S160-Sikostart Electronic Motor Controllermanualarchive.ingersollrandproducts.com/manuals/manuals... · cage motor and a load. In the case of a slipring motor the rotor slots contain

CONTENTS

Page No.

1. Introduction

1.1 Motor Transmission System...................................................................... 1.1

1.2 Conventional Starting Methods ................................................................ 1.4

1.3 Why use SIKOSTART 3RW24 Controllers ................................................. 1.6

1.4 Features of SIKOSTART 3RW24 ............................................................... 1.7

2. SIKOSTART 3RW24 – Principle of Operation

2.1 Starting & Stopping .................................................................................. 2.1

2.2 Continuous Operation .............................................................................. 2.3

2.3 Protection and Control ............................................................................. 2.4

3. Typical applications .................................................................................... 3.1 - 3.5

4. Motor feeder circuit

4.1 Motor Feeder Protection .......................................................................... 4.2

4.2 Parallel Starting of Motors ....................................................................... 4.3

4.3 Installation in parallel with a frequency converter .................................... 4.3

4.4 Operation with Capacitor Bank ................................................................ 4.4

5. Typical Circuit Diagrams ........................................................................... 5.1 - 5.10

6. Product Range, Technical Data ................................................................... 6.1 - 6.5

7. Dimension Drawing .................................................................................... 7.1 - 7.3

8. Installation & Commissioning

8.1 Installation Tips ......................................................................................... 8.1

8.2 Commissioning Tips ................................................................................. 8.3

9. Troubleshooting.......................................................................................... 9.1 - 9.2

10. Maintenance, spare parts, accessories .................................................. 10.1 - 10.3

A Appendix – Engineering, starter selection .............................................. A1.1 - A1.6

1.1 Motor Transmission System

The three phase asynchronous motor has beenthe workhorse of the industry for a long time dueto a) its robust and simple construction, and b) itslow need for maintenance.

Three-phase asynchronous motorThe three-phase asynchronous motor features athree-phase winding in the stator which produces arotating magnetic field owing to its relative physicalposition with respect to one another and therelative phase displacement of the current flowingthrough them. The rotation speed is nSy = 60 x f1/p(nSy = synchronous speed in min–1; f1 = mainsfrequency in Hz; p = number of pole pairs).

This rotational field induces currents in thewindings of the rotor which produce a torquewhich inturn accelerates the rotor in the directionof the rotational field.

The asynchronous motor cannot, however, reachthe synchronous speed, as also during no-loadoperation it needs a slight torque to overcome itsown frictional losses. At synchronous speed, theinduced voltage and thus the rotor current andtorque would become zero.

It therefore does not run at synchronous speed, i.e.exactly in phase with the stator field, but alwaysasynchronously.

The characteristic points on the torque/speed curveare the locked rotor (or initial) torque MA, the pull-uptorque MS, the breakdown torque MK and the ratedtorque MN (*Fig 1.1).

To ensure that a motor can run up to rated speed atall, the motor torque MM must be greater than theload torque ML for the entire starting time, asotherwise, motor will be stalled. The differencebetween MM and ML is the accelerating torque MB,and it must therefore always be greater than zero.

This must be taken into account particularly in caseof a pronounced pull-up torque (or saddle point), asthis is the smallest torque which occurs duringrunning up until rated speed is reached.

For each asynchronous motor, the actual shape ofthe torque/speed characteristic is determined bythe constructional particulars of the rotor.

SIKOSTART Introduction

1. Introduction 1

1.1

MA Locked rotor torqueMS Pull-up torqueMK Breakdown torqueMM Motor torqueML Load torqueMB Accelerating torqueMN Rated torquenK Rotational speed at breakdown torquenN Rated speednsy Synchronous speednS Rotational speed at pull-up torque

Fig. 1.1Typical torque/speed characteristics of a squirrel-cage motor and a load

In the case of a slipring motor the rotor slotscontain three-phase windings. One end of eachwinding is connected internally while the otherends are brought out to the terminal block viasliprings and carbon brushes.

The controlled starting of the motor is achieved bythe successive bridging out of resistors in the rotorcircuit (*Fig. 1.2).

Owing to their complicated construction and theresistors,slipring motors are more expensive andrequire more maintenance work than squirrelcagemotors. Therefore, they are used mainly inapplications in which a relatively high initial torqueis required, but in which the starting current maynot exceed the rated current to any great extent(e.g. mills and hoists).

If a slipring motor is to be operated using a soft startcontroller e.g. SIKOSTART, it needs a fixedresistance in the rotor circuit (here e.g. RLV2) toensure that the motor has sufficient acceleratingtorque MB to run up. This resistance can be bridgedonce the motor has come up to speed.

In the case of a squirrel-cage motor, rotorwindings are not accessible. The rotor slots containbars of copper, bronze or aluminium and the endsare connected on both sides via shorting rings.Aluminium rotor bars are cast directly into the rotorslots. Common forms of squirrel-cage rotor are thewedge cage bar, the high cage bar and the doublecage bar (*Fig. 1.3)

The characteristic values of a motor such as lockedrotor torque, pull-up torque and breakdown torqueas well as the initial starting current and ratedcurrent can be found in the relevant catalogues (theM11 catalogue for Siemens motors). If needed, thetorque/speed characteristic can be determinedfrom this with sufficient accuracy.

In the torque/speed characteristic as shown in(Fig. 1.3) it can be seen, for example, that thebreakdown torque for motors with a highresistance in the rotor circuit is located at speedsclose to zero and that the curve has no “saddle”.This type of motor is therefore used when a highinitial torque is required.

In case of squirrel-cage motors with a pre-determinded slot form, the torque/speedcharacteristic can only be influenced via thefrequency of the value of the terminal voltage.

Fig. 1.2Torque/speed characteristic of a slipring motor withvarious rotor resistances

Fig. 1.3Torque/speed characteristic of cage motors withvarious rotor types

Introduction SIKOSTART

1.2

Transmission systemWhen using a gearbox between the motor and theload, the moment of inertia of the load must bereferred to the motor speed to determine theeffective moment of inertia at the motor shaft:

JL(M) = JL x (nL/nM)2

The same principle applies to the torque. The loadtorque characteristic must be convertedproportionally to the transmission ratio and theefficiency of the transmission system:

ML (M) = M

L x (n

L/n

M) x 1/h


ML Load torqueML(M) Load torque referred to the motor shaftnM Motor speednL Load speedh Efficiency of the transmission systemJL Moment of inertia of the loadJL (M) Moment of inertia of the load referred

to the motor shaft

Characteristic data of some transmission systems

Type of transmission Transmission ratio Transmission efficiencynM hhhhhnL

Spur gear system upto 8 single-stage 0.96...0.99

6to 45 two-stage 0.91...0.97

30to 250 three-stage 0.85...0.97

Worm gear upto 8 single-stage 0.50...0.70 single gear

0.70...0.80 double gear

Belt drive upto 8 0.94...0.97

Chain drive upto 6 0.97...0.98

Friction gear system upto 6 0.95...0.98

NoteIn some lists, machine manufacturers specify the “flywheel moment (or rotative moment) GD2” instead ofthe moment of inertia J. Its numerical value, assuming it was specified in “kgm2”, should be convertedusing the following formula.

[GD2][J] = (J in kgm2)4

1

1.3

1.2 Conventional starting methods

The most prevalent way of providing electricalenergy to the motor has been through starters,which consisted of one or a combination ofelectromechanical switching devices calledcontactors.

Direct-on-line startingThis is the most common and simple way ofcontrolling energy flow to an induction motor. Fullline voltage is applied on the stator terminals whilethe rotor is stationary. The low impedance,characteristic of the stator when the motor is bothstationary and accelerating, results in high linecurrent. The typical starting current for Direct-on-line starting is in the range of 6 - 7 times the fullload current. The starting current is independent ofthe motor load - the current increases with theacceleration of the motor finally falling to the ratedcurrent when the motor reaches its full speed. Asthe torque generated is proportional to the current,such starting is also associated with high startingtorque.

Although direct-on-line is the simplest and mosteconomical method of starting, the apparentadvantages get offset by high cost penalties interms of increased maintenance, reduced life ofthe transmission system and higher risk of motorfailure.

Direct-on-line starting sometimes become unviablewhen loads are operated in DG sets, because offrequent tripping of the DG during high currentsurges associated with DOL starting.

Star-delta startingStar delta starting is the simplest form of reducedvoltage starting. The motor is started in starconfiguration, and then after a preset time isswitched over to delta configuration. Starting in starreduces the voltage applied to the motor terminalsand when the motor accelerates to 80% ratedspeed the changeover is made to Deltaconfiguration. If the motor has not acceleratedsufficiently before switching to delta, a very highcurrent will flow as in DOL starting.

During starting in star mode; the generated torqueis one third of the rated torque. If a drive requires40% rated torque to break away then one has torevert to other means of starting rather that star-delta starting.

Fig. 1.4Starting characteristics for direct-on-line starting inthe delta configuration

Fig. 1.5Starting characteristic in the case of star-deltastarting


1.4

Auto-transformers and stator-resistancestartersAuto-transformer and stator-resistance startersallow starting torque and currents to be reduced bydecreasing the initial terminal voltage. Theresistances are cut in steps as the motor reachesfull speed. Frequently the resitances are movableblades immersed in an electrolytic liquid. Suchstarters are usually bulky and expensive, both interms of cost and maintenance.

The starting procedure may comprise more thanone stage which naturally involves extensivecontrol circuit and switchgear.

Furthermore the starting resistors dissipate a hugeamount of heat during starting.

Fig. 1.6Schematic diagrams of the auto-transformer andstator-resistance starting methods

In the following table the value ranges of lockedrotor torque and initial current for the conventionalstarting methods are summarized:

Direct-on-line Star-delta Resistance Auto- SIKOSTARTstarting starting starting transformer starting

starting

Locked rotor 1.5 ... 2.8 MN 0.5 ... 0.9 MN 0.5 ... 0.75 MN 0.4 ... 0.85 MN 0.06 ...2.8 MN

MN torque

Initial current 4 ... 8 IN 1.8 ... 2.5 IN 1.5 ...6 IN 1.5 ...6 IN Adjustable

Required no. 3 min. of 6 3 3 3/6*of motorterminals

* Delta connection SIKOSTART

Summary:� A common characteristic of all the conventional

starters is that they do not allow fineadjustment of motor parameters (current,torque) to match the specific problems duringstarting.

� The specific requirements like smooth increasein supply voltage, gradual increase in torquevalues in tune with the motor acceleration,smooth stopping of the motor on removal ofsupply or current limit during starting can onlybe met with the help of electronic motorcontrollers like SIKOSTART 3RW24.


1

1.5

1.3 Why use SIKOSTART 3RW24Controller ?

Too often the starter/motor combination is the leastconsidered component of the entire installation andfor too long the occurrence of motor burnouts,damaged drive systems and resultant productiondowntime has been tolerated as an inevitablemaintenance cost. But things have changed withthe introduction of electronic motor controllerssuch as the SIKOSTART 3RW24.

Electronic motor controllers 3RW24 control thevoltage applied to asynchronous motors duringstart up, reducing the starting current and torque toprovide a smooth, stepless acceleration.

The derived benefits from such starting are thefollowing:-

A. The MotorChemical and Process Industry

Application: Fluid pumping

Problem: Frequent start/stop of the motors usingconventional methods of starting cause damage tothe motor shaft.

Solution: Due to the reduction of starting torque andalso the starting current, the electrical and mechanicalstresses on the motor are reduced to a great extent.This has a great bearing in the longevity of the motor.

Start/Stop by use of electronic motor controller3RW24 eliminates damage of the motor shaft.

B. The Drive GearSteel Plants

Application: Cold Rolling Mills

Problem: High torque transients during startingcause high stress on the chain gear.

Solution: Smooth increase in operating voltageduring start up eliminates transient torqueassociated with conventional starting methodsthereby increasing the life of driving gears such asbelts, chains, couplings, gears etc.

Use of electronic motor controller 3RW24 reducesstarting torque thereby increasing chain life.

C. The LoadTextile Industry

Application: Ring frame machines

Problem: Due to start with sudden jerks thethreads tend to break.

Solution: Loads are protected from current andtorque surges during start up operations. Jerk

starts in conveyors are eliminated, water hammereffects in pumps are reduced and wear and tear intextile machines is reduced due to smooth start.

Use of electronic motor controller 3RW24 ensuressmooth acceleration thereby preventing suchbreakdowns.

D. The Supply VoltageMines and Quarries

Application: Crusher & Excavatrors

Problem: If working on a DG set, the startingcurrent has to be limited to prevent frequenttripping of the DG set.

Solution: The supply voltage regulation isimproved by reduction of starting currents andavoidance of transient current surges during startup. The minimum torque required determines thestarting current and stepless control of voltageavoids current surges.

Electronic motor controller 3RW24 reduces startingcurrents and transients thereby preventingfrequent tripping.

E. Energy SavingSoftware, Healthcare, Pharmaceutical Industry

Application: Refrigeration compressors.

Problem: The compressor has an ON - Off dutycycle. But as the motors are hardly turned offduring NO load periods there are huge energylosses.

Solution: Operation of the equipment “OnDemand” rather than ON load - OFF loadcontinuous running can lead to more efficientenergy planning and savings in Energy Bills.Frequent start/stop by conventional methodsdecrease the lifetime of the electromechanicaldevices.

Electronic motor controllers 3RW24 enablefrequent starting and stopping of the motorbecause of reduced electrical and mechanicallosses. Moreover due to reduction of voltageduring no load periods there is some energysavings.


1.6

F. Process SafetyMunicipal Corporations, Waterworks etc.

Application: Sewage, water pumping

Problem: Damages are caused in pipe work due to“water hammer” effects.

Many application requires smooth stopping of themotor, like conveyors in bottling plants, centrifugalpumps to avoid water hammer effects etc.

Solution: Smooth stop by Electronic motorcontroller 3RW24 reduces “water hammer” effectand ensures long life of the pipelines.

For all the above reasons electronic motorcontrollers 3RW24 are increasingly being used inindustry and the trade. Electronic motor controllers3RW24 provide complete protection for all drivesby restricting the motor torque and starting current.

The benefits of using an electronic motorcontroller 3RW24 can be summarized asfollows:

1. MechanicalReduced cost of transmission components

- low starting torque.

- starting torque adjustable to requirement.

Reduced maintenance costs

- low starting torque reduces belt slip.

Lower repair costs

- fatigue effects reduced (star/delta, transformerand single phase starting cause high currentpeaks).

2. ElectricalLow starting current

- compared to other conventional modes ofstarting.

Low maintenance costs

- lower rating contactors with zero currentswitching.

Machine protection

- electronic overload trip included with I-Optionfeature.

1.4 Features of SIKOSTART 3RW24

a) Standard Features

1. Soft Start

� Adjustable torque (0 - 100%)

� Adjustable ramp time (6-50 sec)

2. Soft stop

� Adjustable ramp time (6-50 sec).

b) Optional features (with I Option)

1. Impulse start with switch on pulse to overcomebreakaway friction (starting inertia).

2. Starting with current limit (100 - 450% Ie).

3. Energy saving by improving the power factorcosf, during no load periods. This feature isparticularly important for drives having longidling periods or running for a long period below10% normal load.

4. Monitoring of input power with overload trip(stall protection). A relay contact opens when aset limit is exceeded. This can be used as a stallor overload protection of the motor.

5. Overload trip, fixed adjustment between 20 to200% Ie.

6. Feed forward current control to damp possibledrive oscillations (e.g. “water hammer” effectswith pumps).

1.7


1

Whatever circuit is chosen, the ability to changemodes between the standard circuit and the deltaconnected circuit, will always provide a realalternative to the conventional mechanical andelectromechancial starters.

Typical Application Areas� Machines with gearbox, belt or chain drives.

� Drives using pole change motors.

� Conveyor belts (also high speed and high loadbelts).

� Machines with high moments of inertia e.g.mills, centrifuges, compactors.

� Grinding machines, circular saws.

� Fans and compressors.

� Pumps, in particular, to reduce “waterhammer” effect with I Option card (dampingcircuit).

� Reverse flow heat exchangers.

� Mixers, extruders, stone crushers.

� Hoists, escalators

� Machine tools, textile machines, wiredrawingmachines, injection molding machines etc.

1.8

Rated current Ie of starter corresponds to 57% of

nominal motor current In

6 conductors (as in star-delta starters) to the motor.Wiring effort approx. 60% of that of the standard circuit.

Fig. 1.8 Delta Connection


Circuit DesignsThe electronic motor controller 3RW24 can beoperated in two types of circuits.

Standard ConnectionWith this circuit, the switching devices fordisconnecting and protecting the motor are simplyinstalled in series with the soft starter, the motor isconnected to the soft starter with 3 conductors.

Delta connectionIn this case the wiring is similar to star/deltastarters. The phases of the soft starter areconnected in series with the separate motorwindings. The advantage in this connection is thatthe soft starter has to only carry the phase current,approximately 57% of the motor current In

(conductor current). The conductor current and thephase current are related by the factor 1.73. For thesame kW rating of a motor by using a deltaconnected soft starter one can opt for lower framesizes.

Choice of connectionsThe standard circuit requires the least wiring outlay.The wiring outlay for the delta connected softstarter is double as that of the standardconnection. But when upgradations are made tosoftstarter from star-delta starters delta connectedsoftstarters prove to be an economical choice.

Fig. 1.7 Standard Connection

Rated current Ie of starter corresponds to nominal

motor current In

3 conductors to the motor

L1L2L3N

SIKOSTART SIKOSTART 3RW24 - Principle of operation

2.1

2. SIKOSTART 3RW24 – Principle of operation

2.1 Starting and stopping

The SIKOSTART 3RW24 electronic motorcontrollers are designed for soft start and softstop of three phase asynchronous motors andemploy a fully controlled three phase thyristorcircuitry.

Each of the phases L1, L2 and L3 has twothyristors in anti parallel configuration.

Soft startingBy controlling the switch-on-point of the thyristorsrelative to voltage zero crossing in each half waveof the alternating current cycle the energy flowingto the motor is controlled. For the purpose of softstarting the voltage is continuously ramped upfrom a base voltage, by controlling the firing angleof the thyristors. The rate of firing angle of thethyristors (ramp time) is also adjustable. The basevoltage is set to supply sufficient torque to achievebreakaway and the ramp rate is adjusted accordingto the inertia of the load. The actual voltage appliedto the motor during starting is a function of bothload (motor) impedance and the thyristor firingangle. Once the motor reaches its rated speed thethyristors are turned FULL – ON.

Free coasting to stop, direct switchingoff of the mains voltageIf the supply voltage is switched off directly, themotor coasts down to stop over a perioddetermined by the moment of inertia of the driveand the frictional losses. Higher the moment ofinertia longer is the time taken to stop.

Both the situations may be undesirable either forreasons of safety with regard to material fatigue orbecause of unwanted abrupt stopping of the load.

The torque and current curves for different voltages(in each case constant values of the terminalvoltage) referred to the rated voltage, arerepresented by dotted lines in Figure 2.1. The boldcurves correspond to a start during which theterminal voltage is increased as function of time.

Fig. 2.1Torque and starting current characteristics duringstarting with a voltage ramp

Fig. 2.2Soft starting with voltage ramp

2

Fig. 2.5 Behaviour of the terminal voltage duringswitch-off with the “pump stop” function.

Soft stopWith soft stop operation the voltage applied to themotor is reduced to zero as a ramp function(adjustable). This is typically the case of conveyorbelts, escalators or hoists, to ensure that thematerial being conveyed does not fall over causingaccidental hazards.

The main contactor is opened with zero current oncompletion of ramp down. If zero current switchingwithout soft stop is required, the deceleration rampshould be set to the minimum time. This increasesthe life of the main switching contactor.

It may be noted that soft stopping is not the sameas Braking. Braking is achieved, with electronicbrakes, by means of injecting DC current in any ofthe two phases.

If a new ON command is given during softstopping, the stopping operation is immediatelyinterrupted and the motor is re-started.

Caution !!!The drive and the feeder (Motor, overload relay,contactor etc.) must be selected for the highercurrent drawn during the stopping operation.

Pump stopOwing to the very small moment of inertia ofcentrifugal pumps and the counter pressure of theliquid in the piping system, the pump drive cancome to an abrupt standstill upon switch-off.This can cause severe pressure shock waves,known as “Water hammer”, in the piping systemwhich can produce loud noises and can lead tomechanical problem of non-return valves and flaps.The problems described above can be avoided ifthe voltage at the motor terminals is notinterrupted suddenly (free coasting) after the OFFcommand, but is lowered over a period of time insuch a way that the actual delivery of the pump isreduced gradually to zero.For that, the torque characteristics of the motorand pump during run down must be taken intoconsideration.The “Pump stop” function of SIKOSTART 3RW24recognizes changes in the torque characteristics ofthe drive during run-down and actively controls themotor terminal voltage in such a way that anoptimal soft stop is achieved.The duration of the pump stop can be adjustedfrom 6 s to a maximum of 50 s by means ofpotentiometer (STOP TIME).If a new ON command is given during the pumpstop, the stopping operation is immediately brokenoff and the motor is re-started.

Fig. 2.4 Behaviour of the terminal voltage duringswitch-off with the “soft stop” function

SIKOSTART 3RW24 - Principle of operation SIKOSTART

2.2

Fig. 2.3 Speed curve for the various types of stop

Caution !!!The drive may already come to a standstillbefore the stopping time has elapsed whichmeans that a non-zero voltage may still existacross the motor terminals for a few seconds.

The drive and the feeder (motor, overload relay,conductor, etc.) must be selected for the highercurrent drawn during the stopping operation.

Note on Water HammerLike any other moving fluid, flowing water hasmomentum. When subjected to a sudden change inflow, the energy associated with the flowing water issuddenly transformed into pressure at that location. Theforce with which this pressure strikes the walls of thepipe can be compared to hammer blow. This occurrenceis referred to as “water hammer”. Flow changes canoccur due to operation of valves, starting and stoppingof pumps or directional changes caused by pipefittings.The intensity of water hammer effect will depend onthe rate of change in the velocity or momentum.

Another reason for water hammer is cavitation. This iscaused by steam bubble forming or being pushed intoa pipe completely filled with water. As the trappedbubble losses its latent heat, the bubble implodes, thewall of water comes back together and the force createdcan be severe.

SIKOSTART SIKOSTART 3RW24 - Principle of operation

2.2 Continuous operation

Full ONIn electronic motor controller 3RW24 the voltageapplied to the motor terminals is gradually rampedup from a base voltage to full mains voltage. Afterthe motor attains full speed the thyristors are fullyturned ON.

The power unit for 3RW24 is rated for 150% of therated current Ie. During Full ON condition the3RW24 monitors the following parameters:

� All phases present and are symmetrical

� Heat sink temperature

� Control voltage

� Connection for thermistor motor protection

Operation with a bypass contactorThe use of a bypass contactor is recommended toreduce losses during continuous operation.

On the one hand the power loss in the thyristors isreduced, and on the other hand the power unit canbe used to better advantage since it can cool downmore quickly (even to the ambient air temperature)before a new start.

The bypass contactor can be energized via theinternal “motor running” relay in SIKOSTART3RW24 (Typical circuit diagrams). Within 2 s afterthe end of the run-up sequence, the contacts ofthe bypass contactor must have closed, otherwisethe SIKOSTART 3RW24 is in FULL ON mode.

In contrast to the main contactor which is selectedin accordance with utilization category AC-3, the

2.3

2

H

~ ~= =

A

M

EP UM

PM PN

2BH

ME

MH

MU

Command "Ramp-up"

Signal "In Operation"

Command "Enable"

Signal "End of Ramp"

Phase current

Signal "Overload"

Con

trol

inpu

tsC

ontr

ol o

utpu

ts

BF

SW

CONTROL CIRCUIT TRIGGER SET

P12

N12

RAMP FUNCTION GENERATOR

2

2

2

2

I-OPTION

SEPARATE CONTROL MODULE WITHLINE & DELTA CONNECTED STARTERS Line Connection Delta Connection

2

B

INTERNAL SET VALUES

L1 L1

L1 L1

2 110 - 415V ±5%~ 2 110 - 415V ±5%~

3 110...500 V/220...690 V~ 3 110...500 V/220...690 V~

T1 T1

W1

V1

U1 U2U2

V2

W2

L2 L2

L2 L2

T2 T2

L3 L3

L3 L3

T3 T3

M3~

M3~

..........................................................

........................................................................

.........

Fig. 2.6Circuit with bypass contactor

Fig. 2.7 Schematic for SIKOSTART 3RW24

Block diagram

bypass contactor need only to be selected for AC-1switching duty. This is because, it only needs toconduct the operational current of motor and doesnot have to switch the starting current.

Even in the bypass contactor configuration, all thestopping modes (free coasting, soft stop, pumpstop) are permitted.

With the controlled stopping modes (soft stop,pump stop) the bypass contactor is swichted offvia the internal “motor running” relay before theSIKOSTART takes over the current for the stop.

2.3 Protection and control

I-Option card:The use of the I-Option card is recommended atpowers above 45 kW and with pump drives.

Electronic device protectionSIKOSTART is provided with a built-in thermistor,which trips the SIKOSTART in the event ofovertemperature.

Short circuit protection of wiring:Conventional short circuit protection of theconnections to the controller and to the motor inaccordance with the wiring regulations must beprovided for. Circuit breakers or additional fusescan be used.

Semiconductor fuses:It is recommended to use semiconductor fuses (asper the selection table) for protection of thethyristors against transient short circuit surges.Semiconductor fuses being fast acting preventthe thyristors against such hazards.

SIKOSTART 3RW24 - Principle of operation SIKOSTART

2.4

Thermal protection for motor:SIKOSTART is designed for continuous operationwith motors up to the rated power. Overloadprotection to motor should be separately provided.Suitable protection is a thermal overload relay,micro processor based motor protection relay3RB12, a motor starter, thermistor motorprotection or a combination of above can beprovided depending on the criticality of load.

Single step overload protectionMonitoring of the input power. A relay contactopens when a set limit is exceeded. This can beused as a stall or overload protection for the motor.

The measured power is also available as an analogsignal.

Caution !!!The heatsink may reach high temperatures.Depending on the type of device, the maximumheatsink temperature during continuousoperation may be as high as 85O C.

3.1

SIKOSTART Typical applications

3

3. Typical applications

3.1 Pumps

Load characteristic: M ~ n2

The load torque increases with the square of therotational speed (*Figures 3.1 to 3.3)

Examples:Centrifugal pumps, submersible pumps, vacuumand high-pressure pumps feeding into open pipenetworks (in the case of a closed valve the finaltorque value is approx. 50% of the value applicablefor a fully opened valve).

Problem:Particularly in the case of pumps, the pressurewave (“water hammer”) resulting from suddenacceleration and deceleration of the water columnmust be prevented.

This phenomenon can damage not only the pumpitself, but also the piping and the check-valves (non-return valves) in the piping system. Furthermore, itcan cause a loud bang which may disturb thosewho live near the pump station.

Solution with SIKOSTART 3RW24:The SIKOSTART 3RW24 can effectively prevent thepressure-wave by the functions “soft start” and“pump stop”.

In this way, the intervals between maintenancecan be prolonged and downtime due to excessivemechanical stress becomes a thing of the past.

As pumps normally only have a low moment ofinertia, selection of the correctly sized SIKOSTARTcontroller can usually be carried out directly fromthe catalogue. Only as an exception (e.g. if themoment of inertia of the total drive is greater than10 times the moment of inertia of the motor alone)please refer back to Siemens.

Selection of the correct setting:The starting voltage should not be too high(Fig. 3.2) as otherwise the water hammer may notbe prevented.

It should also not be too low (Fig. 3.3), otherwisethe motor may not start swiftly.

For the entire period of acceleration up to ratedspeed, the motor torque should be higher than theload torque by approximately 15% of the torque itwould produce at full rated terminal voltage(Fig. 3.1)

Fig. 3.1Correct setting of the starting parameters

Fig. 3.2Incorrect setting of the starting parameters* accelerating torque too high

Fig. 3.3Incorrect setting of the starting parameters* starting voltage too low and accelerating

torque too small

3.2 Fans

Load characteristic: M ~ n2

The load torque increases with the square of therotational speed(*Figures 3.4 to 3.6).

Examples:Fans, blowers feeding into open ducting networks(in the case of a closed damper, the final torquevalue is approx. 50% of the value applicable for afully opened valve), machines with centrifugalaction, propeller drives on ships, stirrers,centrifuges, drives causing motion in a straight lineagainst air resistance.

Problem:Fans usually have a very large moment of inertia(from 10-times to 200-times the moment of inertiaof the motor itself is possible).

In the case of direct-on-line starting, such a highmoment of inertia will require the full startingcurrent to flow for a long period of time which cancause an undesirable drop in the network voltage.

In the case of star-delta starting, there usually is anundesirable current and torque impulse at theinstant of the switch-over from the star to the deltaconfiguration. If the motor characteristics happento be unfavourable, this can almost be equal to adirect-on-line start.

Solution with SIKOSTART 3RW24:

The functions “soft start” and “current limiting”prevent high starting currents.

Selection of the correct setting:The starting voltage should not be too high(Fig. 3.5), otherwise the corresponding initialstarting current may still reach an unacceptablehigh value before the current limit function takeseffect.

Also, if the current limiting function is not beingused, the ramp time should not be too short(Fig. 3.6) as otherwise the full network voltage willbe connected to the motor terminals too earlyduring run-up, and thus the full starting current maystill flow.

For the entire period of acceleration upto ratedspeed, the motor torque should be higher than theload torque by approximately 15% of the torque itproduces at full rated terminal voltage (Fig. 3.4).


Fig. 3.5Incorrect setting of the starting parameters* starting voltage too high

Fig. 3.6Incorrect setting of the starting parameters* ramp time too short

Typical applications SIKOSTART

3.2

3.3


3

3.3 Mills

Load characteristic: M ~ 1/nThe load torque decreases with increasingrotational speed (*Figures 3.7 to 3.9).

Examples:Ball mills, lathes, turning and milling machines,winders and peeling machines.

Problem:For the initial start, mills need a high breakawaytorque. There-after, the required torque to maintainrotation and to accelerate the drive decreases withincreasing rotational speed.

Therefore, the drive must be provided withsufficient energy to start the mill turning, but there-after, during running up to speed, the currentdrawn should not be higher than absolutelynecessary.

This means that star-delta starting is usually notpossible as only 1/3 of the motor torque is availablein the star configuration and the motor would onlyrun up after switching over to the delta stage. Thiswould, in effect, be equal to a direct-on-line start.

Solution with SIKOSTART 3RW24:By means of the impulse start function (or “kick-start”), for which the level of switch on pulse canbe set between 0 to 200% of rated current, thedrive motor is provided with just enough torque forthe mill to start turning. Afterwards the torque isdropped as to match the motor torque to the loadtorque characteristic.

Selection of the correct setting:The starting impulse should not be too high(Fig. 3.8) as this would be equivalent to a direct-on-line start and thus the full starting current wouldflow and the maximum accelerating torque wouldbe applied to the load.

The starting torque impulse should be only a littlegreater than the breakaway torque of the mill, andthe motor torque should be reduced again asquickly as possible after the shaft starts turning(Fig. 3.7).


Fig. 3.8Incorrect setting of the starting parameters* starting switch on pulse setting too high

Fig. 3.9Incorrect setting of the starting parameters* starting switch on pulse setting too high.

3.4 Conveyor belts, elevators,escalators

Load characteristic: M = const.The load torque is constant over the entire range ofthe rotational speed (Figures 3.10 to 3.12). An initialbreakaway torque impulse may be required.

Examples:Hoists, piston pumps and compressors actingagainst constant pressure, enclosed blowers,rolling mills, conveyor belts, mills without fanaction, machine tools with constant cutting force,escalators.

Problem:In the case of direct-on-line starting and stoppingpersons or objects being conveyed could fall overand be injured or damaged, respectively.

In the case of a soft starter with a non-adjustableimpulse start function, the start could beequivalent to a direct-on-line start.

If the initial start voltage is too low, the motor isblocked by the load torque for too long before thevoltage is ramped up high enough (M ~ U2) and themotor torque becomes larger than the load torque.

In the case of a star-delta starter, the drive wouldonly run up after the switch-over to the deltaconfiguration, which would be equivalent to adirect-on-line start.

Solution with SIKOSTART 3RW24:The functions soft start, soft stop and, if required,the impulse start function which is adjustable,ensure that the SIKOSTART is ideally suited for thesoft starting and stopping of conveyor belts,elevators and escalators.

Selection of the correct setting:The starting impulse setting should not be too high(Fig. 3.11) as this would be equivalent to a direct-on-line start and thus the full starting current wouldflow and the maximum accelerating torque wouldbe applied to the load.

The starting voltage should not be set too low(Fig. 3.12) to ensure that the motor starts to run upat the moment the start signal is given.


Fig 3.11Incorrect setting of the starting parameters* starting voltage too high

Fig. 3.12Incorrect setting of the starting parameters* initial starting voltage too low

Typical applications SIKOSTART

3.4


3.5

3

3.5 Calenders

Load characteristic: M ~ nThe load torque increases linearly with therotational speed (*Figures 3.13 to 3.15).

Examples:Calenders, screw conveyors (starting with screwchambers that are not filled), machines forsmoothing textiles and paper, mangles.

Problem:Calenders typically comprise two rollers positionedone above the other.

These turn in opposite directions and press paperor fabric between their contact surfaces.

Even in the case of direct-on-line starting, the largemoment of inertia of the rollers causes long run-uptimes during which the full starting current wouldflow.

Also, owing to the high accelerating torque duringdirect-on-line starting, there may be a danger oftearing the paper of fabric during run-up. This wouldcause a production standstill and down-time.

Solution with SIKOSTART 3RW24:By means of the functions “soft start” and “softstop”, SIKOSTART 3RW24 effectively avoids thehigh accelerating torques and limits the startingcurrent.

Selection of the correct setting:The start voltage should not be too high (Fig. 3.14)to ensure that the starting current and theaccelerating torque are low.

The ramp time should not be too long as otherwisethe motor may stall at low rotational speed(Fig. 3.15). If this happens, the internal temperaturein the starter will rise sharply causing the solid-state device protection of the SIKOSTART tooperate.

For the entire period of acceleration up to ratedspeed, the motor torque should be higher than theload torque by approximately 15% of the torque itwould produce at full rated terminal voltage(Fig. 3.13).


Fig. 3.14Incorrect setting of the starting parameters* initial starting voltage too high

Fig. 3.15Incorrect setting of the starting parameters* ramp time too long

4 Motor feeder circuit

The compact unit SIKOSTART 3RW24 isincorporated within a normal motor feeder circuitbetween the main switchgear and motor (*Fig. 4.1)

In principle, the rest of the motor feeder remainsunchanged and is designed in terms of the motorpower rating.

In spite of the considerable decrease in startingcurrent which may be achieved through the use ofthe SIKOSTART, all the elements of the main circuitshould be dimensioned for direct-on-line startingand in accordance with the prospective short-circuit conditions.

Depending on the ramp time, the limited startingcurrents, which are always still greater than themotor rated current, may flow for a relatively longerperiod of time. This should be borne in mindparticularly when selecting the overload protectionof the motor.

This also applies for the stopping mode, soft stopand pump stop which, unlike the case when themotor coasts to a stop, cause an additional currentto flow during run-down.

For the short-circuit protection of the powerthyristors in the SIKOSTART, super-fast acting semi-conductor fuses are recommended (*page 4.4 &4.5). Table 4.1 provide suggestions for thedimensioning of the motor feeder for normalstarting conditions (moment of inertia of the totaldrive JTot < 10 x Jmotor; and motor with rotor classKL10, which means that starting against a loadtorque of up to 100% the motor rated torque ispossible even at an undervoltage of 5%).

Fig. 4.1Principle configuration of a typical motor feeder

Motor feeder circuit SIKOSTART

4.1

4.2

SIKOSTART Motor feeder circuit

4

4.1 Motor feeder protection

The optimum motor feeder protection can beprovided by an overload relay, general purpose HRCfuses and semiconductor fuses.

This can be seen clearly from the diagram below, inwhich the short-circuit and overload protectioncurves for a 37 kW motor feeder are illustrated.

The overload relay is responsible for protectingthe motor against overload, the HRC fuses forprotecting the switching elements and conductorsagainst overload and short-circuit and the semi-conductor fuses for protecting the thyristorsagainst short-circuit.

Naturally, the HRC fuses and the overload relaymay be substituted by a circuit-breaker.

In other words, each and every protection elementhas its particular purpose.

Semiconductor fuses should always be used forthyristors as they provide fast and safe protectionfor the sensitive semi-conductors at high short-circuit currents. Moreover, in case of a short-circuit,a fuse can be replaced faster than a string ofthyristors which saves long downtimes.

Fig. 4.2Characteristics ofthe protectionelements in amotor feederincorporating aSIKOSTART

4.3 Installation in parallel with afrequency converter

If the motor has to be connected to a SIKOSTARTmotor controller in parallel with a frequencyconverter, then the load side of the SIKOSTARTmust be disconnected from the motor (ContactorK3) when the converter is in use to protect the RCprotection circuits of the thyristors from beingdamaged through high frequency voltage producedby the converter (Fig. 4.3).

Whether a contactor on the load side of theconverter (K4) is also necessary must be checkedby the user for each individual case.

F1 Line fuses for SIKOSTART

F2 Line fuses for frequency converter

F2.1 Overload relay

F3 Semiconductor fuses for SIKOSTART

G1 SIKOSTART

G2 Frequency converter

K1 Main contactor for SIKOSTART

K2 Main contactor for converter

K3 Motor contactor for SIKOSTART

K4 Motor contactor for converter

M1 Three-phase asynchronous motor

Fig. 4.4 : Operation in parallel installation with afrequency converter

4.2 Parallel starting of motors

The power rating of a SIKOSTART must be at leastas great as the sum of all the motor power ratings.Proper derating should be done if the applicationdemands.

The loads should have similar characteristic torque/speed curves and similar moment of inertia.

Fig. 4.3Parallel starting of several motors with oneSIKOSTART


4.3

4.4 Operation of a motor with apower factor correctioncapacitor

Power factor correction capacitors should beswitched out of the motor feeder circuit during thestarting phase, since the wave form distortionresulting from the starting may cause them tobecome overloaded and/or damaged (*Fig. 4.5).The “motor running” output relay may be used toreconnect the capacitors after the motor has run upto speed.

The power factor correction capacitors must neverbe connected between the SIKOSTART and themotor!

Fig. 4.5 : Operation of a motor with power factorcorrection capacitors

4.4

SIKOSTART Motor feeder circuit

4

Table 4.1 : Normal starting, Ta = 45oCDesign and selection recommendations for motorfeeder circuits incorporating a SIKOSTART undernormal starting conditions and 45oC servicetemperature. Recommendations are made formotor feeders with or without fuses.

Fig. 4.6Configuration of the motor feeder circuit with orwithout fuses

M1

Motor rated output power 7.5 kW

Motor rated current at 415 V 16 A

G1 SIKOSTART (Line Conneced) at 45oC 3RW2428

SIKOSTART (Delta Conneced) —

F3 Short-circuit protection for SIKOSTART (per phase) 100 ASITOR fuse-links 3NE4121single-poletriple-pole

F1 Fuse configuration HRC fuses 3NA3810-7Y

K1 Main isolating contactor AC-3 3TF32

F2 Overload relay2) 3UA5200-2B

K1 Fuse-line configuration, 415VMain isolating contactor 3TF32Q1 (Type 2 for r, Type 1 for Iq) Circuit-breaker2) 3RV1121..

K2 Bypass contactor AC-1 3TF30

M1

Motor rated output power 11 kW 15 kW 22 kW 30 kW

Motor rated current at 415 V 20.8 28 A 40 A 53 A

G1 SIKOSTART (Line Conneced) at 45oC 3RW2429 3RW2430 3RW2431 3RW2432

SIKOSTART (Delta Conneced) — — — 3RW2430

F3 Short-circuit protection for SIKOSTART (per phase) 125 A 125 A 160 A 160 ASITOR fuse-links 3NE4122 3NE4122 3NE4124 3NE4124

F1 Fuse configuration HRC fuses 3NA3820-7Y 3NA3820-7Y 3NA3824-7Y 3NA3830-7Y

K1 Main isolating contactor AC-3 3TF33 3TF44 3TF46 3TF47

F2 Overload relay2) 3UA5200-2C 3UA5500-2D 3UA5800-2F 3UA5800-2P

K1 Fuse-free configuration, 415 V Main isolating contactor 3TF44 1) 3TF441) 3TF46 1) 3TF471)

Q1 (Type 2 for r, type 1 for lq) Circuit-breaker2) 3RV1121.. 3RV1131.. 3RV1131.. 3RV1142..

K2 Bypass contactor AC-1 3TF32 3TF44 3TF46 3TF46

Table 4.1

Q1 Circuit-breakerF1 HRC fusesF2 Overload relayF3 Semiconductor fuses (3NE4)K1 Main contactorK2 Bypass contactorG1 SIKOSTARTM1 MotorTa Ambient air temperature

4.5


M1

Motor rated output power 37 kW 45 kW 55 kW 75 kW 90 kW

Motor rated current at 415 V 65 A 78 A 96 A 131 A 156 A

G1 SIKOSTART (Line Conneced) at 45oC 3RW2433 3RW2434 3RW2435 3RW2436 3RW2437

SIKOSTART (Delta Conneced) 3RW2431 3RW2432 3RW2433 3RW2434 3RW2435

F3 Short circuit protection for SIKOSTART 315 A 315 A 450 A 500 A 500 A(per phase) SITOR fuse-links 3NE4330-6 3NE4330-6 3NE4333-6 3NE4334-6 3NE4334-6

F1 Fuse configuration HRC fuses 3NA3832-7Y 3NA3832-7Y 3NA3136-7Y 3NA3140-7Y 3NA3144-7Y

K1 Main isolating contactor AC-3 3TF47 3TF50 3TF50 3TF51 3TF52F2 Overload relay2) 3UA5800-2U 3UA5830-5B 3UA583-5C 3UA6230-5A 3UA6250-5B

K1 Fuse-free configuration, 415 V Main isolating contactor 3TF451) 3TF501) 3TF501) 3TF511) 3TF521)

Q1 (Type 2 for r, Type 1 for Iq) Circuit-breaker2) 3RV1142.. 3RV1142.. 3RV1142.. 3VL3725.. 3VL3725..

K2 Bypass contactor AC-1 3TF46 3TF46 3TF50 3TF51 3TF51

M1

Motor rated output power 315 kW 400 kW

Motor rated current at 415 V 540 A 690 A

G1 SIKOSTART (Line Conneced) at 45oC 3RW2443 3RW2444

SIKOSTART (Delta Conneced) 3RW2441 3RW2442

F34 Short circuit protection for SIKOSTART 2 x 500 A 2 x 710 A(per phase) SITOR fuse-links 2 x 3NE4334-6 2 x 3NE4337-6

F1 Fuse configuration HRC fuses – –

K1 Main isolating contactor AC-3 3TF68 3TF69Q1 (Type 2 for r, Type 1 for Iq) Circuit breakers 3WN61 3WN61

F2 Overload relay2) 3RB12 3RB12

K2 Bypass contactor AC-1 3TF68 3TF69

1) Iq = 50 kA2) Normal Starting = class 10

M1

Motor rated output power 110 kW 132 kW 160 kW 200 kW 250 kW

Motor rated current at 415 V 189 A 228 A 280 A 345 A 430 A

G1 SIKOSTART (Line Conneced) at 45oC 3RW2438 3RW2439 3RW2440 3RW2441 3RW2442

SIKOSTART (Delta Conneced) 3RW2436 3RW2437 3RW2438 3RW2439 3RW2440

F3 Short circuit protection for SIKOSTART 500 A 710 A 710 A 710 A 2 x 500 A(per phase) SITOR fuse-links 3NE4334-6 3NE4337-6 3NE4337-6 3NE4337-6 3NE4334-6

F1 Fuse configuration HRC fuses 3NA3252-7Y 3NA3260-7Y 3NA3260-7Y 3NA3365-7Y 3NA3365-7Y

K1 Main isolating contactor AC-3 3TF53 3TF54 3TF55 3TF56 3TF57F2 Overload relay2) 3UA6230-5C 3UA6230-5C 3UA6230-50 3UA6230-5E 3UA6230-5F

K1 Fuse-free configuration, 415 V Main isolating contactor 3TF531) 3TF451) 3TF551) 3TF561) 3TF571)

Q1 (Type 2 for r, Type 1 for Iq) Circuit-breaker2) 3VL3725.. 3VL3725.. 3VL4731.. 3VL5763.. 3VL5763..

K2 Bypass contactor AC-1 3TF52 3TF54 3TF54 3TF56 3TF57

5.1

5. Typical Circuit Diagrams

Note :

* With I-Option card only (C. T. connection)

** Fan supply

230 V AC external power supply

*** Thermistor or thermostat motor protection

Basic connections with isolated contacts

F2 - Overload relay

Q1 - MPCB / ACB / MCCB

K1/K2 - Main isolating contactors (AC-3 rated)

F3 - Semiconductor Fuses (Optional)

BH - Command "Ramp-up"

BF - Command "Enable"

ME - Monitoring signal "In operation"

MH - Monitoring signal "End of ramp"

Only with I-Option card

MU - Monitoring signal "Overload".

SIKOSTART Typical Circuit Diagrams

5

5.2

Note :


** Fan supply

230 VAC external power supply


Control through PLC

Basic connections for PLC with 24 V = industry logic

Q1- MPCB / ACB / MCCB

K1 - Main isolating contactor (AC-3 rated)

F3 - Semiconductor Fuses (Optional)

F2 - Overload relay

L - is preferably to be earthed. Remove link49-50 if there is a potential difference betweenL - and PE (max. permissible voltage 60 V)

Typical Circuit Diagrams SIKOSTART

5.3


5

Note :

* With I-Option only (C. T. connection)

** Fan supply


Recommended connection : SIKOSTART 3RW24 Line Connection for Soft Start(also with I-OPTION card)

G1 = SIKOSTART

F1 = Motor feeder HRC fuses

K1 = Main isolating contactor (AC-3 rated)

F3 = Semiconductor fuses (Optional)

K3 = Bypass contactor (Optional)

S1 = ‘OFF’ push button (Momentary command)

S2 = ‘ON’ push button (Momentary command)

F2 = Overload relay


5.4

Recommended connection : SIKOSTART 3RW24, Delta Connection for Soft Start(also with I-Option card)

G1 = SIKOSTART





S1 = ‘OFF’ push button (Momentary Command)

S2 = ‘ON’ push button (Momentary Command)

F2 = Overload relay

*MU - only with I-Option card

Note :


** Fan supply



5.5

5

Note :


** Fan supply


Recommended connection : SIKOSTART 3RW24, Line Connection Soft Start and Soft Stop(also with I-Option card)

G1 = SIKOSTART




F2 = Overload relay


S1 = ‘OFF’ push button(Momentary Command)

S2 = ‘ON’ push button(Momentary Command)

K2 = Auxiliary contactor (4 NO)


5.6

Note :


** Fan supply

230 VAC, external power supply

Recommended connection : SIKOSTART 3RW24, Line connection as a Soft Start and Soft Stopfor reversing application

G1 = SIKOSTART



K1f = Main isolating contactor in forwarddirection

K1R = Main isolating contactor in reversedirection

F2 = Overload relay

ON1 = Forward direction

ON2 = Reverse direction


K2f = Auxiliary contactor (4NO + 4NC)

K2R = Auxiliary contactor (4NO + 4NC)

S1 = ‘OFF’ push button(Momentary Contact)

S2.0 = ‘ON’ push buttonS2.1 (Momentary Contact)

5.7


5

Note :

* With I-Option card only (C.T. Connection)

** Fan supply


Recommended connection : SIKOSTART 3RW24, Line connection (also with I-Option) for softstart and speed change of motors in the pole-change Dahlander connection. This connectionprovides for zero-current contactor switching

G1 = SIKOSTART





K4 = Auxiliary contactor (3NO + 1NC)

K5 = Auxiliary contactor (4NO)

K21 = Contactor - Slow speed

K11 = Aux. Contactor (4NO)

K12 = Aux. Contacor (4NO)

K22-1= Star contactor(Dahlander wdg. only)

S2 = ‘ON’ slow speed(Momentary Command)

S3 = ‘ON’ high speed(Momentary Command)

S1 = ‘Off’ command(Momentary Command)

F2 = Overload relay

F4 = Overload relay


5.8

Note :

* With I-Option card only (C.T. Connection)

** Fan supply


Recommended connection : SIKOSTART 3RW24, Line connection I-Option card combinedwith a star/delta starter for starting with low starting currents (e.g. screw compressors inbypass).

G1 = SIKOSTART


F3 = Semiconductor fuses

K1 = Bypass contactor

F2 = Overload relay

K2 = Delta contactor

K3 = Star contactor

K4 = ON -delay timers

S1 = ‘OFF’ Push button(Momentary Command)

S2 = ‘ON’ Push button(Momentary Command)

K6 = Line contactor

F12 110...415 V~

K3 K2

K2

k4

k4

k4

k4

k3

k3

K1K6

H

K1

K1 K1

K2

21

22

MU*

OFF

ON

S2

S1 F2

PE L1

L1PE

41

1

2

3

4

5

6

7

8

9

10

P10

BH

BF

K1

G1

F3

F2

k4

SW

MH

ME

F

**

49

50

K1

K2 K3

O

PE

SIKOSTART

3RW24

42L2

L2

L3

L3

T1

*

T2 T3

M

3 ~

W1 W2

V1 V2

U1 U2

K6

K6

5.9


5

Note :


** Fan supply


••• Rapid push button start is not possible. Push button must be pressed for sufficient time.

Recommended connection : SIKOSTART 3RW24, Delta connection combined with a star/delta starter for emergency starting)

G1 = SIKOSTART



K1 = Bypass contactor

K2 = Delta contactor

K3 = Star contactor

F2 = Overload relay

K5 = Auxiliary contactor (3NO + 1NC)

K4 = 7PU60 star-delta timer

S1 = ‘OFF’ push button(Momentary Command)

S2 = ‘ON’ push button(Momentary Command)

S3 = Star-delta change over switch

K6 = Line contactor


5.10

Note :

* With I-Option card only

** Fan supply



Recommended connection : SIKOSTART 3RW24, Line connection as a voltage controller(e.g. for running the motor at lower speed, special motor, control of electric heating)

G1 = SIKOSTART

F1 = Motor feeder fuses



US -11 = 10kW potentiometer

F2 = Overload relay

6.1

6. Product range, technical data

Line connection

Table 6.1

Rated Operational Motor Rating Type Reference, Basic VersionCurrent of the at 415V, 45°C operating range 110V - 500V, withcontroller at 45°C Normal Starting protection & Snubber circuit, with

A kW AFan assembly for ³³³³³ 15kW as standard

18 7.5 16 3RW2428-1AA05 *

26 11 20.8 3RW2429-1AA05 *

40 15 28 3RW2430-1AA05 *

52 22 40 3RW2431-1AA05 *

65 30 53 3RW2432-1AA05 *

75 37 65 3RW2433-1AA05 *

95 45 78 3RW2434-1AA05 *

120 55 96 3RW2435-1AA05 *

150 75 131 3RW2436-1AA05 *

190 90 156 3RW2437-1AA05 *

240 110 189 3RW2438-1AA05 *

290 132 227 3RW2439-1AA05 *

350 160 271 3RW2440-1AA05 *

420 200 339 3RW2441-1AA05 *

500 250 398 3RW2442-1AA05 *

650 315 531 3RW2443-1AA05 *

750 400 665 3RW2444-1AA05 *

Without I-Option 0

With I-Option 1

* Position 13 to be filled for I-Option

I-Option * Current limit with torque pulse

* Overload trip

* Power factor (COS f) Improvement

* Energy saving circuit

Note: 220-690V SIKOSTART version - Upon enquiry

6

SIKOSTART Product range, technical data

6.2

Delta connection

Table 6.2

Rated Operational Motor Rating at Type Reference, Basic Version operating range,Current of the 415 V, 45°C 110V - 500V, with protection & Snubbercontroller at 45°C Normal Starting circuit, with Fan assembly as standard

A kW A

40 30 53 3RW2430-1AA06 *

52 37 65 3RW2431-1AA06 *

65 45 78 3RW2432-1AA06 *

75 55 96 3RW2433-1AA06 *

95 75 131 3RW2434-1AA06 *

120 90 156 3RW2435-1AA06 *

150 110 189 3RW2436-1AA06 *

190 132 227 3RW2437-1AA06 *

240 160 271 3RW2438-1AA06 *

290 200 339 3RW2439-1AA06 *

350 250 398 3RW2440-1AA06 *

420 315 531 3RW2441-1AA06 *

500 400 665 3RW2442-1AA06 *

650 500 820 3RW2443-1AA06 *

750 630 1020 3RW2444-1AA06 *

Without I-Option 0

With I-Option 1

* Position 13 to be filled for I-Option

I-Option * Current limit with torque pulse

* Overload trip

* Power factor (COS f) Improvement

* Energy saving circuit

Product range, technical data SIKOSTART

6.3


6

Technical Data : Table 6.33RW2428 3RW2429 3RW2430 3RW2431 3RW2432 3RW2433 3RW2434

Line Connection

Motor power with normal starting (415V) kW 7.5 11 15 22 30 37 45

Rated motor current A 16 20.8 28 40 53 65 78

Delta Connection

Motor power with normal starting (415V) kW – – 30 37 45 55 75

Rated motor current A – – 53 65 78 96 131

Rated operational controller current at 45° C A 18 26 40 52 65 75 95

Constant operation (% of le) 150%

Permissible temp. in operation °C 0 to 45°C

in storage °C - 40 to + 70° C

Operating conditions voltage V 110 to 500 V ± 10%

Main Supply frequency Hz 50 to 60 Hz

Recommended starts per hour 1/h 50 50 10 10 10 10 10

With intermittent periodic duty S4 1/h 20 20 5 5 5 5 5

ON load period F = 50% 1/h 10 10 5 5 5 5 5

Rest time after constant operation with Ie

s 60 300 600 600 720 780 600following by a new start with 250% l

e 60s

Short circuit protection for SITOR A 100 125 125 160 250 315 315

thyristor fuse link Type 3NE4121 3NE4122 3NE4122 3NE4324 3NE4327-6 3NE4330-6 3NE4330-6

Heat dissipated at rated operational current W 55 75 100 150 200 240 280

Weight Kg 3.5 3.5 3.8 3.8 4.1 4.1 16

Cooling Fan Voltage V Convection 230 VAC

Supply A Cooling external power supply

Bypass contactor rating Type AC-3 3TF30 3TF44 3TF46 3TF47 3TF47 3TF49 3TF50

Type AC-1 3TF30 3TF32 3TF44 3TF46 3TF46 3TF46 3TF46

Max. Conductor cross sections Solid mm2 1 to 16 1 to 16 1 to 16 1 to 16 1 to 16 1 to 16 1 to 16'Finely stranded without end sleeves mm2 2.5 to 25 2.5 to 25 2.5 to 25 2.5 to 25 2.5 to 25 2.5 to 25 2.5 to 25Finely stranded with end sleeves mm2 1 to 16 1 to 16 1 to 16 1 to 16 1 to 16 1 to 16 1 to 16stranded mm2 2.5 to 25 2.5 to 25 2.5 to 25 2.5 to 25 2.5 to 25 2.5 to 25 2.5 to 25busbar mm – – – – – – –

Protection IP00

CONTROL CIRCUIT

Rated control voltage V 110 - 415 V Ph + 5%

Rated frequency Hz 50 - 60 Hz

Short circuit protection 4A Operational class 9l / 9G; 6A rapid blow (not included in delivery)

Auxiliary contact rating 440V 2A, 500VA/a.c.

Relay output rated operation current A 3A, AC-15/AC-14 at 240 V

A 0.1A, DC-13 at 240 V AC

A 0.5A, DC-13 at 24VDC

Maximum current cross-sections solid mm2 0.5 - 2.5

Finely stranded with end sleeve mm2 0.5 - 1..5

Tightening torque Nm 0.8 - 1..4

Product range, technical data SIKOSTART

6.4

3RW2435 3RW2436 3RW2437 3RW2438 3RW2439 3RW2440

Line Connection

Motor power with normal starting (415V) kW 55 75 90 110 132 160

Rated motor current A 96 131 156 189 227 271

Delta Connection

Motor power with normal starting (415V) kW 90 110 132 160 200 250

Rated motor current A 156 189 227 271 339 398

Rated operational controller current at 45° C A 120 150 190 240 290 350






Recommended starts per hour 1/h 6 6 6 6 6 6

With intermittent periodic duty S4 1/h 6 6 6 6 6 6

ON load period F = 50% 1/h 6 6 6 6 6 6


s 100 100 100 100 100 100following by a new start with 250% l

e 60s

Short circuit protection for SITOR A 450 500 500 500 710 710

thyristor fuse link Type 3NE4333-6 3NE4334-6 3NE4334-6 3NE4334-6 3NE4337-6 3NE4337-6

Heat dissipated at rated operational current W 340 500 600 700 800 1000

Weight Kg 16 16 30 30 30 30

Cooling Fan Voltage V 230 VAC external power supply

Supply A

Bypass contactor rating Type AC-3 3TF51 3TF52 3TF53 3TF54 3TF55 3TF56

Type AC-1 3TF50 3TF51 3TF51 3TF52 3TF54 3TF54

Max. Conductor cross sections Solid mm2 – – – – – –'Finely stranded without end sleeves mm2 – – – – – –Finely stranded with end sleeves mm2 – – – – – –stranded mm2 95 120 150 185 240 –busbar mm – – – – – 40 x 5

Protection IP00

CONTROL CIRCUIT






A 0.1A, DC-13 at 240 V AC






6.5

6

3RW2441 3RW2442 3RW2443 3RW2444

Line Connection

Motor power with normal starting (415V) kW 200 250 315 400

Rated motor current A 339 398 531 665

Delta Connection

Motor power with normal starting (415V) kW 315 400 500 630

Rated motor current A 531 665 820 1020

Rated operational controller current at 45° C A 420 500 650 750






Recommended starts per hour 1/h 3 3 3 2

With intermittent periodic duty S4 1/h 3 3 3 2

ON load period F = 50% 1/h 3 3 3 2


s 100 100 100 100following by a new start with 250% l

e 60s

Short circuit protection for SITOR A 710 2 x 560 2 x 560 2 x 710

thyristor fuse link Type 3NE4337-6 2 x 3NE4334-6 2 x 3NE4334-6 2 x 3NE4337-6

Heat dissipated at rated operational current W 1200 1400 1800 2300

Weight Kg 42 42 70 70

Cooling Fan Voltage V 230 VAC external power supply

Supply A

Bypass contactor rating Type AC-3 3TF56 3TF68 3TF69 3TF69

Type AC-1 3TF56 3TF57 3TF68 3TF69

Max. Conductor cross sections Solid mm2 – – – –'Finely stranded without end sleeves mm2 – – – –Finely stranded with end sleeves mm2 – – – –stranded mm2 – – – –busbar mm 40 x 10 40 x 10 40 x 10 80 x 15

Protection IP00

CONTROL CIRCUIT






A 0.1A, DC-13 at 240 V AC





7.1

7. Dimension Drawings

3RW2435-3RW2437Fig. 7.2

3RW2438-3RW24401)

Caution: Tightening torque for power terminals not to exceed : 9 Nm.

Caution: Tightening torque for power terminals not to exceed : 3 Nm.

Fig. 7.3

Fig. 7.1 3RW2428-3RW2434

1)Control card to be mounted separately in the panel.The dimension for control card is shown in fig.8.7

All Dimensions in mm

Fans supplied as standard feature forSikostart - 3RW2430

Fans supplied as standard feature

Dimension drawings SIKOSTART

7.2

7

SIKOSTART Dimension drawings

3RW2441-3RW24421)

3RW2443-3RW24441)

Fig. 7.4

Fig. 7.5

7.3

Dimension drawings SIKOSTART

Fig. 7.8Dimensions of C.T.s for 3RW2428 - 3RW2433


Control Card dimensionsControl Card is common for the entire range from 3RW2438 - 3RW2444 - It is recommended to mount thecontrol card on left or right side of Thyristor assembly.

Fig. 7.7


8.1

8. Installation & Commisioning

Warning

These electronic controllers can affect themovement of machinery or moving constructions.The following safety precautions must be takenbefore commissioning

Provide adequate means of preventing personsfrom coming within the dangerous areas of themachinery or moving constructions

Verify that all required Emergency Stop equipmentis installed and functioning.

Non-observance of the safety instructions canresult in severe personal injury or property damage.Only qualified persons should work on or nearthese controllers. The successful and safeoperation of these controllers is dependent onproper transport, storage, planning and installing aswell as commissioning.

Qualified PersonsFor the purpose of this documentation a “qualifiedperson” is one who is familiar with the technicaldata, re-commendations for planning and installing,commissioning instruction and recommendedconnections contained herein and the hazardsinvolved. In addition, he has the followingqualifications:

– Is trained and authorized to energize, de-energize, clear, ground and tag circuits andequipment in accordance with establishedsafety practices.

– Is trained in the appropriate wiring andinstallation regulations

– Is trained in the proper care and use ofprotective equipment in accordance withestablished safety practices

– Is trained in rendering first aid.

8.1 Installation Tips

Mounting PositionSikostart 3RW24 can be installed in OpenSwitchboards, Enclosed boards, Switchgearcabinets. Section 7 of the manual containscontroller mounting dimensions. Airflow throughthe unit is vertical, from bottom to top. It isimportant to locate the controller in a positionwhich allows free airflow vertically through thepower module. The controller must be mountedwith heat sinks in vertical plane.

AltitudeThe maximum permissible altitude is 3000m abovesea level. In case of SIKOSTART 3RW2428-3RW2444 at an altitude of 1000m or more, abovesea level, the rated operating current Ie must bereduced. The rated operating current is shown inFig. 8.3 as a function of altitude.

FixingUse screw bolts in conjunction with plain washers& appropriate securing components, such as springwashers.

Cooling Arrangement (Refer Fig. 8.1)When mounting the controller in an enclosure, theenclosure must be properly sized or ventilated toprovide cooling for the continuous powerdissipation in the thyristors. For the lower ratingSIKOSTART 3RW2428 to 3RW2429 fans neednot be provided. For SIKOSTART 3RW2430 andonwards, fans should be provided for cooling.

When enclosed in a panel, adequate cooling isessential for proper operation of the controller.There should be at least 200mm of clearanceabove and below the controller to allowunimpeded convection or fan air flow throughthe heat sink.

Wire bending allowance may require more thanthis recommended minimum clearance. Location ofinlet air vent should be at least 100mm below thebottom edge of the controller. An outlet air ventarea at least 200mm above the controller top edge.

The vent areas required for each inlet & each outleton customer furnished enclosures, motor controlcentres etc. should be min. 550 sq. cm. Using airfilters impede air circulation and require a fan atinlet and/or outlet.

Proper cut-out (top & bottom) should be providedfor free circulation of air. For alignment in rows, seeFig. 8.2.

The temperature inside the enclosure must bemaintained within the range of 0°C to 45°C.

SIKOSTART Installation & Commissioning

8

8.2

AttentionWhen thermal overload relays are installed in thesame enclosure a barrier should be providedaround the relay to deflect the forced air flow awayfrom the relay.

1. Degree of protection: Complete range IP00.Higher degree requirement must be met by theconstruction of the cubicles at installation site.

Connection and Wiring– Control supply voltage is to be given at terminal

41 & 42

– The main incoming supply is to be given to L1,L2 & L3. Motor side connection should be madeon T1, T2, T3. The correct conductor cross-sections should be selected.

– For auxiliary connections, remove the auxiliaryconnector plug and carry out the wiring as perthe proposed wiring schematic and then fix theconnector plug back on the PCB.

– The Control Unit for Sikostart 3RW2438-3RW2446 to be mounted separately in thepanel and connected to power unit by flat cablesupplied along with the SIKOSTART. Please referthe dimensional drawing.

Warning

While installing the controller in Enclosure,Sikostart internal wiring should not be changed.C.T. wire and length should not be changed.

While testing the Sikostart without load or loadother than motor, contact your nearest SiemensOffice.

Fig. 8.3Rated operation current Ie varies with altitude

Fig. 8.1Mounting inside the enclosure

Fig. 8.2Alignment in Rows

3RW24

Air flow

Air outlet AND/ORFan for cooling

Airinlet

200mm min.

min. 200mm

100mm 100mm

3RW24 3RW24 3RW24

200mm

200mm

200mm

Installation & Commissioning SIKOSTART


8

8.3

8.2 Commissioning Tips

When is a drive optimally set up?Soft start does not mean that drive should take aslong as possible to reach the rated speed. Thiswould mean an unnecessary warming up of themotor. This starting behaviour is characterized by anincreasing humming sound and subsequent slowstarting.

The drive shaft should rather begin to rotateimmediately and accelerate up to rated speed evenand quickly. A very short period of hummingbefore the shaft begins to turn is normallyacceptable.

A) The first setting criterion is the type of start.The following overview is intended to assist inthe selection of the starting mode for the drive:

• Centrifugal pumps, screw-type compressors,ventilators and other loads with quadratic loadtorque characteristics:

® voltage ramp

• Large ventilators, piston pumps, reciprocating(piston-type) compressors, conveyor belts,rollers and other loads with constant loadtorque, mixers or cutter drives, or pole-changingdrives:

• Hoists crushers, mills and other loads withinversely proportional load torque:

® impulse start (Switch on pulse) followed byvoltage ramp

B) The next setting criteria is the initial or limitingvalues for current or voltage. The following mustbe taken into consideration:

The chosen initial value must be sufficiently high toensure that the drive will start to accelerateimmediately. If the starting value selected is toolow, the motor and the power unit of theSIKOSTART will be stressed unnecessarily beforeany work is done by the load.

At first, and under particular circumstances, thissetting may cause a somewhat “rough” start, butneither the motor nor the starter are thermallyoverloaded. This “rough” start may be cured laterby the adjustment of other starting parameters.

Since the starting frequency may be very highduring the commissioning of the drive as a result ofrepeated attempts to achieve the optimum startingparameters, the following tips should be taken intoconsideration:

• For devices 3RW2430 to 3RW2446 the coolingfan should run continuously. This has anadvantage that it maintains a large temperature

difference between the heatsink and thethyristors. Please note that fans are inbuilt3RW2433-3RW2446. For SIKOSTART 3RW2431-3RW2432 fans are optional and it should beordered separately.

• Depending on the size of the drive, sufficientintervals should be observed between startingattempts to allow cooling down of the powerunit.

Steps for Commissioning1. Tighten the control wiring once again after the

panel is installed and power cabling of thepanel is completed.

2. Retighten the plugs of flat cable between thepower board, control board and I-Option board.

3. Check the correctness of control and powerconnections as per our guidelines andapplication suitably. Ensure that controlterminals X1.5 and X1.10 are shorted, ifSIKOSTART is not operated through PLC.

4. In case SIKOSTART is ordered with I-Optionboard check the setting for DIP switch S11 andS12 for parameterising the SIKOSTART forsystem voltage and controller rated current

· Warning: Do not exceed thecurrent setting more thanSIKOSTART rated current.

5. Switch on the mains power-supply and alsothe control-supply. Ensure that fans if providedare continuously ‘ON’ atleast duringcommissioning phase.

6. Depending upon the requirement and desiredfunctions carry-out the potentiometer settingsfor different parameters. The list of starting/stopping functions and potentiometer settingsare given in the chart overleaf.

Note:

Please note that loading of SIKOSTART must beatleast 20% of the SIKOSTART rated current Ie. Donot carry-out the testing of SIKOSTART and motorwith ratings lower than 25% Ie or else RC-enablescircuits and M.O.U. shall be affected.


8.4

Table of operating modes during starting

Potentiometer setting CommentsX set operating value on parameters� left/ � right end stop« any setting

Voltage Potentiometer Pot B and Pot EP - availableramp H X t

R (6 - 50s) only on I-Option card.

M X Uini

(0-100%)B U

iniX (0 ....100% U

N)

A tR

X (6 ... 50s)

Current Potentiometer Feature available only withlimiting H � I-Option card

M �

B X Ilim

Ilim

= 100 - 450% Ie

EPUM X (40-100% I

e)

PM X (20-200% Ie)

Voltage Potentiometerramp with H X (6-50s) = t

RI-option card required.

current M X (0-100% u) = Uini

limiting B X (100-450%) = ILim

AEPUM X (40-100%)PM X (20-200% I

e)

Voltage Potentiometerramp with H X t

R = 6-50s I-option card required.

impulse M X Uini

= 0-100%start B(kick-start) EP X (0-200% I

e)

UM X (40-100%)PM X (20-200% I

e)

Voltage Potentiometerramp with H X t

R (6s - 50s) I-option card required U

M & P

M B

impulse M X Uimp (0-100% U) Potentiometers are available on I-Option cardstart B X I

LIM (100-450% I

e) U

M - For optimising power factor during off-load

(kick-start) EP X (0-200% Ie) period (Effective at 10% loading of motor)and current UM X (40-100% ) PM - Overload trip adjustmentlimiting PM X (20-200% Ie) *ti = 2-5ms inbuilt

Soft Potentiometer Stopping time adjustablestop H « EP, UM, PM and B

M « available only withB « I-Option cardA X (6-50s) = t

R

EP «UM «PM «

Coast Potentiometer Stopping time adjustableto stop H « EP, UM, PM and B

M « available only withB « I-Option cardA �

EP «UM «PM «

8


8.5

Terminals, switches and potentiometers Key drive data

Setting for1 @ closed / ONVoltage S11:0 @ open / OFF

Rated Voltage Voltage range

200 V 190 ... 210 V230 V 220 ... 240 V400 V 380 ... 415 V440 V 420 ... 460 V480 V 460 ... 500 V575 V 550 ... 600 V*690 V 660 ... 690 V*not used/special voltageadjustable with R200

Set switches to appropriate operating voltage

* Voltage setting available only on SIKOSTART with 690V Version.

| | | | | | | |\ \ \ \ \ \ \ \| | | | | | | |

1 2 3 4 5 6 7 8| | | | | | | |1 0 0 0 0 0 0 00 1 0 0 0 0 0 00 0 1 0 0 0 0 00 0 0 1 0 0 0 00 0 0 0 1 0 0 00 0 0 0 0 1 0 00 0 0 0 0 0 1 00 0 0 0 0 0 0 1

Setting for 1 @ closed / ONCurrent S12: 0 @ open / OFF

3RW2924- 3RW2924- 3RW2924- 3RW2924-1AA61 1AA62 1AA63 1AA64

4 A – – –7 A 95 A 190 A 1000 A

12 A 120 A 120 A 1200 A18 A 150 A 290 A 1400 A26 A – 350 A 1600 A40 A – 420 A 1800 A52 A – 500 A 2000 A65 A – 650 A –75 A – 750 A –

Set switches to rated current as in table

Caution : Do not set current to value larger than that on name plate

| | | | | | | |\ \ \ \ \ \ \ \| | | | | | | |

1 2 3 4 5 6 7 8| | | | | | | |0 0 0 0 0 0 0 01 0 0 0 0 0 0 00 1 0 0 0 0 0 00 0 1 0 0 0 0 00 0 0 1 0 0 0 00 0 0 0 1 0 0 00 0 0 0 0 1 0 00 0 0 0 0 0 1 00 0 0 0 0 0 0 1


8.6

Summary chart for commissioning

Soft Start and Soft Stop

Soft start with current limit Soft start, current limit with impulse start

8


8.7

Table 8.1 Functions and Terminations on basic controller

Designation - Function Terminal Logic 0 Logic 1 Explanation

BH - Command “Ramp-up” 7 - 6 Ramp down, Ramp up Green LED BH (V5)lights at ‘1’ or withBF - 0, Voltage limitwith 10 kWpotentiometerbetween terminals7, 6 and 10

BF - Command “Enable” 7 - 8 inhibited enabled Green LED BF (V6)lights at ‘1’

The control inputs underlined use 24V industry logic. The input loading is approx. 10 mA.

Designation - Function Terminal Logic 0 Logic 1 Explanation

ME - Monitoring signal 1 - 2 Fault, no fault Relay with red LED“In operation” BF = 0, with ME (V1) lights at ‘1’,

end of ramp, BF = 1 and following faults areno supply BF > 0 detected:

- Low voltage (control voltage)- Phase failure on switch-on- Over temperature

MH - Monitoring signal 3 - 4 ramp up, end of Relay with red LED“End of ramp” ramp-down ramp (V2) lights at ‘1’

no supply,

Contact rating: 440 V, 2A; 500 VA / A.C.

Designation - Function dark light Explanation

MS - Monitoring signal “Fault” no fault fault Red flashing LED MS(V3) lights at:- Low voltage- Phase failure on switch-on- Over temperature

MR - Monitoring signal negative positive green LED MR (V4)“+ve phase sequence” phase seq. phase seq.

BH, BF, ME, MH Refer to Control Inputs and Outputs above.

ControlOutputs

IndicatingLED’s

ControlInputs


8.8

Terminal list

¥ F

Terminal Designation Signal, function Explanation

L1, L2, L3 Supply voltage 3 AC 110...500V/3 AC 220...690V

T1, T2, T3 Motor 3 AC 110...500V/3 AC 220...690V

PE Protective earth

X1.1 ME Monitoring signal RelayX1.2 “In operation”

X1.3 MB Monitoring signal RelayX1.4 “End of Ramp”

X1.5 BH Command “Ramp up” Bridge X1.5-10X1.6

X1.7 BF Command “Enable” 10 V / 10 mAX1.8 Input

X1.9 SW CT Only with I-OPTIONX1.10 Ground

X1.41 ~ External Control voltage 2 AC 110...400 VX1.42 ~

Connection for fan 230 V ACexternal supply

X1.49 O Ground

X1.50 PE Connection toprotection earth

Table 8.2 Functions and Terminations available with Option-I

Designation - Function Explanation

MU - Overload (terminal 21-22) Relay

P - Input power (terminal 23) 0..10 V/5mA analog output

Rated power = Ö3 UnInSignal scaling - 5 V

U - Motor emf 0...10 V/with 1kW analog output(terminal 25) signal scaling approx. 8V

T - Motor voltage 0-7V/5 mA; analog output(terminal 26)

M-Ground (Terminal 24)

Input from C.Ts**Terminal 9-10

** The CT should only be connected in phase T3.

ControlOutputs(on I-Optioncard)

8


8.9

Table 8.3 Setting of Motor Current on Option-I

I-Option card Setting of Rated motor power [kW] version motor current

Line Deltaon I-option

190- 220- 380- 460- 550-* 660-* 190- 220- 380- 460- 550-* 660-*card

210 V 240 V 440 V 500V 600 V 690 V 210 V 240 V 440 V 500 V 600 V 690 V

4 A 0,55 0,75 1,1 2,2 2,2 3 - - - - - -

7 A 1,1 1,5 2,2 4 4 5,5 - - - - - -

12 A 2,2 3 4 7,5 7,5 11 4 5,5 7,5 11 15 18

18 A 4 5,5 7,5 11 11 15 5,5 7,5 11 18 22 22

3RW2924-1AA61 26 A 5,5 7,5 11 15 18 22 7,5 11 15 22 30 30

40 A 7,5 11 15 22 22 30 15 18 30 37 37 45

52 A 11 15 22 30 30 37 18 22 37 45 45 55

65 A 15 18 30 37 37 45 22 30 45 55 55 75

75 A 18 22 37 45 45 55 30 37 55 75 75 90

95 A 22 30 45 55 55 75 37 45 75 90 90 110

3RW2924-1AA62 120 A 30 37 55 75 75 90 45 55 90 110 110 132

150 A 37 45 75 90 90 110 55 75 110 132 132 160

190 A 45 55 90 110 110 132 75 90 132 160 160 200

240 A 55 75 110 132 132 160 90 110 160 200 200 250

290 A 75 90 132 160 160 200 110 132 200 250 250 315

3RW2924-1AA63350 A 90 110 160 200 200 250 132 160 250 315 315 400

420 A 110 132 200 250 250 315 160 200 315 400 400 500

500 A 132 160 250 315 315 400 200 250 400 500 500 630

650 A 160 200 315 400 400 500 250 315 500 630 630 800

750 A 200 250 400 500 500 630 315 400 630 800 800 1000

* Upon enquiry


8.10

Table 8.4 Potentiometer settings

M-Switch on Torque

H-Ramp Up Time (With Option-I, Ramp Up Time is the time to reach Current Limit)

Without C55 With C55 = 4.7 mf With C55 = 10mf(On Request) (Standard) (On Request)

A-Ramp Down (Without Option-I)

Without C55 With C55 = 4.7mf With C55 = 10mf(On Request) (Standard) (On Request)

B-Current Limit (With Option-I)

of Rated Torque

of Rated Current

8


8.11

EP - Switch-on pulse (With Option-I)

UM - Motor emf at light loadAdjustment of power factor optimizer Energy Saving Circuit (With Option-I)

PM - Overload Trip (With option-I)

of Rated Current

Table 8.5 LED Indications Available on 3RW24

1. ME During Ramp Up / During Ramp Down (Relay Contact)

2. MH End of Ramp Up / By Pass Mode Activated (Relay Contact)

3. MS Phase FailurePhase DetectionLow VoltageOver Temperature on Heat Sink

4. MU Over Load Trip

5. MR Positive / Negative Phase Sequence

6. BH Ramp Up / Ramp Down (Switching Contact)

7. BF Enable / Disable / Emergency Stop (Switching Contact)

8. P Control Voltage (ON)

9. N Control Voltage (ON)

of Ie

of Rated Input Power

9. Troubleshooting

9.1 Operation status and faultindications

The LED’s on the control card of the SIKOSTARTindicate different messages depending on howthey are lit up:

Operating Status LED Colour Error message

Motor Starting (ramp up) BH (V5) Green Command Enable signal = 0i.e. Command logic at terminal Command i.e. BF = 0 (continuously lit)BH=1 (terminal 7-6) ‘ramp up’

Ready LED lights up when BF (V6) Greencommand enable terminal BF=1 Command(terminal 7-8) ‘enable’

Monitoring Signal “In operation” ME (V1) Red‘In operation’

Motor Started (End of ramp) MH (V2) Red

Overload MU (VII) Red Overload (only for Option I)(Steady light)

Fault message MS (V3) Red Fault (flashing LED)Monitoring signal “Fault” - Low voltage

- Phase failure- Over temperature

Monitoring signal for positive MR (V4) Greenphase sequence, LED light-upin positive phase sequence

9.1

Troubleshooting SIKOSTART

9

SIKOSTART Troubleshooting

9.2

Table for fault finding

Fault Possible cause Cure

1. Monitoring signal “fault” · Phase failure · Check supplyLED (MS) flashes · Heat Sink Overtemperature · Allow controller to cool down,

· Low control voltage Select larger unit,· Overload · Check whether drive is blocked,

Reduce switching frequency,· Check Ambient temperature· Check control supply

2. Motor does not start · Fault · See 1.Control inputs BH and BF · Close control inputsopen BH and BF to logic = 1

3. Drive accelerates in an · End of ramp with full · Adjust Pot H to higher setting,uncontrolled manner voltage comes too early turn H ccw.

· Controller faulty · Loading on SIKOSTARTlower than 20% of its rating

· refer to 6.

4. Drive does not accelerate · Controller faulty · refer to 6.to rated speed. · current limit setting · Adjust higher value of limit

too low

5. Control output “End of · Link X1:5-X1:10 missing · Add linkramp” (MH) is not given · Controller faulty · refer to 6.at rated speed

6. Controller suspected to · Fuses on lower assembly · Check fuses, and replace itbe faulty blown with 2A bottlefuse

· LED’s do not light eventhough BH and BF bridged · Replace the control cardand supply present

· Thyristor (s) damaged. · Check contactor functionCheck that the terminalsL1-T1, L2-T2, L3-T3 do nothave a short circuit using a · Check thyristor and replace ifW meter. Undamaged thyristor necessarymuch have a resistance of100KW

· By-pass contactor does not · Replace bypass contactorclose all 3 pole

7. Everything tried without ·• Refer to your nearest Siemenssuccess Sales office with complete

details.

10.4 Spare parts

The available spare parts for SIKOSTART 3RW24can be read from the tables below. In the case ofshorted thyristors in devices 3RW2438-1AA0.. to3RW2444-1AA0.., it is recommended that thecomplete thyristor stack assembly be changed asthe individual disc-type thyristors are embeddedbetween the heatsink plates are difficult to insertat site.

Replacement of a thyristor assembly(3RW2428-1AA0.. to 3RW2437-1AA0..)1. Switch off the starter.

2. Disconnect the main terminals.

3. Remove the electronic control section.

4. Disconnect the incoming & outgoingconnections

5. Mark the conductors and note their wiringposition.

6. Disconnect the wiring.

7. Remove the thyristor module.

8. Remove any remaining heat transfer paste fromthe heatsink (e.g. with methylated spirits)

9. Apply a thin layer-approx. 0.1 mm - of silicon-free heat transfer paste (with approx. 1 W/K m’e.g. type WLPF from Fishcer-Electronic) to thenew module.

10. Install the new thyristor assembly

10.Maintenance, spare parts, accessories

10.1 Safety measures

CautionBefore starting any work on the equipment, ensurethat the system has been isolated correctly interms of the prevailing stipulations!

In addition to the mains circuit, the auxiliary supplyvoltage must also be switched off!

Observe the DIN/VDE 0100 specifications.

The most common safety rules are:

• Disconnect the SIKOSTART from Mains,

• Secure against reconnection,

• Check for no voltage

• Provide guards or covers between the workingarea and adjacent live sections.

10.2 Cleaning

The electronic motor controllers are virtuallymaintenance-free. From time to time, however,dust deposits on the circuit boards and coolingducts should be removed carefully e.g. by usingdry compressed air or suction.

In the case of severe pollution, it is advisable toassess the local degree of pollution after a shortperiod of operation and then to establish theinterval until the next cleaning operation.

10.3 Repairs

If the power module has become defective (e.g.shorted thyristors), the affected phase can bechecked easily by measuring the resistance. It isvery improbable that all thyristors failsimultaneously. The resistance in the voltage-freestate between the line-side and correspondingload-side terminal of a particular phase (e.g. fromL1 to T1) can be measured using an ohmmeter.Undamaged thyristors should have a resistance of> 100 k W . The motor need not be disconnected forthis measurement. However, please ensure thatSIKOSTART is positively disconnected from theMains supply.

10.1

Maintenance, Spare parts SIKOSTART

SIKOSTART Maintenance, Spare parts

10.2

10

A. Thyristor Assembly

SIKOSTART Type Thyristor Qty. required

Line Connection Delta Connection Unit per phase

3RW2428-1AA05. – 3RW2924-1AB01 1

3RW2429-1AA05. – 3RW2924-1AB02 1

3RW2430-1AA05. 3RW2430-1AA06 3RW2924-1AB03 1

3RW2431-1AA05. 3RW2431-1AA06 3RW2924-1AB04 1

3RW2432-1AA05. 3RW2432-1AA06 3RW2924-1AB05 1

3RW2433-1AA05. 3RW2433-1AA06 3RW2924-1AB06 1

3RW2434-1AA05. 3RW2434-1AA06 3RW2924-1AB07 1

3RW2435-1AA05. 3RW2435-1AA06 3RW2924-1AB08 1

3RW2436-1AA05. 3RW2436-1AA06 3RW2924-1AB09 1

3RW2437-1AA05. 3RW2437-1AA06 3RW2924-1AB10 1

3RW2438-1AA05. 3RW2438-1AA06 3RW2924-1AB11 2

3RW2439-1AA05. 3RW2439-1AA06 3RW2924-1AB12 2

3RW2440-1AA05. 3RW2440-1AA06 3RW2924-1AB13 2

3RW2441-1AA05. 3RW2441-1AA06 3RW2924-1AB14 2

3RW2442-1AA05. 3RW2442-1AA06 3RW2924-1AB15 2

3RW2443-1AA05. 3RW2443-1AA06 3RW2924-1AB16 2

3RW2444-1AA05. 3RW2444-1AA06 3RW2924-1AB17 2

B. Power Board

SIKOSTART Type Power Board Power Board Max.

Line Connection Delta Connection Line Delta Unit

3RW2428-1AA051 – 3RW2924 1AA21 – 1

3RW2429-1AA051 – 3RW2924 1AA22 – 1

3RW2430-1AA051 3RW2430-1AA061 3RW2924 1AA23 3RW2924 1AB23 1















C. Snubber Circuit

SIKOSTART Type Snubber Max.

Line Connection Delta Connection Circuit Unit

3RW2436-1AA05. 3RW2436-1AA06. 3RW2924-1AA43 1

3RW2437-1AA05. 3RW2437-1AA06. 3RW2924-1AA44 1

3RW2438-1AA05. 3RW2438-1AA06. 3RW2924-1AA45 1

3RW2439-1AA05. 3RW2439-1AA06. 3RW2924-1AA46 1

3RW2440-1AA05. 3RW2440-1AA06. 3RW2924-1AA47 1

3RW2441-1AA05. 3RW2441-1AA06. 3RW2924-1AA48 1

3RW2442-1AA05. 3RW2442-1AA06. 3RW2924-1AA49 1

3RW2443-1AA05. 3RW2443-1AA06. 3RW2924-1AA50 1

3RW2444-1AA05. 3RW2444-1AA06. 3RW2924-1AA51 1

D. I-Option Card

SIKOSTART Type I-Option Max.

Line Connection Delta Connection Card Unit

3RW2428-1AA05 to 3RW2433-1AA05 3RW2430-1AA06 to 3RW2433-1AA06 3RW2924-1AA61 1



E. Main Controller Board

SIKOSTART Type Main Max.

Line Connection Delta Connection Controller UnitBoard

3RW24..-1AA05. — 3RW2924-1AA80 1

3RW24..-1AA06. 3RW2924-1AA81 1

F. Current Transformer

SIKOSTART Type Current Max.

Line Connection Delta Connection Transformer Unit




G. Fan Assembly

SIKOSTART Type Fan Max.

Line Connection Delta Connection Assembly Unit






10.3

Maintenance, Spare parts SIKOSTART

A1.1

Appendix – Engineering, Starter Selection

Since many drives have normal starting conditions(motor with rotor class KL ³ 10, which means thatwhen switching on directly, even with anundervoltage of 5%, a start with a load torque ofup to 100% of the rated torque is possible, and atotal moment of inertia of the drive JTot < 10 xJmotor), the appropriate SIKOSTART 3RW24 canoften be selected directly from the catalogue.

Calculation by hand

Calculating the starting time for direct-on-line starting:To be able to calculate the starting time, thetorque/speed curves of both the motor and loadare required.

The accelerating torque MB is then calculated as

the difference between the motor torque and loadtorque: MB (n) = MM(n) - ML (n)

The starting time tA is calculated by:

tA = 2 p X JTot X nNò0 1/MB (n) dn.

The functions MM (n) and ML (n) are, however, notgiven as mathematical formulae but usually asvalue tables, typically with 10 to 15 characteristicpoints.

The rotational speed range from zero to the ratedspeed is subdivided into ‘k’ equally sized divisionswithin which the accelerating torque is assumed tobe constant.

The time which the motor requires to pass througheach of these divisions is calculated withMB = constant by:

tAk = 2pDn x JTot/MBk

The calculation therefore represents a method ofapproximation, where the integral is replaced by asum:

tA = 2p x JTot x k

å i=1Dn(i) / MB (i)

Fig. aAccelerating torque when motor and loadcharacteristics are given as table values

JTot Total moment of inertia of motor and loadMB (i) Accelerating torque in division “i”nN Rated speednsyn Synchronous speedtA Starting timeDn(i) Speed increment

(e.g. if 11 pairs of values are given,one tenth of rated speed)

SIKOSTART Appendix – Engineering, Starter Selection

A

Calculating the starting time for softstarting with SIKOSTART:The basic calculation procedure is the same as fordirect starting.

The additional influencing variable which is nowtaken into account is the terminal voltage whichchanges and is controlled by SIKOSTART.

The calculation takes place step by step accordingto the following procedure:

1. Determination of the required initial voltage andinitial current on the basis of the requiredaccelerating torque M

BOS to be provided by

SIKOSTART at the beginning of starting.

During the entire start with SIKOSTART MB

should be ³ 15% MN so that the drive starts

spontaneously, runs up quickly and evenly andthe motor does not increase in temperatureunnecessarily.

UN ML0 and MM0 are given values.

Uini = UN x Ö(MB0S + ML0)/MM0

Iini (S) = Iini x Uini/UN

The time that the motor requires to passthrough the rotational speed interval Dn iscalculated by:

t1 [S] = 2 P /60 x JTot [kg m]2 x Dn [min-1

x 1/MB0S [Nm]

t1 = 1/9.55 x JTot x Dn x 1/MB0S.

2. The terminal voltage applied after this timeinterval is calculated by:

(Uterm - Uini) / (UN - Uini) = tacc/tR

Uterm - Uini = tacc/tR x (UN - Uini)

Uterm = tacc/tR x (UN - Uini) + Uini

Uterm/UN = tacc/tR x (1 - Uini/UN) + Uini/UN)

Uterm(i)/UN = i

å z=1

/tR x (1 - Uini/UN) + Uini/UN.

The accelerating torque for the next rotationalspeed interval Dn results from this voltage value:

MB1 = (Uterm - UN)2 x MM1 - ML1.

Fig. bTorque/speed characteristic of a cage motor with atypical load characteristic (fan).

Dn Speed increment

nN Rated speed

Uini Initial voltage

UN Initial voltage

UN Rated voltage

Uterm Terminal voltage

MN Rated motor torque

ML0 Load torque (t = 0)

MM0 Motor torque (t = 0) for direct-on-line start

MB0 Accelerating torque (t = 0) = MM0S - ML0

MM0S Motor torque (t = 0) for soft start with SIKOSTART

MB0S Accelerating torque with SIKOSTART (t = 0)

= MM0S - ML0 ³ 0.15 x MN

Iini Initial current

Iini(S) Initial current with SIKOSTART

IA Starting current

tZ Ramp time

i

å z=1

tz = tacc = instantaneous value of accumulated time

Fig. cVoltage ramp

Appendix – Engineering, Starter Selection SIKOSTART

A1.2


A1.3

A

To pass through this speed interval Dn at thisaccelerating torque, the motor requires the time:

t2 = 1/9.55 x JTot x n x 1/MB1.

The current flowing during this interval is:

Iini(S)1 = IA x Uterm/UN.

3. The next terminal voltage value is thendetermined again according to the formula inpoint 2.

If this calculation is carried out for all intervals,the sum of all the calculations results in thestarting time t

A for soft starting with

SIKOSTART.

The characteristic curves of the motor torqueMM and the motor current IM may bedetermined in a similar manner.

To calculate the power rating of the SIKOSTART,the values for the effective average startingcurrent IAeff and the starting time tA(S) arerequired.

The effective average starting current iscalculated by: IAeff(S) = SIM(S)/i.

Assuming that the selection of the SIKOSTARTwas based on the rated current of the motor,then the extent to which the starter is over-loaded during starting can be determined by:x = IAeff(S)/IN.

In other words, the selected SIKOSTART will beoverloaded by the fact x during the startingtime tA(S).

The following current loading limits apply to allversions for starting from a cold (ambient airtemperature) or warm state:

cold warm

600% Ie for max. 3s 600% Ie for max. 1s

450 % Ie for max. 16s 450% Ie for max. 7s


250% Ie for max. 120s 250% I

e for max. 60s


150% Ie contin. opera. 150% Ie contin. opera.

Fig. dBehaviour of the terminal voltage (a), motor speed(b) and motor current (c)

Selection

Normal StartingFor all normal applications e.g. pumps, fans &compressors where DOL starting time is 10-20secs and SIKOSTART will be used for soft startingor limiting the motor current upto 300% Ie (ratedcontroller current) this ratings should be used. Thisrating should cover most of the industrialapplication.

Fig. e Normal Starting

Warm :Starting following normal motor operation atrated power

Cold :Starting with cold controller e.g. when using abridging contactor

IB Starting current

Ie Rated controller current

IN Rated motor current

t = Starting time of motor

A1.4


A1.5

A


Engineering Data Sheet

1. Motor data

· Rated output power: kW

· Rated voltage: V

· Mains voltage: Hz

· Rated current: A

· Rated speed: rpm

· Rated torque Nm

· Moment of inertia: kg. m2

Torque / Speed characteristic

(The speed increments do not have to be equal!)

nM 0 100min-1

MM/MN 0

Current/speed characteristic

(The speed increments do not have to be equal!)

nM 0 100min-1

IM/IN

2. Load data

· Type of load (e.g. pump, mill, ...):

· Rated speed: rpm

· Rated torque or rated power: Nm or kW

· Moment of inertia: kg. m2

Torque/speed characteristic

(The speed increments do not have to be of equal!)

nL 0 100min-1

ML/MN 100

(N.B.: Nomenclature refer page 2.1).

3. Starting conditions

· Number of starts per hour:

· Duty cycle: tA:____s, tN:_______s, tp ______s If yes,(relationship between starting time, rated operational time and interval) to which

· Ambient temperature: _____oC no yes value?· Limit the starting current? � Avoid current peaks! � � ________· Limit accelerating torque?��Reduce mechanical stresses! � � ________· Maximum starting time? � � ________· Maximum starting current limitation desired in Amps � � ________· Is it started on network supplied with D-G set � � ________· Is it belt driven or directly coupled to shaft � � ________

Starting frequency

For a starting frequency greater than that given inthe catalogue (jogging mode), the SIKOSTART mustbe selected in terms of the effective averagecurrent Ieff. This is the equivalent continuous currentwhich would cause the same temperature rise asthe given load cycle.

The rated current Ie of the selected SIKOSTART3RW24 must then be at least as great as theeffective average current Ieff.

Ie ³ Ieff = Ö(IAeff2tA + IN

2tN) / (tA + tN +tp)

However, the motor current should be at least

20% of the rated current Ie of the starter.

The loading during starting may not exceed thetime/current limits permissible for the warm state(*page A1.3)!

If the start is calculated with the SIKOSTART3RW24 PC selection program, the effectiveaverage starting current (IAeff) determined can beused as a constant value over the starting time tA

instead of taking individual current values Iini(S)1 toIini(S)k during the corresponding time intervals tA1totAk as would have to be done in the calculation byhand.

Fig. hCurrent vs. time of a load cycle for calculation of the effective average current

tA Starting time, sum of the divisions tA1 to tAk

tP Interval (cooling time)tN Duration of (continuous) operation at motor rated

currentIAeff Effective average starting current for a start with

SIKOSTARTIN Motor rated currentIAeff

2 tN I2t loading during the starting procedure with SIKOSTARTIN

2tN I2t loading during operation at motor rated currentIeff Equivalent continuous current which would cause the

same temperature rise as the given load cycle

A1.6


SIKOSTART Notes

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SIKOSTART

Siemens Ltd.SGR-01-103-038This replaces SGR-01-103-027

'Product development is a continuous process. Consequentlythe data indicated in this booklet is subject to change withoutprior notice. For latest issue contact our Sales Office.'

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S160-Sikostart Electronic Motor Controllermanualarchive.ingersollrandproducts.com/manuals/manuals... · cage motor and a load. In the case of a slipring motor the rotor slots contain