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34

S611 Soft Starter

MN03902011E—May 2012 www.eaton.com

Printed Circuit Board (PCB) Removal

If necessary, mark all cables to aid in proper reattachment.
The PCB is marked with component identification
information adjacent to each connector base. See “PCB
Connector IDs” figure below.

PCB Connector IDs

1.

Disconnect leads from the PCB:

a)

SCR gate leads—two per phase.

b)

Temperature sensor leads—one per phase.

c)

Current transformer leads— one per phase.

d)

User Interface cable.

Note:

All connectors except the User Interface cable use
detents to secure the connection. To remove, pull
each connector directly away from the PCB. Do not
twist or pry to remove connector from PCB. Do not
attempt to separate the connector by pulling on the
wires.

User 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.

Remove the 5 #1 Phillips self tapping screws—one in
each corner, one in center.

3.

Remove PCB from cover assembly.

PCB Reinstallation

1.

Place the PCB into position on the cover assembly.

2.

Install all ﬁve screws by ﬁrst turning the screw
counterclockwise until you feel the screw “drop” into
place. Torque to 8–10 lb-in.

3.

Connect all leads, pressing ﬁrmly until you feel the
connector snap into place.

4.

Reinstall cover assembly.

Cover Reinstallation

1.

As the cover is placed onto the supports, carefully guide
wiring into place.

2.

Ensure that the BYPASS VOLTAGE contactor connector
is properly connected prior to installing the cover
screws.

3.

Install and torque all cover assembly screws to 22–27 lb-in.

4.

Reinstall control wiring.

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Содержание S611

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

Страница 2: ...www comoso com...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 95: ...www comoso com...

Страница 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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