Soft Starter Training - Zest WEG Group · Soft Starter Training ... This method allows a torque...
Transcript of Soft Starter Training - Zest WEG Group · Soft Starter Training ... This method allows a torque...
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Soft Starter Training
Trainer: Andre van der Linde
Soft Starter Theory of Operation
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Main Methods for Starting
Induction Motors
Main Methods for Starting Induction Motors :
A soft starter offers nearly the best starting characteristics
reduced current and a controlled ramp
Direct on-line starter
Star-delta starter
Auto-transformer starter
Soft Starter
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Direct on-line Star-delta
Soft-Starter
Starting Currents Comparison
Current
Time
Soft-Starter Applications
Typical soft-starter applications include the following:
Pumps
Fans
Compressors
Conveyors
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Soft-Starter Advantages
Smooth starting ramp
Reduced peak currents
Precise current limit during starting
Reduced mechanical stress (shock on the load)
Reduced water hammer
No moving parts to wear out
Fault detection
Soft-starters use SCRs (Thyristors) to regulate the amount of voltage
applied to the motor. When correctly set it provides the minimum amount of
voltage necessary to develop the required starting torque.
The voltage is then increased via a programmable ramp thereby providing
the motor with a smooth starting torque and step less ramp to full speed.
Soft-Starter Method of Operation
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Soft Starter Simplified Diagram
Soft Starter Trigering (resistive load)
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SCR Trigering (Inductive load)
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Model Number Identification
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Control Mode
Voltage ramp
Voltage increases according to a preset ramp time and starting current is a
function of ramp time and type of load.
Current Limit
Voltage is applied in order to maintain a preset current level according to
the application
Current Ramp
Maximum current level is also limited during start-up however higher or
lower start-up current limits can be set
Pump Control Optimized control method providing the required torque to start/stop
Hydraulic centrifugal pumps smoothly.
Torque Control
This method allows a torque control with 1 up to 3 setting points
SSW-06 5 Types of control (P202)
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5 Types of control (P202)
When a soft-starter and when a VSD?
A soft-starter only gives a reduced voltage start-up (like a light
dimmer switch)
This reduces starting current and starting torque and
therefore the mechanical stress
What does a soft-starter do?
It gradually ramps up the voltage in a controlled manner and
thereby reduces the starting current
No Speed control on SoftStarter
Soft Starters - Practical Considerations:
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Some practical soft-starter considerations:
Reduced voltage gives reduced torque – MUCH REDUCED!
T is proportional to V²
E.g. A typical motor has a starting torque of 200%, also a
typical soft-starter starting voltage is 30%. The motor starting
torque would then be:
18% - very soft !
Best suited for the type of applications that use reduced
torque like centrifugal pumps & fans mainly.
Practical Considerations
Soft Starter torque & current curves
0.00
1.00
2.00
3.00
4.00
5.00
6.00
7.00
0 10 20 30 40 50 60 70 80 90 100
I DOL T DOL T @ 50% V T @ 30% V I @ 50% V I @ 30% V
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Soft Starter torque & current curves
0.00
0.50
1.00
1.50
2.00
2.50
0 10 20 30 40 50 60 70 80 90 100
T DOL T @ 50% V T @ 30% V
Soft Starter torque curves
0.00
0.50
1.00
1.50
2.00
2.50
0 10 20 30 40 50 60 70 80 90 100
T DOL T @ 500% I T @ 300% I T @ 50% V T @ 30% V
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VSD & Soft-Starterconveyor torque curves
0.0
0.5
1.0
1.5
2.0
2.5
0 10 20 30 40 50 60 70 80 90 100
DOL starting torque Load torque VSD starting torque T @ 30% V Soft-Starter starting torque @ 500% I lim.
The WEG soft-starters can deliver up to 500% current and can
therefore also be used in “high torque” applications such as
conveyors, crushers, screw feeders, large high inertia fans with a
long run-up time etc.
Practical Considerations
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Soft Starter & Motor selection
Soft Starter & Motor selection
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Important To Know To Size a Soft-Starter :
Starts/Hour
Ambient Application
Absorbed power
Torque characteristic
Inertia
Motor Current
Motor Power
Supply Voltage
Number of Conditions
These values can be entered into the SDW software on the
WEG website to make an accurate selection.
Pumps
Starter Method:
Start with acceleration ramp
Function “ Pump Control”
Advantages:
Reduction of “Water hammer”
Reduced current
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Fans
Starter Method:
Start with “current limit”.
Advantage:
Reduced mechanical stress and wear
Reduced current
Compressors
Starter Method:
“Kick-Start” function
Start with voltage ramp
Advantage:
Able to accelerate the inertia
process of the load smoothly
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Starter Method:
Start with “current limit”
Advantage:
Reduction of mechanical wear
Mixers
Conveyor Belt
Starter Method:
Start with “voltage ramp”
Advantage:
Reduction of mechanical
wear
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Soft Starter Installation
INTRODUCTION
Soft-Starters are considered to be “Industrial Electronic” items and
as such should be able to withstand rough working conditions.
This is true.
However, fact is, a Soft-starter is an electronic item. The better the
installation, the less problems and greater reliability the user will
enjoy.
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Mechanical Installation
As for as possible avoid the following:
Direct exposure to sunlight, rain, high moisture and sea air
Exposure to corrosive liquids or gasses
Exposure to excessive vibration
Conductive dust, oil or any conductive particles or materials
Mechanical Installation
Environmental conditions:
Temperature: 0…40ºC – nominal conditions
0…55ºC - with current derating
Relative Air Humidity: 5% to 90%, non-condensing
Maximum Altitude: 1000m – nominal conditions.
1000 - 4000m – with 1% current derating for each
100m above1000m.
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Cooling Airflow
1. Always ensure sufficient room and
ventilation for cooling air flow.
2. Sufficient space – top, bottom and sides.
3. Avoid direct sunlight.
Hints:
1. Use panel fans if in doubt.
2. Remember that trunking impedes air
flow.
3. Rather allow more flow and space than
the minimum requirements.
4. Allow for heating from other
components within the VSD panel.
5. A sealed, clean air conditioned
environment is best.
Panel Ventilation
A totally sealed panel circulates the Soft Starter hot air causing a steady
temperature rise.
Panel design must allow for hot air to be vented.
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Electrical Installation
Important notes:
The AC input voltage must be compatible with the SS rated voltage.
Capacitors for power factor correction must be disconnect at the input (R, S, T) while you are accelerating the load and they must be re-connected after the BY-PASS contactor closed.
The SS MUST be earthed for safety purposes (resistance ≤ 10Ω).
Command Wiring
- Shielded cable;
-Separated from power
cables;
Fuses:
- Slow Blow: installation;
- Ultra rápid: soft-starter
COMMAND
Power Cabling
If there is any risk of
EMI interference with
other equipments.
SSW06 Installation
Contactor
- Maintenance;
- Emergency;
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Electrical Installation
OTHER
LOADS
Controls
Main disconnect switch
For safety purposes – isolation,
protection and maintenance
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OTHER
LOADS
CAPACITORS
BANK
Controls
Fuses
To protect the installation input.
Correctly rated ultra rapid fuses
should be used for SS
OTHER
LOADS
CAPACITORS
BANK
Controls
Contactor
If customer practice demands the
use of a contactor, it may be
used.
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OTHER
LOADS
CAPACITORS
BANK
Controls
Control wiring
Keep seperate from power cables
Cross power cables at 90º
Use screened cables for analogue
signals
Signal and Control Wiring
4 6 3 5
Digital
Inputs
Relay Outputs
7 11
24V 19 21 23
18 20 22 24
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Microcontroller
with software
version label
Relays
SCR firing
connection
Thermostat and current
transformers (CT) input
Inputs and Outputs
Ground
Connector
HMI Conector
Serial RS232
connector
Control Board
CCS6
Signal and Control
connections
Terminal X1A Power board
Terminal X1D Power board
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Terminal X1A Power board
4 6 3 5
Digital
Inputs
Relay Outputs
7 11
24V 19 21 23
18 20 22 24
X1B & X1C Connection
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X1D Connection
X1D Connection
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Thermal Protection for Different Classes
(P640)
M1
(DI1)
3
(DI3)
5
COM
8
PTC
B A
12 13
(DI2)
4
(DI4)
6
(DI5)
7
COM
9
0V
10
24V
11
PTC
ST
AR
T
ST
O
P
GE
NE
RA
L
EN
AB
LE
K1 FAULT
U W V
PE
Soft Starter Commissioning
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1. Check that all connections are correct and tight.
2. Verify that the SS is correctly rated for the motor.
3. Verify that the SS is correctly rated for the supply voltage.
4. Uncouple the load from the motor, or ensure that the load may be
safely turned.
5. Check that the control voltage matches the SS unit control
voltage rating – 220VAC is standard.
Pre-Power Checks
Thermal Protection for
different classes (P640)
36s
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1. Check that the supply voltage is within acceptable range.
(nominal Voltage -15% to +10%)
2. Power up the Electronics Supply
3. Check that the power up was successful.
Initial Power-up
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Soft Starter Parameters
Types of Parameters
Read Only Parameters: Are variables that can only be viewed on the
keypad display, but not changed by the user.
Regulation Parameters: Are Programmable values to be used by the SSW
SSW-06 functions.
Configuration Parameters: Define the SSW characteristics, the functions
to be executed, as well as the Inputs and Outputs functions of the control
board
Motor Parameters: Motor data that are indicated on the motor nameplate
Special Function Parameters: Included here are the stop and kick start
functions
Protection Parameters: Included here are the actuation levels and
actuation time of the motor protection
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Read Only Parameters: P01...P99
Regulation Parameters: P00 & P100 – P199
Configuration Parameters: P200 – P399
Motor Parameters: P400 – P499
Special function Parameters: P500 – P599
Protection Parameters: P600 – P699
Parameters Description
For ease of understanding, the parameters were grouped according to function, as follows:
The SSW06 HMI
It is a very simple and functional interface to operate and
program the soft starter:
Visualization and Parameter Changes
Status Indication
Fault Indication
Soft starter Operation
On/Off, Jog Function, Forward/Reverse
Local/Remote
Detachable
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Use of the SSW06 HMI
7 segment LED Display
with 4 digits
Liquid Crystal
Display with 2 lines
of 16 alphanumeric
characters
Start Key
Stop Key
Local/Remote Key
“ Program ” Key
Increase Key
Decrease Key
FWD/REV Key Jog Key
During this start-up routine the following parameters are set:
1. P201 – Language
2. P150 – Motor connection (Inside delta)
3. P202 – Control mode
4. Parameters relevant to control mode chosen
5. Motor nameplate parameters
6. Motor protection parameter, rated thermal class
Automatically guided start-up routine (P204=5)
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SSW-03
3 Wire
Delta Connection
SSW-03
3 Wire
Star Connection
Normal Connection
Drives and Controls
6 Wire
Inside Delta Connection
Soft Starter line current
reduced to 0.58% Inom.
( 42% reduction )
Inside Delta Connection
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R
S
T
U V W
I TOTAL
I SSW
F1
F2
F3
Circuit-Breaker
1 6
3
2 5
4
R
S
T
U V W
I TOTAL
I SSW
F1
F2
F3
Circuit-Breaker
2
5 6
3
4
1
Motor Connection
Recommended Connection
SSW06
M1
X1A
Q1
Q2
T1
Q2
PE
(DI1)
3
(DI3)
5
COM
8
PTC
B A
12 13
3~
50Hz
380V
(DI2)
4
(DI4)
6
(DI5)
7
COM
9
0V
10
24V
11
1 2 PE 33 34 18 19
RL1 RL2
20 21 22 23 24
RL3
PTC
ST
AR
T
ST
O
P
GE
NE
RA
L
EN
AB
LE
K1 K1 FAULT
R S T
U W V
PE
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End of Course
Thank You