Siemens SIKOSTART 3RW35, Instruction Manual

Page 1: ...S SI IK KO OS ST TA AR RT T 3 3R RW W3 35 5 I In ns st tr ru uc ct ti io on n G Gu ui id de e SFIS 4503A 0600 June 2000 ...

Page 2: ...n used in this manual indicate the degree of hazard that may be encountered by the user These words are defined as Danger Indicates death or serious injury will result if proper precautions are not taken Warning Indicates death serious injury or property damage can result if proper precau tions are not taken Caution Indicates some injury or property damage may result if proper precautions are not ...

Page 3: ...bleshooting 9 1 Maintenance and Troubleshooting 26 9 2 Troubleshooting Tables 26 9 3 Shorted SCR Checks 29 9 4 Thrystor SCR Testing 29 10 Spare and Optional Parts 10 1 Spare Parts 33 10 2 Optional Parts 35 3 IMPORTANT These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with installation operation or...

Page 4: ...tor Wired with Bypass Contactor 16 11 Power Wiring for Single Speed Non Reversing Motor Wired with Bypass Contactor 17 12 SIKOSTART Controller Power and Motor Connections 18 13 SIKOSTART SIKOSTARTTerminal Connections Potentiometers and Indicators 19 14 Dimensions 25 15 Typical Isolated Power Pole and Power Module 29 16 Gate Triggering Test Diagram 30 17 Latching Holding Test Diagram 31 18 Modules ...

Page 5: ...ive system in the following ways 1 the life of mechanical drive transmission elements is extended e g gearbox jerking is substantially reduced resulting in less wear and tear 2 reduced starting current relieves the supply network of cur rent peaks and 3 smoother acceleration of loads eliminates process or product damage 2 Operating Principle 2 1 Function Overview The SIKOSTART 3RW35 controller uti...

Page 6: ...ontroller s front cover Seven potentiometers provide customer adjustments Initial Torque 1 2 initial motor start voltage start time 1 2 the rate of volt age rise accel ramp time Decel timer the length time PUMP STOP power is applied during soft stop Max start volts the max starting voltage limit PFC the energy saver 2 3 Three phase Systems Since the controller can be used with either wye or delta ...

Page 7: ...ws slower and smoother acceleration of the motor and its load 2 4 1 Soft Start with Coast to Stop Figure 5 shows the relationship of voltage and speed with respect to time when a soft start is used with coast to rest The controller potentiometers have been set as follows U The initial voltage is set at approximately 30 T1 The start time setting is greater than 0 T2 The stop time is set at 0 which ...

Page 8: ...ding on the connected inertia When the run coil is de energized the speed decreases throughout the T2 time period and then coasts to zero 3 Controller Selection Each controller has only one rating In Line Table 1 lists the SIKOSTART controller partial catalog numbers and ratings at various rated voltages Table 1 is for In Line wiring configurations only and shows cur rent and horsepower ratings fo...

Page 9: ...losures use bypass contactors or heat exchange devices to maintain the integrity of the NEMA 12 rat ing Establish a maintenance schedule for enclosures with heat exchangers Equipment cleaning frequency should be based on the operating environment 4 3 Installation Precautions The following precautions are intended for use as guidelines for proper installation of the controller Because of the variet...

Page 10: ...perating current and enclosure size and type 4 3 3 Electrical Noise Suppression Noise usually enters solid state controls through power supply lines input lines and output lines Sources of electrical noise which can be suppressed within the power distribution system include 1 inductive loads such as relays solenoids motors and motor starters operated by hard contact devices such as push buttons or...

Page 11: ... watt 220 ohm resistor across each 120V AC coil An appropriately rated varistor or surge suppressor can be used in place of the R C circuit however R C circuits are rec ommended because they limit the rate of rise of noise and thus help eliminate high frequency components 4 5 Power and Motor Connections The controller input terminals L1 L2 and L3 are at the top of the unit and the output terminals...

Page 12: ...d contactor coil and control input B1 B2 is typically run in parallel with the HIGH speed reverse contac tor coil 4 When using the controller with part winding motors these motors must be connected in their full voltage run winding configuration and the three motor leads connected to the controller output terminals 5 The motor frame should be connected to the earth ground terminal 4 6 Control Conn...

Page 13: ...ost the circuit is broken and the controller drops out which shuts off power to the motor Bypass Contactor The applications shown in figures 10 and 11 includes a bypass contactor 2M The bypass contactor is rated to handle the running current of the motor but not the starting current The bypass contactor remains open until the controller has soft started the motor Once the motor is operating at lin...

Page 14: ...Siemens Energy Automation Inc Figure 8 Power wiring for single speed non reversing motors in a vented enclosure circuit breaker left or fusible disconnect right 14 ...

Page 15: ...Siemens Energy Automation Inc Figure 9 Typical power wiring for single speed non reversing motors in a vented enclosure circuit breaker or fusible disconnect 15 ...

Page 16: ...Siemens Energy Automation Inc Figure 10 Typical power wiring for a single speed non reversing motor wired with bypass contactor 16 ...

Page 17: ...Siemens Energy Automation Inc Figure 11 Power wiring for a single speed non reversing motor wired with bypass contactor 17 ...

Page 18: ...Siemens Energy Automation Inc Figure 12 SIKOSTART Controller Power and Motor Connections 18 ...

Page 19: ... 24 Contact NO Run 2 Delayed 27 28 Contact NO Fault 37 38 Contact NO Fault 35 36 Contact NC Up To Voltage 47 48 Contact NO Initial Torque 1 Initial Torque 2 Start Time 1 Start Time 2 Decel Timer Max Start Volts Not Used PFC Power On On Running Flash Phase Loss Up To Voltage Shorted SCR IMPORTANT When the DECEL TIMER is set to a value greater than zero ramp 2 settings become decel settings and run ...

Page 20: ...the energy saving feature On lightly loaded motors the motor voltage is reduced which saves energy If the motor load increases the motor voltage is increased proportionately Note setting PFC to F disables the function Table 4 Potentiometer Setting Values Dial Initial Voltage Start Time Setting Full Voltage Seconds 0 30 0 5 1 33 1 0 2 36 2 0 3 40 4 0 4 43 6 0 5 46 8 0 6 50 10 7 53 12 8 56 15 9 60 2...

Page 21: ...an for the motor operating under the same conditions with balanced voltages For further information refer to NEMA Standard MG 1 14 35 4 Measure individual input AC voltages L1 L2 and L3 to ground On most systems voltage will be about 57 of line voltage and nearly equal Any unbalanced voltage may indi cate an undesired ground in the motor or the SIKOSTART controller 5 Measure the control voltage It...

Page 22: ...roller ramp ends before the motor reaches full speed turn run signal off and increase the T1 setting Repeat trial starts to achieve a smooth acceleration to full speed LED 2 changes from single blinking mode to continuously on before the T1 time elapses Stop Time T2 For most applications the motor load will coast to rest T2 setting equals 0 A soft stop is required for some applications e g to redu...

Page 23: ...ing or Jogging Applications Controller rating to be 133 of motor rating Severe 5 times in any 60 second period Controller rating to be 200 of motor rating Very Severe 10 times in any 60 second period Controller rating to be 300 of motor rating Controller Current Ratings During Start and Run Current Cold 50v vC 115 Continuous 200 480 sec 300 120 sec 450 300 sec 500 20 sec 600 10 sec Adjustment Rang...

Page 24: ...cycle Controller Dual Element Number Amperes Watts Amps A2 sec Fuse Rating 3RW3552 35 84 2000 15 000 60A RK1 3RW3554 57 154 2 250 18 000 100A RK1 3RW3555 69 166 4 000 80 000 100A RK1 3RW3557 80 192 4 000 80 000 100A RK1 3RW3558 105 252 7 850 257 000 150A RK1 3RW3565 131 315 7 850 257 000 200A RK1 3RW3566 195 468 7 850 234 000 300A RK1 3RW3567 248 595 11 000 416 000 400A RK1 3RW3572 361 866 15 000 ...

Page 25: ...0 14 00 7 36 5 00 2 42 12 88 0 62 0 25 4 3 71 3RW356 131 248 11 49 15 00 7 46 9 75 0 87 13 07 1 08 0 25 4 3RW3572 361 13 56 16 4 8 83 11 25 1 16 13 21 1 77 0 25 4 3RW3584 480 720 17 42 20 35 9 10 5 25 3 0 71 17 71 1 24 0 25 8 3RW3586 960 17 62 28 32 8 68 3 99 0 91 25 71 1 13 0 25 8 5 44 5 44 Figure 14 Dimensions 3RW355 3RW3586 Upper Lower Mounting Hole Locations 25 3RW3584 Upper Lower Mounting Hol...

Page 26: ...ondition of NEMA standard ICS 2 1993 Industrial Control and Systems Controllers Contactors and Overload Relays Rated Not MoreThan 2000 Volts AC pr 750 Volts DC This checklist does not represent an exhaustive survey of main tenance steps necessary to ensure safe operation of the equip ment Particular applications may require further procedures Should further information be desired or should particu...

Page 27: ...power is not present check for insecure wiring connections at is not illuminated to the Run coil terminals A1 and A2 at applicable control terminals 13 14 etc and at the control devices e g start stop device isolation con tact used in the input circuit to the Run coil Bad cable connection Remove control power and check that Logic PCB to Snubber or defective printed PCB cable is secure If secure re...

Page 28: ...otor is running while running not energized Check SCR s as described in paragraph 9 3 Motor overload relay Motor is overloaded Check for a mechanical cause of overload and clear trips during starting while running Motor not able to Check that motor comes up to speed when started by applying accelerate load across the line full voltage directly to the motor An alternative is to use the controller w...

Page 29: ...has two inter nally connected cathode terminations a large power cathode terminal and a smaller auxiliary cathode terminal or wire for the control connection A forward biased SCR anode positive cathode negative will turn on and conduct current if positive control voltage is applied to the gate terminal and gate current flows inside the SCR junc tion to the cathode The SCR turns on and stays on at ...

Page 30: ...terminal jumper figures 18 20 to test individual SCR s for reverse blocking and forward off state voltage 2 Connect the megger across anode A and cathode K termi nals of one SCR set megger to 1 000V setting A typical reading of greater than one megohm indicates an accept able SCR and leakage current of less than one milliamp at 1 000V DC 3 Reverse the meter polarity and repeat the step 2 measure m...

Page 31: ...3 Also connect battery positive to the 20 ohm resistor and the other resistor end to the SCR anode A 4 Select DC voltage scale on the multimeter 5 Connect the meter positive to the SCR anode A and meter negative to the cathode K Meter reading should be approximately 9V DC 6 Touch the open 100 ohm resistor end to the appropriate SCR gate TG or LG Meter reading should drop to approx imately 1V DC Op...

Page 32: ...Siemens Energy Automation Inc Figure 18 for 3RW355 Figure 19 for 3RW356 Figure 20 Typical configurations 32 ...

Page 33: ...tage Uc 120V AC and main sup ply voltage Ue 200 400V AC 400 575V AC Each spare part relates to one or more of the ratings e g each cooling fan cor responds to the Amps and Uc ratings regardless of the Ue rat ings Ue All where All means either main voltage selec tion whereas each snubber board corresponds to the Amps and Ue ratings regardless of the Uc ratings Uc All where All means any of the thre...

Page 34: ...RW3958 7DC85 3RW3955 5DC84 3RW3956 5DC85 80 3RW3958 7DC84 3RW3958 7DC85 3RW3956 5DC84 3RW3957 5DC85 105 3RW3958 7DC84 3RW3958 7DC85 3RW3958 5DC84 3RW3958 5DC85 131 3RW3967 7DC84 3RW3967 7DC85 3RW3965 5DC84 3RW3965 5DC85 195 3RW3967 7DC84 3RW3967 7DC85 3RW3966 5DC84 3RW3966 5DC85 248 3RW3967 7DC84 3RW3967 7DC85 3RW3967 5DC84 3RW3967 5DC85 3 Controller 3 Controller 3 Controller 3 Controller 361 3RW3...

Page 35: ...ug to the controller ter minal The Wire Size Range column lists the wire sizes that the lug can accommodate Table 2 in this manual indicates the torque required for the set screw that secures the wire in the lug Complete installation instructions are furnished with each lug kit Note Mount lug under terminal as shown Table 8 Lug Kits Wye Lug Operational Lug Kit Hardware Current Part Torque Wire Siz...

Page 36: ...hout prior notice Printed in the U S A Siemens Energy Automation Inc 1000 McKee Street Batavia IL 60510 Tel 630 879 6000 Tel 800 323 5450 http www siemens com controlsusa 2000 Siemens Energy Automation Inc Siemens is a registered trademark of Siemens AG ...