer the reset to work by removing and reapplying the Start Signal on D1 1I then select Two wire control in the control method menu Dig...

Page 31: ...the motor field has had some chance to die away The thermal capabilities of synergy should be considered Item Description K1 K2 AC3 rated forward reverse contactors K1A K2A 1 second drop out delay ti...

Page 32: ...supply and drops out starter and motors Stop switch drops control supply from contactors and timers stopping both motors Start switch initiates softstart then bypass of motor 1 immediately followed b...

Page 33: ...Synergy Series Soft Start User Manual MAN SGY 017 Version 01 27 06 2016 33 Blank Page...

Page 34: ...ows the user to change the parameter settings one at a time The individual parameters are grouped by categories as on the touchscreen 3 3 Configuration From Touchscreen Use the the on screen buttons t...

Page 35: ...tatus Turns RED if unit has tripped on supply failure Status Messages Motor Side Status Turns RED if unit has tripped on motor side phase loss Returns to previous screen menu Enters Sub Menus Start St...

Page 36: ...Synergy Series Soft Start User Manual MAN SGY 017 Version 01 27 06 2016 36 3 5 Auto Setup Example OL 0 I 0A P 0kW 2 1b 1a 3 4 5 6 7 8 9 3 Configuration and Parameters continued...

Page 37: ...0 0 1 0 0 0 8 2 12 Conveyor Unloaded 10 10 10 7 10 3 5 30 5 1 0 1 0 1 1 1 1 0 1 0 2 10 13 Conveyor Loaded 10 10 10 7 20 5 5 30 5 1 0 1 0 1 1 1 0 0 1 0 2 10 14 Crusher 40 10 10 0 30 3 5 60 5 1 0 1 0 1...

Page 38: ...s 32 Pump Jack 40 10 10 0 20 3 5 40 5 1 0 1 0 1 0 0 0 0 0 1 8 2 33 Rolling mill 40 10 10 0 20 3 5 40 5 1 0 1 0 1 0 0 0 0 0 0 8 2 34 Roots Blower 30 10 10 0 20 4 5 25 5 1 0 1 0 1 0 0 0 0 0 0 8 2 35 Saw...

Page 39: ...ic End Start 3 toggle OFF ON R W 20032 4E40 OFF Rate End Start 3 0 to 100 R W 768 0300 50 P3 Start Settings Start Time s 1 to 300 R W 7104 1BC0 10 Start Pedestal 10 to 100 R W 704 02C0 20 Start Curren...

Page 40: ...100 Shearpin Settings Shearpin Trip toggle OFF ON R W 53793 D221 ON Shearpin Settings Shearpin Trip Current A 100 mtr FLA to 450 synergy rated A R W 27584 6BC0 450 synergy A Shearpin Settings Shearpin...

Page 41: ...53808 D230 OFF L1 L3 L2 Trip toggle OFF ON R W 53807 D22F OFF Remote Start Trip toggle OFF ON R W 53804 D22C ON Current Sensor Trip toggle OFF ON R W 5377 5 D20F OFF Fan Trip toggle OFF ON R W 53782 D...

Page 42: ...eset Digital Input 3 D2 1I High Input 1 Sets Value toggle OFF ON R W 11268 2C04 ON Digital Outputs Digital Output 1 N C 12 Select Function Off Ready Enabled Error Running End Of Start Current Limit iE...

Page 43: ...064 7D40 L1 L2 L3 I1 A 0 to 10 000 Read 33536 8300 0 I2 A 0 to 10 000 Read 33538 8302 0 I3 A 0 to 10 000 Read 33540 8304 0 Current I rms A 0 to 10 000 Read 32896 8080 0 V rms Approx V 0 to 500 Read 32...

Page 44: ...Overload 7 Read 38485 9655 Event Time Last Peak Start Current Last Temperature Last Overload 8 Read 38488 9658 Event Time Last Peak Start Current Last Temperature Last Overload 9 Read 38491 965B Trip...

Page 45: ...re 1 C 20 C to 80 C Read 39681 9B01 ambient Last Temperature 2 C 20 C to 80 C Read 39682 9B02 ambient Last Temperature 3 C 20 C to 80 C Read 39683 9B03 ambient Last Temperature 4 C 20 C to 80 C Read 3...

Page 46: ...s Network Address 1 to 32 R W 16000 3E80 1 Modbus Network Baud Rate Baud 9 600 19 200 38 400 57 600 115 200 R W 16064 3EC0 19 200 Modbus Network Parity none odd even R W 16128 3F00 even Modbus Network...

Page 47: ...separate applications section for more details Default End of list Default Read Write PNU 25664 Auto Setup Trip Class The trip class is a numeric value that correlates the trip time with overload leve...

Page 48: ...ntrol using terminals Functions fixed as shown on screen Three Wire Control Control using terminals Functions fixed as shown on screen Modbus Network Control via remote Modbus network or remote Keypad...

Page 49: ...time depends on the Start Time and Current Limit Off On Off Read Write PNU 19968 Advanced Automatic Settings Automatic End Start 1 Automatically controls the time taken for the motor to start On The r...

Page 50: ...controls the maximum iERS saving level On The maximum iERS saving level BackStop is reset to maximum during each load cycle Off The saving potential may be reduced on applications with heavy load cyc...

Page 51: ...the motor current falls below the current limit level before the end of the Start Time Off The ramp time depends on the Start Time and Current Limit Off On Off Read Write PNU 20032 Advanced Automatic...

Page 52: ...will trip Off The start will continue regardless of the motor current level Off On On Read Write PNU 26880 Advanced Start Settings Start Current Limit Start Current Limit Level The current in Amps at...

Page 53: ...ils to break away Decrease if the motor accelerates too quickly 30 80 75 Read Write PNU 8320 Advanced Start Settings Contactor Delay Time allowed for external contactors to close Increase if contactor...

Page 54: ...een active for too long On The Unit will trip Off The stop will continue regardless of the motor current level Off On Off Read Write PNU 28800 Advanced Stop Settings Stop Current Limit Stop Current Li...

Page 55: ...s30 are selected the Unit current rating i Unit will be reduced to a lower value i rated Trip Class 10 Trip Class 30 Trip Class 10 Read Write PNU 53787 Advanced Motor Protection Low Current Settings L...

Page 56: ...in On The Unit will trip This feature is not active during soft start and soft stop Off The Unit will continue to operate regardless of motor current level Off On On Read Write PNU 27584 Advanced Moto...

Page 57: ...at which the overload will start Normally set to 115 of the set motor current i motor Reduce to speed up trip response 50 I motor 125 I motor 115 I motor A Read Write PNU 21120 Advanced iERS iERS Enab...

Page 58: ...Advanced iERS iERS Level 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 is reduc...

Page 59: ...s TCP Local Touch Screen Modbus Network Local Touch Screen Read Write PNU 44864 Advanced Trip Settings Trip Sensitivity Adjusts the reaction time to fault trips Increase Trip Sensitivity to slow the r...

Page 60: ...thermal overload On The Unit will trip when the Overload capacity ModbusPNU 33408 exceeds 100 Off The Unit will continue to operate regardless of motor current level Off On On Read Write PNU 53787 Ad...

Page 61: ...ected to the PTC terminals On The Unit will trip if the motor thermistor exceed its response temperature or the PTC input is open circuit Off The unit will not trip regardless of motor rotation Off On...

Page 62: ...ad Write PNU 53775 Advanced Trip Settings Current Sensor Trip Detects if the internal current sensors have failed or reading a very low level On The Unit will trip if the internal current sensors fail...

Page 63: ...time is truncated if the motor experiences severe torque fluctuations during the soft stop Off Follows normal soft stop time Off On On Read Write The Shut Down Trips are in operation during the soft s...

Page 64: ...thing 10R is assumed short circuit Off not recommended The Unit will attempt to start and run although the operation may be erratic Operating in this mode for prolonged periods may result in SCR failu...

Page 65: ...onged periods may result in SCR failure Off On On Read Write PNU 53768 Advanced Trip Settings Thermal Sensor Trip Detects if the internal temperature sensor has malfunctioned On The Unit will trip if...

Page 66: ...disabled Off On Off Read Write PNU 53799 Advanced Trip Settings Operation 2 Trip Detects if the logging function has failed to operate normally On Operation 2 trip enabled Off Operation 2 trip disabl...

Page 67: ...d In Line In Delta In Line Read Write PNU 192 Advanced Legacy Delta Mode Allows the Unit to be retro fitted into Delta applications that previously used QFE XFE 5MC On Operates in QFE XFE 5MC delta co...

Page 68: ...Read Write 59392 I O Digital Inputs Control Method Local Touch Screen Control using the button on the keypad User Programmable Control using the terminals Function defined in I O menu Two Wire Contro...

Page 69: ...to be reversed On When the input is on the selected function will be on Off When the input is off the selected function will be on Off On On Read Write PNU 10946 I O Digital Inputs Digital Input 3 D2...

Page 70: ...tput to be reversed On When the selected function is on the output will be on Off When the selected function is on the output is off Off On On Read Write PNU 11585 I O Digital Outputs Digital Output 2...

Page 71: ...Allows the Digital output N 0 44 to be mapped to different functions The output will change in proportion with the selected output Off End of list End Of Start Read Write PNU 11910 I O Digital Output...

Page 72: ...he output voltage varies from 0 to 10V 4 20mA The output current varies from 4 to 20mA 0 10V 4 20mA 0 10V Read Write PNU 9024 I O Analogue Outputs Select Function Allows the Analogue output to be mapp...

Page 73: ...NU 53794 I O PTC Motor Thermistor Trip A single PTC motor thermistor or set of PTC motor thermistors can be connected to the PTC terminals On The Unit will trip if the motor thermistor exceed its resp...

Page 74: ...ency of the 3 phase supply 45 65 Hz Read Only PNU 32064 Monitor Phase Rotation Indicates the phase sequence of the incoming supply RYB L1 L2 L3 RBY L1 L3 L2 L1 L2 L3 L1 L3 L2 L1 L2 L3 Read Only PNU 33...

Page 75: ...Synergy Series Soft Start User Manual MAN SGY 017 Version 01 27 06 2016 75 Continued overleaf PNU 33540 Monitor I3 The RMS current on phase L3 0 10000 0 A Read Only...

Page 76: ...RMS motor current This is the maximum of the 3 phases This value is used for the overload and power calculations 0 10000 0 A Read Only PNU 33024 Monitor True Power Factor The True Power Factor Estimat...

Page 77: ...level of potential saving 100 indicates that Unit is saving at its maximum level Does not indicated real percentage saving 0 100 0 Read Only PNU 22400 Monitor Delay Angle Internal firing delay angle...

Page 78: ...on is active when the motor current is less than the Start Saving Level When the iERS function is disabled internal bypass relays close to improve efficiency 50 I motor 80 I motor 80 I motor Read Only...

Page 79: ...st Trip Displays the last Fault trip 0 65535 0 Read Only PNU 60609 Log Trip Log Last Trip 1 Displays the last Fault trip 1 0 65535 0 Read Only PNU 60611 Log Trip Log Last Trip 3 Displays the last Faul...

Page 80: ...ult trip 7 0 65535 0 Read Only PNU 60617 Log Trip Log Last Trip 9 Displays the last Fault trip 9 0 65535 0 Read Only PNU 100101 Log Trip Log Trip Code Descriptions 101 Input Side Phase Loss Phase L1 m...

Page 81: ...ery low level Check all incoming connections If a main contactor is being controlled by a digital output set to Running check contactor delay is sufficient Read Only PNU 100104 Log Trip Log Trip Code...

Page 82: ...iring Trip One or more of the internal control thyristors SCRs have failed to turn on properly In Line Firing Mode The Unit has detected that the SCRs are not operating as expected Check all incoming...

Page 83: ...are missing on the motor side during the instant of start up when the motor being controlled T1 T2 or T3 phase are missing or at a very low level Check all incoming and outgoing connections Read Only...

Page 84: ...Synergy Series Soft Start User Manual MAN SGY 017 Version 01 27 06 2016 84 Blank Page...

Page 85: ...1001 Short Circuit Thyristor One or more of the internal control thyristors SCRs have failed short circuit The Unit has detected that the SCRs are not operating as expected ISOLATE SUPPLY MOTOR Discon...

Page 86: ...PNU 101202 Log Trip Log Trip Code Descriptions 1202 Current Limit Timeout Trip The motor has been held in current limit longer than the Stop current limit Time It is likely that the current limit lev...

Page 87: ...nd check current limit level Read Only PNU 101401 Log Trip Log Trip Code Descriptions 1401 Shearpin Trip The motor current has been higher than the Shearpin Trip Level for the trip time This trip is n...

Page 88: ...he communication trip is disabled the Unit cannot be stopped in the communications fail Read Only PNU 101801 Log Trip Log Trip Code Descriptions 1801 1802 Bypass Relay Trip One or more of the internal...

Page 89: ...start signal was active during power up or Reset or Parameter Load Turn off remote or if Remote On trip is not required turn off in Trip Settings Read Only PNU 102101 Log Trip Log Trip Code Descriptio...

Page 90: ...ensors used to measure current has failed or is reading a low value Check the connections to the supply and motor as disconnection will result in a zero current reading Check the plate FLA of the moto...

Page 91: ...1 Trip Fail Safe operation A process associated with the Keypad board has been affected and is unable to recover automatically The trip can be reset by either the digital input or keypad or the bus co...

Page 92: ...digital input or keypad or the bus command depending on the control method set It is also possible to reset this trip by cycling the control supply Read Only PNU 38400 Log Trip Log Last Peak Current...

Page 93: ...0 10000 0 A Read Only PNU 38408 Log Trip Log Last peak start current 4 Displays the peak current of the last successful start 4 0 10000 0 A Read Only PNU 38410 Log Trip Log Last peak start current 5 D...

Page 94: ...t 8 0 10000 0 A Read Only PNU 38418 Log Trip Log Last peak start current 9 Displays the peak current of the last successful start 9 0 10000 0 A Read Only PNU 39040 Log Trip Log Last peak stop current...

Page 95: ...3 0 10000 0 A Read Only PNU 39048 Log Trip Log Last peak stop current 4 Displays the peak current of the last successful stop 4 0 10000 0 A Read Only PNU 39050 Log Trip Log Last peak stop current 5 Di...

Page 96: ...0 0 A Read Only PNU 39058 Log Trip Log Last peak stop current 9 Displays the peak current of the last successful stop 9 0 10000 0 A Read Only PNU 39680 Log Trip Log Last temperature Displays the heats...

Page 97: ...0 C Read Only PNU 39684 Log Trip Log Last temperature 4 Displays the heatsink temperature at the end of the last successful start 4 20 80 C Read Only PNU 39685 Log Trip Log Last temperature 5 Displays...

Page 98: ...tart 8 20 80 C Read Only PNU 39689 Log Trip Log Last temperature 9 Displays the heatsink temperature at the end of the last successful start 9 20 80 C Read Only PNU 40320 Log Trip Log Last overload Di...

Page 99: ...rt 3 0 100 0 Read Only PNU 40324 Log Trip Log Last overload 4 Displays the overload level at the end of the last successful start 4 0 100 0 Read Only PNU 40325 Log Trip Log Last overload 5 Displays th...

Page 100: ...Synergy Series Soft Start User Manual MAN SGY 017 Version 01 27 06 2016 100 Blank Page...

Page 101: ...overload 9 Displays the overload level at the end of the last successful start 9 0 100 0 Read Only PNU 35840 Log Totals Log Number of Starts The total number of successful starts 0 42948362 25 0 Read...

Page 102: ...PNU 100001 Device Date Enter current date Date format can be set to either dd mm yyyy or mm dd yyyy Refer to Date format parameter Read Write PNU 14720 Device Time Allows the time to be changed to loc...

Page 103: ...mber 1 32 1 Read Write PNU 16064 Device Networks Modbus Network Settings Baud Rate Sets the serial communications baud rate The available baud rates are 9600 19200 38400 57600 or 115200 9600 115200 19...

Page 104: ...Read Write PNU 15808 Device Networks Timeout ms Communications trip Timeout period To prevent a Communications Trip If enabled the bus must be kept active To keep the bus active there must be at leas...

Page 105: ...are C F All displayed temperatures are F C F C Read Write PNU 62272 Device Parameters to USB Allows the user to save parameters Downloads the parameters from the Unit to the USB drive Data is stored...

Page 106: ...Synergy Series Soft Start User Manual MAN SGY 017 Version 01 27 06 2016 106 Blank Page...

Page 107: ...Synergy Series Soft Start User Manual MAN SGY 017 Version 01 27 06 2016 107 3 14 Functional Summaries continued overleaf 3 Configuration and Parameters continued Figure 3 12 1 Basic Functions...

Page 108: ...2 This is the Kick Pedestal voltage 3 This is the Start Pedestal voltage which the unit drops to after the kick pedestal has passed 4 This is the Stop Pedestal voltage which can be set to values lowe...

Page 109: ...tion 3 Configuration and Parameters continued Notes 1 I LOW Low Amps Level 2 If I LOAD drops below Low Amps Level and Low Current is set to on and Low Amps Time is set to minimum then the unit will tr...

Page 110: ...nd then enter the Dwell period 2 If the unit current limits during start up the start time will be elongated by the amount of time that the unit was current limiting 3 The actual current rises slightl...

Page 111: ...bed above It is not recommended to open the CSV file and edit parameters on a PC and resave the PARAMS file There is also the option to copy Parameters From USB which gives the ability to restore or s...

Page 112: ...Synergy Series Soft Start User Manual MAN SGY 017 Version 01 27 06 2016 112 Blank Page...

Page 113: ...ard The RS 485 communications are accessible from the RJ12 connector see below 1 GND 2 Reserved 3 Not connected 4 Not connected 5 TXD0 A OUT 6 TXD1 B OUT Warning To avoid damage to the unit or to the...

Page 114: ...Settings Address 1 32 Device Networks Modbus Network Settings Baud 9600 115200 Device Networks Modbus Network Settings Parity Odd Even Data bits 8 Stop bits 1 The communication parameters should be se...

Page 115: ...Code This field contains a single byte where the master specifies the type of service or function requested to the slave reading writing etc According to the protocol each function is used to access...

Page 116: ...art address Hi 00 Byte count 02 Start address Lo 01 Data Hi 01 No of registers Hi 00 Data Lo 2C No of registers Lo 01 CRC Lo B8 CRC Lo D5 CRC Hi 09 CRC Hi CA Write Single Register Description writing...

Page 117: ...ressing is zero offset such that the parameter Modbus address corresponds to the register number Modbus Address Memory Map Parameter Modbus Address Modbus Data Address Decimal Hexadecimal 0000 0 0000h...

Page 118: ...f when a new message begins or when it ends is achieved by the absence of data transmission for a minimum period of 3 5 times the transmission time of a data byte Thus in case a message is transmitted...

Page 119: ...pendix B for installation instructions 4 2 1 synergyTM Configuration synergyTM will configure automatically when the module is detected 4 2 2 IP Address Configuration The IP address of the module and...

Page 120: ...will not pass through a router A switch or direct connection with cross over cable must be used Start the Ipconfig software Press the Scan button to have the PC scan for a Synergy The IPconfig utilit...

Page 121: ...work Status LED 2 Module Status LED 3 Network Interface Port 1 4 Network Interface Port 2 5 Link Activity Port 1 6 Link Activity Port 2 Network Status LED LED State Description Off No power or no IP a...

Page 122: ...ultaneous master connections All Modbus functions and addresses available are detailed in Chapter 5 Modbus RTU Communications Table Synergy uses Protocol Addressing Base 0 not PLC Addressing Base 1 If...

Page 123: ...IP Functionality The EtherNet IP communication module offers the following functionality CIP Parameter Object Support Implicit and Explicit messaging Dual switched RJ45 communicationports 10 100 Mbps...

Page 124: ...f which will set and or get a combination of the above parameters The following examples are for connection 6 Extended Control CIP Packet functionality Extended Control O T Packet Control Bit 7 Bit 6...

Page 125: ...ynergy Configuration Synergy will configure automatically when the module is detected 4 4 2 Profibus DP Module Front Panel Indicators Front panel Item 1 Operation mode 2 Status 3 Profibus network conn...

Page 126: ...Bit 14 Bit 13 Bit 12 Bit 11 Bit 10 Bit 9 Bit 8 Network Connect The second Probifbus Standard telegram 1 set point word NSOLL_A is not implemented in this version so will not respond to set values The...

Page 127: ...t Start User Manual MAN SGY 017 Version 01 27 06 2016 127 As with the Outputs the second Probifbus Standard telegram 1 value word NIST_A is not implemented in this version so should be ignored 4 Commu...

Page 128: ...on module into the synergy TM module slot applying slight downward force and forward pitch as shown in Fig 1 As the module moves into the synergy TM unit it will be necessary to reduce the pitch of th...

Page 129: ...Synergy Series Soft Start User Manual MAN SGY 017 Version 01 27 06 2016 129 Blank Page...

Page 130: ...x Off R W Address 320 140 hex Format 8 bit unsigned Note Binary value Kick Start Applies a short duration torque pulse to dislodge sticky loads On The torque pulse is applied at start up when complete...

Page 131: ...Time Time that the torque pulse is applied to load Increase to provide more torque If the load fails to break away Decrease if the motor accelerates too quickly 10 A hex 10 2000 7D0 hex 2000 100 64 h...

Page 132: ...mapped to different PNU functions The output will change in proportion with the selected function By default the output will be at a maximum when the selected function equals its maximum value 0 0 he...

Page 133: ...0 16384 4000 hex Max value 0 0 hex Max value R W Address 9792 2640 hex Format 16 bit unsigned Note Linear Scaling 1 1 Analogue Input Value The value of the analogue Input The internal Analogue to Dig...

Page 134: ...al input D2 1I to be mapped to different functions The selected function will change in proportion with the input Digital inputs can only be mapped if the Control Method is set to User Programmable 0...

Page 135: ...l number stored at the point of manufacture 0 0 0 0 hex 0 255 FF hex 255 Not Applicable R Address 12805 3205 hex Format 8 bit unsigned Note ASCII alpha numeric character Byte 2 Serial Number The devic...

Page 136: ...35 FFFF hex Max Value Not Applicable R Address 12992 32C0 hex Format 8 bit unsigned Note Binary value Screen Lock Stops unauthorised access to read write parameters 0 0 0 0 hex Off 1 1 hex On 0 0 hex...

Page 137: ...ontactor opens and closes On When a zero stop time is set some faults will be ignored when main conatctor opens Off The unit may trip when the main contcator opens 0 0 hex Off 1 1 hex On 0 0 hex Off R...

Page 138: ...signed Note Binary value Start Stop CONTROL COMMAND Start Stop On Starts the Unit Off Stops or Soft stops the Unit To map to digital input refer to PNU10944 PNU10946 0 0 hex Soft Stop 1 1 hex Start 0...

Page 139: ...list 0 0 hex Default R W Address 19840 4D80 hex Format 8 bit unsigned Note Binary value Automatic Pedestal Automatically controls the starting torque On The initial torque is increased until the motor...

Page 140: ...Format 8 bit unsigned Note Binary value Auto Smooth Stop Automatically controls the soft stop to eliminate oscillations that can occur towards the end of the ramp On The soft stop is adjusted when osc...

Page 141: ...t drop quickly enough When the value is set to zero the Automatic Stop is effectively disabled 0 0 hex 0 16384 4000 hex 100 8192 2000 hex 50 R W Address 20672 50C0 hex Format 16 bit unsigned Note Lin...

Page 142: ...mines 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 is reduced 0 0 hex 0 16384 4000 hex 100...

Page 143: ...ote Linear Scaling 1 1mA Current A Value 1000 i rated Unit Class20 Class30 Current Rating 0 0 17000 4268 hex 17 2000000 1E8480 hex 2000 17000 4268 hex 17 A R Address 25664 6440 hex Format 16 bit unsig...

Page 144: ...26880 6900 hex Format 16 bit unsigned Note Linear Scaling 1 1mA Current A Value 1000 Start Current Limit Level The current in Amps at which the soft Start ramp is held Normally set to 350 of motor FLC...

Page 145: ...t Level The current in Amps at which the soft stop ramp is not allowed to go above Normally set to 350 motor FLC Increase if motor decelerates too rapidly The current limit level will effect actual ti...

Page 146: ...1F4 hex 500 0 0 hex 0 V R Address 33024 8100 hex Format 16 bit unsigned Note Linear Scaling 1 0 001 True Power Factor The True Power Factor The True Power Factor Displacement Power Factor x Distortion...

Page 147: ...tal Apparent Power This is an addition of the 3 phases 0 0 0 hex 0 10000000 989680 hex 10000 0 0 hex 0 kVA R Address 34944 8880 hex Format 32 bit unsigned Note Linear Scaling 1 1Var Reactive Power kVa...

Page 148: ...value Ready STATUS INDICATION Ready On Indicates that the Unit is healthy and ready for a start Remains on when Running Off The Unit has not powered up successfully or failed to reset from a trip To...

Page 149: ...because Current Irms is greater or equal to Current Limit Level Off The ramp is not being held because Current Irms is less than Current Limit Level To map to digital output refer to PNU11584 PNU1158...

Page 150: ...Value 1000 Last peak start current 6 Displays the peak current of the last successful start 6 0 0 0 0 hex 0 10000000 989680 hex 10000 0 0 hex 0 A R Address 38414 960E hex Format 32 bit unsigned Note L...

Page 151: ...time 0 0 GMT time hh mm ss R Address 38482 9652 hex Format 6 Bytes Note Time ms since midnight bytes5 4 3 2 and Days since 01 01 1984 bytes1 0 Last peak start current Last Temperature Last Overload 6...

Page 152: ...1mA Current A Value 1000 Last peak stop current 5 Displays the peak current of the last successful stop 5 0 0 0 0 hex 0 10000000 989680 hex 10000 0 0 hex 0 A R Address 39052 988C hex Format 32 bit uns...

Page 153: ...es1 0 Last peak stop current 5 Time Displays the event time 0 0 GMT time hh mm ss R Address 39122 98D2 hex Format 6 Bytes Note Time ms since midnight bytes5 4 3 2 and Days since 01 01 1984 bytes1 0 La...

Page 154: ...rature 3 Displays the heatsink temperature at the end of the last successful start 3 0 0 7872 1EC0 hex 20 1280 500 hex 80 Not Applicable C R Address 39684 9B04 hex Format 16 bit Highbyte b11 b8 LowByt...

Page 155: ...nd of the last successful start 9 0 0 7872 1EC0 hex 20 1280 500 hex 80 Not Applicable C R Address 40320 9D80 hex Format 16 bit unsigned Note Linear Scaling 1 0 006104 Last overload Displays the overlo...

Page 156: ...0 hex 100 0 0 hex 0 R Address 40329 9D89 hex Format 16 bit unsigned Note Linear Scaling 1 0 006104 Last overload 9 Displays the overload level at the end of the last successful start 9 0 0 0 0 hex 0 1...

Page 157: ...or will stop in the set time 0 0 hex Off 1 1 hex On 1 1 hex On R W Address 53770 D20A hex Format 8 bit unsigned Note Binary value Shut Down 2 This features controls the soft stop improve stability On...

Page 158: ...tor Off The Unit will attempt to start and run although the operation may be erratic Operating in this mode for prolonged periods may result in SCR failure 0 0 hex Off 1 1 hex On 1 1 hex On R W Addres...

Page 159: ...evel 0 0 hex Off 1 1 hex On 0 0 hex Off R W Address 53792 D220 hex Format 8 bit unsigned Note Binary value Overload Trip The Unit has an Overload function that is an electronic equivalent to a thermal...

Page 160: ...Note Binary value Operation 2 Trip Detects if the logging function has failed to operate normally On Operation 2 trip enabled Off Operation 2 trip disabled 0 0 hex Off 1 1 hex On 1 1 hex Off R W Addre...

Page 161: ...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 Modbus Network Control via remote Modb...

Page 162: ...16 bit unsigned Note Linear Scaling 1 1 See Trip Code Descriptions Last Trip 8 Displays the last Fault trip 8 0 0 0 0 hex 0 65535 FFFF hex 65535 0 0 hex 0 R Address 60617 ECC9 hex Format 16 bit unsig...

Page 163: ...ytes Note Time ms since midnight bytes5 4 3 2 and Days since 01 01 1984 bytes1 0 Last Trip 8 Time Displays the event time 0 0 GMT time hh mm ss R Address 60699 ED1B hex Format GMT time Note hh mm ss L...

Page 164: ...set to Running check contactor delay is sufficient R Address 100104 18708 hex Format Note The Trip Number shown in PNU Name is a decimal value 104 117 Input Side Phase Loss Any or all phases missing...

Page 165: ...shown in PNU Name is a decimal value 401 Motor Side Phase Loss One or all of the phases are missing on the motor side during the instant of start up T1 T2 or T3 phase are missing or at a very low leve...

Page 166: ...e is a decimal value 1001 Short Circuit Thyristor One or more of the internal control thyristors SCRs have failed short circuit The Unit has detected that the SCRs are not operating as expected ISOLAT...

Page 167: ...Name is a decimal value 1302 Overload Trip The motor current has exceeded 475 i Unit for a time greater than 250ms The Unit is attempting to start an application that is outside its capacity with a h...

Page 168: ...failed to close The internal bypass relay has failed or the control supply is to weak Ensure 24VDC supply meets the requirements specified in the Quick Start Guide R Address 101802 18DAA hex Format No...

Page 169: ...or Delay under Start Settings is sufficient 104 117 Input Side Phase Loss Any or all phases missing when the motor is being controlled running L1 L2 or L3 are missing or at a very lowlevel Check all i...

Page 170: ...o ensure the heatsink is cooled sufficiently the Synergy will trip if the fans fail to operate Check Synergy fans for signs of damage or contamination 1001 Short Circuit Thyristor One or more of the i...

Page 171: ...to open The internal bypass relay has failed or the control supply is too weak Ensure 24VDC supply meets the requirements specified in Electrical Installation Chapter 2 or the Quick Start Guide 1901...

Page 172: ...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 parameter save has been unsuc...

Page 173: ...will temporarily be disabled if a continual failure is detected When the trip is turned ON it is reset using the either the digital input or keypad or bus command depending on the control method set I...

Page 174: ...the supply voltage At normal running speed the field will take a fixed quantity of energy regardless of the torque demanded by the mechanical load The energy required to support the load torque is det...

Page 175: ...nd The effect is shown in the Figure below NOTE the curves shown in Fig 3 are the full speed end of the conventional torque current curves The present considerations do not affect soft starting option...

Page 176: ...s to do continuously and automatically 7 3 Additional Benefits in Practice It is usual to select a standard motor with a rating somewhat higher than the maximum demand of the driven load The motor sel...

Page 177: ...f heating losses in cabling because of the lower voltages Further energy saving and other benefits deriving from the soft starting process itself Reduced total energy demand Reduced wear and tear Redu...

Page 178: ...f the programmable inputs and controlled by the driven process iERS Intelligent Energy Recovery System will sense when at a level where we will gain no benefits from Energy Saving the SYNERGY will ene...

Page 179: ...mode selected The method of power factor management described does not affect motor performance nor does it detract from the motor s capability to respond to changes in load demand This feature of the...

Page 180: ...from standstill to full speed and to maintain full speed efficiently at all torque levels up to the design full load torque Most modern induction motors have characteristics that are wholly suitable...

Page 181: ...to the motor It is therefore important to ensure that the motor employs techniques such as rotor skewing in its construction to suppress the effects of harmonic fluxes and avoid rough starting This is...

Page 182: ...extended start times and or higher over currents If very high inertia loads are involved then an analysis of the starting characteristics should be made This will require accurate data about the motor...

Page 183: ...2 7 Replacement of Fluid Couplings Soft starters can replace fluid couplings yielding benefits of higher efficiency running and lower costs to the user If the coupling is used to magnify the available...

Page 184: ...10 25 Usually high inertia Centrifugal fan dampers open 10 25 Usually high inertia very long ramp times Centrifugal blower valve closed 25 35 Centrifugal blower valve open 30 40 Can have long ramp tim...

Page 185: ...he electronic control system but rather to offer an outline of its various capabilities 8 3 2 The Induction Motor In order to appreciate the benefits of using an electronic controller it is important...

Page 186: ...onous speed in order to develop power the slip speed and hence the term asynchronous The following graph is of an induction motor torque speed curve and illustrates this most important characteristic...

Page 187: ...and drive mechanisms Broadly speaking the motor speed torque characteristic is controlled by the rotor resistance a motor with high rotor resistance can generate it s peak torque pull out torque at s...

Page 188: ...l load is small can produce torque oscillations in the shaft causing severe wear to transmissions gears and drives Excessive acceleration when the load inertia is high such as in centrifugal fans caus...

Page 189: ...dings generating a voltage whose frequency depends on the rotor speed If the load inertia is small such as in a pump or if the friction is high there could be a significant loss of speed during the ti...

Page 190: ...silicon controlled rectifier SCR or in Europe the Thyristor it is the basis on which all soft starting systems are built The characteristic of most interest is the ability of the thyristor to switch r...

Page 191: ...n load Where motor speeds cannot be varied an optimising version of semiconductor motor controller such as Synergy will also produce energy savings in lightly loaded motors Less sophisticated systems...

Page 192: ...connected Owing to the variable quality and performance of many so called inverters and soft starters available to the unsuspecting purchaser international standards for these products have been devel...

Page 193: ...standard as EN 60947 4 2 The Synergy has been type tested in accordance with the test procedures and levels laid down in the product standard 9 3 Mandatory Requirements Within the EU Applicable to any...

Page 194: ...he Soft Starter and understand exactly the implications for meeting EMC requirements It is likely that failure to do so will result in the purchase and installation of inappropriate equipment IMPORTAN...

Page 195: ...distances and may cause interference to any neighboring consumers connected to the common low voltage supply network Allowable levels for conducted emissions generated by semiconductor motor controll...

Page 196: ...to a soft starter 9 7 7 Strategies for Attaining and Maintaining EMC Compliance Where possible minimize the effect of electrical interference by using the strategies listed below Locate the Synergy So...

Page 197: ...Synergy Series Soft Start User Manual MAN SGY 017 Version 01 27 06 2016 197 Blank Page...

Page 198: ...overload protection configurable through the user interface Overload trip settings are determined by the Motor Current setting and the Trip Class setting Trip class choices are Class 10 Class 20 and C...

Page 199: ...t allowed is 3 5 times FLC Tx denotes the duration of the controlled overload currents during starting stopping operating or maneuvering For example Tx 17 means that the maximum allowed overload curre...

Page 200: ...Rated Current A Class 10 O L Multiple X Class 10 O L Time Tx Starts Hour S Duty F SGY 101 17 3 5 17 5 90 SGY 103 22 SGY 105 29 SGY 107 35 SGY 109 41 SGY 111 55 SGY 113 66 SGY 115 80 SGY117 100 SGY 20...

Page 201: ...Trip Class 20 Trip Class 30 Rated Starting Capability 3x Motor Current 23secs 4x Motor Current 19secs 4x Motor Current 29secs 3 5x Motor Current 17secs Max Starts per Hour 5 starts hour 5 starts hour...

Page 202: ...114 75 113 SGY 113 SGY 115 SGY 117 45 80 60 77 75 139 100 133 SGY 115 SGY 117 SGY 201 55 100 75 96 90 173 125 166 SGY 117 SGY 201 SGY 203 75 132 100 124 110 229 150 215 SGY 201 SGY 203 SGY 205 90 160...

Page 203: ...the applied voltage Usually expressed as a multiple of motor full load current Kick start Voltage The percentage of supply voltage applied before commencing ramp up when a load has a high breakaway to...

Page 204: ...Synergy Series Soft Start User Manual MAN SGY 017 Version 01 27 06 2016 204 Blank Page...

Page 205: ...load starterview The file will be a windows compressed zip file which can be opened by double clicking it in Windows explorer Then within the shown zip folder double click the setup exe This will run...

Page 206: ...rView via Windows Control Panel and repeat the installation A3 3 User Interface Once open StarterView is ready to use It always starts up with an image identity this will be removed when a file is loa...

Page 207: ...ning Parameter Files Parameter files can be loaded into the viewer by either using the File Open Parameter menu or by drag and dropping a file onto the application File Open Dialogue On the initial ru...

Page 208: ...present to help navigation through the data The right hand pane contains two tabs The first showing the selected parameter details in a table At the bottom of the tab the parameter value is displayed...

Page 209: ...from the Filters Language tab The third column headed Value shows the values assigned to each parameter followed by the fourth column head Default containing the default values If the value differs f...

Page 210: ...he value can be edited The Filter and Language Tab This tab has two functions The first is to enable the refining of the displayed parameters in the table view bye the selection of filters The second...

Page 211: ...erwise thy will be rendered in English Search Above the main table is a search box As characters are typed in to the box any parameter rows that contain a name field partly matching the characters wil...

Page 212: ...table is large then the time taken may be considerable Print and Print Preview work in the same way as standard Windows applications The email will create a PDF file that is attached to an email Ther...

Page 213: ...does this by intelligently decoding each event and then allowing the user to filter out events rows or event values columns that are not of interest then showing events and event values that are of i...

Page 214: ...therefore many of the values may be blank showing a in their cells There a several values that all events share These include Event Entry number Event Type Date and Time stamps and deltas Some values...

Page 215: ...selected data point is indicated by the cross hairs placement and the coordinate value shown at the top As the mouse cursor is moved over the graph when the chart control is in focus the cross hairs w...

Page 216: ...l time Print Email and PDFs Just like the parameter view there are four buttons under the table that allow output of the current table to a print preview a printer an email attachment or and PDF file...

Page 217: ...ll by checking the required ZIP file and then press finish The Release Builder tab will now show the version that was selected This will be remembered for subsequent runs of the Builder To continue at...

Page 218: ...will track the copy This will take time dependent on the hardware speeds There is no way to cancel this process once it has started removing the stick during the process will corrupt data and could d...

Page 219: ...FAT32 Part number USB KEY is a USB flash drive that has been verified to work with synergyTM Other flash drives may not physically fit or may not perform correctly Available to purchase from Fairford...

Page 220: ...MAN SGY 017 Version 01 27 06 2016 220 Double click on the new directory and inside to display of the unit update files Select all files and copy them to the route directory of the USB flash drive A4...

Page 221: ...een shows the current installed firmware version and the firmware version previously copied to the USB flash drive Depress the Start Firmware Update button Confirm the firmware update by pressing YES...

Page 222: ...FAN 003 1 Cooling fan replacement for synergyTM series soft starters 80 x 80 x 15 mm 201 203 FAN 014 1 Cooling fan replacement for synergyTM series soft starters 80 x 80 x 20 mm 205 FAN 007 1 2 Cooli...

Page 223: ...ed before the fans can be taken off They MUST be refitted using the supplied push rivets after the fans have been attached A5 User Serviceable Items continued fit blue wires from new fan and Synergy i...

Page 224: ...SGY 307 and SGY 309 A5 User Serviceable Items continued Remove 4 screws on lower end moulding Slide lower end moulding off busbars Pull wires off connectors Fan held with M4 screws in 2 positions Rem...

Page 225: ...w the LCD display Use a small screwdriver to lever the rivets out 3 When removing the LCD display and PCB Slowly Lift from the top left corner 4 Gently remove the LCD and PCB at an angle so they can b...

Page 226: ...the socket is locked with the FFC cable firmly connected gently place the board back in to the previous position using the same angled technique 8 Place pcb flat in position 9 Make sure the screen is...

Page 227: ...es only an Ethernet cable for communication Please see Section 4 1 A6 2 Network Connection For a configuration where the is only one synery TM unit one to one the remote and main unit can be directly...

Page 228: ...ual MAN SGY 017 Version 01 27 06 2016 228 For multiple base units connected to the keypod the use of SGY 011 is highly recommended See diagram below A5 Remote Keypod Setup continued SGY 011 SGY 010 SG...

Page 229: ...nnect to connect to that particular starter The status screen Fig 3 on the remote touchscreen will display the current starter it is connected to by displaying the starter s node address and serial nu...

Page 230: ...y be used with the standard on board Modbus RTU connection It can not be used with Anybus modules The remote touchscreen is a Modbus RTU master device A PLC HMI or other Modbus Master device cannot be...

Page 231: ...Synergy Series Soft Start User Manual MAN SGY 017 Version 01 27 06 2016 231 Notes...

Page 232: ...Synergy Series Soft Start User Manual MAN SGY 017 Version 01 27 06 2016 232 Notes...

Page 233: ...Synergy Series Soft Start User Manual MAN SGY 017 Version 01 27 06 2016 233...

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