NORD BU0135 User Manual

BU 0135

Motor Starter Manual

SK 105E…175E

SK 105E…175E Motor Starter Manual Safety information

NORD Motor Starters

(Starters, Sort Starters, Reverse Starters)

Safety and operating instructions

for motor starters

1. General

During operation, motor starters may, depending on their protection class, have live, bare, moving or rotating parts or hot surfaces.

Unauthorised removal of covers, improper use, incorrect inst allation or operation causes a risk of serious personal injury or material damage.

Further information can be found in this documentation. All transportation, installation, initialisation and maintenance work

must be carried out by qualified personnel (compliant with IEC 364, CENELEC HD 384, DIN VDE 0100, IEC 664 or DIN VDE 0110, and national accident prevention regulations).

For the purposes of these basic safety instructions, qualified personnel are persons who are familiar with the ass embly, installation, commissioning and operation of this product and who have the relevant qualifications for their work.

2. Proper use in Europe

Motor starters are components intended for ins tallation in electrical systems or machines.

When installed in machines, the drive power convert er must not be commissioned (i.e. commencement of the proper use) until it has been ensured that the machine m eets the provisions of the EC Directive 2006/42/EEC (Machinery Directive); EN 60204 must also be complied with.

Commissioning (i.e. implementation of t he proper use) is only permitted if the EMC directive (2004/108/EEC) is complied with.

CE-labelled m otor starters meet the requirements of the Low Voltage Directive 2006/95/EEC. The harmonized standards stated in the Declaration of Conformity are used for the drive power converters.

Technical data and information for connection conditions can be found on the rating plate and in the documentation, and must be complied with.

The motor starters may only be used for safety functions which are described and explicitly approved.

3. Transport, storage

Information regarding transport, storage and correct handling must be complied with.

4. Installation

The installation and cooling of the equipment must be implemented according to the regulations in the corresponding documentation.

(as per: Low Voltage Directive 2006/95/EEC)

The motor starter must be protected against impermissible loads. Especially during transport and handling, components must not be deformed and/or insulation distances must not be changed. Touching of electronic components and contacts must be avoided.

Motor starters have electrostatically sensit ive components, which can be easily damaged by incorrect handling. Electrical components must not be mechanically damaged or destroyed (this may cause a health hazard!).

5. Electrical connections

When working on live drive components, the applicable national accident prevention regulations must be complied with (e.g. BGV A3, formerly VBG 4).

The electrical installation must be im plement ed according t o the applicable regulations (e.g. cable cross-section, fuses, earth lead connections). Further instruct i ons can be found in the documentation.

Information about EMC-compliant installation – such as shielding, earthing, location of filters and installation of cables can be found in the drive power converter docum entation. These instructions must be complied with even with CE marked motor starters. Compliance with the limiti ng values specified in the EMC regulations is the responsibility of t he manufacturer of the system or machine.

6. Operation

Systems in which motor starters are installed must be equipped, where necessary, with addi tional monitoring and protective equipment as per the applicable safety requirements, e.g. legislation concerning technical equipment, accident prevention regulations, etc.

The parameterisation and configuration of the m otor starter must be selected so that no hazards can occur.

All covers must be kept closed during operation.

7. Maintenance and repairs

After the motor starter is disconnect ed from the power supply, live equipment components and power connections should not be touched immediately, because of possible charged capacitors. Observe the relevant information signs located on the drive power converter.

Further information can be found in this documentation.

These safety instructions must be kept in a safe place!

2 BU 0135 GB-2713

SK 105E…175E Motor Starter Manual Concerning this document

Documentation

Designation: BU 0135 GB Part No.: 607 1302 Device series: SK 105E, SK 115E, SK 125E, SK 135E, SK 145E, SK 155E, SK 165E, SK 175E Device types: SK 1x5E-301-340-A, SK 1x5E-751-340-A, 0.25 - 7.5kW, 3~ 200-500V

Version list

Designation of previous issues

BU 0135 GB, July 2013 Part No. 607 1302 / 2713

Software Version

V 1.0 R0 First version based on BU 0200 DE / 2011

Publisher

Getriebebau NORD GmbH & Co. KG

Rudolf-Diesel-Str. 1 • D-22941 Bargteheide • http://www.nord.com/ Tel.: +49 (0) 45 32 / 289-0 • Fax +49 (0) 45 32 / 289-2555

Intended use of the motor starter:

Compliance with the operating instructions is essential for fault-free operation and the

acceptance of any warranty claims. These operating instructions must be read before working with the device!

These operating instructions contain important information about servicing. They must therefore be kept close to the device.

SK 1x5E motor starters are devices for industrial and commercial plants for operating three-phase asynchronous motors with squirrel-cage rotors.

SK 1x5E motor star ters are devices f or fixed installati on on motors or in the vicinit y of the motors to be operate d. All details regarding technical data and permissible conditions at the installation site must be complied with.

Commissioning (commencement of the intended use) is not permitted until it has be en e ns ured that the machine com plies with the EMC Directive 2004/108/EEC and that th e conformity of the end product meets the Machiner y Direct iv e 2006/42/EEC (observe EN 60204).

Comments

 Getriebebau NORD GmbH & Co. KG, 2013

BU 0135 GB-2713 3

SK 105E…175E Motor Starter Manual

1 GENERAL INFORMATION ...................................................................................................... 6

1.1 Overview .............................................................................................................. 7

1.2 Delivery ................................................................................................................ 7

1.3 Scope of supply ................................................................................................... 8

1.4 Safety and installation information ...................................................................... 9

1.5 Certifications ...................................................................................................... 10

1.6 Nomenclature / type codes ................................................................................ 12

1.7 Version with protection class IP55 / IP66 .......................................................... 15

2 ASSEMBLY AND INSTALLATION ....................................................................................... 16

2.1 Installation and assembly .................................................................................. 16

2.2 Dimensions of the motor starter ........................................................................ 20

2.3 Wiring guidelines ............................................................................................... 23

2.4 Electrical Connection ......................................................................................... 24

2.5 Electrical connection of the power unit .............................................................. 25

2.6 Electrical connection of SK 1x5E control unit .................................................... 28

2.7 Plug connectors ................................................................................................. 32

2.8 ATEX Zone 22 for SK 1x5E (in preparation) ..................................................... 35

2.9 Outdoor installation ............................................................................................ 40

1.5.1 European EMC Directive ........................................................................................ 10

1.5.2 UL and cUL approval(in preparation) ...................................................................... 10

1.5.3 C-Tick labelling ....................................................................................................... 11

1.5.4 RoHS compliance ................................................................................................... 11

1.6.1 Type code for basic unit .......................................................................................... 13

1.6.2 Type codes / Adapter unit - Technology Unit .......................................................... 13

1.6.3 Type codes / Optional modules .............................................................................. 13

2.1.1 Mounting the hous ing bo x ....................................................................................... 17

2.1.2 Adapters for different motors .................................................................................. 18

2.1.3 Installation of the motor starter ............................................................................... 19

2.1.4 Option locations in the device ................................................................................. 20

2.2.1 Power rating / Motor size ........................................................................................ 20

2.2.2 SK 1x5E mounted on motor .................................................................................... 21

2.2.3 SK 1x5E for wall-mounting...................................................................................... 22

2.5.1 Mains connections (L1, L2, L3, PE) ........................................................................ 26

2.5.2 Motor cable (U, V, W, PE)....................................................................................... 26

2.5.3 Electro-mechanical brake ....................................................................................... 27

2.6.1 SK 1x5E control terminal versions .......................................................................... 29

2.6.2 Details of the SK 1x5E control connections ............................................................ 30

2.6.3 Control connections for SK 1x5E communication ................................................... 31

2.7.1 Plug connectors for power connections .................................................................. 32

2.7.2 Plug connectors for control connection ................................................................... 33

2.8.1 Modified SK 1x5E for compliance with Category 3D ............................................... 36

2.8.2 Options for ATEX Zone 22 3D ................................................................................ 36

2.8.3 Commissioning information..................................................................................... 38

2.8.4 EC Declaration of Conformity (in preparation) ........................................................ 39

3 DISPLAY AND CONTROL .................................................................................................... 41

3.1 Diagnostic LEDs on the motor starter ............................................................... 42

3.2 Overview of external control devices ................................................................. 43

4 COMMISSIONING .................................................................................................................. 44

4.1 Factory settings ................................................................................................. 44

4.2 Commissioning the motor starter....................................................................... 44

4.2.1 Connection.............................................................................................................. 44

4.2.2 Configuration .......................................................................................................... 45

4.3 AS Interface ....................................................................................................... 49

4.3.1 The bus system ...................................................................................................... 49

4 BU 0135 GB-2713

Table of Contents

4.3.2 Features .................................................................................................................. 50

4.3.3 Bus structure and technology .................................................................................. 50

4.3.4 Commissioning of the AS Interface ......................................................................... 52

4.3.5 Technical data for AS interface ............................................................................... 55

4.3.6 Functions of the ASI I/O bits ................................................................................... 55

4.4 PROFIBUS ................................................... Fehler! Textmarke nicht definiert.

4.4.1 Features .................................................................................................................. 56

4.4.2 Connection .............................................................................................................. 56

4.4.3 Addressing .............................................................................................................. 57

4.4.4 Displays .................................................................................................................. 58

4.4.5 Process data ........................................................................................................... 59

5 PARAMETERISATION ........................................................................................................... 60

5.1 Parameter ........................................................................................................... 61

5.1.1 Operating displays .................................................................................................. 62

5.1.2 Basic parameters .................................................................................................... 63

5.1.3 Motor and characteristic curve parameters ............................................................. 66

5.1.4 Control terminals ..................................................................................................... 67

5.1.5 Additional parameters ............................................................................................. 69

5.1.6 Information .............................................................................................................. 72

6 OPERATING STATUS MESSAGES ...................................................................................... 77

6.1 SimpleBox display .............................................................................................. 77

6.2 Table of possible error messages ...................................................................... 78

6.3 Table of possible warning messages ................................................................. 79

6.4 Table of possible reasons for the operating status "switch-on disabled" ........... 79

7 TECHNICAL DATA ................................................................................................................. 80

7.1 General data forSK 1x5E motor starter series ................................................... 80

7.2 Motor starter electrical data ................................................................................ 81

7.3 Electromagnetic compatibility ............................................................................. 82

7.4 EMC limit value classes ..................................................................................... 83

7.5 Operation with FI circuit breakers ....................................................................... 83

8 ADDITIONAL INFORMATION ................................................................................................ 84

8.1 Maintenance and servicing information .............................................................. 84

8.1.1 Maintenance Instructions ........................................................................................ 84

8.1.2 Repair information ................................................................................................... 84

8.2 Abbreviations in this manual .............................................................................. 85

9 KEYWORD INDEX .................................................................................................................. 86

BU 0135 GB-2713 5

SK 105E…175E Motor Starter Manual

1 General information

The SK 1x5E series is based on the tried and tested NORD platform. These devices feature a compact design with optimum characteristics.

Due to dual phase control, not onl y a pure motor start, but also a soft start is possible. T he phase control process was selected s o that the res ulting harm onic torques are k ept as low as possible. A c omprehensiv e spectrum of monitoring functions rounds off the range.

This series of devices can be adapted to individual requirements by means of extension modules. Due to the numerous setting options, these inverters are capable of operating all three-phase motors.

The power range is from 0.25kW to 7.5kW. The device is equipped with an integrated mains filter. This manual is based on the device sof tware V1.0 R0 (see P707) of the motor s tarter. If the motor star ter

uses a different software version, this may cause differences. If necessary, the latest manual should be downloaded from the Internet (www.nord.com

For the various versions of the device series SK 105E…SK 175E there are differences in functions, the integrated AS interface or the integrated PROFIBUS interface.

Typically, this series of devices is installed directly on a three-phase asynchronous motor. Alternatively, optional accessories are available for m ounting the devices close to the motor, e.g. on the wall or on a machine frame.

In the simplest config uration, ev en without a PC or contr ol box, all of the mos t important par ameter s can be set using up to four potent iometers and the four DIP switches . LEDs are pr ovided for the diagnostics of the operating status. The use of a control module is therefore not absolutely necessary.

In order to gain access to all parameters, the internal RS232 PC interface (RJ12) can be used, or an optional SimpleBox or Param eterBox may be used. I n this case, t he parameter settings which are changed by the user are saved in the flash memory of the device.

A permanent connection via the RS 232 interface is not intended for normal operation.

6 Pre-series version BU 0135 GB-2713

1.1 Overview

x x x

This manual describes al l of the possib le f unctions and equ ipm ent. T he equipm ent and f unctions are limited according to the t ype of device (SK 105 E…175E). T ype SK 175E d evices have t he maxim um configuration level.

Basic features of the SK 1x5E:

• 2 digital inputs

• 2 digital outputs

• Temperature sensor input (TF+/TF-)

• Control and connection of an electromechanical brake

• Motor overload protection (I

• Mains and motor phase failure monitoring

• Flux monitoring (monitoring of minimum current)

• Automatic phase sequence detection

• Can be installed directly on, or near to the motor

• Permissible ambient temperature -25°C to 50°C (please refer to the technical data)

• Integrated EMC line filter for limit curve category C1

• 4x DIP switches and up to four potentiometers for configuration

• LEDs for diagnostics

• RS232 interface via RJ12 plug

Additional features: Differences between the in dividual versions (SK 10 5E / … SK 175E) are summ arised in the following table

and will be described in this manual.

Additional features

Feature 105E 115E 125E 135E 145E- 155E- 165E- 175E-

Soft start function Reversing function Two additional digital inputs AS interface (4I / 4O) PROFIBUS-DP (4I / 4O)1

SK 145E … SK 175E devic es ar e avail abl e as ( -ASI) versions with an integra ted AS i nterf ac e and as ( -PBR) versions with integrated PROFIBUS DP. The version with integrated PROFIBUS DP is only available on request.

t triggering characteristic according to EN 60947)

x x x x x x x x

ASI ASI ASI ASI PBR PBR PBR PBR

1 General

1.2 Delivery

Check the equipment immediately after delivery/unpacking for transport damage such as deformation or loose parts.

If there is any damage, contact the carrier immediately and carry out a thorough assessment.

Important! This also applies even if the packaging is undamaged.

Only available on request and as an alternative to the ASI interface.

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SK 105E…175E Motor Starter Manual

1.3 Scope of supply

Standard version: IP55 (optionally IP66) Operating instructions as PDF file on CD-ROM including NORD CON (PC parameterising software)

Available accessories: Matching RJ12 to SUB-D9 adapter cable to connection to a PC (Selection) RS485-RS232 conversion for connecting control boxes SK CSX-3H, SimpleBox, 4-digit 7-segment LED display SK PAR-3H, ParameterBox, plain text LCD display

Expansion module: internal SK CU4-24V-123-B, internal 24V mains unit 1~ 230V SK CU4-24V-140-B, internal 24V mains unit 1~ 400V SK CU4-REL, internal setpoint converter with 2 relays SK TIE4-SWT, direction selector switch module

2 2 2

External SK TU4-PBR, external PROFIBUS® module

SK TU4-CAO, external CANopen® module SK TU4-DEV, external DeviceNet™ module SK TU4-ECT, external EtherCAT® module

SK TU4-PNT, external PROFInet® module SK TU4-POL, external POWERLINK® module SK TU4-EIP, external Ethernet/IP™ module

SK TU4-24V-123-B, external 24V mains unit 1~ 230V SK TU4-24V-140-B, external 24V mains unit 1~ 400V SK TI4-TU-BUS or NET or MSW, connection unit TU4 SK TIE4-WMK-TU, wall-mounting kit TU4 SK TU4 MSW, external maintenance switch

NOTE: Details for the use o f t he relev ant b u s sy ste ms c an be found in the applicable su pple men ta ry bu s manual .

> www.nord.com

External bus modules can be used to control the motor starter via their additional digital inputs and outputs.

Parameterisation via the field bus module s is not possible!

8 Pre-series version BU 0135 GB-2713

1.4 Safety and installation information

t be maintained.

ages for up to 1

minute after being switched off at the mains. Starter terminals, motor cables and motor

Touching open or free terminals, cables and equipment components can lead to severe injury

with the electrical supply

ufacturer. Unauthorised modifications and the use of spare parts and additional equipment which has not been purchased from or recommended by the manufacturer of the device may cause fire,

This product is intended for use in an industrial environment and is subject to sales cause high frequency interference, in which case the user may be required to take

SK 1x5E motor starters are equipment for use in industrial high voltage systems and are operated at voltages that could lead to severe injuries or death if they are touched.

• Installation and other work may only be carried out by qualified electr icians and with the device disconnected. The operating instructions must always be available to these persons and must be strictly observed.

• Local regulations for the installation of electrical equipment and accident prevention must be complied with.

• For safe isolation from the mains, all p oles of the sup ply cable to the m otor starter m ust be disconnected.

• Even during motor standst ill (e.g. cause d by an electronic bl ock, block ed drive or output terminal short circuit), t he li ne conn ection ter m inals, motor term inals an d brak ing res istor terminals may still conduct hazardous voltages. A motor standstill is not identical to electrical isolation from the mains.

• Warning, under certain s ettings the m otor s tarter can star t automatic ally after the mains are switched on.

• The motor starter is onl y intended for permanent connection and m ay not be operated without effective earthing connections that comply with local regulations for large leakage currents (> 3.5m A). VDE 0160 stipulates the installation of a second earthing conductor or an earthing conductor cross-section of at least 10 mm

• SK 1x5E motor starters are maintenanc e free in norm al operation. T he cooling surf aces must be regularly cleaned with compressed air if the ambient air is dusty.

1 General

CAUTION

The heat sink and all other metal components can heat up to temperatures above 70°C. When mounting, sufficient distance from neighbouring components mus

When working on the components, allow sufficient cooling time beforehand Protection against accidental contact may need to be provided.

ATTENTION

DANGER TO LIFE!

Under certain circumstances, the motor starter can continue to carry volt terminals may carry voltage!

or death! Work may only be carried out by qualified specialist electricians and

to the equipment disconnected!

CAUTION

Children and the general public must be kept away from the equipment! The equipment may only be used for the purpose intended by the man

electric shock and injury. Keep these operating instructions in an accessible location and give them to all operators!

WARNING

restrictions according to IEC EN 60947-4-2. In a domestic environment, this product can appropriate measures.

BU 0135 GB-2713 Pre-series version 9

An appropriate measure would be the inclusion of a recommended mains filter.

SK 105E…175E Motor Starter Manual

1.5 Certifications

1.5.1 European EMC Directive

If the SK 1x5E is installed a c c ording to t he r ec om mendations in this m anual, it meets all EMC d irective requirements, as per the EMC product st andard for semiconductor m otor control devices EN 60947-4. (see als o Sectio n 7.3, Electromagnetic Compatibility [EMC].)

1.5.2 UL and cUL approval (in preparation)

At present the approvals are in the process of preparation. All SK 1x5E motor starters include motor overload protection. Further technical details can be found in

Section 7.2.

NOTE

"Integral solid state short circuit protection does not provide branch circuit protection. Branch circuit protection must be provided in accordance with the National Electric Code and any additional local codes."

NOTE

cUL Approval - File No. E171342

“Suitable For Use On A Circuit Capable Of Delivering Not More Than 100000 rms Symmetrical Amperes, 500 Volt s maximum and when protected by RK5 class or faster fuses as indicated in chapter 7.2.”

“Suitable For Use On A Circuit Capable Of Delivering Not More Than 10000 rms Symmetrical Amperes, 500 Volts maximum and when protected by Circuit Breaker (inverse time trip type) in accordance with UL 489”, current and voltage ratings according to instruction manual.

„The torque value for the field wiring terminals for mains circuit terminals, motor terminals, break terminals and breaking resistor terminals must be 11 … 15 lb-in (1.2 … 1.5Nm). The torque value for the field wiring terminals for control circuit terminals must be 4.4 … 5.3 lb-in (0.5 … 0.6Nm).”

“The device has to be mounted according to the manufacturer instructions.” "Use 80°C Copper Conductors Only"

(only refers to connection cables (mains and motor cables but not control cables) "These products are intended for use in a pollution degree 2 environment"

10 Pre-series version BU 0135 GB-2713

1.5.3 C-Tick labelling

1 General

NORD SK 1x5E series motor starters fulfill all the relevant regulations in Australia and New Zealand.

1.5.4 RoHS compliance

SK 1x5E series motor starters are designed to be RoHS compliant according to Directi ve 2002 / 95/ EEC

N 23134

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SK 105E…175E Motor Starter Manual

1.6 Nomenclatur e / type codes

Unique type codes have been defined for the individual modules and devices. These provide individual details of the device type and its electrical data, protection class, fixing version and special versions. A differentiation is made according to the following groups:

Group Example of type code

Basic unit SK 175E-751-340-A (-C) Connection unit Technology Unit (optional terminal box module) SK TI4-TU-MSW (-C-WMK-TU) Optional modules SK TU4-MSW (-C) Extension modules SK TIE4-M12-INI

SK 1x5E

motor starter

Optional terminal

box module

Optional module

SK TU4-xxx (-…)

The type designation r es ult ing from this type code c an be o bta ine d f r om the name plate which is attached to or printed on the relevant module.

12 Pre-series version BU 0135 GB-2713

1.6.1 Type code for basic unit

SK 175E-751-340-B (-C)

IP protection class: Standard

= IP55, C =

“coated” Radio interference filter: B = Class C1 Mains voltage: x40 = 200 - 500V Number of mains phases: 3xx = 3-

phase Digits before decimal point for power: 0 = 0.xx, 1 = 0x.x0, 2 = 0xx.0 Device nominal power: 301 = 3.0kW, 751 = 7.5kW Device series: SK 105E, SK 115E, SK

125E,

SK 135E,

SK 145E, SK 155E, SK 165E, SK 175E

(...) Options, only implemented if required

SK TI4-TU-MSW (-C-WMK-TU)

Wall mounting kit: -1 = Size 1

+ 2 IP protection class: Standard = IP55, C = “coated” IP66 Suitable device types: NET = optional net module (e.g. TU4-24V-… )

MSW = maintenance switch

(SK TU4

-MSW

BUS = optional bus module (e.g. CANopen: TU4-CAO)

Group:

TU = Technology unit

Device series: SK TI4 = Adapter unit SK TI4

(...) Options, only implemented if required .

SK TU4-24V-123-B (-C)

IP protection class: Standard = IP55, C = “coated” IP66 Radio interference filter: B = Class C1 Mains connection: 123 = 1~ 230V*, 140 = 1~ 400V* Option type: 24V = 24V power supply, FUSE Option series: TU4 = external Technology Unit,

CU4 = = internal customer unit

*) The voltage depends on the motor starter used; please also refer to the technical data. (...) Options, only implemented if required.

1 General

1.6.2 Type codes / Adapter unit - Technology Unit

1.6.3 Type codes / Optional modules

For optional modules

BU 0135 GB-2713 Pre-series version 13

SK 105E…175E Motor Starter Manual

Optional external

Technology Unit, SK TU4-…

Optional internal

Customer Unit, SK CU4-…

14 Pre-series version BU 0135 GB-2713

" and are modified

that the cable and the cable gland are carefully

from the device (if necessary use loops). This is the only way to ensure permanent

1.7 Version with protection class IP55 / IP66

The SK 1x5E motor starters and additio nal modules are availa ble in protection class es IP55 (standard) or IP66 (optional).

Protection class IP66 must always be stated when ordering! There are no restrictions or diff erences t o the scope of functions in either prot ection c lass. In or der to dif fer-

entiate the protection c lasses, m odules with prot ection c lass IP66 are g iven an ex tra “-C” (coated à coated PCBs) in their type designation.

e.g. SK 175E-751-340-A-C

IP55 version: The IP55 version of the SK 1x5E is t he standard version. Both vers ions (motor-mounted, m ounted on the

motor or wall-mounted on a wall brack et) are available. In additio n, all adapter units, tec hnology units and customer units are available for this version.

IP66 version: In contrast to the I P55 vers ion th e IP66 version is a m odified option. F or this version, bot h var iants (m otor-

integrated, close to motor) are also available. The modules available for the IP66 version (adapter units, technology units and cus tomer units) have the same func tionalities as the corr esponding modules for the IP55 version.

NOTE

1 General

Special measures:

Impregnated PCBs, Powder coating RAL 9006 (white aluminium) for housing Low pressure test

NOTE

The modules for the IP66 design are identified by an additional "-C according to the following special measures listed below.

For all versions, care must be taken matched. Wherever possible, the cables should be inserted so that water is deflected away

compliance with the required protection class.

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SK 105E…175E Motor Starter Manual

2 Assembly and installation

2.1 Assembly

The motor starters are availa ble in various sizes depending on th eir output. They only differ with regar d to their possibilities for adaption to the matching motors. The external dimensions of both sizes are

identical. Size 1 is matched to motor size 80-100. Size 2 is matched to motor size 132.

Motor-mounted version Wall-mounted version

16 Pre-series version BU 0135 GB-2713

2 Assembly and installation

1x5E must be carried out by NORD as special measures

have to be implemented. IP66 components retrofitted on site cannot ensure that this protection

2.1.1 Mounting the housing box

On delivery of a complete drive unit (gear unit + motor + fr equency inverter) SK 1x5E motor star ters are always fully installed and tested.

NOTE

Mounting of an IP66-compliant SK class is guaranteed.

When delivered separately, the motor starter includes the following components:

• Motor starters

• Screws and contact washers for mounting the motor terminal box.

• Pre-fabricated cable for motor and PTC connections

Procedures:

1. If necessary, remove the original terminal box from the NORD motor, so that only the base of the

terminal box and the terminal strip remain.

2. Set the bridges for the correc t motor circuit and connect the pre-fabric ated cables for motor and PTC

connections to the respective connection points on the motor.

3. Mount the cast housing on the terminal box base of the NO RD m otor us ing the exis ting scre ws and s eal

as well as the enclos ed toothed / contact w ashers. Position the cas t housing with the d ome facing the A-side of the motor (looking towards the A bearing cover). Check the adaptability for different motor manufacturers.

If necessary, the plas tic cover (1) for the electronics m ust be carefully removed in order to m ake the screw fastenings to the base of the terminal box.

4. Connect the motor cables U, V, W to the power terminal block and t he PT C cable TF+, TF- to the control

terminal block 38, 39.

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SK 105E…175E Motor Starter Manual

Adapter plate

Seal

Motor Size 71

Motor starter SK 1x5E BGI

Example

2.1.2 Adapters for different motors

In some cases, the term inal box attachments are diff erent for different sizes of m otor. Therefore it may be necessary to use an adapter to mount a motor starter.

In order to guarantee t he max imum protec tion class I P55 / I P66 of the e ntire un it, the pr otec tion cl ass of the motor starter must also correspond to this value.

NORD motor

sizes

Size 63 – 71 Size 80 – 112 Size 132 not possible Direct mounting

Overview of adapter kits

Name Add-on SK 1x5E Part No.

Adapter kit size 63-71 to KK80-112

(Adapter kit I)

SK TI4-3 adapter kit_80-112

(Adapter kit II)

Add-on

SK 1x5E Size 1

with adapter kit I

Direct mounting

Adapter plate, terminal box frame seal and screws

Add-on

SK 1x5E Size 2

not possible

with adapter kit II

275119050

275274321

NOTE

18 Pre-series version BU 0135 GB-2713

The adaptability of motors from other manufacturers must be checked individually! Information for the conversion of controlled drive units to the SK 1x5E can be found in BU0320.

2 Assembly and installation

2.1.3 Installation of the motor starter

The housing cover must f irst be rem oved in or der to m ake the elect rical co nnections t o the SK 1x5E. T o do this, unscrew the 4 fastening screws, so that the housing cover can be removed upwards.

After the electrical connections of the supply cables have been made, the housing cover can be replaced. To achieve the maxim um protection c lass IP 55/IP6 6, care m us t be tak en that all t he fas tening sc re ws of the

housing cover are tightened diagonally, step-by-step and with the torques stated in the table below. For the cable gland of the connecting cable , appropriate scr ewed connections f or cable cross-s ection must

be used.

Motor starter size Screw size Tightening torque

Size I M5 x 25 3.5Nm ± 20% Size II M5 x 25 3.5Nm ± 20%

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SK 105E…175E Motor Starter Manual

2.1.4 Option locations in the device

The drawing above shows the various mounting locations for the optional modules. Option location 1 is used for the mounting of an internal bus module or internal mains unit. External bus modules, 24 V power supplies can be implemented at option locations 3L or 3R. Option locations 4 and 5 are used for the installation of M12 sockets or plug connectors or for cable glands. Of course, only one option can be mounted at a single option location.

Option location

1 Internal Mounting location for customer units SK CU4-… 3* on side Mounting location for

3 A/B* on side Cable gland M25 Not available if location

4 *, 5 * * R and L (right and left side)

Position Meaning Size

Sizes 1 - 2

• External technology units SK TU4-…

• HARTING plug connectors

on side Cable gland M16 Not available if

Comments

3 is occupied or SK TU4-… is fitted.

SK TU4-… is fitted.

2.2 Dimensions of the motor starter

2.2.1 Power rating / Motor size

Mains / Power category SK 1x5E

Size

3~ 200-240V 3~ 380-500V

Size I

Size II

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0.12 ... 1.5kW 0.25 ... 3.0kW

2.2 ... 4.0kW 4.0 ... 7.5kW

2 Assembly and installation

2.2.2 SK 1x5E mounted on motor

Size Housing dimensions SK 1x5E / Motor Weight of

Motor

∅ g

g 1 n o p

SK 1x5E without motor

Approx. [kg]

Size I

Size II

Size 71 * 145 177.5 Size 80 165 171.5 236 Size 90 S / L 183 176.5 251 / 276 Size 100 201 185.5 306 Size 80 ** 165 193.5 Size 90 S / L ** Size 100 ** 201 209.5 306 Size 112 ** 228 219.5 326 Size 132 S / M 266 216.5 373 / 411

183 198.5 251 / 276

All dimensions in [mm] *) including additional adapter and seal (18mm) [275119050] **) including additional adapter and seal (20mm) [275274321]

221

214

236

154 2.0

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SK 105E…175E Motor Starter Manual

∅

2.2.3 SK 1x5E for wall-mounting

The SK 1x5E can be installed in the vicinity of the motor by means of an optional wall mounting kit.

Wall mounting SK TIE4-WMK-1

total weight Approx. [kg]

Device type Size

Housing dimensions

g2 n p p2 d e

Size I à SK TIE4-WMK-1

Part No. 275 274 000 Size II à SK TIE4-WMK-2

Part No. 275 274 001 All dimensions in [mm]

113 221 154 205 64 180 5.5 2.6

115,5 221 154 235 64 180 5.5 2.6

All possible installation orientations are permissible for wall mounting.

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2 Assembly and installation

The control cables, mains cables and motor cables must be laid separately. In no

The test for high voltage insulations must not be used on cables which are connected to the

simultaneously connected to

the motor starter and the PC, as potential shifts may cause damage, especially to the PC.

2.3 Wiring guidelines

The motor starters have be en developed for use in an industr ial environm ent. In this environm ent, high le vels of electromagnetic interference can inf luence the motor starter. In genera l, correct installation ensures safe and problem-f ree operation. To meet the limiting values of the EMC directives, the following i nstructions should be complied with.

(1) Ens ure that a ll equipm ent in th e control c abinet or field is s ecurel y earthed us ing shor t earthing c ables

which have large cross-sections a nd are connected to a comm on earthing point or earthing rail. It is especially important th at all control dev ices connected to the motor star ter (e.g. an automat ion device) are connected to the same earthing point as the motor starter itself, using a short cable with large cross-section. Flat conductor s (e.g. metal clam ps) are preferable, as they have a lower impedance at high frequencies.

(2) The bonding cable of the motor controlled by the motor starter should be connected directly to the

earthing terminal of the as sociated motor star ter. The presence of a c entral earthing bar in the contr ol cabinet and the grouping together of all bonding conductors to this bar normally ensures safe operation. (See also Section 7.3 / 7.4(EMC))

(3) W here possible, shielded cables should be used for control circuits. The shielding at the cable end

should be carefully sealed and it must be ensured that the wires are not laid over longer distances without shielding.

(4) The control cables should be installed as far as possible from power cables, using separate cable

ducts, etc. Where cables cross, an angle of 90° should be ensured as far as possible.

(5) Ens ure that the contactors and brake chok es in the cabinet are interference protected , either by RC

circuits in the case of AC contactors, or by “free-wheeling” diodes for DC contactors, whereby the interference protectors must be positioned on the contactor coils. Varistors for over-voltage limitation are also effective.

In addition, an EMC-compliant cabling must be ensured. (See also Section 7.3 / 7.4 (EMC)).

The safety regulations must be complied with under all circumstances

when installing the motor starter!

ATTENTION

NOTE

circumstances should they be laid in the same protective pipes/installation ducts.

motor starter.

With the use of a ParameterBox SK PAR-3H this must never be (See also Manual BU0040)

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SK 105E…175E Motor Starter Manual

installed and commissioned by qualified personnel

In particular, the general and regional installation and safety regulations for work on high voltage

must the regulations concerning correct use of tools

Dangerous voltages can be present at the mains input and the motor connection terminals even

d screwdrivers on these terminal

Ensure that the input voltage source is not live before setting up or changing connections to the

2.4 Electrical Connection

WARNING

The housing cover must be removed from the SK 1x5E in order to make the electrical connections. Proceed as follows:

1. Switch off the mains supply and if necessary check and observe the waiting period.

2. Loosen the 4 Allen screws (4mm).

3. Carefully lift the housing cover vertically from off the housing box.

4. The electrical connections and the option slots are now freely accessible.

THE DEVICES MUST BE EARTHED. Safe operation of the devices requires that is

in compliance with the instructions provided in this Manual.

systems (e.g. VDE) must be complied with as and the use of personal protection equipment.

when the motor starter is not in operation. Always use insulate fields.

unit. Ensure that the motor starter and motor are specified for the correct supply voltage.

5. Replace the cover

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6. Evenly tighten the Allen screws in a cross-wise direction.

2 Assembly and installation

2.5 Electrical con nect ion of the power unit

All connection terminals are located in the housing box of the motor starter.

One terminal level is provided for the power connections and one for the control connections.

The earthing connections (device earthing) are located on the base in the cast housing.

Before and while the device is connected, the following must be observed:

1. Ens ure that the m ains s uppl y provides the corr ect voltage and is suitable for the current required (see Section 7 Technical Data).

2. Ensure that suitable circuit breakers with the specified nominal current range are inserted between the voltage source and the inverter.

3. Connect the mains voltage directly to the terminals L

4. T o connect the motor, three f lexible wires U-V-W should be used when mounting the motor.

5. For wall-mounting a 4-conductor shielded motor cable (recommended) to th e terminals U-V-W and

earth should be used.

NOTE: if certain wiring sleeves are used, the maximum connection cross-section can be reduced.

Screwdriver: Use a 0.6 x 3.5 mm slot-head screwdriver to connect the power unit.

NOTE: Only use copper cables with temperature class 80°C or equivalent for connection. Higher

temperature classes are permissible.

ATTENTION: This device produces high frequency int erference, whi ch may make additio nal suppression

and PE.

1-L2-L3

measures necessary in domestic environments. (Details in Section. 7.3 / 7.4 (EMC))

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SK 105E…175E Motor Starter Manual

Main

2.5.1 Mains connections (L1, L2, L3, PE)

No special safety meas ures are required on the m ains input side of the m otor starter. It is advisable t o use normal mains fuses (see technical data) and a main switch or circuit breaker.

400V devices are designed for three phase mains voltage 200...500V (L1/L2/L3). For the exact specification, please refer to the technical data in Section 7. Isolation from or c onnection to the mains must al ways be carried out for all the pol es and synchronously

(L1/L2/L3).

Connection to earth is made via screw terminals in the cast housing of the device.

Connection cross-section:

0.5...10mm For looping of the mains voltage, up to a

cable cross-section of 2 x 4.0mm wire end sleeves must be used.

Tightening torque:

1.2 ... 1.5Nm

rigid/ flexible cable AWG 20-6

double

Main

2.5.2 Motor cable (U, V, W, PE)

Connection cross-section:

0.5 ... 10mm AWG 20-6

Tightening torque:

1.2 ... 1.5Nm

rigid/ flexible cable

Main

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2 Assembly and installation

For the connection of a mechanical brake to the terminals of the motor starter, parameters

107 / P114 (brake application time / release time ) must be adjusted. In order to prevent

Brake connection terminal 79/80

2.5.3 Electro-mechanical brake

Connection of an electr omagnetic br ake is pos sible for all SK 1x5E devices . To control the brak e, an outp ut voltage is generated to ter minals 79 / 80 (MB+ / MB-) by the motor starter to terminals 79 / 80 (MB+ / MB-) (also refer to Sections 2.6.1 to 2.6.2). This depends on the supply voltage. The assignment is as follows:

Mains voltage / Alternating current (AC) Brake coil voltage (DC)

230 V ~ 105 V = 400 V ~ 180 V =

460 V ~ / 480 V ~ 205 V =

The allocation of the cor rect brak e or brak e coil volta ge m ust be taken into ac count in the design with reference to the mains voltage of the motor starter.

NOTE

P damage to the brake control, a value ≠ 0 must be set in parameter (P107).

The following settings for (P107/P114) are recommended for NORD brakes: BRE5, BRE10, BRE40 : 0.02s, BRE20, BRE60, BRE100, BRE150: 0.03s, BRE250: 0.04s,

Connection terminals: Screw terminals, 0.6 x 3.5 mm slot-head screwdriver

Connection cross-section: 0.2 ... 2.5mm

, AWG 24-14, rigid or flexible, without wire end sleeves

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