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Eaton IT S801 Soft Starter User Manual

1. 4 If Used L1 112 Fuse 2 L11 L12 1000 2 f 000 X2 Fuse GND 1A 42 t 4 x2 ro o oO L N Power Supply 120V AC 24V DC ino oo T Terminal E NG Board MX P cCfC 1 Inputs 2 24V DC Only 3 i Or o 4 Internal CH Reset 13 Auxiliary Run Contact nun 14 24V DC or Hand a 95 120V AC SL MO o MX 96 Ne Internal Remote uxiliary Som Input 98 S Contact Hi Auto CAUTION IT Soft Start Alarm Applying voltages other than 24V DC to terminals P thru may cause serious damage to soft start control board 4 Figure 3 13 Basic Connection Diagram Using 95 96 Trip Contacts for Soft Starter with HAND OFF AUTO RESET with 120V AC Alarm and Run Indication See Notes on Page 3 18 3 16 For more information visit www EatonElectrical com MN03902008E EIN Cutler Hammer IT S801 Soft Starter User Manual June 2006 IT Soft Start oo S on Incoming J 99 02 EN E t C T2 Lines C E3 T3 O oo HE Circuit Breaker If Used r ooo IL 11283 P
2. Figure 8 2 Troubleshooting Flowchart 2 Table 8 1 Troubleshooting Status LED Off Symptom Indication Possible Problem Possible Solution No indication on the unit or on the CIM Loss of 24V DC power Failed CIM Failed control board Check control wiring Verify 24V DC power available from power supply Check power supply fuse circuit breaker Disconnect the CIM If the Status LED lights replace the CIM If not control board may be defective Contact Eaton Contact Eaton No status light but CIM is powered Failed LED indication Reset the unit verify operation Cycle 24V DC control power to the unit Symptom Indication Table 8 2 Trouble Possible Problem shooting Status LED Green Possible Solution Status LED green no indication on the CIM Line power fault Check wiring connection on load and line side Check line power breakers fuses Verify 24V DC power on P terminal Then verify power is cycled to terminal 1 For more information visit www EatonElectrical com 8 3 IT S801 Soft Starter User Manual E TN Cutler Hammer June 2006 Table 8 3 Troubleshooting Fault Shown on CIM hardware failure or load disconnect Symptom Indication Possible Problem Possible Solution S S LED is lit High temperature Allow system to cool down with 24V DC applied to
3. Internal Auxiliary Reset et Contact F 13 z2 MB n Bypass i Read E A 95 eady CAUTION LT 96 Fault Applying voltages other than 24V DC to H G 98 HI Internal Auxiliary terminals P thru 4 may cause serious Contact damage to soft start control board Pilot Lights When Used Figure 3 10 Basic Connection Diagram for Soft Starter with HAND OFF AUTO RESET with PLC shown with 120V AC Alarm and Run Indication Incoming a 1 l L3 5 T3 6 Lines L2 3 T2 4 Disconnect Means CAUTION Applying voltages other than 24V DC to terminals P thru 4 may cause serious damage to soft start control board To Separate 120V AC Suppl pply L1 1 ch 1 bL AA enmt jen Soft Starter ne tt av DO A a Soft Start CT MERE 44 P Terminal KOS top 1 Board Start LL I a Inputs ad 2 P24v DC Only 3 K o o 4 Internal Auxiliary n Reset 13 Contact o n Bypass CH 14 L 95 Ready Fault 0 e Lom 7 4 98 NW Internal Auxiliary Contact Pilot Lights When Used Figure 3 11 Basic Connection Diagram for Soft Starter with START STOP RESET JOG with 24V DC Alarm and Run Indication See Notes on Page 3 18 3 14 For more information visit www EatonElectrical com MN03902008E EIN June 2006 Cutler Hammer
4. Misapplication Incorrect setting Soft stop is designed to increase stopping time for loads that would otherwise stop suddenly upon removal of power It cannot cause the motor to stop faster than its normal coast down time Increase initial torque T2 Decrease ramp time tr Increase current limit setting T2 Increase kick start torque T1 Increase kick start time tk Motor starts too quickly Incorrect setting Increase ramp time tr Decrease initial torque T2 Decrease current limit setting T2 Decrease kick start torque T1 Decrease kick start time T2 For more information visit www EatonElectrical com 8 7 IT S801 Soft Starter User Manual EIN Cutler Hammer June 2006 8 8 For more information visit www EatonElectrical com MN03902008E E T N Cutler Hammer June 2006 SSS Chapter 9 Parts and Service Renewal Parts Table 9 1 Renewal Parts Description Catalog Number CIM Blank Cover Filler EMA68 CIM for Standard Unit EMA71 CIM for Pump Control Option EMA72 Panel Mounting Kit 3 ft Cable EMA69A 5 ft Cable EMA69B 8 ft Cable EMA69C 10 ft Cable EMA69D Control Wire Connector 12 pin 5 mm pitch Connector EMA5 for Control Wiring IT S801 Soft Starter User Manual Service For additional information on this product or technical assistance please call our Customer Sup
5. A 2 For more information visit www EatonElectrical com MN03902008E EIN Cutler Hammer IT S801 Soft Starter User Manual June 2006 Thermal memory is incorporated to accurately monitor motor operating temperature Ambient temperature does not affect soft starter function within its operating limits The overload trip class can be set to class 5 10 20 or 30 The setting determines the time to trip based on the severity of the overload condition OVLD 5 10 20 30 TRIP TRIP O CLASS Figure A 2 Setting Trip Class and FLA on the CIM The normal overload trip setting may be disabled for the next start by placing the overload ON DISABLE switch in the DISABLE position This raises the overload fault trip point to 12596 of the maximum current rating of the frame size The overload trip resets to its normal set value for all subsequent starts To affect another start the ON DISABLE switch would need to be moved to the ON position and then back into the DISABLE position This same action is possible by momentarily connecting terminal 3 to the 24V DC terminal prior to start This only affects the next start and not any subsequent starts unless terminal 3 is again momentarily connected to the 24V DC prior to the start MN03902008E For more information visit www EatonElectrical com A 3 IT S801 Soft Starter User Manual E T N Cutler Hammer June 2006 Jam Detection This feature is selectable ON DISABLE
6. Never megger a motor while it is connected to the IT Soft Starter Disconnect the leads at the IT Soft Starter before meggering the motor Ne jamais r gler un moteur alors qu il est branch au d marreur progressif T D brancher les fils au d marreur progressif IT Avant de r gler le moteur Nunca efect e pruebas del motor con un meg hmetro mientras est conectado al arrancador Soft Starter IT Desconecte los cables en el arrancador IT antes de usar el meg hmetro Notes Notice Avis Aviso The S801V Soft Starter includes Le d marreur progressif S801V El arrancador suave S801V mounting hardware 8 1 4 20 x inclut des mat riels de support incluye piezas met licas de 1 5 Allen hex head cap screws vis t te hexagonale montaje tornillos Allen de and special washers Do not 8 1 4 20 x 1 5 et des rondelles cabeza hexagonal de 8 1 4 20 x substitute for this hardware See sp ciales Ne substituer pas 1 5 y arandelas especiales No Figure 3 6 on Page 3 6 for panel pour ces mat riels Consulter la las sustituya Consulte la hole locations Applicable codes Figure 3 6 de la Page 3 6 pour les Figura 3 6 que aparece en la or standards must be considered locations des trous dans le p gina 3 6 para conocer las before locating and mounting the panneau Tenir compte des ubicaciones de los orificios del soft starter The four special normes et des codes existants panel Antes de ubicar y montar rect
7. Danger High Voltage Danger Haute Tension Peligro alto voltaje Hazardous voltage can cause electric shock and burns Always disconnect power before proceeding with any work on this product Une tension lectrique dangereuse peut causer des chocs lectriques et des br lures Il faut toujours d brancher l alimentation lectrique avant de travailler sur ce produit Voltajes peligrosos que pueden causar descargas el ctricas y quemaduras Siempre desconecte la energia el ctrica antes de efectuar cualquier trabajo en el equipo Note For additional motor and system protection a Metal Oxide Varistor MOV may be installed on the line side of the unit An MOV can also be installed on the load side of the Soft Starter if additional protection is desired Generally it is more common to use a MOV on the line side Refer to the instructions provided with the MOV kit 1 ForT Uand V Frame Soft Starters remove line and load terminal covers by removing the screws that hold each cover and the MOV if installed onto the unit Note For N and R Frame Soft Starters it is not necessary to remove the covers in order to wire the device Proceed to step 3 2 After screws are removed slide covers off of unit Set the covers and screws aside 3 Position lugs and install lug mounting screws according to instructions provided with the kit Tighten lug mounting screws provided with the kit to 120 Lb in 13 6 Nem 4
8. If terminal P is at 24V DC momentary application of 24V DC to terminal 1 will initiate a start sequence for all S801 soft starters Note With level sensing control if 24V DC is maintained on terminal 1 Start and removed from the permissive circuit at any time the unit will initiate a stop The unit will restart on application of 24V DC to terminal P if a 24V DC is still available on pin 1 to start from Terminal Block Input 3 must also be enabled b the device shows a green status light not faulted and c auto reset is enabled on the Control Interface Module CIM See the Edge and Level Sensing Control section on Page 3 20 for more details If the auto reset feature is used CAUTION must be exercised to assure that any restart occurs in a safe manner MN03902008E For more information visit www EatonElectrical com 3 19 IT S801 Soft Starter User Manual EIN Cutler Hammer June 2006 5 Terminal 2 Jog mode If 24V DC power is applied to this terminal while terminal P is at 24V DC the soft starter will operate in the jog mode as long as 24V DC is on terminal 2 and no faults occur In jog mode the soft starter will operate only on the thyristors and the bypass contactors will not close 6 Terminal 3 Overload disable Momentary application of 24V DC to terminal 3 prior to a start raises the overload fault trip point to 125 of the maximum rating of the frame size for the next start only E
9. A current value of greater than 3 x FLA setting will stop the motor on a jam fault If a jam is detected the soft starter shuts down and the Jam light illuminates Note Jam detection is active only after the motor has reached full speed and is in bypass mode If jam is disabled and the unit is in bypass and a jam occurs the soft starter will trip on contactor overcurrent if the motor current exceeds 4x the starter maximum ampere rating Unit Will Trip Jam Protection Set at 300 of IT Soft Starter Motor FLA Setting Current Normal Operating Current Time Figure A 3 Jam Detection A 4 For more information visit www EatonElectrical com MN03902008E EIN Cutler Hammer IT S801 Soft Starter User Manual June 2006 Stall Detection This feature is selectable ON DISABLE If the soft starter detects a stall condition greater than 2x FLA setting at end of ramp the soft starter shuts down and the Stall light illuminates Note If stall detection is off and a stall occurs during start the soft starter will trip on SCR over current if the motor current exceeds 3x the FLA setting at the end of ramp Stall Protection Set for 200 of IT Soft enl Motor FEA IT Soft Starter Will Trip at End of Ramp Actual Motor Current Current Normal Operating Current Time Figure A 4 Stall Detection Phase Loss Current Unbalance Detection and Load Disconnect This feature
10. Cutler Hammer June 2006 C 4 For more information visit www EatonElectrical com MN03902008E EIN June 2006 Cutler Hammer IT S801 Soft Starter User Manual SS Appendix D Special Function Options This section covers the descriptions identification installation and setup of factory installed options that are not provided with the standard S801 soft starter Pump Control Option This option is intended to reduce the potential for water hammer in a centrifugal pump system by utilizing a starting and stopping algorithm developed for pump control Upon a start command the speed of the motor is increased under the control of the T Soft Starter microprocessor to achieve a gentle start After the speed has reached its nominal value the bypass contactors close and the pump operates as with any other starter Upon a stop command the bypass contactors are opened and the motor speed is decreased in a tapered manner to gradually slow the flow until the motor is brought to a stop The start and stop ramp times are user adjustable and are to be set for the application requirements The pump control option is a factory installed feature Factory installed options are designated by the eighth character in the catalog number Unmodified IT Soft Starters have an N as their eighth character IT Soft Starters with the pump control option have a P as their eighth character as in S801XXXP3S Installation Setup Install and wire
11. E Te Cutler Hammer IT S801 Soft Starter User Manual June 2006 Supersedes July 2002 Pub 49003 Rev L MN03902008E For more information visit www EatonElectrical com EIN Cutler Hammer IT S801 Soft Starter User Manual June 2006 Important Notice Please Read The product discussed in this literature is subject to terms and conditions outlined in Eaton Electrical Inc selling policies The sole source governing the rights and remedies of any purchaser of this equipment is the relevant Eaton Electrical Inc selling policy NO WARRANTIES EXPRESS OR IMPLIED INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF TRADE ARE MADE REGARDING THE INFORMATION RECOMMENDATIONS AND DESCRIPTIONS CONTAINED HEREIN In no event will Eaton Electrical Inc be responsible to the purchaser or user in contract in tort including negligence strict liability or otherwise for any special indirect incidental or consequential damage or loss whatsoever including but not limited to damage or loss of use of equipment plant or power system cost of capital loss of power additional expenses in the use of existing power facilities or claims against the purchaser or user by its customers resulting from the use of the information recommendations and descriptions contained herein The information contained in this manual is subject to change without notic
12. Wire the appropriate line and load conductors to the IT Soft Starter as required by NEC and local codes based on the device rating 5 Torque bolts as directed by Table 3 3 on Page 3 9 of this manual Figure 3 7 V Frame Shown with Terminal Cover Removed and EML30 Lug Kit Installed on Load Side 6 Slide the line and load covers back into place on the soft starter 3 10 For more information visit www EatonElectrical com MN03902008E EIN Cutler Hammer IT S801 Soft Starter User Manual June 2006 7 Reinstall the cover screws through the cover and the MOV if installed 8 Insert two outer cover screws through cover 9 Align cover and torque all cover screws to 5 Lb in 0 6 Nem Do not overtighten screws Control Wiring Inputs Using the wiring diagrams in Figures 3 9 through 3 14 and Tables 3 4 and 3 5 as guides connect the control wiring as required for your application N Caution N Attention N Precauci n Only apply 24V DC to the Appliquer seulement 24V CC a la Aplique solo 24 V CC al bloque terminal block unless specified barrette a bornes sauf ce manuel de terminales a menos que se otherwise in this manual All offre d avis contraire Tout le especifique lo contrario en este control wiring is 22 12 AWG cablage de commande est de manual Todo el cableado de 0 33 2 5 mm Failure to follow calibre 0 33 2 5 mm 22 12 control es de 0 33 2 5 mm this caution could result in severe AWG
13. and Overtemperature see flash codes Verify operation of unit cooling fans tr setting Clear any blockage or restriction of air flow Possible hardware failure see flash codes If code 32 is indicated check actual motor start time vs tr set time tr should not be set more than 2 3 seconds longer than the actual motor start time Reset tr Contact Eaton Load disconnect Check shaft coupler between motor and load JAM LED is lit Fault exists in memory Press the RESET button located below the CIM to clear the fault Current has exceeded Jam program level Clear the cause of the jam FLA setting too low for application Check that it matches motor nameplate current STALL LED is lit Fault exists in memory Press the RESET button located below the CIM to clear the fault Unit failed to reach rated speed 90 at end of ramp Clear the cause of the stall in the application Verify ramp time is sufficient for application Verify initial torque setting is sufficient for application FLA setting too low for application Check that it matches motor nameplate current PH LOSS LED is lit Phase loss or unbalanced line current One or more line voltages are missing or low Verify proper line voltage present and that no other equipment was affected Confirm line power connections are correct and tight Check line power fuses
14. at S801 with two passes through ferrite of the DC Power Leads and a single pass through ferrite of the I O Control Leads 3 Add ferrite Fair Rite 40443167251 to Load Leads at S801 with two passes through ferrite 4 2 For more information visit www EatonElectrical com MN03902008E EIN Cutler Hammer IT S801 Soft Starter User Manual June 2006 Short Circuit Ratings Table 4 5 Short Circuit Ratings Soft Starter Three Phase Short Circuit Rating Frame Size 240V 480V 600V 690V N 10 kA 10 kA 10 kA R 10 kA 10 kA 10 kA T 18 kA 18 kA 18 kA 00 U 30 kA 30 kA 30 kA V 42 kA 42 kA 42 kA E Catalog No S801T V3S devices are UL Listed and suitable for use on a circuit capable of delivering not more than 18 kA symmetrical amperes 690 volts maximum when protected by a Ferraz Shawmut Amp Trap Form 101 Cat No A700S800 4 800 Amp 700 Volt Semiconductor Protection Fuse Catalog No S801V V3S devices are UL Listed and suitable for use on a circuit capable of delivering not more than 42 kA 690 volts maximum when protected by a Ferraz Shawmut Type PSC Cat No A070URD7311600 1600 Amp 700 Volt Semiconductor Protection Fuse Catalog No S801T__V3S devices tested per IEC 60947 4 2 to Type 1 Short Circuit Withstand Requirements to 18 kA 690 volts with Cutler Hammer Cat No NW3800T33W 800 Amp 690 Volt circuit breaker Catalog No S801V V3S devices tested per IEC 60
15. 0 25 uF at 250V AC q TI Bypass 95 Hi 120V AC Supply cue Z Ready VU 96 H amp TI Fault 98 Figure 3 16 120V AC Control Using a Supplemental Line Contactor In some installations it may be necessary to use an electromagnetic contactor in series with the soft starter In this case it is recommended that the contactor be placed on the load side of the soft starter The contactor must be closed prior to starting the soft starter and remain closed until the Soft Starter has been stopped to ensure proper soft starter and system operation If an electromagnetic contactor is used on the line side of the soft starter additional control circuitry must be supplied by the user when using edge level control to ensure the line power is supplied to the soft starter before control power 24V DC is applied If this sequence is not followed the soft starter will fault on either a phase loss or zero voltage crossing fault This control scheme is illustrated in Figure 3 17 3 22 For more information visit www EatonElectrical com MN03902008E EIN Cutler Hammer IT S801 Soft Starter User Manual June 2006 START LT L O O G9 X Side Adder 1 120V AC Soft Starter 24V 24V DC Ze PP 1 T On Delay 6 Seconds Auto X Isolation Contactor Reset ON L1 480V
16. 179 9 E Hd FE E e n UJ LES GH E 12 72 d L 7 73 d 323 1 196 3 Figure 3 5 U Frame 200 mm Approximate Dimensions in Inches mm MN03902008E For more information visit www EatonElectrical com IT S801 Soft Starter User Manual EIN Cutler Hammer June 2006 9 84 7 23 250 0 183 7 7 AE L is Y TA e O 00 ea Il e e d o o0 0 15 63 ee 397 0 EA Mounting e do e Holes R 16 57 Slots 420 8 e e M N 11 03 280 2 ET BO 00 JE CA 27 6 8 L 28 7 2 Dia Typ 3 74 Typ 4 Places 95 0 4 Places Figure 3 6 V Frame 290 mm Approximate Dimensions in Inches mm 3 6 For more information visit www EatonElectrical com MN03902008E E T N Cutler Hammer June 2006 Required Mounting Hardware Table 3 1 Required Mounting Hardware IT S801 Soft Starter User Manual Frame Quantity Torque Size Screw Size Washer Size Required Required N 10 32x0 5 Standard 10 Lockwasher and 4 15 Lb in Flat Washer 1 7 Nem R 1 4 20 x 0 625 Standard 1 4 Lockwasher and 4 25 Lb in Flat Washer 2 8 Nem T and U 1 4 20 x 0 625 Standard 1 4 Lockwasher and 6 30 Lb in Flat Washer 3 4 Nem V 1 4 20
17. 250 125 100 150 125 300 250 400 350 S801V42N3S 465 140 250 280 150 125 150 150 350 300 450 400 S801V50N3S S801V50V3S 530 160 280 335 150 150 200 150 450 350 500 450 S801V65N3S S801V65V3S 590 180 315 375 200 150 200 500 400 600 500 S801V72N3S S801V72V3S 651 200 355 425 600 450 700 600 S801V85N3S S801V85V3S 754 220 400 465 600 500 800 700 S801V10N3S See Application Notes Appendix C MN03902008E For more information visit www EatonElectrical com B 5 IT S801 Soft Starter User Manual EIN Cutler Hammer June 2006 Table B 6 30 Second Ramp 4 Starts per Hour 450 Current Limit 40 C Three Phase Motors kW Rating 50 Hz hp Rating 60 Hz Max 380 200V 230V 460V 575 690V Catalog Current 230V 400V 440V 1 0SF 1 15SF 1 0SF 1 15SF 1 0SF 1 15SF 1 0SF 1 15SF Number Frame Size N 21 5 5 10 12 5 5 5 5 5 15 10 15 15 S801N37N3S 40 11 18 5 22 10 10 10 10 30 25 30 30 S801N66N3S Frame Size R 55 15 25 30 15 15 20 15 40 30 50 40 S801R10N3S 75 22 37 45 20 20 25 20 50 50 60 60 S801R13N3S Frame Size T 151 45 80 90 50 40 50 50 100 100 150 125 S801T18N3S S801T18V3S 215 63 110 132 60 60 75 60 150 150 200 150 S801T24N3S S801T24V3S 264 80 140 160 75 75 100 75 200 150 250 200 S801T30N3S S801T30V3S Frame Size U 300 90 160 185 100 75 100 100 200 200 300 250 S801U36N3S 340 100 180 200 100 100 125 100 250
18. 350 S801V65N3S S801V65V3S 480 147 257 295 150 150 200 150 400 350 500 450 S801V72N3S S801V72V3S 590 180 315 375 200 150 200 200 500 400 600 500 S801V85N3S S801V85V3S 650 205 370 415 250 200 250 200 500 450 600 500 S801V10N3S See Application Notes Appendix C B 4 For more information visit www EatonElectrical com MN03902008E EIN Cutler Hammer IT S801 Soft Starter User Manual June 2006 Table B 5 15 Second Ramp 4 Starts per Hour 450 Current Limit 40 C Three Phase Motors kW Rating 50 Hz hp Rating 60 Hz Max 380 200V 230V 460V 575 690V Catalog Current 230V 400V 440V 1 0SF 1 15SF 1 0SF 1 15SF 1 0SF 1 15SF 1 0SF 1 15SF Number Frame Size N 29 7 5 125 15 7 1 2 7 12 10 7 1 2 20 15 25 20 S801N37N3S 49 12 5 22 25 15 10 15 15 30 30 40 40 S801N66N3S Frame Size R 73 18 5 37 40 20 20 25 20 50 40 60 60 S801R10N3S 94 25 45 55 30 25 30 30 60 60 75 75 S801R13N3S Frame Size T 155 45 80 90 50 40 60 50 100 100 150 125 S801T18N3S S801T18V3S 219 63 110 132 60 60 75 60 150 150 200 150 S801T24N3S S801T24V3S 280 80 150 160 75 75 100 75 200 200 250 250 S801T30N3S S801T30V3S Frame Size U 345 100 185 200 100 100 125 100 250 200 350 300 S801U36N3S 405 110 200 250 125 100 150 125 300 250 400 350 S801U42N3S Frame Size V 345 100 185 200 100 100 125 100 250 200 350 300 S801V36N3S 405 110 200
19. SCRs must cool down to avoid exceeding their thermal limits Appendix B Ratings Cooling and Power Losses gives the S801 s application ratings for various starting conditions Staying within these specified limits should avoid over temperature trips When the S801 control circuit senses that the internal temperature has increased above a preset value internal fans are tuned on to assist in cooling To maximize fan life the fans are only turned on when needed Further discussion of fan operation can be found in Appendix B Control The software contained in the S801 T Soft Starter is the heart of the product This software allows you to control nearly every aspect of the soft starter s functionality In this section various features and protection options are described Starting Options The following starting choices are available in the S801 Note that the motor current observable with a standard RMS indicating meter may not be correct because of its non sinusoidal nature during starting It is suggested that the starting current be estimated from the T4 or T2 setting and the tabulation in Table 6 1 on Page 6 4 MN03902008E For more information visit www EatonElectrical com 5 1 IT S801 Soft Starter User Manual EIN Cutler Hammer June 2006 Soft Start with Selectable Kick Start This mode of operation works in both the Ramp Start and Current Limit Start modes A kick start or boost allows the motor to draw greater current t
20. a relay is used in conjunction with an electronic control it is highly recommended that a noise suppression snubber diode be placed across the relay coil as shown in Figure 3 15 This diode offers two benefits First the suppression of any electrical noise generated when the relay coil is de energized Second the diode delays the opening of the relay slightly as it dissipates the energy stored in the relay coil This delay is often long enough to compensate for the potential effects of a mechanical shock opening the control contact A typical suppression diode is a 1N4001 aa 13 21 TZ Bypass 95 See L i TZ Ready in aaa 186 gt t Fault RY UI 98 Figure 3 15 24V DC Control MN03902008E For more information visit www EatonElectrical com 3 21 IT S801 Soft Starter User Manual EIN Cutler Hammer June 2006 120V AC Control When a relay is used in conjunction with an electronic control it is highly recommended that a noise suppressor be used across the relay coil In the case of an AC coil the noise suppressor is made up of a series connected resistor and capacitor as shown in Figure 3 16 Usually the delay in the relay opening is very small so if the system is subject to shock a delay should be added in the external control before the contact change of state is recognized The resistor is rated 100 ohms at 0 5 watts The capacitor is
21. aa ees 5 3 Figure 5 5 S0m STOP xeu gre RR RTE RRR R dee US motio ea es 5 4 Figure 6 1 Soft Start Control Interface Module CIM cree eee eee 6 1 Figure 6 2 Setting Trip Class and FLA on the CIM 6 2 Figure 6 3 Programming the Kick Start Sequence 6 4 Figure 6 4 Programming the Ramp Start Sequence 6 5 Figure 6 5 Programming the Current Limit Start 6 6 Figure 6 6 Programming the Soft Grop ees 6 7 Figure 8 1 Troubleshooting Flowchart 1 8 2 Figure 8 2 Troubleshooting Flowchart 2 8 3 Figure A 1 Overload Trip Curves 0 cc cece eee eee eens A 2 Figure A 2 Setting Trip Class and FLA on the CIM A 3 Figure A 3 Jam D tection sedoa setis Sen er kem A Gee HAN A 4 Figure A 4 Stall Detection A 5 Figure D 1 IT Soft Starter CM D 1 Figure D 2 Pump Start Ramp and Soft Pump Stop D 2 iv For more information visit www EatonElectrical com MN03902008E EIN Cutler Hammer IT S801 Soft Starter User Manual June 2006 List of Tables Table 3 1 Required Mounting Hardware 3 7 Table 3 2 Weight Support Requirements 3 7 Table 3 3 Line and Load Power Wiring 3 9 Table 3 4 12 Pin Terminal Block Wirin
22. circuit breakers and disconnects Press the RESET button located below the CIM to clear the fault Phase voltages or currents unbalanced Check same solutions as for phase loss Confirm motor current balanced when connected across the line with balanced line voltage If not replace motor If line voltage balance but load voltage not contact Eaton Check load connections at soft starter and at motor terminal box PH REV LED is lit Line voltage is not in ABC configuration Verify proper wiring arrangement OVLD TRIP LED is lit Motor is overloaded Check motor for load problems FLA not set to motor ratings Verify that the FLA setting matches the motor nameplate current Consider any Service Factor being used Trip class set improperly Adjust trip class setting on CIM Fault exists in memory Press the RESET button located below the CIM to clear the fault If the fault remains maintain 24V DC power applied to the unit and allow the system to cool down for at least 9 minutes and try again Failed current sensor Contact Eaton For more information visit www EatonElectrical com MN03902008E E TN Cutler Hammer IT S801 Soft Starter User Manual June 2006 To obtain the fault flash codes from the CIM hold the RESET button located below the CIM down
23. go R E HA ODOD 0 II o g 7 44 E 7 92 189 0 00 0 E Ey 201 2 0000 3 OL e O0000 0 Ge Figure 3 3 R Frame 110 mm Approximate Dimensions in Inches mm 3 4 For more information visit www EatonElectrical com MN03902008E E T N IT S801 Soft Starter User Manual Cutler Hammer June 2006 7 65 6 22 m 194 4 R P 158 0 a ES oe BO e 3 il LE 00 0 Hi WU i an dun doa ZR De Ch Slo 822 9 AH BEL BL ER LJ LT Ld 28 2 95 an ita Slots Typ Slots oe eo Y 6 Plates 5 91 150 0 gt Slots NG Figure 3 4 T Frame 200 mm Approximate Dimensions in Inches mm 11 77 299 0 47 Mounting O e 5 20 132 0 8 Mounting e ala e O Oe O o Y 00000000000000000000000000 5 20 132 0 Mounting Slots Pole Centers o uU for M6 1 4 Screws Up to 6 Quantity mmm r m O T MAHALIN Wi a La Bra 7 08 el O 4
24. in any direction IT S801 Soft Starter User Manual Physical Table 4 2 Weight Frame Size Weight of Unit N 5 8 Lbs 2 6 Kg R 10 5 Lbs 4 8 Kg T and U 48 Lbs 21 8 Kg with lugs 41 Lbs 18 6 Kg without lugs V 103 Lbs 46 8 Kg with lugs 91 Lbs 41 4 Kg without lugs Table 4 3 Agency Standards and Certifications Standard Certifications UL UL 508 CSA CSA 22 2 14 1995 IEC 60947 4 2 CE See Table 4 4 MN03902008E For more information visit www EatonElectrical com 4 1 IT S801 Soft Starter User Manual CE Conformance Table 4 4 EMC Immunity E T N Cutler Hammer June 2006 Immunity Severity Level Electrostatic Discharge 4 kV contact discharge IEC 61000 4 2 8 kV air discharge Electromagnetic Field 10 V m IEC 61000 4 3 80 1000 MHz 2 angles Fast Transient Bursts 2 kV 5 kHz rep 2 min intervals IEC 61000 4 4 1 2 50 uS 8 20 uS Surges 2 kV Line to earth IEC 61000 4 5 1 kV Line to Line 1 minute intervals Conducted RF 10 V rms IEC 61000 4 6 15 80 MHz 50 Hz Magnetic Field N A IEC 61000 4 8 Voltage dips 3096 dip 10 mS Interrupt 6096 dip 100 mS IEC 61000 4 11 100 interrupt 05 S Emissions Radiated EN 55011 Class A Conducted EN 55011 Class A 1 The 24V DC power supply must be grounded 2 Add ferrite Fair Rite 40444173551 to DC Power Leads and Control I O Leads all through one ferrite
25. of the following motor protective features found at the top of the CIM These include e Overload Jam Stall Phase Loss Load Disconnect Phase Reversal Protection To enable a feature move its dip switch to ON To disable a feature move its dip switch to DISABLE Note Disabling any of the motor protective features does not disable any of the IT Soft Starter s protective features as shown in the flash code table on Page 8 5 Manual Auto Fault Reset Select auto or manual reset on the Control Interface Module When a fault is present if auto reset is on it will attempt to reset the fault every 2 5 seconds If the cause of the fault has been eliminated the fault will be reset If the fault has not been eliminated the fault status will be maintained After the fault is reset the soft starter can be restarted as normal To manually reset the fault after its cause has been cleared if auto reset is off press the FAULT RESET button below the CIM or apply 24V DC to terminal 4 of the control terminal block Note The motor does NOT automatically restart after a fault is reset UNLESS the soft starter is equipped for Level Sensing Control See Edge and Level Sensing Control section on Page 3 20 6 2 For more information visit www EatonElectrical com MN03902008E EIN Cutler Hammer IT S801 Soft Starter User Manual June 2006 Special Function S F Options On occasion a special function option is purchased a
26. or apply 24V DC to terminal 4 and count the number of times all the LEDs on the CIM flash For example if you see three flashes and then two more flashes after a short pause the flash code is 32 The CIM can provide multiple flash codes if more than one error condition caused a stop Once you see the same flash code repeated you have seen all the flash codes for the error conditions that caused the stop For example if you see three flashes a pause then two flashes a pause then four flashes a pause then one flash the flash codes are 32 and 41 If you then see three flashes a pause then two flashes you are seeing the first code again This means you have seen all the flash codes for this stop You may now release the RESET button or remove 24V DC from terminal 4 Note that if an overload trip has occurred 24V DC power must be applied to allow the overload thermal memory to reset Depending on the overload history prior to the latest trip this may be as long as 9 minutes A list of flash codes and the faults they represent is shown in Table 8 4 Table 8 4 Troubleshooting Soft Starter Fault Flash Codes Sent to CIM Code Fault Possible Cause 11 Thermal overload See Table 8 3 12 Motor stall See Table 8 3 13 Motor jam See Table 8 3 14 Phase reversed LED See Table 8 3 15 Pole over temperature See Table 8 3 16 SCR failed to fire Extreme settings on lightly loaded motor Loose connection or defective unit 21 15V power supp
27. the labels attached to the equipment This section explains their meaning YOUR SAFETY IS INVOLVED T The Safety Alert Symbol means ATTENTION BECOME ALERT VOTRE SECURITE EST EN JEU f Le symbole d alerte signifie ATTENTION SOYEZ VIGILANT ALERTA SU SEGURIDAD EST EN JUEGO El s mbolo de alerta de seguridad significa jATENCI N jESTE A Danger A Danger 4h Peligro Danger means that failure to follow the safety statement will result in serious personal injury death or substantial property damage Danger signifie que l inobservation de l nonc de s curit entrainera des blessures corporelles graves la mort ou des d g ts mat riels substantiels Peligro significa que si no se respeta la indicaci n de seguridad se producir n lesiones personales graves la muerte o da o considerable a la propiedad Warning 4h Avertissement Advertencia Warning means that failure to follow the safety statement could result in serious personal injury death or substantial property damage Avertissement signifie que l inobservation de l nonc de securite pourrait entrainer des blessures corporelles graves la mort ou des degats materiels substantiels Advertencia significa que si no se respeta la indicacion de seguridad se pueden producir lesiones personales graves la muerte o da os considerables a la propiedad A Caution AN Attention N Precauci n C
28. turn controls the torque developed by the motor After the motor reaches speed contacts are closed to bypass the thyristors The S801 is designed to fulfill the industrial service requirements for applications such as Chillers Pumps and Machine Tools that require less than 8596 of the motor s rated starting torque for worst case starting condition The S801 meets all relevant specifications set forth by NEMA ICS 1 ICS 2 and ICS 5 UL 508 IEC 60947 4 2 CE and CSA This user manual covers everything you need to know in order to install set up operate troubleshoot and maintain the S801 However no publication can take into account every possible situation If you require further assistance with any aspect of this product or a particular application please contact us For contact information please see Chapter 9 MN03902008E For more information visit www EatonElectrical com 1 1 IT 801 Soft Starter User Manual E T N Cutler Hammer June 2006 General Appearance Notes Shown with Lugs Optional Base Lug Cover Line Input Reset Button Control Interface Module CIM Status LED Detachable 12 Pin Terminal Block Load Output Figure 1 1 The Cutler Hammer Intelligent Technologies 7 S801 Soft Starter e The Control Interface Module CIM is mounted directly on the face of the unit e The base supports the soft starter and all internal and external components e The lug cover T U and V frames
29. x 1 5 Ouantity 4 8 50 Lb in Grade 8 Allen head 1D 0 270 5 6 Nem hex cap screws OD 0 495 0 505 Max 0 055 Thick Quantity 4 Special Washer Included with V Frame Units Weight Support Requirements Table 3 2 Weight Support Requirements Frame Size Weight of Unit N 5 8 Lbs 2 6 Kg R 10 5 Lbs 4 8 Kg TandU 48 Lbs 21 8 Kg with lugs 41 Lbs 18 6 Kg without lugs 103 Lbs 46 8 Kg with lugs 91 Lbs 41 4 Kg without lugs MN03902008E For more information visit www EatonElectrical com 3 7 IT S801 Soft Starter User Manual Power Wiring Using the wiring diagrams in Figures 3 9 through 3 14 and Table 3 3 below as guides connect the line Motor and Power Supply wiring in accordance with appropriate local and national codes E T N Cutler Hammer June 2006 Note To provide optimum motor protection the Line and Motor power wiring should be tightly bundled and run perpendicular to the orientation of the S801 Safety Notices Danger High Voltage Danger Haute Tension Peligro alto voltaje Hazardous voltage can cause electric shock and burns To avoid shock hazard disconnect all power to the controller motor or other control devices before any work is performed on this equipment Failure to do so will result in personal injury death or substantial property damage Une tension lectrique dangereuse p
30. 200 350 300 S801U42N3S Frame Size V 300 90 160 185 100 75 100 100 200 200 300 250 S801V36N3S 340 100 180 200 100 100 125 100 250 200 350 300 S801V42N3S 380 110 200 220 125 100 150 125 300 250 350 300 S801V50N3S S801V50V3S 420 129 220 257 150 125 150 150 350 300 450 350 S801V65N3S S801V65V3S 460 140 250 280 150 125 150 150 350 300 450 400 S801V72N3S S801V72V3S 500 150 257 300 150 150 200 150 400 350 500 450 S801V85N3S S801V85V3S 560 160 277 325 200 150 250 200 500 400 600 500 S801V10N3S See Application Notes Appendix C B 6 For more information visit www EatonElectrical com MN03902008E EIN Cutler Hammer IT S801 Soft Starter User Manual June 2006 Severe Duty Ratings Table B 7 5 30 Second Ramp 5 4 Starts per Hour or 530096 Current Limit Three Phase Motors kW Rating 50 Hz hp Rating 60 Hz Max 380 200V 230V 460V 575 690V Catalog Current 230V 400V 440V 1 0SF 1 15SF 1 0SF 1 15SF 1 0SF 1 15SF 1 0SF 1 15SF Number Frame Size N 22 5 5 10 11 5 5 7 1 2 5 15 10 20 15 S801N37N3S 42 11 18 5 22 10 10 15 10 30 25 40 30 S801N66N3S Frame Size R 65 15 30 33 15 15 20 15 50 40 50 50 S801R10N3S 80 22 40 45 25 20 30 25 60 50 75 60 S801R13N3S Frame Size T 115 33 59 63 30 30 40 30 75 75 100 100 S801T18N3S S801T18V3S 150 45 80 90 50 40 50 50 100 100 150 125 S801T24N3S S801T2
31. 3S 203 650 109 S801V65V3S S801V72N3S 225 720 127 S801V72V3S S801V85N3S 265 850 164 S801V85V3S S801V10N3S 310 1000 215 B 8 For more information visit www EatonElectrical com MN03902008E EIN Cutler Hammer IT S801 Soft Starter User Manual June 2006 A Appendix C Motor Application Considerations Using MOVs Most utility power systems experience periodic transient voltages Line or power factor correction capacitor switching nearby lightning strikes utility supply faults or a user starting or shutting down a large load such as a motor can cause these voltages The IT Soft Starter has been designed to handle transient voltages of up to 4 kV lasting up to 20 pS If transient voltages of greater magnitude or longer duration than the standard withstand capability are expected a protective module must be installed The protective module contains metal oxide varistors MOVs MOVs are devices that remain in a passive state until a transient voltage occurs Under the transient condition the MOV turns on and holds the peak line voltage down to a level less than the IT transient voltage rating When the transient clears the MOV returns to a passive state Eaton offers two MOV option kits Table C 1 MOV Kit Options Catalog Number Description EMS38 600V max MOV for S801N and S801R Soft Start side mounted EMS39 600V max MOV for S801T S801U and S801V Soft Start EMS41 690V max MOV for S801T V35 and
32. 4V3S 192 55 100 110 60 50 75 60 150 125 200 150 S801T30N3S S801T30V3S Frame Size U 240 75 110 147 75 60 75 75 200 150 200 200 S801U36N3S 305 90 160 185 100 75 100 100 250 200 300 250 S801U42N3S Frame Size V 240 75 110 147 75 60 75 75 200 150 200 200 S801V36N3S 305 90 160 185 100 75 100 100 250 200 300 250 S801V42N3S 365 110 185 220 125 100 150 125 300 250 350 300 S801V50N3S S801V50V3S 420 129 220 257 150 125 150 150 350 300 450 350 S801V65N3S S801V65V3S 480 147 257 295 150 150 200 150 400 350 500 450 S801V72N3S S801V72V3S 525 160 280 335 150 150 200 150 450 350 500 450 S801V85N3S S801V85V3S 575 172 303 370 200 150 250 200 500 450 600 500 801V10N3S See Application Notes Appendix C Severe Duty Ratings are defined as any combination of parameters that exceed the Standard Duty Ratings where the ramp time is over 30 seconds the number of starts per hour exceeds 4 or the current limit set is over 300 Example 35 Second Ramp 5 Starts per Hour 350 Current Limit 40 C Ambient MN03902008E For more information visit www EatonElectrical com B 7 IT S801 Soft Starter User Manual EIN Cutler Hammer Cooling June 2006 Microcontroller controlled fans are used to cool the IT Soft Starter The fans are turned on when the temperature of any of the thermal sensors exceeds preset value Once the fans are started they will not go off until the temperature goes below the off set point fo
33. 56 180 S801T18V3S S801T24N3S 75 240 S801T24V3S S801T30N3S 95 304 S801T30V3S U S801U36N3S 112 360 S801U42N3S 131 420 S801U50N3S 156 500 V S801V36N3S 112 360 S801V36V3S S801V42N3S 131 420 S801V42V3S S801V50N3S 156 500 S801V50V3S S801V65N3S 203 650 S801V65V3S S801V72N3S 225 720 S801V72V3S S801V85N3S 265 850 S801V85V3S 801V10N3S 320 1000 See Application Notes Appendix C Note The FLA current adjust dial is settable to any point within its range MN03902008E For more information visit www EatonElectrical com A 1 IT S801 Soft Starter User Manual E T N Cutler Hammer June 2006 Overload Trip Curves 10000 0 115 Class 5 1000 0 ELLE ss Class 10 Class 20 X Class 30 A A N X ER VIN K 3 AB M E H 9 N N N co M a 100 0 x S o i i N KI Tal M Y NX gt M Class 30 P Q ime VK M aT A Ki b A x SS aN ei NI N Sia Class 10 Class 20 N Shy UM NJ A MA IN Sh NG EMI M Ps Class 5 T NT ts 10 0 2 A SN EN PS ng Nad e Tu VM F pad Saal RENE Di NG Rt 1 0 0 100 200 300 400 500 600 700 800 900 Percent FLA Figure A 1 Overload Trip Curves
34. 6 AN Caution AN Attention N Precauci n The S801V soft starter weighs approximately 100 Lbs 45 kg To prevent personal injury or equipment damage use proper lifting equipment such as a floor crane to safely lift and install the soft starter A lifting eye is provided at the line end of the soft starter Le d marreur progressif S801V pese environ 45 kg 100 livres Pour viter des blessures corporelles ou des d g ts mat riels utiliser une machine de levage appropri e comme une grue d atelier pour soulever et installer le d marreur progressif sans encombre Un ceillet de levage est pr vu au c t ligne du d marreur progressif El arrancador suave S801V pesa aproximadamente 45 kg 100 Ib Para evitar que se produzcan lesiones personales o da os al equipo use el equipo para elevar adecuado como un brazo de elevaci n a fin de levantar e instalar con seguridad el arrancador suave Se proporciona una argolla de izada en el extremo de del arrancador suave AN Caution AN Attention N Precauci n Only apply 24V DC to the terminal block unless specified otherwise in this manual All control wiring is 22 12 AWG 0 33 2 5 mm Failure to follow this caution could result in severe damage to the controller Appliquer seulement 24V CC la barrette bornes sauf ce manuel offre d avis contraire Tout le c blage de commande est de calibre 0 33 2 5 mm 22 12 AWG L i
35. 947 4 2 to Type 1 Short Circuit Withstand Requirements to 42 kA 690 volts with Cutler Hammer Cat No RW420T33W 2 kA 690 Volt circuit breaker Note Short circuit protection must be applied on the line side of the soft starter MN03902008E For more information visit www EatonElectrical com 4 3 IT S801 Soft Starter User Manual E TN Cutler Hammer June 2006 4 4 For more information visit www EatonElectrical com MN03902008E EIN Cutler Hammer IT S801 Soft Starter User Manual June 2006 CI ETE Chapter 5 Functional Description Power The S801 Soft Starter controls the voltage applied to a three phase induction motor in order to control the starting torque and provide a smooth starting characteristic Within the soft starter are three power poles each of which includes a set of anti parallel SCRs thyristors in parallel with a contact During a start the conduction periods of the SCRs are continuously adjusted to apply a gradually increasing voltage to the motor resulting in gradually increasing torque and a smooth start As the motor reaches its rated speed the power pole contacts are closed bypassing the SCRs for the most efficient operation 3 Phase AC Line Voltage Figure 5 1 Soft Starter SCRs For each start the length of time the SCRs are conducting current as well as the magnitude of that current determine how hot the SCRs will get Between successive starts the
36. AC Mains L2 L3 Figure 3 17 24V DC Control with Edge Sensing If it is desired to place an electromagnetic contactor on the line side of the soft starter when using level control no additional control circuitry is required A start can be completed when the line power is supplied to the unit after the control power 24V DC providing the auto reset feature is enabled and the unit has a green light status with 24V DC on pin 1 The soft starter will not fault on either a phase loss or zero voltage crossing faults If the auto reset feature is enabled CAUTION must be exercised to assure that any restart occurs in the safe manner MN03902008E For more information visit www EatonElectrical com 3 23 IT S801 Soft Starter User Manual EIN Cutler Hammer June 2006 3 24 For more information visit www EatonElectrical com MN03902008E E T N Cutler Hammer June 2006 SS Chapter 4 Specifications Environmental Table 4 1 Environmental Specifications Item Specification Temperature Range Operating 40 F 122 F 40 C 50 C Storage 58 F 158 F 50 C 70 C Elevation Up to 6 600 ft 2000m Above 6 600 ft 2000m derate 0 5 per 330 ft 100m Humidity Functional to 95 non condensing Operating Orientation Any Pollution Degree IEC 60947 1 3 Shock Resistance 15g in any direction Vibration Resistance 3g
37. AER ops alec id coke de RE KA Berane SE S Squirrel Gage Motor 2 cess crire same e tree DAG Pa A die den ete SC A Wye Delta Motor oocooccocoo nii mi eme ine e peie ee a i Part Winding MOto onu ir NE R R a Dual Voltage Motor Multi Speed Motor Other Winding Connigurations 000 eh Power Factor Correction Capacitors CHAPTER D SPECIAL FUNCTION OPTIONS Pump Control OptIOn 5 sin cache E Ee Cea eR Wie cae ir le Ca ee da Extended Ramp Option IT S801 Soft Starter User Manual A 1 A 2 A 4 A 5 A 5 A 6 C 1 C 1 C 2 C 2 C 2 C 2 C 3 C 3 MN03902008E For more information visit www EatonElectrical com IT S801 Soft Starter User Manual E TN Cutler Hammer June 2006 List of Figures Figure 1 1 The Cutler Hammer Intelligent Technologies T S801 Soft Starter 1 2 Figure 3 1 Warning Tag a timido er SET d NAL ANGLE Ee 3 3 Figure 3 2 N Frame 65 mm e e rh 3 4 Figure 3 3 R Frame 110 mm N ZR 0 a rR Ra Ra n 3 4 Figure 3 4 T Frame 200 mm 3 5 Figure 3 5 U Frame 200 mm 3 5 Figure 3 6 V Frame 290 mm 3 6 Figure 3 7 V Frame Shown with Terminal Cover Removed and EML30 Lug Kit Installed on Load Side 10 Figure 3 8 Terminal Block ss iassa eere ho Rm Re dees ege EEN om niis 3 11 Figure 3 9 Basic Connection Dia
38. AWG 50 Lb in 5 6 Nem N A Standard with a Box Lugs 4 6AWG 45 Lb in 5 0 Nem 8 AWG 40 Lb in 4 5 Nem 10 14 AWG 35 Lb in 4 0 Nem R Supplied 1 Box Lug 14 8 AWG 90 100 Lb in N A Standard with 2 5 10 mm 10 1 11 3 Nem Box Lugs 6 4 AWG 16 25 mm 3 3 0 AWG 27 95 mm T and U EML22 2 4 1 0 MCM 250 Lb in 28 3 Nem 2 21 2 53 5 mm 4 0 500 MCM 250 Lb in 28 3 Nem 107 240 mm 4 0 500 MCM 250 Lb in 28 3 Nem 107 240 mm 2 0 300 MCM 225 Lb in 25 5 Nem 70 150 mm 2 0 300 MCM 225 Lb in 25 5 Nem 70 150 mm V 4 0 500 MCM 250 Lb in 28 3 Nem 2 107 240 mm 4 0 500 MCM 250 Lb in 28 3 Nem 107 240 mm EML32 609 4 0 500 MCM 250 Lb in 28 3 Nem 107 240 mm EML33 4 2 0 300 MCM 225 Lb in 25 5 Nem 70 150 mm Requires special lug cover Check with Eaton for availability CSA approved 350 MCM 500 MCM MN03902008E For more information visit www EatonElectrical com 3 9 IT S801 Soft Starter User Manual EIN Cutler Hammer June 2006 Lugs for T U and V Frame T U and V frame units are supplied standard without lugs If lugs are needed they can be ordered through your local Eaton distributor Each lug kit contains three lugs mounting hardware and instructions for use on either line or load side of the IT Soft Starter Catalog numbers and wire ranges for lug kits are listed in the table above Lug Installation
39. All LEDs should momentarily light Cycle 24V DC control power to the unit Allow unit to reset Bypass opened during run Press the RESET button located below the CIM to reset the fault Verify that the 24V DC power supply rating is large enough to close the bypass contacts with a minimum output rating of 250 watts for 0 15 seconds Table 8 6 Trouble shooting Excess Noise Vibration in Motor Symptom Indication Possible Problem Possible Solution Motor vibration during start up Load fluctuations Check load conditions Misapplication Verify that motor is a standard squirrel cage induction motor Ramp time set too low for application Torque set too low for application Load voltage or current unbalanced but line voltage is balanced Hardware failure Check line and load connections to soft starter and connections at motor terminal box Contact Eaton Motor vibration during normal run Load fluctuations Check load conditions Check motor connections Table 8 7 Troubleshooting Audible Noise from Soft Starter Bypass Fails to Close Chatters Symptom Indication Possible Problem Possible Solution Audible Noise Bypass contact Check 24V DC control power to soft starter from soft starter chatter Verify 24V DC power supply meets power inrush requirements 250 watts for 0 15 seconds Loose connect
40. IT S801 Soft Starter User Manual IT Soft Start r K RIT 1 C T1 01 01 L1 Incoming tU C T2 Lines 02 02 LZ M C S T3 ED NEN HS Circuit Breaker CT l4 If Used L1 112 Fuse 2 Li L12 Sagay Fuse 7 GND 1A 9 p 2 ro o a L L N l Power Supply 120V AC 24VDC lg o nj Be Tr Terminal Board Mx Jog P 4 KL 1 Inputs S T 2 24V DC Only Jog MX 3 o c 4 Internal Reset 43 Auxiliary Run Contact Run 100Q 25ufd A C 14 24V DC 1 2W 250V AC HH Start CP 95 120V AC sk Mx olo O MX 96 HN Internal Stop Auxiliary 98 E Contact MX ault D Ht O Jog CAUTION ry 99 Applying voltages other than MM 24V DC to terminals P thru 4 Alarm may cause serious damage to soft start control board Figure 3 12 Basic Connection Diagram Using 95 96 Trip Contacts for Soft Starter with START STOP RESET JOG with 120V AC Alarm and Run Indication See Notes on Page 3 18 MN03902008E For more information visit www EatonElectrical com 3 15 IT S801 Soft Starter User Manual E TN Cutler Hammer June 2006 e Frames 1 LC TI 01 01 L1 i C Ka a a VUES o tS Circuit Breaker 1 l
41. IT S801 Soft Starter User Manual June 2006 o Bunt 2 100 Bypass Initial kN AA le Start JL Run gt Time Seconds Figure 5 3 Ramp Start Current Limit Start This mode is typically used when it is necessary to limit the maximum current during startup Starting torque T2 can be programmed from 5 to 85 of the motor s across the line locked rotor torque corresponding to 23 to 92 of the motor s across the line locked rotor current The T2 default is 35 The ramp time is programmable from 0 5 to 180 seconds The factory default is 9 seconds The control is not linear to allow finer setting of short ramp times The first half of the control adjusts from 0 5 to 20 seconds the next quarter from 20 to 60 seconds and the last quarter from 60 to 180 seconds The unit will limit current to the specified torque When the motor is up to speed it will go into bypass Initial 1 glorque 3 T2 o Le or 100 Bus tr je Start Le Run gt Time Seconds Figure 5 4 Current Limit Start Pump Start The pump control option is addressed in Appendix D MN03902008E For more information visit www EatonElectrical com 5 3 IT S801 Soft Starter User Manual Soft Stop Soft Stop Standard E T N Cutler Hammer June 2006 This feature is used for applications that require a controlled extended stop It is designed for high frictional loads that tend to stop suddenly when vol
42. L inobservation de cet 22 12 AWG Si no respeta esta damage to the controller nonc pourrait entrainer des precauci n se pueden producir d g ts mat riels au contr leur da os graves al controlador gir T 13 14 95 96 98 Figure 3 8 Terminal Block Table 3 4 provides the 12 pin terminal block wiring capacity and torque requirements for the control wiring Table 3 4 12 Pin Terminal Block Wiring Capacity Number of Torque Wire Size Conductors Requirements 22 14 AWG 2 3 5 Lb in 0 4 Nem 0 33 2 5 mm 12 AWG 1 3 5 Lb in 0 4 Nem 4 0 mm MN03902008E For more information visit www EatonElectrical com 3 11 IT S801 Soft Starter User Manual Input Descriptions The IT Soft Starter has the following control inputs Table 3 5 S801 Terminal Block Control Wiring E T N Cutler Hammer Terminal Block Default Input Negative 24V DC nominal see Table 3 6 for sizing P Hardwired Stop 24V DC only 1 Start 24V DC only 2 Jog Forward 24V DC only 3 Overload Disable 24V DC only 4 Fault Reset 24V DC only 13 Relay close connects to 14 14 3 Amps 120V AC 24V DC 10 Amps Max Resistive Switching 95 N C Connects to 96 Relay closure connects to 98 96 3 Amps 120V AC 24V DC 10 Amps Max Resistive Switching 98 3 Amps 120V AC 24V DC 10 Amps Max Resistive Switching 13 and 14 Closed when i
43. REV O ON DISABLE MANUAL RESET AUTO RESET RAMP START CURRENT LIMIT 65 OVLD 5 10 20 30 TRIP TRIP 5 O CLASS TIME Sec Made in U S A Figure 6 1 Soft Start Control Interface Module CIM Note The S801 does not have to be powered to make adjustments to the control interface module Once the unit is energized it will communicate with the CIM and load the set parameters into the soft starter Allow the unit 2 seconds to ensure communication checks are complete and values are set To verify CIM is operational press the Fault Reset button below the CIM or apply 24V DC to terminal 4 If the CIM is powered and communicating all the LEDs will momentarily flash MN03902008E For more information visit www EatonElectrical com 6 1 IT S801 Soft Starter User Manual EIN Cutler Hammer June 2006 Trip Class To begin programming the S801 choose the trip class and FLA settings desired The trip class setting is made by moving the dip switches into the appropriate position to match the class overload desired OVLD 5 10 20 30 TRIP TRIP O CLASS Figure 6 2 Setting Trip Class and FLA on the CIM Find the motor FLA value on Table A 1 Set the FLA dial to the proper position See Figure A 1 for the thermal overload trip curves Example For a trip Class 5 both DIP switches should be set up to the left Protective Features You may choose to enable or disable each
44. S 135 40 63 80 40 30 50 40 100 75 125 100 S801R13N3S Frame Size T 180 51 90 110 60 50 60 60 150 125 150 150 S801T18N3S S801T18V3S 240 75 110 147 75 60 75 75 200 150 200 200 S801T24N3S S801T24V3S 304 90 160 185 100 75 100 100 250 200 300 250 S801T30N3S S801T30V3S Frame Size U 360 110 185 220 125 100 150 125 300 250 350 300 S801U36N3S 420 129 220 257 150 125 175 150 350 300 450 350 S801U42N3S 500 150 257 300 150 150 200 150 400 350 500 450 S801U50N3S Frame Size V 360 110 185 220 125 100 150 125 300 250 350 300 S801V36N3S 420 129 220 257 150 125 175 150 350 300 450 350 S801V42N3S 500 150 257 300 150 150 200 150 400 350 500 450 S801V50N3S 650 200 355 425 250 200 250 200 500 450 600 500 S801V65N3S S801V65V3S 720 220 400 450 300 250 600 500 700 600 S801V72N3S S801V72V3S 850 257 475 500 350 300 700 600 900 700 S801V85N3S S801V85V3S 1000 277 525 50 400 350 800 700 900 800 S801V10N3S 2 Definite purpose rating of 4 starts per hour 1 every 15 minutes 15 sec ramp 300 curent limit 40 C See Severe Duty ratings on Page B 7 if parameters are exceeded See Application Notes Appendix C MN03902008E For more information visit www EatonElectrical com B 1 IT S801 Soft Starter User Manual EIN Cutler Hammer June 2006 Table B 2 25 Second Ramp 4 Starts per Hour 300 Current Limit 40 C
45. S 960 302 510 540 350 300 800 700 900 800 S801V10N3S See Application Notes Appendix C MN03902008E For more information visit www EatonElectrical com B 3 IT S801 Soft Starter User Manual EIN Cutler Hammer June 2006 Table B 4 50 Second Ramp 2 Starts per Hour 300 Current Limit 50 C Three Phase Motors kW Rating 50 Hz hp Rating 60 Hz Max 380 200V 230V 460V 575 690V Catalog Current 230V 400V 440V 1 0SF 1 15SF 1 0SF 1 15SF 1 0SF 1 15SF 1 0SF 1 15SF Number Frame Size N 21 5 5 10 11 5 5 5 5 15 10 15 15 S801N37N3S 42 11 18 5 22 10 10 15 10 30 25 40 30 S801N66N3S Frame Size R 60 15 30 33 15 15 20 15 40 40 50 50 S801R10N3S 80 22 40 45 25 20 30 25 60 50 75 60 S801R13N3S Frame Size T 115 33 59 63 30 30 40 30 75 75 100 100 S801T18N3S S801T18V3S 150 45 80 90 50 40 50 50 100 100 150 125 S801T24N3S S801T24V3S 192 55 100 110 60 50 60 60 150 125 200 150 S801T30N3S S801T30V3S Frame Size U 280 80 150 160 75 75 100 75 200 200 250 250 S801U36N3S 340 110 180 200 100 100 125 100 250 200 350 300 S801U42N3S 380 110 200 220 125 100 150 125 300 250 350 300 S801U50N3S Frame Size V 280 80 150 160 75 75 100 75 200 200 250 250 S801V36N3S 340 110 180 200 100 100 125 100 250 200 350 300 S801V42N3S 380 110 200 220 125 100 150 125 300 250 350 300 S801V50N3S 420 129 220 257 150 125 150 150 350 300 450
46. S801V V35 The EMS38 is panel mounted while the EMS39 and EMS41 are mounted directly on the IT Soft Starter In situations where an MOV must be used the installer may choose to apply a different transient absorption device but it must be equivalent to the EMS38 EMS39 or EMS41 These MOVs may also be used on the load side of the soft starter where long cables connect the motor to the soft starter or where the cables are located outdoors Squirrel Cage Motor This is the most common application The motor is configured with three motor leads available In this case wire the motor to the soft starter with one lead per phase observing proper phase rotation An in sight disconnect means should be installed per code requirements MN03902008E For more information visit www EatonElectrical com C 1 IT S801 Soft Starter User Manual EIN Cutler Hammer June 2006 Wye Delta Motor The wye delta motor is a traditional way of achieving a reduced voltage start using regular contactors and starters In this method the motor is constructed with all six leads brought out to connect the unit in a wye configuration This allows about 5896 of the current 3396 starting torque to be applied during start up A timer is used to control the circuit and switch to the delta configuration as the unit approaches full speed In this case wire the six lead motor in a standard delta configuration The soft starter is then used to control the
47. Three Phase Motors kW Rating 50 Hz hp Rating 60 Hz Max 380 200V 230V 460V 575 690V Catalog Current 230V 400V 440V 1 0SF 1 15SF 1 0SF 1 15SF 1 0SF 1 15SF 1 0SF 1 15SF Number Frame Size N 34 9 15 18 5 10 7 1 2 10 10 25 20 30 25 S801N37N3S 63 15 30 33 20 15 20 20 40 40 60 50 S801N66N3S Frame Size R 96 25 45 55 30 25 30 30 75 60 75 75 S801R10N3S 120 33 63 63 40 30 40 40 75 75 100 100 S801R13N3S Frame Size T 150 45 80 90 50 40 50 50 100 100 150 125 S801T18N3S S801T18V3S 215 63 110 132 60 60 75 60 150 150 200 150 S801T24N3S S801T24V3S 278 80 147 160 75 75 100 75 200 200 250 250 S801T30N3S S801T30V3S Frame Size U 320 90 160 185 100 75 125 100 250 200 300 250 S801U36N3S 380 110 200 220 125 100 150 125 300 250 350 300 S801U42N3S 460 140 250 280 150 125 150 150 350 300 450 400 S801U50N3S Frame Size V 320 90 160 185 100 75 125 100 250 200 300 250 S801V36N3S 380 110 200 220 125 100 150 125 300 250 350 300 S801V42N3S 460 140 250 280 150 125 150 150 350 300 450 400 S801V50N3S 610 185 315 375 250 150 200 200 500 450 600 500 S801V65N3S S801V65V3S 680 200 375 445 200 250 200 600 500 700 600 S801V72N3S S801V72V3S 810 250 450 500 300 300 700 600 900 700 S801V85N3S S801V85V3S 890 290 510 560 400 350 700 600 900 700 S801V10N3S See Application Notes Appendix C B 2 For more information visit
48. V DC Control Power Supply When selecting a 24V DC power supply for your S801 it must meet the following steady state and inrush characteristics e Steady State Minimum 25 watts e Inrush Minimum 240 watts for 150 mS e Voltage on the S801 s and terminals must not exceed 30V DC to prevent hardware damage The soft starter will shut down at approximately 19V DC It is recommended that Cutler Hammer power supplies be used as other power supplies may not be able to meet the inrush current requirements The following Cutler Hammer power supplies are available Table 3 6 Cutler Hammer Power Supplies Catalog Steady State Inrush Number Wattage Wattage Input Voltage PSS55A 55W 250W 115V AC PSS55B 55W 250W 230V AC PSS55C 55W 250W 360 480V AC Note A minimum wire size of 14 AWG should be used between the power supply and the 24V DC and terminals For more information visit www EatonElectrical com MN03902008E EIN Cutler Hammer IT S801 Soft Starter User Manual June 2006 Control Wiring Application Notes AN Caution AN Attention N Precauci n Only apply 24V DC to the Appliquer seulement 24V CC a la Aplique solo 24 V CC al bloque terminal block unless specified barrette a bornes sauf ce manuel de terminales a menos que se otherwise in this manual All offre d avis contraire Tout le especifique lo contrario en este control wiring is 22 12 AWG cablage de commande est de
49. al Auxiliary Contact e La olo P _ Stop a 1 tart i de o o 2 y puts Jog 3 o o 4 Reset 7 r 13 TX 14 H C 1 Incoming l Lines t i Disconnect Means EASE dog i l l Lago l CPT O 120V l l l _E l le CAUTION Applying voltages other than 24V DC to terminals P thru 4 may cause serious damage to soft start control board S H to L Pilot Lights When Used lt In Bypass 95 Ready 96 TX Fault 98 Hi Internal Auxiliary Contact J Figure 3 9 Basic Connection Diagram for Soft Starter with START STOP RESET JOG with 120V AC Alarm and Run Indication See Notes on Page 3 18 MN03902008E For more information visit www EatonElectrical com 3 13 IT S801 Soft Starter User Manual E TN Cutler Hammer June 2006 71 respi 1 E vw3e 136 Incoming l Lines i l L2 3 T2 4 e L11 T1 2 wa To Separate aria l Disconnect 120V AC Supply Soft Starter Means ooo i S IE PS 24VDC l ki Qng ai o 1 T CD av bo CPT WO Hand 120v I 24V O 7 N Soft Start l EE EN en 1 P Terminal Auto 1 1 Board Inputs 2 24v DC Only 3 E o o 4
50. angular rounded washers avant de localiser et de monter le el arrancador suave se deben must be used on the two d marreur progressif Les quatre considerar los c digos o las innermost mounting holes on rondelles rectangulaires normas pertinentes Las cuatro both the line and load side of the circulaires sp ciales doivent tre arandelas rectangulares soft starter utiliser aux deux trous de redondas especiales se deben support les plus int rieurs surle usar en los dos orificios de c t ligne et le c t charge du montaje que se encuentren m s d marreur progressif al interior en los lados de l nea y de carga del arrancador suave MN03902008E For more information visit www EatonElectrical com Xi IT S801 Soft Starter User Manual E TN Cutler Hammer June 2006 xii For more information visit www EatonElectrical com MN03902008E EIN Cutler Hammer IT S801 Soft Starter User Manual June 2006 Sl Chapter 1 Overview General Introduction The Cutler Hammer Intelligent Technologies S801 IT Soft Starter from Eaton s electrical business is an electronic self contained panel or enclosure mounted motor soft starting device It is intended to provide three phase induction motors with a smooth start both mechanically and electrically The S801 Soft Starters utilize six thyristors connected in a full wave power bridge Varying the thyristor conduction period controls the voltage applied to the motor This in
51. aution means that failure to follow the safety statement may result in minor or moderate personal injury or property damage Attention signifie que l inobservation de l nonc de s curit peut entrainer des blessures corporelles mineures ou mod r s ou des d g ts mat riels Precauci n significa que si no se respeta la indicaci n de seguridad se pueden producir lesiones personales menores o moderadas o da os a la propiedad Notice Avis Aviso Notice means that failure to follow these instructions could cause damage to the equipment or cause it to operate improperly Avis signifie que l inobservation de ses instructions pourrait entrainer des degats ou le mauvais fonctionnement de l quipement Aviso significa que si no se siguen estas instrucciones se pueden producir da os al equipo o provocar que funcione de manera incorrecta vi For more information visit www EatonElectrical com MN03902008E EIN Cutler Hammer IT S801 Soft Starter User Manual June 2006 IT Soft Starter Safety Statements The following safety statements relate to the installation operation and troubleshooting of Cutler Hammer Motor Starters Notice Avis Aviso Make sure you read and understand the procedures in this manual before you attempt to operate or set up the equipment Bien lire et comprendre les proc dures contenues dans ce manuel avant de tenter le fonctionnement ou
52. ce Le fait d teindre l interrupteur de sectionnement pendant le fonctionnement du d marreur progressif IT entrainera la d faillance du d marreur progressif et des degats l quipement ou risque au personnel No aplique un dispositivo de desconexi n a la salida del arrancador IT Soft Starter a menos que se utilice un medio para apagar el arrancador cuando el interruptor de desconexi n est abierto La apertura del interruptor de desconexi n mientras el arrancador IT est operando puede ocasionar un funcionamiento incorrecto El cierre del interruptor de desconexi n mientras el arrancador IT est operando producir una falla de dicho arrancador como tambi n potenciales da os a los equipos y riesgo para el personal Note Short circuit protection must be applied on the line side of the soft starter The S801 is to be wired into the three phase line feeding the three main motor input leads as would be done for normal across the line starting It must not be wired internally between motor windings Refer to the motor nameplate for correct wiring information for normal across the line operation Contact Eaton if a special motor wiring requirement exists before wiring your starter By factory default the S801 is to be connected with an ABC phase rotation on the incoming power wiring If the motor turns in the incorrect direction upon energization exchange two phases at the motor terminal box or at the output ter
53. ched 90 of speed at the end of ramp the unit will trip off line and you will receive a stall indication on the control interface module This could indicate that the load characteristics have changed load is jammed full damaged etc If it occurs during initial commissioning of the unit you will need to increase the current limit setting increase the length of the ramp or both to allow enough time and energy to bring the motor up to speed Note The t pot is not linear to allow finer setting of short ramp times The first half of the control adjusts from 0 5 to 20 seconds the next quarter from 20 to 60 seconds and the last quarter from 60 to 180 seconds The maximum value of t can be modified at the factory for special orders applications Contact Eaton for more information Initial Torque S T2 o 5 Ramp Set to 0 100 Bypass tr je Start d Run gt Time Seconds Figure 6 5 Programming the Current Limit Start 6 6 For more information visit www EatonElectrical com MN03902008E E TN Cutler Hammer June 2006 Programming the Soft Stop Soft Stop IT S801 Soft Starter User Manual The last item to be programmed is the soft stop This feature slowly reduces the voltage applied to the motor to extend its stop time JAN Caution AN Attention N Precauci n Soft Stop is not an emergency stop If a quick stop is desired additional control is req
54. dge and Level Sensing Control Edge Sensing Edge sensing is denoted with an S in hte last character of the Catalog Number Example S801T30N3S Edge sensing requires 24V DC power be momentarily applied to pin 1 with terminal P at 24V DC to initiate a start under all conditions After a stop or fault occurs the 24V DC must be removed then reapplied to pin 1 before another start can occur This control configuration should be used when restarting of the motor after a fault or stop must be supervised manually or as a part of a control scheme The cycling of 24V DC power to terminal 1 before starting is required regardless of the position of the auto reset switch on the CIM Level Sensing Level sensing is denoted with a B in the last character of the Catalog Number Example S801T30N3B Level sensing will enable a motor to restart after a fault is cleared without cycling 24V DC power to terminal 1 as long as e Terminal P is supplied with 24V DC to start from Terminal Block Input 3 must also be enabled e The auto reset switch on the CIM is set to enabled e All faults have been reset This control configuration should be used where it is desirable to restart a motor after a fault without additional manual or automatic control An example of this condition would be on a remote pumping station where it is desirable to automatically restart a pump after a power outage without operator intervention If the auto re
55. do de parada suave Soft Stop no es una parada de emergencia y no puede hacer que la carga se detenga m s r pido que su tiempo de rodadura libre normal Si se desea desconectar la alimentaci n se requiere un control adicional para abrir los 24 V CD al terminal No es recomendable usar el terminal P para iniciar la desconexi n de la alimentaci n For more information visit www EatonElectrical com MN03902008E EIN Cutler Hammer IT S801 Soft Starter User Manual June 2006 EA Chapter 6 Configuration Programming the S801 To program and operate the S801 a Control Interface Module CIM is required The CIM Catalog Number EMA71 is for use with all models S801N S801R S801T S801U and S801V The CIM serves as the interface between the operator and the soft starter control circuitry to program the soft starter The CIM dip switches and rotary controls are used to select the soft starter settings When making adjustments to the CIM under normal operation the LEDs will function as follows A change to any dip switch will cause all LEDs to flash momentarily An adjustment to any POT will cause all LEDs to light and stay lit until the adjustment of the POT has been completed While selecting these parameters 24V DC power may be applied to the soft starter but it is not required ss TRIP O Cutler Hammer EMA71 OVERLOAD ON DISABLE JAM O ON DISABLE STALL O ON DISABLE PH LOSSO ON DISABLE PH
56. e Cover Photo The Cutler Hammer Intelligent Technology S801 Soft Starter Family MN03902008E For more information visit www EatonElectrical com IT S801 Soft Starter User Manual E TN Cutler Hammer June 2006 EX ES Table of Contents LIST OF FIGURES rein n gea Ee En AE ANNE Rx dw dE E A eee eS iv LIST OF TABLES 22 ehh nne V SAFETY The Meaning of Safety Statements ees vi IT Soft Starter Safety Statements vii Dangers Warnings Cautions and Notes viii CHAPTER 1 OVERVIEW General Introduction lille eee 1 1 General Appearance Notes 1 2 CHAPTER 2 RECEIPT UNPACKING General 25 22 pagba Ee Lanne kh nI hahha DADA TERTRE E e EE 5 2 1 Rule Te Mile e 22 RS ANG cece La exa NER ur PRN TA eso REGES 00 2 1 og add AA 2 CHAPTER 3 INSTALLATION Mo NntiNg a AA E 3 1 Power WINING AA EE 3 8 Control Wiring Inputs esee risse resan as samaa a nE e E a e E E E E 3 11 CHAPTER 4 SPECIFICATIONS Sne UE 4 1 PHYSIC albeit Aarne coming A a EE EE E 4 1 CE Conformance ee eee eee hs 4 2 Short Circuit Ratings SR a E a SR D eae DALA BIL m NR ede wanted od 4 3 CHAPTER 5 FUNCTIONAL DESCRIPTION Ne evi e a A a ee eee eS 5 1 REEL AA a 5 1 CHAPTER 6 CONFIGURATION Programming the S801 6 1 Trip Classi hide cha NAAN A a Ge ER EL es 6 2 Prot
57. ective Features 6 2 Manual Auto Fault Reset 6 2 Special Function SFE secre me Bee pass este ee rer Roe in ee ees 6 3 OPTIONS c Ir 6 3 Programming the Start e 6 3 CHAPTER 7 SETUP AND STARTING let e TEE 7 1 A a a a a e a a a a e E E 7 1 CHAPTER 8 TROUBLESHOOTING General erp 8 1 Before You Begin to Troubleshoot 8 1 Define the Problem 4444 22 8 2 CHAPTER 9 PARTS AND SERVICE Renewal Parts ls csto ie eus ipa NP nri iid resar doe ye eas ENN ER A 9 1 Tele e E E Kaanak E E E E E ia a a bi 9 1 ii For more information visit www EatonElectrical com MN03902008E E TN Cutler Hammer June 2006 Table of Contents Continued CHAPTER A PROTECTION Thermal Overload i42 exe ek WAR REE ha DD WE Ux Ye DAANG Overload Trip Curves eee eee n eens Jam Detection 2 ve uy adder ba A x eal R Stall Detection zzi as he esas eae ens Swe Be Oe KANIN a euo pius Phase Loss Current Unbalance Detection and Load Disconnect Phase Reversal Detection eee han Protective Features Review CHAPTER B RATINGS COOLING AND POWER LOSSES Horsepower and kW Ratings A Ars CP Power LoOSSeS c eet R R Ad ANNE Ree EE OE E EA EN ana CHAPTER C MOTOR APPLICATION CONSIDERATIONS USING MOVS iine Ke a ak cas
58. er Chapter 8 Troubleshooting General In this section of the manual we present a procedure you can follow to diagnose a problem with your S801 While many potential situations are outlined in this section it is possible you may run into a problem that is not covered here If you have worked through the following troubleshooting procedure and find that you require further assistance please contact Eaton Please have the following information ready when you call Order No if available Catalog Number Style Number Serial Number CIM DIP Switch Settings CIM Pot Settings Before You Begin to Troubleshoot 4h Warning 4h Avertissement 4h Advertencia Make sure you read and understand the procedures in this manual before you attempt to operate or set up the equipment Bien lire et comprendre les proc dures contenues dans ce manuel avant de tenter le fonctionnement ou la mise en place de l quipement Aseg rese de leer y entender los procedimientos en este manual antes de intentar operar o configurar el equipo Danger High Voltage Danger Haute Tension Peligro alto voltaje Do not work on energized equipment unless absolutely required If troubleshooting procedure requires equipment to be energized all work must be performed by properly qualified personnel following appropriate safety practices and precautionary measures Ne pas tra
59. erload Adjustment Settings Table A 2 Trip Reset coord eee oc sent aber EA A Rees Seed a ees KAG Table A 3 Protection Settings Table B 1 15 Second Ramp 4 Starts per Hour 300 Current Limit 40 C Table B 2 25 Second Ramp 4 Starts per Hour 300 Current Limit 40 C Table B 3 15 Second Ramp 4 Starts per Hour 300 Current Limit 50 C Table B 4 50 Second Ramp 2 Starts per Hour 300 Current Limit 50 C Table B 5 15 Second Ramp 4 Starts per Hour 450 Current Limit 40 C Table B 6 30 Second Ramp 4 Starts per Hour 450 Current Limit 40 C Table B 7 gt 30 Second Ramp gt 4 Starts per Hour or gt 300 Current Limit Table B 8 Maximum Power Loss Table C 1 MOV Kit Opttons RRR R RR R RRR RRR R RR RR DUWWWWWWULETTODOO Qm ELE b JQ EMA QO zl NO OOQ E WW WM MN03902008E For more information visit www EatonElectrical com V IT S801 Soft Starter User Manual Safety E TN Cutler Hammer June 2006 Eaton s electrical business has made every effort to provide you with the safest motor starters on The Meaning of Safety Statements the market However we wish to point out how to safely operate and troubleshoot your starter You will find various types of safety information on the following pages and on
60. eut causer des chocs lectriques et des br lures Pour viter des chocs lectriques d brancher l alimentation du contr leur du moteur ou des autres appareils de contr le avant d y effectuer du travail L inobservation de ces instructions entrainera des blessures corporelles graves la mort ou des degats mat riels substantiels Voltajes peligrosos que pueden causar descargas el ctricas y quemaduras Para evitar descargas el ctricas desconecte la alimentaci n del controlador del motor u otros dispositivos de control antes de efectuar cualquier trabajo en el equipo El incumplimiento de estas medidas ocasionar lesiones personales la muerte o dahos importantes al material Do not apply a disconnect device on the output of the T Soft Starter unless a means to turn off the soft starter when disconnect switch is open is utilized Opening disconnect while the T Soft Starter is operating may cause a malfunction Closing disconnect switch while the T Soft Starter is operating will result in a soft starter failure and potential equipment damage and personnel hazard Ne pas appliquer un appareil de sectionnement sur la sortie du d marreur progressif IT moins qu un moyen d teindre le d marreur progressif quand l interrupteur de sectionnement est ouvert soit utilis Le fait d ouvrir l interrupteur de sectionnement pendant le fonctionnement du d marreur progressif IT peut entrainer une d faillan
61. g Capacity 3 11 Table 3 5 S801 Terminal Block Control Wiring 3 12 Table 3 6 Cutler Hammer Power Supplies 3 18 Table 4 1 Environmental Specifications 4 1 Table 4 2 Weight a Oe NG PAG AL E eund d aren doas Dahlia Table 4 3 Agency Standards and Certifications Table 4 4 EMC Immunity 44444 hh Table 4 5 Short Circuit Ratings 00 00 ccc ee teen eens Table 6 1 Torque Setting and Percent Locked Rotor Table 8 1 Troubleshooting Status LED Off Table 8 2 Troubleshooting Status LED Green Table 8 3 Troubleshooting Fault Shown on CIM Table 8 4 Troubleshooting Soft Starter Fault Flash Codes Sentto CIM Table 8 5 Troubleshooting Fault Not Shown on CIM Table 8 6 Troubleshooting Excess Noise Vibration in Motor Table 8 7 Troubleshooting Audible Noise from Soft Starter Bypass Fails to Close Chatters Table 8 8 Troubleshooting Unit Will Not Stop Table 8 9 Troubleshooting Other Symptoms Not Listed Table 9 1 Renewal Parts Table A 1 Ov
62. gram for Soft Starter with START STOP RESET JOG with 120V AC Alarm and Run Indieatton cece eens 3 13 Figure 3 10 Basic Connection Diagram for Soft Starter with HAND OFF AUTO RESET with PLC shown with 120V AC Alarm and Run Indication sd dne eu pror URP ERE ERR E Eon diese 3 14 Figure 3 11 Basic Connection Diagram for Soft Starter with START STOP RESET JOG with 24V DC Alarm and Run Indication 3 14 Figure 3 12 Basic Connection Diagram Using 95 96 Trip Contacts for Soft Starter with START STOP RESET JOG with 120V AC Alarm and RUN Indication 225 cesos ote De vue RE ace sere se Reh we Fhe EE e 3 15 Figure 3 13 Basic Connection Diagram Using 95 96 Trip Contacts for Soft Starter with HAND OFF AUTO RESET with 120V AC Alarm and RUN Indicatii i2 de RUPES eek ee Keke ee EE Ner ORR eRe eS 3 16 Figure 3 14 Basic Connection Diagram Using 95 96 Trip Contacts for Soft Starter with START STOP RESET JOG with 24V DC Alarm and Run INdICAtION ria ii cece nated A Danton de Reda mac RE RU ox KS 3 17 Figure 3 15 24V DC Control rh emere rne e IR a od 3 21 Figure 3 16 120V AC Control 3 22 Figure 3 17 24V DC Control with Edge Sensing 3 23 Figure 5 1 Soft Starter SCRs 5 1 Figure 5 2 Selectable Kick Gart 5 2 Figure 5 3 Ramp Start scere mde dur e deed e EN done 5 3 Figure 5 4 Current Limit Start xar a iewe eia NE RR e
63. guration either ramp Figure 6 4 or current limit Figure 6 5 To select the ramp start move the bottom dip switch toward RAMP START In this mode the motor torque is ramped up from an initial start level by increasing the motor current until the motor is started or the ramp time has elapsed The initial starting torque point is selected by adjusting the T2 dial to the level required by the application T2 s range is 596 to 8596 of the motor s across the line locked rotor torque Equivalent values of across the line locked rotor current versus torque are shown in Table 6 1 Page 6 4 Once the initial torque point is determined the ramp time must be selected by adjusting the t dial from 0 5 to 180 seconds At the end of the ramp time the motor should be at full speed If the motor is at 9096 of rated speed or more and its current is less that 2 x FLA the bypass contacts will close connecting the motor directly across the input line power If the motor has not reached 9096 speed or its current is greater than 2 x FLA at the end of the ramp time the soft starter will trip A stall fault will be indicated on the CIM This could indicate that the load characteristics have changed load is jammed full damaged etc If it occurs during the initial commissioning of the unit you will need to increase the initial torque setting adjust the ramp time or both Note The t control is not linear to allow finer setting of short ramp times The fir
64. he two lower middle screws with special flat washer and lockwasher into the panel before lifting the soft starter These two screws will assist in mounting Special mounting hardware is included with the soft starter Hardware supplied must be used Hook lifting equipment to the soft starter lifting eye If you are using a crane minimize the chain length between the boom and the soft starter Make sure that the back of the soft starter is oriented to the panel mounting surface Make sure that the lifting equipment hook is fully engaged with the soft starter lifting eye before lifting Slowly lift the soft starter to about 2 in 5 cm above the mounting location Then move it back against the mounting panel Carefully lower the soft starter onto the two mounting screws Make sure the screws align with the slots on the load end of the soft starter and that the two washers are between the soft starter base and the screw head Install and tighten the remaining six mounting screws washers and lockwashers Then tighten the two lower middle screws Tighten all eight screws to 50 Lb in 5 6 Nem Disengage and remove the lifting equipment 4h Warning 4h Avertissement 4h Advertencia After mounting the unit remove and discard the lifting eye and packaging bolts before continuing with the installation process Apr s que l appareil sera support enlever et jeter les ceillets de levage et les boulons de l emballage avant de p
65. id power systems and services for industrial mobile and aircraft equipment intelligent truck drivetrain systems for safety and fuel economy and automotive engine air management systems powertrain solutions and specialty controls for performance fuel economy and safety Eaton has 60 000 employees and sells products to customers in more than 125 countries For more information visit www eaton com Eaton Electrical Inc 1000 Cherrington Parkway Moon Township PA 15108 4312 USA tel 1 800 525 2000 www EatonElectrical com 2006 Eaton Corporation All Rights Reserved Printed in USA e ut e r a m m e r Publication No MIN03902008E CPG June 2006
66. ions Remove power from unit check all connections Loose mountings Remove power from unit check all mounting hardware For more information visit www EatonElectrical com MN03902008E IT S801 Soft Starter User Manual E TN Cutler Hammer Table 8 8 Troubleshooting Unit Will Not Stop Symptom Indication Possible Problem Possible Solution Motor will not shut off Control wiring is incorrect Verify 24V DC is removed from P terminal Verify no strands from 24V DC are in contact with P terminal Bypass fails to open Shorted SCR Open disconnect Remove all power from unit and check continuity of poles Open disconnect Remove all power from unit and check continuity of poles Table 8 9 Trouble shooting Other Symptoms Not Listed Symptom Indication Possible Problem Possible Solution Motor short circuited Motor stops too quickly under soft stop Winding fault ts soft stop is set too low Identify and correct motor fault Verify all power connections are secure Verify no shorts exist in cabling or the motor terminal box Adjust ts time longer Misapplication If friction load is too great motor may stall during soft stop reduce load if possible Motor stops too slowly under soft stop Motor starts too slowly ts Soft Stop is set too long Adjust ts time as required
67. is selectable ON DISABLE The phase loss and unbalance current protection features monitor the line voltage and current respectively If a phase voltage is lost or the line current is unbalanced more than 40 from the average of all three phases the soft starter shuts down and the Phase Loss light is illuminated See the CIM flash code table on Page 8 5 for indication of the possible cause Load disconnect protection feature monitors the line current If the phase rotation is not ABC the soft starter shuts down and the SS TRIP light is illuminated See the CIM flash code table on Page 8 5 for indication of the possible cause Phase Reversal Detection This feature is selectable ON DISABLE The phase reversal protection feature monitors the phase rotation of the incoming power line If the phase rotation is not ABC the soft starter shuts down and the Phase Reverse light is illuminated MN03902008E For more information visit www EatonElectrical com A 5 IT S801 Soft Starter User Manual EIN Cutler Hammer June 2006 Protective Features Review Thermal Motor Overload The thermal overload is designed to protect the motor from heating caused by drawing too much current If the motor is overloaded the current drawn rises and heats the motor The FLA sets the trip threshold and the trip class 5 10 20 or 30 is set on the CIM If the device trips on a thermal overload an internal timer is started which inhib
68. its a reset for three minutes After this timer expires the device may be reset and the thermal fault is cleared At this point another internal timer is started this timer is 26 x 3 or 48 minutes If another trip occurs before this timer expires the reset inhibit time is increased to 6 minutes Once the trip level reaches 3 it will take 144 minutes to go back to level 2 then 96 minutes to get back to level 1 To get from level 3 to a reset thermal overload at level 1 it takes 288 minutes without a trip A reset thermal overload at level 1 means the next thermal overload trip will have a three minute reset inhibit as shown in Table A 2 Table A 2 Trip Reset Reset Time to Previous Trip Reset Inhibit Time Trip Level 3 minutes 48 minutes 2 6 minutes 96 minutes gt 3 9 minutes 144 minutes Cycling power on the device will typically NOT clear the thermal trip The thermal pile and the reset inhibit time are saved to the non volatile memory These values are reloaded when the device boots and the timer is restarted at the full reset time This means if the 3 minute inhibit timer has been running two minutes cycling power will require the user to wait the full three minutes before a reset can clear the overload fault If the device is shut down when the overload fault is tripped the temperature is also saved to the non volatile memory If the device is left to cool and then powered the temperature read from the se
69. ive humidity is 0 95 non condensing e The environment is dry clean and non corrosive e The unit will not be subjected to high shock or vibration conditions MN03902008E For more information visit www EatonElectrical com 2 1 IT S801 Soft Starter User Manual EIN Cutler Hammer June 2006 2 2 For more information visit www EatonElectrical com MN03902008E E T N Cutler Hammer June 2006 Es Chapter 3 Installation Mounting Models S801N S801R S801T S801U and S801V The S801 is easy to mount It does not require any special tools IT S801 Soft Starter User Manual To aid you with panel layout refer to the dimension drawings in Figures 3 2 through 3 6 of this manual Drill and tap holes per mounting hole location as shown To mount the unit use all the hardware specified in Table 3 1 on Page 3 7 Tighten to the torque specified The T U and V frame S801 is supplied with a lifting eye mounted on the center phase of the line end of the device This will aid in mounting the unit 4h Warning 4h Avertissement 4h Advertencia After mounting the unit remove and discard the lifting eye and packaging bolts before continuing with the installation process Model S801V Apr s que l appareil sera support enlever et jeter les illets de levage et les boulons de l emballage avant de poursuivre l installation Despu s de montar la unidad retire y elimine la argolla de izada y los
70. l linearly decrease upon a stop command extending the stop time Note that in some applications the motor will come to a stop in less than the selected t time if t is set too long Percent Voltage 100 Coast to Soft Stop Time Seconds le Run 1 Soft Stop E Figure 6 6 Programming the Soft Stop The pump control option includes a special soft stop feature intended to prevent water hammer upon shutdown in centrifugal pump applications See pump control option in Appendix D for specific information MN03902008E For more information visit www EatonElectrical com 6 7 IT S801 Soft Starter User Manual EIN Cutler Hammer June 2006 6 8 For more information visit www EatonElectrical com MN03902008E EIN Cutler Hammer IT S801 Soft Starter User Manual June 2006 TRE Chapter 7 Setup and Starting Line Power e Line power must be applied prior to the application of the 24V DC control power to prevent a phase loss or zero voltage crossing protection fault e Terminal P must have 24V DC applied to ENABLE the soft starter e The soft starter will start when 24V DC is applied to terminal P and either terminal 1 or 2 goes from OV DC to 24V DC e Remove 24V DC from terminal P to initiate a stop e f either terminal 1 or 2 remains connected to 24V DC when terminal P is opened the soft starter will stop e Terminals 1 through 4 are activated by
71. la mise en place de l quipement Asegurese de leer y entender los procedimientos en este manual antes de intentar operar o configurar el equipo 4h Warning 4h Avertissement 4h Advertencia This instruction manual should be used for proper installation setup and operation of the starter Improperly installing and maintaining this product can result in serious personal injury or property damage Before attempting installation setup or operation read and understand all of this manual Ce manuel d instructions doit tre utilis pour l installation mise en place et op ration r gl s d un d marreur La mauvaise installation et entretien de ses produits pourraient entrainer des blessures corporelles graves ou des dommages mat riels Avant de tenter l installation ou l entretien bien lire et comprendre ce manuel en entier Este manual de instrucciones debe utilizarse para la correcta instalaci n configuraci n y operaci n del arrancador La instalaci n o el mantenimiento inadecuado de este producto puede ocasionar serias lesiones personales o da os al material Antes de intentar la instalaci n la configuraci n o la operaci n lea y entienda todo el manual Danger High Voltage Danger Haute Tension Peligro alto voltaje There can be line voltage potential at the motor load terminals even with the starter in the OFF state This is due to the possible leakage across the thyristo
72. le For a motor with an across the line locked rotor current of 6 x FLA the initial current would be limited to 5 5 x FLA or 0 92 x 6 x FLA for a T1 setting of 85 or 92 of locked rotor current The across the line locked rotor torque versus equivalent starting current values are found in Table 6 1 MN03902008E For more information visit www EatonElectrical com 6 3 IT S801 Soft Starter User Manual EIN Cutler Hammer June 2006 Table 6 1 Torque Setting and Percent Locked Rotor Percent Locked Torque Setting Rotor Current 85 92 71 84 56 75 45 67 36 60 27 52 19 44 14 37 9 30 5 23 3 16 1 10 These are typical values for a NEMA design B type motor The starting torque versus locked rotor current relationship will vary for other NEMA design types as determined by the manufacturer Next adjust the time setting tk to apply the kick start torque from 0 to 2 seconds Note If a kick start is not required for your application set T1 to 5 and t to 0 Kick Start Torque Bypass le Start gt Run gt Time Seconds Figure 6 3 Programming the Kick Start Sequence 6 4 For more information visit www EatonElectrical com MN03902008E EIN Cutler Hammer IT S801 Soft Starter User Manual June 2006 Programming the Ramp Start Sequence Ramp Start The next element to be determined is the start confi
73. ly low Weak control power or defective unit 22 Phase loss See Table 8 3 23 Bypass dropout Weak control power or defective unit 24 SCR Contactor overcurrent Only if stall or jam disabled load amps excessive 25 Phase unbalance See Table 8 3 26 Non volatile memory error Internal control board fault 31 Zero voltage cross failure Control power applied out of sequence or power factor correction capacitors on motor 32 Shorted SCR phase loss load See Table 8 3 disconnect 33 Load disconnect Load Current falls below 1 16 of FLA setting Can be disabled by setting phase loss to disable 34 SCR instantaneous overcurrent Current exceeded start ratings during the starting or stopping mode 41 24V power supply low Improper 24V DC supply or weak control power 42 Timer system fault Internal control board fault 43 Watchdog reset occurred E UE electrical noise or internal control board ault 44 PLL DSP Internal control board fault 45 Illegal address DSP Internal control board fault MN03902008E For more information visit www EatonElectrical com 8 5 IT S801 Soft Starter User Manual E TN Cutler Hammer June 2006 Table 8 5 Troubleshooting Fault Not Shown on CIM Symptom Indication Possible Problem Possible Solution Status LED is lit no indication on CIM No communication with CIM Sensor failure Verify connection between soft starter and CIM Press the RESET button located below the CIM
74. manual Todo el cableado de 0 33 2 5 mm Failure to follow calibre 0 33 2 5 mm 22 12 control es de 0 33 2 5 mm this caution could result in severe AWG L inobservation de cet 22 12 AWG Si no respeta esta damage to the controller nonc pourrait entra ner des precaucion se pueden producir d g ts mat riels au contr leur da os graves al controlador 1 Connect DC common negative to terminal using a minimum wire of 14 AWG 2 5 mm 2 Connect 24V DC positive to terminal using a minimum wire of 14 AWG 2 5 mm 3 Terminal P permissive circuit Must be energized at 24V DC to enable operation of all S801 soft starters For all units if power is removed from the permissive circuit at any time the unit will initiate a stop sequence including a soft stop if enabled Note With level sensing control if 24V DC is removed from the permissive circuit at any time the unit will initiate a stop and restart when 24V DC is reapplied to terminal P if a 24V DC is still available on pin 1 to start from Terminal Block Input 3 must also be enabled b the device shows a green status light not faulted and c auto reset is enabled on the Control Interface Module CIM See the Edge and Level Sensing Control section on Page 3 20 for more details If the auto reset feature is used CAUTION must be exercised to assure that any restart occurs in a safe manner 4 Terminal 1 Start mode
75. minals of the soft starter Changing the input wiring will cause a voltage phase reversal trip 3 8 For more information visit www EatonElectrical com MN03902008E EIN Cutler Hammer IT S801 Soft Starter User Manual June 2006 If the input phase sequence to the S801 must be ACB the incoming phase sequence will need to be changed to ACB Setting ACB as the incoming phase sequence causes the ABC incoming phase sequence to cause a voltage phase reversal trip IMPORTANT The reversing contactor must never be switched while the soft starter is operating In order to gain the full benefit of the S801 with a reversing contactor the S801 needs to be OFF when switching the direction The soft starter settings must account for catching a motor spinning in the opposite direction upon soft restarts The time required for slowing the motor to a stop and then ramping up to speed in the opposite direction adds to the overall starting time This will also impact the overload protection setting See Motor Application Considerations section in Appendix C of this manual for information on typical motor winding configurations Line and Load power wiring data is shown in Table 3 3 Table 3 3 Line and Load Power Wiring Wire Sizes Number Frame Number of Cu 75 C Torque of Kits Size Lug Kit Options Conductors Lug Type Only Requirements Required N Supplied 1 Box Lug 2
76. momentarily applying 24V DC e f either terminal 1 or 2 remains connected to 24V DC when terminal P is opened the soft starter will stop e OntheR T U and V frame soft starters when the bypass contactors close a momentary sound similar to contactor chattering can be heard The three single phase contactors closing in a staggered manner over a very short period of time cause this sound This is part of normal operation and should not be misinterpreted as a dirty pick up e Fortwo wire control jumper terminals P and 1 together Jog e Terminal P must have 24V DC applied e Terminal 2 is edge sensitive This means that there must be a transition for 0 to 24V DC to jog e In jog the unit will follow the normal start ramp as long as terminal 2 is at 24V DC e To stop remove the 24V DC from terminal 2 e Jog operates the same as a normal start except that the bypass contactors will not close and the soft stop is not functional Note Jog is only intended for short term jogging of the motor and not for long term two wire control For two wire control tie terminals P and 1 together and connect to 24V DC to start and disconnect from 24V DC to stop MN03902008E For more information visit www EatonElectrical com 7 1 IT S801 Soft Starter User Manual E TN Cutler Hammer June 2006 7 2 For more information visit www EatonElectrical com MN03902008E E T N Cutler Hammer June 2006 IT S801 Soft Starter User Manual o
77. n bypass Contact is normally open 95 and 96 Closed System OK Opened Fault 95 and 98 Opened System OK Closed Fault See Using an Auxiliary Relay section on Page 3 21 June 2006 Pins 95 96 and 98 are a Form C contact 95 acts as common 96 is a normally closed contact and 98 is a normally open contact On any fault that trips the unit or causes it not to start 96 opens and 98 closes The control wiring is connected to the soft starter by a 12 pin removable terminal block located on the front of the unit Each terminal is capable of holding one or two 22 14 AWG 0 33 2 5 mm wires or one 12 AWG 4 mm wire The terminals should be tightened to 3 5 Ib in 0 4 Nm For more information visit www EatonElectrical com MN03902008E E T N Cutler Hammer June 2006 Typical Control Wiring Diagrams Each diagram illustrates a typical wiring scheme for the options described The terminal IT S801 Soft Starter User Manual block represents the soft starter The additional Cutler Hammer items shown on the diagrams are not included but they may be purchased from Eaton Pei a ne J To Separate 120V AC Supply O tl a Soft Starter L3 5 T3 6 L2 3 T2 4 Ka L11 T1 2 NA eus 710 24V DC Soft Start Terminal Board 24V DC Only Intern
78. nd installed on the T soft starter The special function may be enabled or disabled with this dip switch The pump control option is a special function option It is addressed in Appendix D Edge sensing is denoted with an S in the last character of catalog number Ex 801 N3S Level sensing is denoted with an B in the last character of catalog number EX 5801 5 noe N3B 690V rated S801 are denoted with an V in the last part of catalog number not available in the U Frame Programming the Start This procedure covers programming the start characteristics of the soft starter There are two configurations to choose from e Ramp Start sequence e Current Limit Start sequence Set the bottom dip switch to make your choice A kick start is available for either ramp or current limit start The pump control option includes a variation of the ramp start suitable for centrifugal pump applications See Appendix D for specific information Programming the Kick Start Sequence Kick Start The first set of parameters to be set on the CIM is for Kick Start Figure 6 3 This feature is designed to assist the starter in overcoming a high friction load and break the rotor free prior to the normal start Two parameters must be set The kick start torque value T1 can be set from 5 to 85 of the motor s across the line starting torque This setting also equates to a percentage of locked rotor current of 23 to 92 For examp
79. nel hole locations Applicable codes or standards must be considered before locating and mounting the soft starter The four special rectangular rounded washers must be used on the two innermost mounting holes on both the line and load side of the soft starter Le d marreur progressif S801V inclut des mat riels de support vis t te hexagonale 8 1 4 20 x 1 5 et des rondelles sp ciales Ne substituer pas pour ces mat riels Consulter la Figure 3 6 de la Page 3 6 pour les locations des trous dans le panneau Tenir compte des normes et des codes existants avant de localiser et de monter le d marreur progressif Les quatre rondelles rectangulaires circulaires sp ciales doivent tre utiliser aux deux trous de support les plus int rieurs sur le c t ligne et le c t charge du d marreur progressif El arrancador suave S801V incluye piezas met licas de montaje tornillos Allen de cabeza hexagonal de 8 1 4 20 x 1 5 y arandelas especiales No las sustituya Consulte la Figura 3 6 que aparece en la p gina 3 6 para conocer las ubicaciones de los orificios del panel Antes de ubicar y montar el arrancador suave se deben considerar los c digos o las normas pertinentes Las cuatro arandelas rectangulares redondas especiales se deben usar en los dos orificios de montaje que se encuentren m s al interior en los lados de l nea y de carga del arrancador suave Drill and tap the eight mounting holes Thread t
80. nobservation de cet nonc pourrait entrainer des degats mat riels au contr leur Aplique s lo 24 V CC al bloque de terminales a menos que se especifique lo contrario en este manual Todo el cableado de control es de 0 33 2 5 mm 22 12 AWG Si no respeta esta precauci n se pueden producir da os graves al controlador N Caution AN Attention N Precauci n Soft Stop is not an emergency stop and cannot make the load stop faster than its normal coast to stop time If removal of control is desired additional control is required to open up the 24V DC to terminal Using terminal P to initiate power removal is not recommended Le ralentissement progressif n est pas une commande d arr t d urgence et ne peut pas servir acc l rer l arr t de la charge par rapport au temps de ralentissement programm Si le retrait de la commande est souhait un contr le suppl mentaire est requis pour ouvrir le 24V CC la borne Il n est pas recommand de commencer couper l alimentation partir de la borne P El modo de parada suave Soft Stop no es una parada de emergencia y no puede hacer que la carga se detenga m s r pido que su tiempo de rodadura libre normal Si se desea desconectar la alimentaci n se requiere un control adicional para abrir los 24 V CD al terminal No es recomendable usar el terminal P para iniciar la desconexi n de la alimentaci n N Caution AN Atte
81. nsor is compared to the saved temperature If the current temperature is 87 or less of the saved temperature a full thermal pile rest is initiated The unit monitors the following condition for overload e Thermal current Overload monitors RMS current with a 5 10 20 or 30 second delay time based on Trip Class setting Table A 3 Protection Settings Protective Features Settings Factory Default Overload FLA Dial Range 32 100 of rated current 32 Trip Class 5 10 20 30 5 Fault Reset Auto Manual Manual Jam On Disable On Stall On Disable On Phase Loss and Load Disconnect On Disable On Phase Reversal On Disable On Overload On Disable On A 6 For more information visit www EatonElectrical com MN03902008E EIN Cutler Hammer IT S801 Soft Starter User Manual June 2006 Appendix B Ratings Cooling and Power Losses Horsepower and kW Ratings Standard Duty Ratings Table B 1 15 Second Ramp 4 Starts per Hour 300 Current Limit 40 C Three Phase Motors kW Rating 50 Hz hp Rating 60 Hz Max 380 200V 230V 460V 575 690V Catalog Current 230V 400V 440V 1 0SF 1 15SF 1 0SF 1 15SF 1 0SF 1 15SF 1 0SF 1 15SF Number Frame Size N 37 10 18 5 18 5 10 10 10 10 25 20 30 30 S801N37N3S 66 18 5 30 37 20 15 20 20 50 40 60 50 S801N66N3S Frame Size R 105 30 55 59 30 25 40 30 75 60 100 75 S801R10N3
82. ntion N Precauci n Soft Stop is not an emergency stop If a quick stop is desired additional control is required to open up the 24V DC to terminal Using terminal P for a quick stop is not recommended Le ralentissement progressif n est pas une commande d arr t d urgence Si un arr t rapide et d sir un contr le suppl mentaire est requis pour ouvrir le 24V CC la borne Il n est pas recommand d utiliser la borne P pour un arr t rapide La parada suave no es una parada de emergencia Si desea una parada r pida se requiere control adicional para suministrar 24 V DC al terminal No se recomienda el uso del terminal P para una parada r pida For more information visit www EatonElectrical com MN03902008E E T N Cutler Hammer June 2006 Cautions continued IT S801 Soft Starter User Manual AN Caution AN Attention N Precauci n Soft Stop does not provide any braking It cannot cause the motor and its load to stop faster than their normal unpowered coast down time Le ralentissement progressif n assure aucun freinage Il ne peut pas servir acc l rer l arr t du moteur et sa charge par rapport au temps de ralentissement programm La parada suave no proporciona ning n tipo de freno No puede hacer que el motor y su carga se detengan con mayor rapidez que su tiempo normal de funcionamiento por inercia AN Caution An Attention N Precauci n
83. o develop additional torque to breakaway a high friction load The kick start torque is programmable from 5 to 85 of motor s across the line locked rotor torque corresponding to 23 to 92 of the motor s across the line locked rotor current The factory default is 5 The kick start time is programmable from 0 0 seconds to 2 0 seconds If no kick start is desired set the kick start torque T1 and kick start time tx to zero Kick Start Tim o 5 g ZS To Bypass tk gt lt tr gt L 1 le Start d Run gt Time Seconds Figure 5 2 Selectable Kick Start Ramp Start This mode of operation is the most commonly used form of soft start The motor is accelerated using an initial torque T2 value of 5 to 85 of across the line locked rotor torque corresponding to 23 to 92 of the motor s across the line locked rotor current The factory default is 35 The torque is then increased over the range of the programmed acceleration ramp start time tr by increasing the motor voltage This can be programmed from 0 5 to 180 seconds The factory default is 9 seconds The first half of the control adjusts from 0 5 to 20 seconds the next quarter from 20 to 60 seconds and the last quarter from 60 to 180 seconds The unit will limit current to the specified torque When the motor is up to speed it will go into bypass 5 2 For more information visit www EatonElectrical com MN03902008E E TN Cutler Hammer
84. o not apply a disconnect device on the output of the IT Soft Starter unless a means to turn off the soft starter when disconnect switch is open is utilized Opening disconnect while the IT Soft Starter is operating may cause a malfunction Closing disconnect switch while the IT Soft Starter is operating will result in a soft starter failure and potential equipment damage and personnel hazard Ne pas appliquer un appareil de sectionnement sur la sortie du demarreur progressif IT a moins qu un moyen d eteindre le demarreur progressif quand l interrupteur de sectionnement est ouvert soit utilis Le fait d ouvrir l interrupteur de sectionnement pendant le fonctionnement du d marreur progressif IT peut entra ner une d faillance Le fait d teindre l interrupteur de sectionnement pendant le fonctionnement du d marreur progressif IT entrainera la d faillance du d marreur progressif et des d g ts l quipement ou risque au personnel No aplique un dispositivo de desconexi n a la salida del arrancador IT Soft Starter a menos que se utilice un medio para apagar el arrancador cuando el interruptor de desconexi n est abierto La apertura del interruptor de desconexi n mientras el arrancador IT est operando puede ocasionar un funcionamiento incorrecto El cierre del interruptor de desconexi n mientras el arrancador IT est operando producir una falla de dicho arrancador como tambi n potenciale
85. only reduces the chance of accidental contact with live cabling e The 12 pin terminal block is detachable for easy wiring 1 2 For more information visit www EatonElectrical com MN03902008E EIN Cutler Hammer IT S801 Soft Starter User Manual June 2006 TR Chapter 2 Receipt Unpacking General Upon receipt of the unit verify that the catalog number and unit options stated on the shipping container match those stated on the order purchase form Inspect the equipment upon delivery Report any crate or carton damage to the carrier prior to accepting the delivery Have this information noted on the freight bill Eaton is not responsible for damage incurred in shipping Unpacking Remove all packing material from the unit Be sure to remove all packing material from lug locations Also make sure no packing material blocks the airflow near the fans For V frame units verify mounting hardware has been included with shipment Check the unit for any signs of shipping damage If damage is found after unpacking report it to the freight company Retain the packaging materials for carrier to review Verify that the unit s catalog number and options match those stated on the order purchase form Storage It is recommended that the unit be stored in its original shipping box crate until it is to be installed The unit should be stored in a location where e The ambient temperature is 58 F 158 F 50 C 70 C e The relat
86. orrection Capacitors Power factor correction capacitors should be installed on the line side of the soft starter It is recommended that at least 10 feet of cable be between the capacitor and the soft starter The power factor correction capacitors can be switched with a separate contactor NEMA ICS2 1988 Part 2 210 81 01 provides recommendations for when a separate contactor should be used to switch the power factor correction capacitor including high inertia loads reversing motors frequently jogged motors and multi speed motors It is not recommended that the power factor correction capacitors be used on the load side of the soft starter If used on the load side the overload relay will measure the combination of capacitor and motor current causing the overload relay to not function correctly AN Attention N Precauci n AN Caution Never megger a motor while it is connected to the IT Soft Starter Disconnect the leads at the IT Ne jamais regler un moteur alors qu il est branche au demarreur progressif IT Debrancher les fils Nunca efect e pruebas del motor con un megohmetro mientras este conectado al arrancador Soft Starter IT Desconecte los cables en el arrancador IT antes de usar el megohmetro au demarreur progressif IT Avant de regler le moteur Soft Starter before meggering the motor MN03902008E For more information visit www EatonElectrical com C 3 IT S801 Soft Starter User Manual EIN
87. oursuivre l installation Despu s de montar la unidad retire y elimine la argolla de izada y los pernos de embalaje antes de continuar con el proceso de instalaci n For more information visit www EatonElectrical com MN03902008E E T N Cutler Hammer June 2006 44 WARNING AVERTISSEMENT REMOVE LIFTING EYE BEFORE WIRING NOT AN ELECTRICAL CONNECTION CAN CAUSE SEVERE INJURY DEATH OR DAMAGE EQUIPMENT RETIRER LOEILLET DE LEVAGE AVANT DE CABLER PAS UNE CONNEXION ELECTRIQUE PEUT CAUSERDES BLESSURES GRAVES LA MORT OU DES DOMMAGES A L QUIPEMENT Figure 3 1 Warning Tag IT S801 Soft Starter User Manual MN03902008E For more information visit www EatonElectrical com 3 3 IT S801 Soft Starter User Manual E TN Cutler Hammer June 2006 Dimensions i POHOA 3 O E 00000 li E E E 3 B q 6 28 6 87 E g 1745 Eloo gt ald 159 6 ogh UN Figure 3 2 N Frame 65 mm Approximate Dimensions in Inches mm 27 6 8 Typ 4 Places 1v E 4 37 eo A b 111 0 g A
88. ower Supply 480V AC 24V DC oo O fe T T i Terminal HG l E Board MX Jog P Lem Ge 1 Inputs FA 2 24V DC Only Jog MX 3 l 1 o Ce 4 Internal n yy Reset 13 Auxiliary gt lt Run Contact Run 14 24V DC Start or 2 3 95 120V AC olo O 96 No Internal Stop D T T HC 98 Auxiliary MX Diode Fault Contact ll J di CAUTION Ha Applying voltages other than yx Diode 24V DC to terminals P thru 4 may cause serious damage Alarm to soft start control board Figure 3 14 Basic Connection Diagram Using 95 96 Trip Contacts for Soft Starter with START STOP RESET JOG with 24V DC Alarm and Run Indication See Notes on Page 3 18 MN03902008E For more information visit www EatonElectrical com 3 17 IT S801 Soft Starter User Manual EIN Cutler Hammer June 2006 Notes 1 Aminimum of wire of 14 AWG 2 5 mm should be used between the power supply and the 24V DC and terminals 2 See Using an Auxiliary Relay section on Page 3 21 if it is desired to use a relay instead of an indicating lamp for terminals 13 14 95 96 and 98 3 If an isolation or reversing contactor is used upstream of the S801 Eaton recommends that the user choose the edge level sensing option Each diagram illustrates a typical wiring scheme for the options described The terminal block represents the soft starter The additional Cutler Hammer items shown on the diagrams are not included but can be purchased from Eaton 24
89. pernos de embalaje antes de continuar con el proceso de instalaci n AN Caution AN Attention N Precauci n The S801V soft starter weighs approximately 100 Lbs 45 kg To prevent personal injury or equipment damage use proper lifting equipment such as a floor crane to safely lift and install the soft starter A lifting eye is provided at the line end of the soft starter Le d marreur progressif S801V pese environ 45kg 100 livres Pour viter des blessures corporelles ou des d g ts mat riels utiliser une machine de levage appropri e comme une grue d atelier pour soulever et installer le d marreur progressif sans encombre Un ceillet de levage est pr vu au c t ligne du d marreur progressif El arrancador suave S801V pesa aproximadamente 45 kg 100 Ib Para evitar que se produzcan lesiones personales o da os al equipo use el equipo para elevar adecuado como un brazo de elevaci n a fin de levantar e instalar con seguridad el arrancador suave Se proporciona una argolla de izada en el extremo de del arrancador suave MN03902008E For more information visit www EatonElectrical com 3 1 IT S801 Soft Starter User Manual E T N Cutler Hammer June 2006 Notice Avis Aviso The S801V soft starter includes mounting hardware 8 1 4 20 x 1 5 Allen hex head cap screws and special washers Do not substitute for this hardware See Figure 3 6 on Page 3 6 for pa
90. port Center at 1 800 356 1243 or visit our web site at www EatonElectrical com Service and repair is available from Eaton or several factory authorized regional service centers Please contact Eaton s Product Integrity Center at 800 345 0434 for the location nearest to you For field service or start up assistance 24 hours a day 7 days a week please call 800 498 2678 MN03902008E For more information visit www EatonElectrical com 9 1 IT S801 Soft Starter User Manual EIN Cutler Hammer June 2006 9 2 For more information visit www EatonElectrical com MN03902008E E T N Cutler Hammer June 2006 EsP Appendix A Protection Thermal Overload IT S801 Soft Starter User Manual The IT Soft Starter features an electronic motor overload protection feature This is intended to protect the motor and power wiring against overheating caused by excessive current for extended periods of time Note Short circuit protection must be applied on the line side of the soft starter Entering the motor full load current rating using the FLA current adjust dial programs trip current It is programmable from 3296 100 of the unit s rated current Table A 1 Overload Adjustment Settings Catalog FLA Current Frame Size Number Range N S801N37N3S 11 37 S801N66N3S 20 66 R S801R10N3S 32 105 S801R13N3S 42 135 d S801T18N3S
91. r A dual voltage motor should be wired into the appropriate configuration for the line voltage it is being applied to Refer to the motor nameplate for the correct wiring information The soft starter must be selected for the appropriate line voltage Multi Speed Motor Some motors have multiple windings to allow operation at different base speeds The multiple speeds are sometimes utilized for soft starting and other times for a process requirement of the machine to which it is attached If only one speed is required the motor should be wired for that speed If multiple speeds are required the appropriate contactors will need to be connected to the output of the soft starter The contactors must be in the selected speed position before the soft starter is started The motor must be stopped and the soft starter turned off before the speed selection contactors are changed C 2 For more information visit www EatonElectrical com MN03902008E E T N Cutler Hammer June 2006 IT S801 Soft Starter User Manual Other Winding Configurations Motors with other winding configurations designed for specific characteristics should be wired in a fashion consistent with their intended use The motor nameplate contains information on the available configurations The motor winding configuration chosen must be appropriate for the available line voltage The soft starter must also be selected on the basis of the configuration chosen Power Factor C
92. r 10 minutes The fans will also be turned on whenever the IT is started stopped or jogged The fans will remain on for 10 minutes to assure the SCRs are adequately cooled prior to the next start If a temperature is sensed above a second preset level a Pole Over Temperature Fault will occur This fault cannot be reset until the temperature returns to a safe level Note The fans will only operate if 24V DC is applied to the and terminals Cycling power during the 10 minute timeout after a start stop or jog will reset the fans to off Power Losses The following table lists the maximum power loss for each IT Soft Starter when it is operating in the across the line mode with its bypass contactor pulled in These losses should be used in conjunction with the losses of another cabinet mounted device to determine the enclosure size and any cooling requirements Table B 8 Maximum Power Loss Frame Catalog Current Across the Line Size Number Range Losses Watts N S801N37N3S 11 37 30 S801N66N3S 20 66 33 R S801R10N3S 32 105 47 S801R13N3S 42 135 55 T S801T18N3S 56 180 37 S801T18V3S S801T24N3S 75 240 40 S801T24V3S S801T30N3S 95 304 45 S801T30V3S U S801U36N3S 112 360 76 S801U42N35 131 420 92 S801U50N3S 156 500 116 V S801V36N3S 112 360 56 S801V36V3S S801V42N3S 131 420 64 S801V42V3S S801V50N3S 156 500 78 S801V50V3S S801V65N
93. rabaje en equipos en funcionamiento a menos que sea absolutamente necesario Si un procedimiento de soluci n de problemas requiere que el equipo permanezca encendido todo el trabajo lo debe realizar personal adecuadamente calificado respetando las pr cticas de seguridad y las medidas preventivas correspondientes 4h Warning 4h Avertissement 4h Advertencia After mounting the unit remove and discard the lifting eye and packaging bolts before continuing with the installation process Apr s que l appareil sera support enlever et jeter les ceillets de levage et les boulons de l emballage avant de poursuivre l installation Despu s de montar la unidad retire y elimine la argolla de izada y los pernos de embalaje antes de continuar con el proceso de instalaci n 4h Warning 4h Avertissement 4h Advertencia Make sure you read and understand all of the safety statements in the safety section of this manual before you begin troubleshooting S assurer de bien lire et comprendre les nonc s de s curit dans le passage de s curit de ce manuel avant de commencer le d pannage Antes de comenzar a solucionar problemas aseg rese de leer y comprender todas las indicaciones de seguridad que aparecen en la secci n de seguridad de este manual MN03902008E For more information visit www EatonElectrical com IT S801 Soft Starter User Manual E T N Cutler Hammer June 200
94. rs Unit does not provide galvanic isolation Always disconnect input power before servicing the starter or motor Il peut exister une tension de ligne potentielle aux bornes de charge du moteur bien que le d marreur soit dans en tat d arr t Cela s explique du fait de fuites possibles travers les redresseurs au silicium Le produit ne fournit pas l isolement galvanique Toujours d brancher l alimentation avant de travailler sur le d marreur ou le moteur Aun con el motor desactivado puede haber voltaje de l nea en los terminales de la carga del motor Esto se debe a una posible fuga a trav s de los tiristores La unidad no brinda aislamiento galv nico Desconecte siempre la alimentaci n antes de trabajar sobre el arrancador o el motor Notice Avis Aviso Power factor capacitors Do not connect power factor correcting capacitors to the load side of the starter They will cause the starter to fail If capacitors are used they must be connected to the line side of the starter as far upstream as possible Condensateurs de compensation Ne pas raccorder ces appareils au c t charge du d marreur Cela entrainera la d faillance du d marreur Si des condensateurs sont utilis s ils doivent tre raccorder au c t ligne du d marreur aussi loin amont que possible Capacitores correctores del factor de potencia No conecte estos capacitores del lado de la carga del arrancador Esto oca
95. s multiply the scale value for t by 2 to determine the actual time setting with the factory default being 0 0 seconds These adjustments are application dependent and should be made to minimize any surge or water hammer effects Typically t would not be set short since the stop might not differ much from a coast to stop The soft stop time adjustment may often be in the range of 30 to 40 seconds but needs to be set appropriately for the system requirements If reduction or elimination of water hammer is not achieved it may be necessary to lengthen t to achieve the desired result Note that long stop times will result in greater motor heating than shorter stop times This can affect the number of start stop cycles allowed per hour due to the IT Soft Starter or motor thermal limits Coast to Stop 100 Speed ts Soft Pump Stop Time Seconds Figure D 2 Pump Start Ramp and Soft Pump Stop The t adjustment is tapered to provide for easier setting of both long and short times The first half of the control adjusts from 0 5 to 20 seconds the next quarter from 20 to 60 seconds and the last quarter from 60 to 180 seconds The t adjustment is linear with a time scale twice that shown in the CIM Extended Ramp Option This option allows for a longer ramp acceleration time of 0 5 to 360 seconds The Extended Ramp option is a factory installed option designated by the tenth character in the Catalog N
96. s applied to the motor Go to Figure 8 1 Troubleshooting Flowchart 1 2 The IT Soft Starter trips during start up or fails to reach rated speed before going into bypass Go to Figure 8 1 Troubleshooting Flowchart 1 3 The IT Soft Starter trips or stops running during normal running conditions Go to Figure 8 1 Troubleshooting Flowchart 1 4 None of the above situations match the problem Go to Figure 8 2 Troubleshooting Flowchart 2 What is the condition of the status LED Green Consult Consult Status LED Off Status LED Green Table 8 1 Table 8 2 Are there any red LEDs No on the CIM Consult Consult Fault Shown on CIM Fault Not Shown on CIM Table 8 3 Table 8 5 Figure 8 1 Troubleshooting Flowchart 1 8 2 For more information visit www EatonElectrical com MN03902008E E TN Cutler Hamme r IT S801 Soft Starter User Manual Yes Consult Appropriate Symptom Table Does the unit run even intermittently Is the IT Soft Starter Status LED Lit y y Excess N F Noise Vibration IT Sn Stair in Motor Bypass Fails to Close Chatters U Other Symptom Not Listed Unit Will Consult Not Stop Status LED Off Running Table 8 1 Consult Figure A 1
97. s da os a los equipos y riesgo para el personal viii For more information visit www EatonElectrical com MN03902008E E TN Cutler Hammer June 2006 Dangers continued IT S801 Soft Starter User Manual Danger High Voltage Danger Haute Tension Peligro alto voltaje Hazardous voltage can cause electric shock and burns Always disconnect power before proceeding with any work on this product Une tension lectrique dangereuse peut causer des chocs lectriques et des br lures Il faut toujours d brancher l alimentation lectrique avant de travailler sur ce produit Voltajes peligrosos que pueden causar descargas el ctricas y quemaduras Siempre desconecte la energ a el ctrica antes de efectuar cualquier trabajo en el equipo Danger High Voltage Danger Haute Tension Peligro alto voltaje Do not work on energized equipment unless absolutely required If troubleshooting procedure requires equipment to be energized all work must be performed by properly qualified personnel following appropriate safety practices and precautionary measures Warnings Ne pas travailler sur d quipement sous tension sauf si c est absolument n cessaire Si des m thodes de d pannage exigent que l quipement soit sous tension tout travail doit tre faire par du personnel qualifi suivant des pratiques de s curit et des mesures de pr caution appropri es No t
98. set feature is used CAUTION must be exercised to assure that any restart occurs in a safe manner 3 20 For more information visit www EatonElectrical com MN03902008E EIN Cutler Hammer IT S801 Soft Starter User Manual June 2006 Using an Auxiliary Relay The IT Soft Starter contains one Form A and one Form C set of auxiliary contacts to indicate its status A contact between terminals 13 and 14 indicates when the IT is in bypass The contacts between terminals 95 and 96 and 95 and 98 indicate the T is in a normal or tripped state Often these contacts are used as shown in Figures 3 9 through 3 14 with indicating lamps In some installations the user may wish to use an electromagnetic relay for indication of the status at a remote location for use by a programmable controller PLC or in a 120V AC or 24V DC control circuit If the IT Soft Starter is subject to mechanical shock during operation it is possible that these contacts may momentarily open causing nuisance fault tripping of down stream devices When used with an indicating lamp a momentary contact opening would not be observed In order to assure proper application it is suggested that the following recommendations be followed PLC Interface It is suggested that a 20 mS delay be programmed to assure the contact status before a change of status is indicated The application and the environmental issues will determine the exact requirements 24V DC Control When
99. sionar la falla de este ltimo Si se usan capacitores deben conectarse del lado de la l nea del arrancador tan lejos de la entrada como sea posible For more information visit www EatonElectrical com vii IT S801 Soft Starter User Manual E TN Cutler Hammer Dangers Warnings Cautions and Notes Dangers June 2006 A Danger High Voltage Danger Haute Tension Peligro alto voltaje Hazardous voltage can cause electric shock and burns To avoid shock hazard disconnect all power to the controller motor or other control devices before any work is performed on this equipment Failure to do so will result in personal injury death or substantial property damage Une tension lectrique dangereuse peut causer des chocs lectriques et des br lures Pour viter des chocs lectriques d brancher l alimentation du contr leur du moteur ou des autres appareils de contr le avant d y effectuer du travail Linobservation de ces instructions entra nera des blessures corporelles graves la mort ou des d g ts mat riels substantiels Voltajes peligrosos que pueden causar descargas el ctricas y quemaduras Para evitar descargas el ctricas desconecte la alimentacion del controlador del motor u otros dispositivos de control antes de efectuar cualquier trabajo en el equipo El incumplimiento de estas medidas ocasionara lesiones personales la muerte o da os importantes al material D
100. st half of the pot adjusts from 0 5 to 20 seconds the next quarter from 20 to 60 seconds and the last quarter from 60 to 180 seconds The maximum value of t can be modified at the factory for special orders applications Contact Eaton for more information o 3 5 100 B e o ypass l l Initial l Torque T2 tr e Le Start JL Run gt Time Seconds Figure 6 4 Programming the Ramp Start Sequence MN03902008E For more information visit www EatonElectrical com 6 5 IT S801 Soft Starter User Manual EIN Cutler Hammer June 2006 Programming the Current Limit Start The process for programming with the Current Limit Start Figure 6 5 is similar to the process for the Ramp Start To select the Current Limit Start option move the dip switch to the right This will activate the current limit start up profile In the current limit startup mode you set a maximum current during the start This value T2 can be set from 5 to 85 of the across the line locked rotor torque See Table 6 1 Page 6 4 for values Next set the start time t for the start This value can be set from 0 5 to 180 seconds Note The ramp time is set to zero automatically At the end of the ramp the motor should be at full speed If the motor is at 90 of rated speed or greater of this value and current is less than 2 x FLA the bypass contacts will then close and the unit will run at full speed If it has not rea
101. tage is removed from the motor The ramp down time is programmable from 0 to 60 seconds The factory default is 0 seconds The voltage is gradually reduced over the ramp down time ts slowing the motor and its load Percent Voltage 100 Coast to Soft Stop le Run Time Seconds T bh Soft Stop gt Figure 5 5 Soft Stop Note This is not an electronic brake function and cannot make the load stop faster than its normal coast to stop time This feature can only extend the stop time In some applications the motor will come to a stop in less than the selected ts time if ts is set too long Soft Pump Stop The pump control option is addressed in Appendix D AN Caution AN Attention N Precauci n Soft Stop is not an emergency stop and cannot make the load stop faster than its normal coast to stop time If removal of control is desired additional control is required to open up the 24V DC to terminal Using terminal P to initiate power removal is not recommended Le ralentissement progressif n est pas une commande d arr t d urgence et ne peut pas servir acc l rer l arr t de la charge par rapport au temps de ralentissement programm Si le retrait de la commande est souhait un contr le suppl mentaire est requis pour ouvrir le 24V CC la borne Il n est pas recommand de commencer couper l alimentation partir de la borne P El mo
102. uired to open up the 24V DC to terminal Using terminal P for a quick stop is not recommended Le ralentissement progressif n est pas une commande d arr t d urgence Si un arr t rapide et d sir un contr le suppl mentaire est requis pour ouvrir le 24V CC la borne Il n est pas recommand d utiliser la borne P pour un arr t rapide La parada suave no es una parada de emergencia Si desea una parada r pida se requiere control adicional para suministrar 24 V DC al terminal 4 No se recomienda el uso del terminal P para una parada r pida AN Caution AN Attention N Precauci n Soft Stop does not provide any braking It cannot cause the motor and its load to stop faster than their normal unpowered coast down time Le ralentissement progressif n assure aucun freinage Il ne peut pas servir acc l rer l arr t du moteur et sa charge par rapport au temps de ralentissement programm La parada suave no proporciona ning n tipo de freno No puede hacer que el motor y su carga se detengan con mayor rapidez que su tiempo normal de funcionamiento por inercia The soft stop feature has one setting ramp time t programmable from 0 to 60 seconds If t is setto 0 when a stop command is given the bypass contacts will open and the de energized motor will coast to a stop as if connected to an electromagnetic starter If t is set longer than this coast down time the soft stop output voltage wil
103. umber Standard Ramp S801 IT Soft Starters have an S as their tenth character S801 IT Soft Starters with the Extended Ramp option have an L as their tenth character as in S801XXXX3L Note that long ramp times will result in greater motor heating than shorter ramp times This can affect the number of start stop cycles allowed per hour due to the IT Soft Starter or motor thermal limits Installation Install and wire your IT Soft Starter per the instructions found in the beginning of this manual Set up the soft starter per the instructions found in Chapter 7 of this manual D 2 For more information visit www EatonElectrical com MN03902008E Company Information Eaton s electrical business is a global leader in electrical control power distribution and industrial automation products and services Through advanced product development world class manufacturing methods and global engineering services and support Eaton s electrical business provides customer driven solutions under brand names such as Cutler Hammer Powerware Durant Heinemann Holec and MEME which globally serve the changing needs of the industrial utility light commercial residential and OEM markets For more information visit www EatonElectrical com Eaton Corporation is a diversified industrial manufacturer with 2005 sales of 11 1 billion Eaton is a global leader in electrical systems and components for power quality distribution and control flu
104. vailler sur d quipement sous tension sauf si c est absolument n cessaire Si des m thodes de d pannage exigent que l quipement soit sous tension tout travail doit tre faire par du personnel qualifi suivant des pratiques de s curit et des mesures de pr caution appropri es No trabaje en equipos en funcionamiento a menos que sea absolutamente necesario Si un procedimiento de soluci n de problemas requiere que el equipo permanezca encendido todo el trabajo lo debe realizar personal adecuadamente calificado respetando las pr cticas de seguridad y las medidas preventivas correspondientes We highly recommend that you read this entire section of the manual before you begin to troubleshoot the T Soft Starter You may want to obtain the following equipment to aid you in troubleshooting e Multimeter e Clamp on ammeter Always assume the S801 has high voltage applied and take proper precautions while troubleshooting the soft starter and associated equipment Read all precautions at the front of this manual before starting the troubleshooting process MN03902008E For more information visit www EatonElectrical com 8 1 IT S801 Soft Starter User Manual EIN Cutler Hammer June 2006 Define the Problem There are four basic problem types you may encounter with the S801 To begin select the situation below that most closely matches your problem 1 The IT Soft Starter fails to start No power i
105. voltage and motor torque without the need for additional circuitry An in sight disconnect means should be installed per local code The IT Soft Starter must be wired into the three phase line feeding the three main motor input leads as would be done for normal across the line starting It must not be wired internally between motor windings in an inside the delta configuration If an inside the delta starting configuration is desired please contact Eaton for details about our inside the delta soft starters designated S801 D Part Winding Motor The part winding motor is another design created to help achieve a soft start to the load A part winding motor is constructed of two separate but parallel windings When using a traditional starter the first winding would receive full voltage This winding supplies as much as 400 of the motors FLA about 45 starting torque in a delta configuration for motor start up After a timed delay full voltage is applied to the second winding The second winding acts in parallel with the first to provide for normal running current Part winding motors are available in both a wye and delta configuration dependent upon the manufacturer Refer to the motor nameplate for the correct wiring information In this case wire the two windings in parallel The soft starter is then used to control the current applied to the motor An in sight disconnect means should be installed per code requirements Dual Voltage Moto
106. www EatonElectrical com MN03902008E EIN Cutler Hammer IT S801 Soft Starter User Manual June 2006 Table B 3 15 Second Ramp 4 Starts per Hour 300 Current Limit 50 C Three Phase Motors kW Rating 50 Hz hp Rating 60 Hz Max 380 200V 230V 460V 575 690V Catalog Current 230V 400V 440V 1 0SF 1 15SF 1 0SF 1 15SF 1 0SF 1 15SF 1 0SF 1 15SF Number Frame Size N 34 9 15 18 5 10 7 1 2 10 10 25 20 30 25 S801N37N3S 63 15 30 33 20 15 20 20 40 40 60 50 S801N66N3S Frame Size R 96 25 45 55 30 25 30 30 75 60 75 75 S801R10N3S 120 33 63 63 40 30 40 40 75 75 100 100 S801R13N3S Frame Size T 150 45 80 90 50 40 50 50 100 100 150 125 S801T18N3S S801T18V3S 215 63 110 132 60 60 75 60 150 150 200 150 S801T24N3S S801T24V3S 278 80 147 160 75 75 100 75 200 200 250 250 S801T30N3S S801T30V3S Frame Size U 320 90 160 185 100 75 125 100 250 200 300 250 S801U36N3S 380 110 200 220 125 100 150 125 300 250 350 300 S801U42N3S 460 140 250 280 150 125 150 150 350 300 450 400 S801U50N3S Frame Size V 320 90 160 185 100 75 125 100 250 200 300 250 S801V36N3S 380 110 200 220 125 100 150 125 300 250 350 300 S801V42N3S 460 140 250 280 150 125 150 150 350 300 450 400 S801V50N3S 610 185 315 375 250 150 200 200 500 450 600 500 S801V65N3S S801V65V3S 680 200 375 445 200 250 200 600 500 700 600 S801V72N3S S801V72V3S 830 257 450 500 300 300 700 600 900 700 S801V85N3S S801V85V3
107. your JT Soft Starter per the instructions found in the beginning of this manual The pump control option is enabled by the S F ENABLE DISABLE DIP switch located on the control interface module CIM To enable this feature position this switch in the ENABLE position When the pump control is enabled the RAMP START CURRENT LIMIT DIP switch is disabled The default becomes RAMP START See Figure D 1 ss TRIP O Cutler Hammer EMA72 OVERLOAD ON DISABLE JAM O ON DISABLE STALL O ON DISABLE PH LOSS O ON DISABLE PH REV O ON DISABLE MANUAL RESET AUTO RESET S F ENABLE DISABLE CURRENT LIMIT OVLD 5 10 20 30 1 TRIP TRIP H 5 Ti Bo 5 T2 85 O CLASS pc ncc AL FLA eee TIME Sec Made in U S A Figure D 1 T Soft Starter CIM MN03902008E D 1 For more information visit www EatonElectrical com IT S801 Soft Starter User Manual EIN Cutler Hammer June 2006 Adjustment All of the adjustments to the IT Soft Starter are made as noted in the user manual The major difference between the standard IT Soft Starter and one with the pump start option is the special algorithm for gentle start and stop with centrifugal flow loads to minimize the potential for water hammer Tr located on the CIM adjusts the start ramp It has a range of 0 5 to 180 seconds The factory default is 9 seconds The soft stop time is adjusted by t which has a range of 0 0 to 120 second

Eaton IT S801 Soft Starter User Manual

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