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XLD User Manual

1. 27 203 112 255 175 044 550_ 285 201 115 255 175 Xpritexipioe as ss 128 044 Xi Hs0toxip 250 38 152 312 12 044 165 10 159 9 028 xipo to 1 323 243 123 313 18 044 243 133 373 044 443 303 123 24 044 Xipi5 0X D 3006 502 363 55 43 04 NEMA aX pauvre _ _157 122 19 028 24 24 329 225 25 05 36 169 345 285 05 550 as 36 169 465 345 05 721 FloorMounted lt B gt c gt LN C gt Motortronics XLD Series Digital Solid State Soft Starter 39 1250A Chapter 3 Motor Overload Protection 3 1 Solid State Overload Protection The XLD Series Starter provides true U L listed Thermal Overload Protection as a built in function of the main digital processor For maximum protection it simulates the tripping action of a bimetallic overload relay with the accuracy and repeatability of a digital control system yet is adjustable over a wide range and can be easily programmed for different trip curves 3 1 1 Thermal Memory
2. The XLD Series microprocessor uses a sophisticated Thermal Register to keep track of motor heating and cooling over time regardless of the starter s power status The XLD Series does not forget that the motor has been running even if power to the starter is turned off and back on Continuous overload protection is provided based on the true thermal condition of the motor 3 1 2 Thermal Capacity The Thermal Register is displayed as a percentage This percentage is the motor s remaining thermal capacity The percentage value begins at 100 showing that the motor is cool As the motor heats up or moves toward an overload condition the percentage begins to drop The Thermal Capacity is derived from the programmed motor nameplate Full Load Amps FLA in Function F001 the Service Factor rating in Function F002 and the Overload Trip Class in Functions 2003 and F004 Setting these functions to the proper values will provide maximum protection yet eliminates nuisance tripping 3 1 2 a Motor Full Load FLA Setting Use Function F001 to enter motor FLA as indicated on the motor nameplate Do not calculate for service factor this is programmed separately in 2002 Note If F001 is left at the factory default the unit will not operate If the user attempts to start the XLD without entering the motor nameplate FLA into this Function the XLD will Fault and the display will read nFLA for no Full Load Amps 3 1 3 Disabling the Overload P
3. 24 XLD Series Kick Start Digital Solid State Soft Starter 39 1250A 5 5 4 Kick Start Mode Note Do not use the Kick Start feature unless you determine that you need it Usingthis feature may eliminate many of the mechanical and electrical benefits of using a Soft Starter F022 Kick Start Factory Setting 0 Disabled Range 0 1 Kick start applies a pulse of voltage to the motor to produce a momentary kick of high torque to break the motor load free from high friction or frozen components When F022 1 this voltage pulse begins the initial voltage applied in either F011 or F015 Voltage level is adjusted by F023 and the time duration of the pulse is adjusted by FO24 F023 Kick Voltage Factory Setting 65 Range 10 100 Sets the voltage level of the Kick Start feature The setting of F023 should be higher than F011 and F015 and high enough to provide benefit in the worst starting condition F024 Kick Time Factory Setting 0 8 seconds Range 0 1 2 seconds Sets the duration of time the Kick Start voltage is applied 5 5 5 Decel Mode Deceleration is a feature of the Soft Starter which slowly decreases the applied voltage to the motor when a stop command is given resulting in a gentle decrease in motor torque Deceleration provides a way to extend the stopping time so that abrupt stopping does not occur Deceleration is useful with centrifugal pumps material handlers and conveyors whe
4. 5 3 1 Status Display Mode The Status Display Mode displays three phase motor current information and the thermal capacity remaining Status mode 0000 The initial display on power up is four digits and the decimal This indicates the motor current for Phase A of the motor 0000 Scroll up to display four digits only no decimal This indicates the motor current for either Phase B or C While viewing Phase A press the UP arrow once to view Phase B or twice to view Phase C current H000 Scroll up to display the H This indicates that this value is the remaining thermal capacity of the motor as a percentage i e 70 7096 remaining thermal capacity Reading Phase Current and Thermal Capacity See Example 0120 Indicates that Phase A is drawing 120 amps Press the UP arrow EBEN phase 0121 Indicates that Phase is BAS drawing 121 amps Press the UP arrow EB SIME Phase NOTE Decimal points are not AE present in the readouts 0120 Phase for Phase B and Phase C 0120 Indicates that Phase C is HOS ee Thermal drawing 120 amps Display Press the UP arrow Reading Phase Current H051 Indicates that the motor has and 51 of its thermal capacity Thermal Capacity remaining 5 3 2 Program Mode Use the Program Mode to view or change Function Fn settings To enter the Program Mode press the Fn key once The first time you enter Program Mode after power has been c
5. Programming a higher NEMA Class overload during start ramp up will eliminate nuisance tripping in higher inertia or high friction loads The starter s At Speed detection circuit determines when the motor has reached full speed based on closed loop feedback signals When the At Speed condition is reached the overload trip curve will shift from the Start to the Run level as programmed in Functions F003 and F004 See Section 5 for programming details Motortronics XLD Series Digital Solid State Soft Starter 39 1250A XLD Series Overload Trip Curves 1 000 100 Time in Seconds Class 30 Class 25 Class 20 Class 15 Class 10 Class 5 LL Ep M Note Factory default setting is Class 10 for both Start and Run Overload Protection Motortronics 9 XLD Series Digital Solid State Soft Starter 39 1250A Chapter 4 Connections 4 1 Power Connections TB1 120V Control Power Source 120V Control Power Return Unit comes standard with 120VAC control Order 240VAC control as an option if required Connect appropriate power lines to the unit input terminals marked L1 L2 L3 Avoid routing power wires near the control board Connect the motor leads to the unit terminals marked T1 T2 T3 Refer to NEC standards for wire length and sizing Never interchange input and output connections to the unit This could cause e
6. Relay Contacts All the relay contacts are FORM C common N O N C except the optical triac output Motortronics recommends fusing all contacts with external fuses TB2 is the terminal block for all auxiliary contacts Each contact is explained in the following sections See Chapter 9 for main control board layout Programmable Relays Three programmable relays are on TB2 which is located on the main control board The relays are rated for 240 5 and 1200 VA Factory settings for these relays are AUX 1 Run Stop F050 1 AUX 2 At Speed Stop F051 2 AUX 3 Any Trip F052 14 Motortronics 11 XLD Series NO NC C NC C NC Programmable Programmable Programmable lay 1 Relay 2 Relay 3 AUX2 Optical Triac Driver F050 F051 F052 RUN STOP SPEED FAULT M 240 VAC 5 A 1200 VA TB4 Common Dual Ramp NO Fault Signal 240 VAC 50 mA Interlock Digital Solid State Soft Starter 39 1250A 4 2 6 Fault Signal An optical AC switch triac driver is used for fault indication This signal energizes with the fault LED The optical output is rated for 240 VAC 50 mA maximum 4 2 7 Resetting Faults To reset faults press the RESET key on the keypad 4 2 8 Enabling the Jog Function Closing Pins 1 and 2 will enable the Jog feature A contact closure between Pins 3 and 5 is also required
7. amp Code Description Explanation Probable Cause Solution Ref Short Circuit Trip Probable cause 1 If SCA occurs immediately upon Start command circuit functioned as Toe in the Water protection Current during the first 1 4 second was disproportionate to the applied test voltage injected at that time Check load conductors for cuts or damage Check motor connections for shorts Megger motor windings and repair as necessary 2 If SCA trip occurs later during acceleration current exceeded 9x starter max amp rating for 12 5 milliseconds Motor windings may have a high Over resistance short Megger motor and repair as necessary Current Over Current during Acceleration Start mode Over Current during Short Circuit Trip Electronic Fuse protection Current exceeded 9x Constant Speed Run mode starter max amp rating for 12 5 milliseconds Probable cause 1 Motor windings or load conductors are shorted phase to phase or phase to ground Megger and repair as necessary 2 Possible multiple shorted SCRs but not in a combination that allows a current path to the motor when off see Shunt Trip above Test SCRs as per section 8 2 and replace as necessary None No Full Load Amps Motor nameplate Full Load Amps FLA was not entered by the user P Starter will not operate without this information See section 3 1 None Reset Reset of fault condition is successful The starter is ready for the next N A Start command Attempted
8. the input on TB4 Pins 1 and2 If this input is left open the XLD will ignore all Jog settings The Jog feature provides an output from the SCRs only while this input is closed It will not continue ramping to full acceleration This feature can Jog the motor at either a preset Voltage or a preset Current Selection of either Voltage or Current Jogging follows the selected Ramp Profile The Jog mode is determined then by F010 above and whether you have selected ramp 1 or ramp 2 See the table below for Function numbers relating to the Jog Function in each Ramp Profile Dual Ramp Input Open Dual Ramp Input Closed Ramp 1 2 F010 Initial Jog Torque Initial Jog Torque Setting Reference Torque Reference 4 F019 Voltage Jog Factory Setting 50 Range 5 100 Sets the voltage level of the Jog feature typically is used to check rotation alignment or to slowly move a load into position Jogging at a set voltage has no current control so the duration of the applied voltage must be limited to prevent excessive motor heating 2020 Time of Voltage Jog Factory Setting 10 seconds Range 1 20 seconds Set to minimize motor heating during a voltage jog This setting is the maximum allowable time for jogging the motor 2021 Current Jog Factory Setting 150 Range 100 500 Sets output of a current Jog The jog feature is typically used to check rotation alignment or slowly move a load into position Motortronics
9. this feature when acceleration time is not critical To achieve Voltage Ramping with Current Limit set the Ramp Profile F010 to 0001 or 0003 Voltage Ramp and the Maximum Current Limit setting F014 to a desired lower setting as determined by your applications requirements 3 Current Ramping Closed Loop Torque Ramping is good for smooth linear acceleration of output torque Output voltage is constantly updated to provide this linear current ramp and therefore the available torque is maximized at any given speed The best use of this feature is for applications where rapid changes in torque may result in load damage or equipment changes Examples would be long overland conveyors where belt stretching may occur fansand mixers where blade warping is a problem material handling systems where stacked products may fall over or break Motortronics 47 XLD Series Digital Solid State Soft Starter 39 1250A This feature can be used with or without the Maximum Current Limit setting achieve Current Ramping with the XLD set the Ramp Profile F010 to 0002 or 0004 Current Ramp and the Maximum Current Limit setting F014 to the desired level 4 Current Limit Only Current Step starting means using the Current Limit feature exclusively without the benefit of soft starting by ramping the voltage or current first This will maximize the effective application of motor torque within the limits of the motor In thi
10. 0 Use this function only for emergency restart Motor damage may result 120V control power is available at TB1 terminals 1 and 6 220V on special order units If this light is not on check the following 1 Main power is available if a Control Power Transformer is supplied 2 Control power is off or fuse is blown If fuse is blown check for shorts in the control circuit 3 Cable to the display is connected Output current display Decimal point after the last digit indicates Phase A See section 5 3 for more details If the value does increase after a Start command is given check the following 1 The factory installed jumper on TB1 between terminals 2 and 3 has been removed and no external sensing device is wired to them See section 4 3 for additional information 2 An external device as described above is wired and is preventing a Start command from working Correct the external problem Current has dropped and stabilized The XLD uses closed loop monitoring of the output current curve to determine when the motor has reached full speed If this light does not come on after a Start command the probable causes are 1 The current limit setting is too low and is not allowing the motor to accelerated to full speed Overload is imminent Stop the motor and adjust the current limit setting 2 Mechanical problems are preventing the current from stabilizing long enough to be detected Examples are Check valves undulating load
11. 0 Range 50 100 of Unit Max Current Set the value of this function to the motor nameplate Full Load Amps FLA Adjustments for service factor are not necessary when programming this function See note below If the motor nameplate FLA is not available use typical values as shown in NEC NEMA standard MG 1 or other reputable third party source motor manufacturer etc Note To prevent adjusting the settings beyond the starter Max Amp rating the range of adjustment for the Motor Nameplate FLA will vary to reflect the Service Factor as programmed into F002 At the default setting of 1 0SF the full range of adjustment from 50 100 6 of the Max Amp rating is available For example 2002 1 15 to reflect 1 15SF the maximum FLA programmable into F001 will be limited to 85 of the starter Max Amp rating 100 15 Motortronics 20 XLD Series F002 F003 F004 F005 2006 Digital Solid State Soft Starter 39 1250A Service Factor Factory Setting 1 0 S F Range 1 00 1 30 Set value according to the Service Factor SF data provided on the motor s nameplate This value affects several protection features so it must be accurate Setting the SF too high may result in motor damage in overload conditions Setting SF too low may cause nuisance trips Overload Class During Start Factory Setting 10 Class 10 Range 5 30 NEMA UL Class Set value to the motor protection overload class requi
12. Disabled AUX 1 AUX2 AUX3 Optical Triac Driver con Teatures F050 F051 F052 240 VAC 50 mA RUN STOP AT SPEED FAULT e MB F065 F070 All Time Values Eastern Standard Time Standard Time Motortronics 33 a 9 240 VAC 5 1200 VA XLD Series 4 VOLTAGE gt Digital Solid State Soft Starter 39 1250A 6 2 Start up Check List 6 3 INITIAL TORQUE RUN CURRENT Sequence of Operation e Supply voltage matches the rated supply voltage of the unit Horsepower and current ratings of the motor and unit match or the unit is higher rating nitial ramp time and torque adjustments have been checked Power lines are attached to the unit input terminals marked L1 L2 and L3 Motor leads are connected to the lower terminals marked T1 T2 and T3 Appropriate control power is applied and or control connections have been made Power on light located on the front of the unit turns on when control power is applied Four seven segment LED readouts are visible The motor s FLA has been programmed in function F001 e The thermal overload is properly set Use F003 and F004 to set OL Class The motor area and equipment are clear of people and parts before start up Sequence of Operation Apply three phase power to the unit The motor should run only when the start command is applied Apply control power and check that t
13. Protection Functions Adjustment Setting Factory Group Function Range Increments Setting 50 100 of starter Max Amp rating Upper limit of range automatically adjusts downward as Service Factor is increased Motor Nameplate Service Factor 1 00 1 30 0 05 1 0 5 5 30 UL Class Overload Class During Start Overload Time Trip Curve za Class 10 Em 5 30 UL Class Overload Class During Run Overload Time Trip Curve Class 10 0 Overload Reset 1 1 0 Manual 5 5 1 2 Disabled Overload 5 4 2 Starting Mode Functions A Adjustment Setting Factory Group Function Range Increments Setting Ramp Select Range is 1 4 Setting to 1 Ramp 1 VR Ramp 2 VR Setting to 2 Ramp 1 CR Ramp 2 CR Setting to 3 Ramp 1 VR Ramp 2 CR Setting to 4 Ramp 1 CR Ramp 2 VR Section 0 Starter disabled until set to FLA Motor Nameplate FLA Motor FLA must be programmed for proper unit operation Motor and Overload Section 1 VR1 VR2 VR Voltage Ramp CR Current Ramp 200 600 nai Accel Ramp Time of Ramp 2 1 120 seconds Max Current Limit of Ramp 2 200 600 note1 350 5 4 3 Jog Mode Functions Group Function Adjustment Setting Factory Section Increments Setting 5 1 Voltage Jog Starting Mode Note 1 Current percentages are based on Motor
14. Replacing SCR Devices 8 4 Replacing Printed Circuit Board Assembly Chapter 9 Printed Circuit Board Layout 9 1 Typical Wiriing Diagram 9 2 Power Board and CPU Board PC Board Assembly Appendix 1 Ramp Profile Details Appendix 2 Decel Mode Application Considerations Appendix 3 Parameter Lock User Password Instructions Appendix 4 Soft Starter Settings Warranty Policy XLD Series Digital Solid State Soft Starter 39 1250A Chapter 1 Introduction 1 1 General The XLD Series is a digitally programmable solid state reduced voltage soft starter Its six SCR design features a voltage current ramp with an anti oscillation circuit for smooth load acceleration The SCRs are sized to withstand starting currents of 50096 for 60 seconds compared to 850 for 30 seconds from other manufacturers The XLD Series features smooth stepless ramp control which reduces motor inrush current and excessive wear on the mechanical drive train components In addition to having easy to understand diagnostic LEDs the XLD Series includes a programmable keypad for setting operating parameters for the ideal starting cycle Starting torque ramp time current limit dual ramp and decel control are standard features on the XLD Series By simply adjusting the unit s starting torque ramp time and current limit functions the starting electrical characteristics of the motor can be matched to the mechanical characteristics of the drive train f
15. Series depending on the horsepower amperage rating of the unit Isolated SCRs are used smaller units and hockey puck type SCRs are used in larger units Refer to Chapter 9 for the main control board layout Changing an Isolated SCR Remove both line and control power from unit tag and lock out WARNING Failure to remove both line and control power before starting this procedure may cause personal injury or death Label the location of wires connected to the SCR Remove the mounting screws lugs and associated wiring from the existing SCR Make sure the surface to which the power module mounts is clean and free from dirt nicks and scratches Apply thermal grease uniformly along the grooved area Spread the grease thinly 3 mil thick to completely cover the base of the power module and minimize air pockets The grease must be free of contamination Replace the screws and tighten down firmly All mounting screws should be 44lb in Units with a maximum amperage rating of up to 48A should use 26 Ibs in busbar and power lugs Units with maximum amperage of 60A 120A should use 44 Ibs in busbar and power lugs Reconnect all busbars lugs and wires Check to make sure the gate and cathode are wired correctly Use the following chart to verify the wiring of J5 J6 and J7 After verifying that all wiring is correctly connected test the SCR Destination Board Pin Main Circuit Load cathode Outp
16. action is not possible Probable cause 1 The starter is in the Run mode The starter must be in the Stopped None Inhibited mode before changes can be entered 2 The parameter that is being entered has been locked out with the Over Current during Deceleration Stop mode Customer Password See section 5 5 9 for details Multiple Faults Indicates the rare occurrence of multiple simultaneous faults The LEDs associated with those faults should illuminate The Coast Down Lock Out timer has been enabled by the user and the None Coast Down Lock Out time has not yet expired when a Start command is given See section F039 F040 5 5 6 for details The Starts per Hour Lock Out timer has been enabled by the user and SHLo None Start per Hour Lock Out the time has not yet expired when a Start command is given See section 2041 F042 5 5 6 for details The Time Between Starts Lock Out timer has been enabled by the user None Time between Starts Lock Out and the time has not yet expired when a Start command is given See F043 F044 section 5 5 6 for details Any one of the above Lock Out Protection features is preventing None Lock Out Timer engaged operation until the timer expires See section 5 5 6 for additional details F040 F044 Remaining time values are located at F045 F048 PASS Noe Successful password entry Customer password was entered and accepted Parameter lock is now F060 released All user functions can be accessed Nona Password
17. assembly Recommended Transformer Sizes Up to XLD 180 50 VA 100 VA 250 VA XLD 220 50 VA 100 VA 500 VA XLD Model by Amps Recommended Transformer Sizes for Control Power Note If power is used for additional accessory items Lights fans etc contact factory for sizing Motortronics XLD Series Digital Solid State Soft Starter 39 1250A 4 2 2 Three Wire Connection 4 2 3 4 2 4 4 2 5 For standard 3 wire control connect 120VAC to pins 1 6 of TB1 Connect normally closed stop button between pins 3 and 4 TB1 Connect normally open start button between pins 4 and 5 of terminal block TB1 Jo 1 1 LS Start Interlock Stop Control Control Power Power Source Return Three Wire Connection Two Wire Connection An alternate connection for unattended operation replaces start stop push buttons by connecting a maintained contact closure between pins 3 and 5 on TB1 When the maintained contact is used for start stop it is necessary to set the overload relay to the manual reset position This will prevent the motor from restarting if the thermal overload trips and then cools off Warning When two wire connection method is used the user s control circuit must be interlocked to prevent automatic restart when protective devices reset Refer to section 3 1 3 b Interlock Start Control Contact Control Power Power Source Return Two Wire Connection
18. begin to rotate while preventing torque shock damage to mechanical components Accel Ramp Time of Ramp 2 Factory Setting 10 seconds Range 1 120 seconds Sets the time between the initial torque set with F015 or F016 and either the Max Current Limit set with F014 or full output voltage Set time to enable soft starts without stalls Also consider your motor s application For example centrifugal pumps may require a shorter time See notes under F013 for more details Motortronics 23 XLD Series iQ Time 20 sec Voltage Jog Jog Current Setting Ramp 1 Current Ramp Current Jog Digital Solid State Soft Starter 39 1250A 2018 Max Current Limit Ramp 2 Factory Setting 350 Range 200 600 Sets the maximum motor current that the XLD Starter will allow during ramp 2 This limit applies to both voltage and current type ramping Current will be limited to this setting until either the motor reaches full speed or the over load protection feature trips 2003 Current percentages are based on the Motor FLA as programmed in F001 Once the motor has reached full speed the current limit feature is inactive Section 5 5 3 Jog Mode Caution Continuous use of the Jog feature either the voltage type F019 or the current type F021 risks thermal motor damage or nuisance tripping The Jog Function is another user optional feature and is controlled by closing
19. damaged Remove the faulty SCR device noting the direction in which the SCR is oriented The new SCR puck must be inserted in the same direction Make sure the SCR mounting surface tools and hands are clean and free from dirt nicks and scratches Do not sand or scrape SCR mounting surface If necessary super fine Scotch Brite pads can be used to clean the heatsink before installing the new SCR Apply a thin 3 mil thick layer of thermal grease uniformly along both sides of the SCR Spread the grease to cover the entire surface of both sides of the SCR in a manner that minimizes air pockets The grease must be free of contamination Locate the centering pin in the bottom and top of the heatsink and center it in the SCR hole making sure that the SCR is pointed in the same direction as the SCR that was removed in step 6 Locate the centering pin in the top heatsink and center it in the SCR hole Caution If center pin is not placed correctly it will damage the SCR and the heat sink Hand tighten the clamps evenly so that the same number of threads appear at both ends of the U clamp Tighten the clamp 1 4 turn at a time alternating sides of the U clamp until the correct force is reached Check the gauge or spin washer every time the clamp nuts are tightened 1 4 turn to ensure that the SCR is not over torqued The gauge reading should be similar to the initial reading taken in step 2 If the clamp uses the spin washer gauge verify
20. date time fault in F078 was detected Fault History 3 Oldest Fault Factory Setting 0000 Range NA Displays 2 digit fault number See Chapter 7 Time Stamp Fault 3 Factory Setting 00 00 Range HH MM where HH 00 23 and MM 00 59 Displays time fault in F081 was detected Date Stamp Fault 3 Factory Setting 01 01 Range MM DD where MM 01 12 and DD 01 31 Displays date time fault in F081 was detected Functions F084 through F087 display information from the Run Time Elapsed Time meter and Run Cycle counter Run time includes Accel Run Decel and Jog operations Run Time Hours Factory Setting 0000 Range 000 9 999 9 hours Run counts in excess of 999 9 are recorded in F085 Run Time K Hours Factory Setting 0000 Range 0000 9999 K hours 0001 in readout means a run time of 1 000 hours F086 Run Counts Factory Setting 0000 Range 0000 9999 Run counts in excess of 9999 are recorded in F087 F087 Run Counts 10K Times Factory Setting 0000 Range 0000 9999 10 thousand times 0001 in readout means a run count of 10 000 operations Motortronics 394 XLD Series Digital Solid State Soft Starter 39 1250A Chapter 6 Start up 6 1 Quick Start Your new XLD Series So t Starter is factory preset for a wide variety of applications and often can be used with minimal adjustment 6 1 1 Three Step Process Interlock Stop Start Control Control Po
21. during Constant Speed Run mode Digital Solid State Soft Starter 39 1250A FnList Explanation Probable Cause Solution Ret Over Current Trip based on user settings This protection is not enabled until the very end of the Accel ramp OCA Trip may indicate a Stalled Motor condition Observe motor acceleration and correct problem or increase the trip settings Over Current Trip based on user settings Probable cause 1 Shear Pin trip to protect against mechanical damage Correct mechanical problem or adjust trip delay settings to match conditions 2 Shock Load i e a sudden increase in torque requirements Check load problem or adjust trip delay settings to match conditions 3 Possible short circuit at levels lower than faults 25 27 Check load wiring and or motor windings 2033 F035 Current in at least one phase is less than 20 of unit rating This protection is disabled for the first 3 seconds of ramp time to allow current to increase Usually indicates miswiring of a Bypass Contactor Power is not passing through current transformer Refer to Appendix 4 for correct wiring Current in at least one phase is less than 20 of unit rating Probable cause 1 Line power loss on one phase Check line voltage power fuses etc 2 Load conductor is disconnected or open without shorting Check continuity 3 Miswiring as described above if ramp time is set below 3 seconds Heat sink temperature exceede
22. in which to dissipate The sound of that shock wave is referred to as Water Hammer The energy in that shock wave can be Check Valve extremely damaging to pipes fittings flanges seals and mounting systems Closes Slowly By using the Soft Stop deceleration feature of the XLD the pump output torque is gradually and gently reduced which slowly reduces the pressure in the pipe When the Output Pressure is just slightly lower than the Head TET TNT Pressure the flow slowly reverses and closes the Check Valve By this time Closed there is very little energy left in the moving fluid and the Shock Wave is avoided When the output voltage to the motor is low enough to no longer be needed the XLD will end the Decel cycle and turn itself off Another common application is on material handling conveyors as a means to prevent sudden stops that may cause products to fall over or to bump into one another In overhead crane applications Soft Stopping of the Bridge or Trolley can prevent loads from beginning to over swing on sudden stops Volts 9 Output to Motor Stop Command 100 from control system BDL Begin Decel Level F026 6096 Decel Shut Off Level F027 30 Decel Ramp Time F028 Motortronics 50 XLD Series Digital Solid State Soft Starter 39 1250A Appendix 3 Parameter Lock User Password Instructions F060 Parameter Lock User Passw
23. is a One Shot feature so when another value is entered as shown below this function automatically returns to the default state When F061 1 the values stored in the Thermal Register and all of the Lockout Timers will be cleared This will allow an emergency restart without having to wait for proper cool down time or lockout timers to expire WARNING Clearing the Thermal Register to allow restarting without proper cool down time after an Overload Trip will risk motor damage and fire Use only where emergency restart is necessary without regard to these potential hazards When F061 2 the values of all functions will be reset to the factory default settings Use this feature when settings conflict or have been tampered with This is also useful when you lose track of experimental settings and wish to start over Note This will not reset F060 Parameter Lock User Password F062 Reserved F063 z Reserved for Factory Use F064 z Reserved for Factory Use Motortronics 30 XLD Series Digital Solid State Soft Starter 39 1250A 5 5 9 a Real Time Clock Settings Functions F065 through F070 set the system real time clock The time clock is primarily used in date time stamping Fault History Time clock automatically adjusts for leap years Time clock does not automatically adjust for daylight savings time F065 Year Factory Setting Year of manufacture Range 2000 to 2047 F066 Month Factory Setting Mo
24. surges severe belt stretching etc Stop the motor and adjust ramp parameters to accommodate mechanical systems If the motor continues to accelerate check the following 1 Motor rotors bars laminations or frame are defective Have motor tested by a qualified repair shop 2 Loose motor connection usually picked up by Phase Imbalance but not if it is not enabled by user Check connections and repair replace If the motor does not accelerate or breaker trips power fuses blow check the following 3 Remove power and check SCRs as per section 8 2 Pay particular attention to the gate to cathode integrity as outlined in the instructions If defective replace SCRs 4 If all other tests do not identify the problem the main control board assembly must be replaced Motortronics 39 XLD Series Digital Solid State Soft Starter 39 1250A 8 2 SCR Testing Procedure Remove both line power and control power from the unit and lock out Disconnect any two motor load leads and any two line leads Disconnect the SCR connections to main control board J5 J6 and J7 Refer the Chapter 9 for the main control board layout Note the type of color coding of the wires connected to J5 J6 J7 Motortronics uses two possible configurations Both configurations have 4 wires going to each plug The first configuration consists of 4 wires color coded black yellow grey and white The second configuration consists of 4 wires color coded
25. 10 of FLA for more than 2 seconds the starter will trip Over Current Shear Pin Trip Factory Setting 0 Disabled Range 0 1 If F033 1 Enabled starter will trip when the output current of any phase exceeds the amount set with F034 for the time specified with F035 Can be referred to as a Shear Pin Trip and can be used to protect mechanical components from breaking due to jammed loads Over Current Trip 96 Factory Setting 125 Range 100 300 Use to set the trip level for an over current condition for any phase Percentage is based on FLA F001 setting Motortronics 26 XLD Series Time Under Current Trip F036 1 fun time Time coast Down rime Down Time Off 5 4 Coast Down Backspin Lockout F035 F036 F037 F038 F039 F040 F041 F042 Note Digital Solid State Soft Starter 39 1250A Over Current Trip delay Factory Setting 1 second Range 1 20 seconds Provides a time delay to prevent nuisance trips from short duration transients Using default settings if the output current of any phase exceeds 125 of FLA for more than 1 second the starter will trip Under Current Trip Factory Setting 0 Disabled Range 0 1 If 2036 1 Enabled starter will trip when the output current of any phase drops below the amount set with F037 for the time specified with F038 Fault condition is ofte
26. 60 Range 0 100 of line voltage Use to drop voltage to a level where there is a noticeable effect on motor torque during decel mode Decel Shut Off Voltage Factory Setting 3096 Range 0 to BDL 1 Sets the level where motor torque during decel is no longer effective Always set this function lower than the setting of F026 Begin Decel Level Decel Ramp Time Factory Setting 10 seconds Range z 1 60 seconds Sets the maximum time for the deceleration ramp to go from the Begin Decel Level setting F026 to the Decel Shut Off Voltage F027 Since motor heating increases as voltage is lowered the setting should not exceed the time necessary to achieve the deceleration effect F029 Reserved 5 5 6 Protection Features F030 F031 F032 F033 F034 Current Imbalance Trip Factory Setting 0 Disabled Range 0 1 If F030 1 Enabled starter will trip when the output current between any two phases exceeds the amount set with F031 for the time specified with 2032 Current Imbalance Trip 96 Factory Setting 10 Range 5 30 Use to setthe trip level for current imbalance between any two phases Percentage is based on FLA F001 setting Current Imbalance Trip Delay Factory Setting 2 seconds Range 1 20 seconds Provides a time delay to prevent nuisance trips from short duration transients Using default settings if the difference in output current between two phases exceeds
27. A second ramp profile is available for use should you need it but unless wired to do so the XLD defaults to Ramp 1 This section describes functions for Ramp 1 with references to function numbers that do the same thing for Ramp 2 if required Refer to Appendix 2 for a detailed description of the differences in Ramp Profiles and their uses F010 F010 Profile Ramp Profile Selection Factory Setting 1 Range 1 4 This Function selects the type of Ramp Profile desired Ramp profiles can be either Voltage Ramp or Current Ramp See Appendix 2 for details Each Ramp Profile consists of 3 settings Initial Torque Ramp Time and Maximum Current Limit Because there are two ramps available there are 4 settings to cover the combinations of profiles possible you are not using the 2nd ramp the XLD will ignore all settings in reference to Ramp 2 Select Voltage Ramp by setting F010 1 factory default When Voltage Rampis selected Set Initial Torque with F011 see below Set Ramp with F013 see below Set Maximum Current Limit with F014 see below Or Select Current Ramp by setting F010 2 When Current Ramp is selected Set Initial Torque with F012 see below Set Ramp Time with F013 see below Set Maximum Current Limit with F014 see below Ramp Type 1 2 Voltage Voltage 2 CurentRamp CurentRamp Setting 2 Selection Voltage Ramp 2011 F012
28. Full Load Amps FLA as entered in F001 Motortronics 17 XLD Series Digital Solid State Soft Starter 39 1250A 5 4 4 Kick Start Mode Functions Group Function Adjustment Setting Factory Section Range Increments Setting 1 5 0 Disabled 1 Enabled 5 4 5 Decel Mode Functions Adjustment Setting Factory Group Function Range Increments Setting 1 Kick Start 0 Disabled Kick Start Section O Disabled Coast to Stop 1 Enabled except in event of OL Trip 2 Enabled continued Decel on OL Trip 5 4 6 Protection Features djust t ttin Factor 5 Group Function Adjustmen Setting aSa y Section Range Increments Setting 1 5 0 Disabled 1 Enabled 0 Disabled Current Imbalance Trip Delay 1 20 seconds Over Current Shear Pin Trip uu 0 Disabled 5 5 6 Deceleration Ramp 0 Disabled Current Imbalance Trip Over Current Shear Pin Trip 96 50 300 note1 125 Over Current Trip Delay 1 20 seconds Under Current Trip 0 Disabled Under Current Trip Delay 1 60 seconds Coast Down Lockout Timer 0 Disabled 5 5 6 1 Enabled Coast Down Lockout Time 1 60 minutes 0 Disabled Starts per Hour Lockout 1 Enabled 5 5 LL c 5 2 o 2 5 5 6 0 Disabled 5 5 6 2 5 5 6 6 Disabled 5 5 Time Between Starts Lockout 0 Disabled 1 Enabled coast Down Timer vae 1 9600Seoonds Vewow o 558 Stans
29. Reset If Automatic Reset is necessary change from Manual Reset to Automatic Reset by using Function F005 See Section 5 for details In this mode a 3 wire control circuit will be capable of restart when the XLD Series has reset itself after the cool down period Warning Two wire control systems may restart without warning when Auto Reset is selected Extreme caution should be exercised To prevent automatic restarting with two wire control systems use external interlocking to provide sufficient warning and safety to operators A Warning Label such as the one provided in the packet with this manual must be placed to be visible on the starter enclosure and or the equipment as required by local code WARNING MOTOR CONNECTED TO THIS EQUIPMENT MAY START AUTOMATICALLY WITHOUT WARNING 3 2 NEMA Class Trip Curves The XLD Series Soft Starter provides six NEMA Class trip curve options 5 10 15 20 25 and 30 Program the appropriate curve according to the characteristics of your motor and load NEMA Class trip curves are based on a common tripping point of 60096 of rated current Curves vary by the amount of time before the unit trips As an example a Class 20 curve will trip in 20 seconds at 600 The factory default setting of Class 10 will trip in 10 seconds at 600 3 2 1 Dual Overload Trip Curves The XLD Series Soft Starter provides two separate Overload Trip Protection Curves one for starting and one for running conditions
30. Starts Per Hour Time Between Starts and Any Lockout Note 1 Enabled via programming Motortronics 32 XLD Series Digital Solid State Soft Starter 39 1250A 1 2 Specifications and Performance Features Cont d Metering Functions Phase Currents Remaining Thermal Capacity Elapsed Time Run Cycle Counter Lockout Time Values Remaining time of any enabled lockout timer Fault Codes Abbreviated fault codes indicating trip and operating mode Fault History Last 3 faults with Time and Date Stamps Serial Communications Protocol Modbus RTU Signal RS 485 Network Up to 247 devices per mode Functionalit Full operation status view and programming y via communications port Operator Interface LED Readout 4 digit alpha numeric high brightness 7 segment display Keypad 7 functions keys with tactile feedback Status Indicators 8 LEDs Remote Mount Capability Up to 10 feet 3 meters from chassis Clock and Memory Operating Memory DRAM loaded from and at initialization Factory Default Storage Flash field replaceable Customer Settings and Status Non volatile no battery backup necessary Real Time Clock Lithium ion battery for clock memory only 10 years life span Motortronics 3 XLD Series Chapter 2 Installation 2 1 2 2 2 3 2 4 Digital Solid State Soft Starter 39 1250A Receiving Unpacking Upon receipt of the product you should immed
31. Voltage Ramp Initial Voltage of Ramp 1 Factory Setting 60 Range 0 100 Sets the initial voltage of ramp 1 when F010 1 or 3 The initial torque level should be set to provide just enough torque to make the motor shaft begin to rotate while preventing torque shock damage to mechanical components Initial Current of Ramp 1 Factory Setting 200 Range 0 600 Sets the initial current of ramp 1 when F010 z 2 or 4 Current percentages are based on the Motor FLA as set in F001 The initial torque level should be set to provide just enough torque to make the motor shaft begin to rotate while preventing torque shock damage to mechanical components Motortronics 22 XLD Series Initial Current F013 014 F015 F016 F017 Digital Solid State Soft Starter 39 1250A Accel Ramp Time 1 Factory Setting 10 seconds Range 1 120 seconds Sets the time between the initial torque set with 2011 F012 and either the Max Current Limit set with F014 or full output voltage Set time to enable soft starts without stalls Also consider your motors application For example centrifugal pumps may require a shorter ramp time Note Ramp time is affected by the following conditions 1 Current limit will extend the ramp time if the motor does not reach full speed while in current limit mode 2 Anti oscillation circuit will shorten the ramp time if the motor reaches full speed be
32. W MOTORTRONICS Solid State AC Motor Control XLD SERIES Digital Solid State Soft Starter 39 1250 A INSTALLATION amp OPERATION MANUAL REV2 1 01032601MN 2012 Phasetronics Inc dba as Motortronics Table of Contents XLD Series Digital Solid State Soft Starter 39 1250A Chapter 1 Introduction 1 1 General 1 2 Specifications and Performance Features Chapter 2 astra tup iniurias 2 1 Receiving and Unpacking 2 2 Location 2 3 Initial Unit Inspection 2 4 Warning 2 5 Mounting and Cleaning 2 6 Power Terminal Wire Range and Tightening Torque 2 7 Dimensions Chapter 3 Motor Overload Protection 3 1 Solid State Overload Protection 3 2 NEMA Class Trip Curves Chapter 4 Connections 4 1 Power Connections 4 2 Control Connections 4 3 Interlock Connection Chapter 5 Programming 5 1 Introduction 5 2 Digital Interface 5 3 Display Modes 5 4 Function List 5 5 Function Descriptions Chapter 6 Start Up sssssiumunannsnnanennaaus 6 1 Quick Start 6 2 Start up Check List 6 3 Sequence of Operation Chapter 7 Fault Conditions 7 1 Fault Codes and Numbers In History Chapter 8 Troubleshooting 8 1 Failure Analysis 8 2 SCR Testing Procedure 8 3
33. as reached full speed the Current Limit feature becomes inactive In the Voltage Ramp Profile the Voltage output is increased until the Current Limit is reached The Ramp Time is the maximum time it will take for the voltage to increase until the Current Limit setting takes over Under some load conditions Current Limit may be reached before the Ramp Time has expired In the Current Ramp Profile output voltage varies to provide a linear increase in current up to the Current Limit setting and Ramp Time is the time that it will take to getthere Aclosed loop feedback of motor current allows continuous updating of the output to maintain this ramp profile Because most induction motors will not start below 200 current the current limit set point is adjustable down to only 200 Use this feature to prevent voltage drop in your electrical supply portable emergency generator stalling or to satisfy utility restrictions on starting power Caution While the XLD is in Start mode there is no maximum Current Limit time Excessive start time may however lead to motor stalling causing an Overload Trip If this happens try raising the Current Limit setting to accommodate your load conditions If the Current Limit setting cannot be increased try using Current Limit without ramping features Current Limit Only as described previously Motortronics 49 XLD Series Digital Solid State Soft Starter 39 1250A Appendix 2 Decel Mode A
34. ction an auxiliary Shunt Trip relay shoul be be programmed for Shunt Trip and should be interlocked with a shunt trip breaker or in line contactor In the event of a shunt trip do not re power the unit without repairing the power poles Shorted SCR has been detected in the unit Refer to section 8 2 for instructions on checking SCRs Over Current LED illuminates for two sets of fault conditions over current and short circuit If unit experiences output current of any phase in excess of the value programmed F034 over current trip 95 for the time period specified Over Current in F035 over current trip delay this LED will illuminate and either OCA or will be displayed If unit experiences a short circuit fault condition the Over Current LED illuminates and either SCA SCC or SCd will be displayed This trip is fixed at 10 times the full load motor current and is not adjustable One or more of the phase currents is low or has been lost while the Phase Loss motor was starting or running Over Temp Motor starter has tripped due to heat sink over temperature Starter s motor overload has tripped The overload must be reset before the fault can be cleared Display 4 digit 7 segment display Over Load Motortronics 13 XLD Series Digital Solid State Soft Starter 39 1250A 5 3 Display Modes There are three modes of display the Status Display mode the Program mode and the Fault mode
35. d unit design limits Probable cause 1 Excessive internal heat Check ambient conditions 2 Failed Bypass Contactor Check to make sure contactor closes when At Speed LED lights 3 Blocked ventilation NEMA 1 only Make sure vents are clear of all obstructions and filters if supplied are clean 4 Excessive dirt build up on heat sinks Clean heat sinks regularly or use NEMA 12 model I2T thermal overload has tripped during acceleration start mode Thermal Capacity as determined by thermal register is zero Probable cause 1 Excessive load on motor Change operating conditions or user larger motor 2 Inadequate acceleration settings Increase current limit or shorten ramp time Refer to section 5 5 2 and Appendix 1 3 High friction starting conditions Try using Accel Kick feature see section 5 5 4 4 Overload Trip class during Start F003 is set too low to allow acceleration Change settings to next higher trip class consult motor manufacturer F001 F003 I2T thermal overload has tripped during acceleration start mode Thermal Capacity as determined by thermal register is zero Probable cause 1 Excessive load on motor Change operating conditions or user larger motor 2 Inadequate acceleration settings Increase current limit or shorten F001 F002 ramp time Refer to section 5 5 2 and Appendix 1 F004 3 Motor and or load bearings are failing Check mechanical systems and repair 4 Overload Trip Class durin
36. e during single phase load was turned on or shorted in the same system Check Deceleration Stop mode power supply system or adjust Trip Delay settings F032 to allow for necessary transients n Under Current Trip based on user programmed settings In Start mode Under Current during NO POLES d this trip function is disabled UCA may indicate a load loss at the very end Acceleration Start mode of Acceleration 90 speed or Under Current Trip based on user programmed settings Probable cause 1 Loss of load Check couplings belts or other drive train components Correct load or mechanical problems 2 Loss of Prime on pumps that are not self priming Check seals and Under Current during Constant mechanical systems for leaks and repair Speed Run mode 3 Trip threshold setting is too high for normal operation Adjust F036 F038 sensitivity with F037 4 Load is overhauling especially on conveyors Short duration overhauls can be filtered using Trip Delay setting in F038 Repeated problems may require disabling this protection in F036 Under Current Trip based user programmed settings In Decel mode Under Current during AME this trip function is disabled once the output current drops below 90 of Deceleration Stop mode FLA UCA may indicate load loss at the very beginning of Deceleration Motortronics 37 XLD Series Digital Solid State Soft Starter 39 1250A Fault Fault or i Fn List Code
37. eature Disabling Password Protection Parameter Lockout Changing function F060 to 0000 will disable the user password Motortronics 51 XLD Series Digital Solid State Soft Starter 39 1250A Appendix 4 Soft Starter Settings The following chart may be used to record the changes made to the factory settings Function Revised Motor FLA 20 me smem RE Oo osso me omma F006 F009 No record required me mw LLL SY mw mw 2 TC me ewm meam ___ _ __ me wmem mm me _ __ _ me me ma wm mm mw _______ me omma ES ES _ mw mw mw 2 mw mw eomm _____ RO 2 __ Motortronics 52 XLD Series Digi
38. entry Error The password that you are trying to enter is invalid Check with authorized user personnel for password information The data or setpoint entered into a Function has been accepted and None Successful parameter change stored into memory as the new value is ag have been successfully returned to the Factory Default Motortronics 38 XLD Series Fault or Code Description Tripped Remaining Thermal Capacity XXX will show number value from 000 to 100 Retentive memory has been Cleared Control Power is present Phase A Current Motor has reached Full Speed Motor vibrates or growls Digital Solid State Soft Starter 39 1250A Explanation Probable Cause Solution Control power was cycled and the Start command given while the starter was in a tripped condition The existing fault condition will display after the Start command is removed Thermal capacity remaining in the motor As this number counts down toward zero the motor is approaching an overload condition After Overload Trip occurs this number will increase back toward 100 as the motor cools The value at which an Overload Trip can be reset will dynamically changes as the XLD learns the amount of Thermal capacity that is used on successful start attempts Required Thermal Capacity to start can be displayed F049 After entering a value of 2 into F061 the Thermal Register and all Lock Out Timer values will be cleared reset to
39. fore end of ramp Max Current Limit of Ramp 1 Factory Setting 350 Range 200 600 Sets the maximum motor current that the XLD Starter will allow during ramp 1 This limit applies to both voltage and current type ramping Current will be limited to this setting until either the motor reaches full speed or the over load protection feature trips F003 Current percentages are based on the Motor FLA as programmed in 2001 Once the motor has reached full speed the current limit feature is inactive For Ramp 2 user optional ramp This ramp is selected by closing the input on Terminals TB4 Pins 1 and 3 If this input is left open the XLD will respond only to ramp 1 settings as listed above Since ramp 2 is always used in combination with ramp 1 different combinations of ramp profiles can be selected in F010 Refer to Appendix 1 for additional information Initial Voltage of Ramp 2 Factory Setting 60 Range 0 100 Sets the initial voltage of ramp 2 when F010 1 or 4 The initial torque level should be set to provide just enough torque to make the motor shaft begin to rotate while preventing torque shock damage to mechanical components Initial Current of Ramp 2 Factory Setting 200 Range 0 600 Sets the initial current of ramp 2 when F010 2 or 3 Current percentages are based on the Motor FLA as programmed in 2001 The initial torque level should be set to provide just enough torque to make the motor shaft
40. g Not Applicable Range z 1 3600 Seconds Display for information only value cannot be altered by the user Time Between Starts Lockout Readout only for user s viewing of remaining time value of Starts per Hour Lockout Timer Starts per Hour Factory Setting Not Applicable Range 1 10 Starts Display for information only value cannot be altered by the user Readout only for user s viewing of the accumulated Starts per Hour value used in the Lockout function Time Value Between Starts Factory Setting Not Applicable Range z 1 3600 Seconds Display for information only value cannot be altered by the user Readout only for user s viewing of remaining time value of Minimum Time Between Starts Timer Motortronics 28 XLD Series ug 8 EH Programmable Relay Setting Descriptions Any Lockout 15 17 Digital Solid State Soft Starter 39 1250A F049 Thermal Capacity to Start Factory Setting Not Applicable Range 0 100 Thermal Capacity Display for information only value cannot be altered by the user Readout only for user s viewing of the motor Thermal Capacity percentage required to allow a Reset after an Overload Trip Use this function in conjunction with the Remaining Thermal Capacity to be able to predict when a restart will be allowed This value is automatically updated by the XLD whenever a successful start sequence has been accomplished The XLD essentially learns how much Ther
41. g Run F004 is possibly set too low Change settings to next higher trip class only if motor is rated Motortronics 36 XLD Series Digital Solid State Soft Starter 39 1250A Co Die Explanation Probable Cause Solution I2T thermal overload has tripped during acceleration start mode Thermal Capacity as determined by thermal register is zero Probable cause 1 Excessive load on motor Change operating conditions or user larger motor 2 Inadequate acceleration settings Increase current limit or shorten F001 2002 ramp time Refer to section 5 5 2 and Appendix 1 3 Decel time is set oo long or Stop Voltage is too low Adjust decel 2025 F028 settings or increase motor capacity 4 Back flow back spin prevention device has failed to operate Motor is being spun backwards during Decel mode Check and correct mechanical systems Motor thermal Overload during Deceleration Stop mode Shorted SCR during Acceleration No voltage drop from Line to Load in at least one phase Probable cause Start mode 1 At least one SCR is shorted conducting Test as per section 8 2 and replace 2 One line or load conductor is open broken without shorting Check connections and repair 3 Bypass failed to open one phase upon stop command Check contactor for mechanical problems or welded contacts and repair 4 SSC indicates processor failure since Shorted SCR protection must be Shorted SCR du
42. he Power On LED comes on Verify that the motor s FLA is correctly programmed F001 Apply the start command The motor should begin to accelerate When the motor reaches full speed the At Speed LED comes on f the motor decelerates or stops during the acceleration period hit the stop button immediately and open the disconnect line If the unit does not follow this operational sequence please refer to Chapter 8 Troubleshooting Motortronics 34 XLD Series Digital Solid State Soft Starter 39 1250A Chapter 7 Fault Conditions 7 1 Fault Codes and Numbers in History Fault Code Examples Over Load During Accel Over Current During Accel IL Current Imbalance During Accel History Fault Number Fault Code shown in F075 Trip Event F078 F081 1 OCA 2 OCC 3 Ocd 4 PLA 5 PLC PLd OtA Otc Otd 10 OLA 11 OLC 12 OLd 13 SSA 14 SSC 15 SSd A three character fault code is displayed in the LED display at the time of the trip event For instance if Function F003 overload protection is set too low for the size of the load the code OLA will be displayed Its corresponding number will be entered into the fault history In this case the number 0010 will be available for display in the window of function F075 Fault History The time the fault was detected is available in Function F076 It is expressed as hh mm So if the fault occurred at 10 00 am F076 would disp
43. iately do the following Carefully unpack the unit from the shipping carton and inspect it for shipping damage if damaged notify the freight carrier and file a claim within 15 days of receipt Verify that the model number on the unit matches your purchase order Confirm that the ratings sticker on the unit matches or is greater than the motor s HP and current rating Location Proper location of the XLD Series is necessary to achieve specified performance and normal operation lifetime The XLD Series should always be installed in an area where the following conditions exist Ambient operating temperature Chassis unit to 50 C 32 to 122 F Enclosed unit 0 to 40 C 32 to 104 F Protected from rain and moisture Humidity 5 to 95 non condensing Free from metallic particles conductive dust and corrosive gas Free from excessive vibration below 0 5G Open panel units must be mounted in the appropriate type of enclosure Enclosure size and type must be suitable to dissipate heat generated by the soft starter Contact factory for assistance in sizing enclosures Initial Unit Inspection Make a complete visual check of the unit for damage which may have occurred during shipping and handling Do not attempt to continue installation or start up the unit if it is damaged Check for loose mechanical assemblies or broken wires which may have occurred during transportation or handling Loose electrical connec
44. ion Advanced features must be enabled via programming The only parameter that MUST be set by the user is motor FLA 1 MOTOR FLA F001 must be programmed for unit to operate 5 2 Digital Interface The XLD Soft Starter includes an intuitive digital keypad with eight LEDs seven command keys and an LED display with four alphanumeric digits Clears the trip indicator and releases the trip relay Enters or exits the program mode LI LJ Shunt Shorted Over Phase Navigates through the Status Display Mode scrolls up through the list Trip SCR Current Loss i s me Up Arrow of functions increases the value of an active flashing digit and scrolls through the history of fault conditions Right Arrow Each keypress shifts the active flashing digit to the right one position use to change function number or value Navigates through the Status Display Mode scrolls down through the Down Arrow list of functions decreases the value of an active flashing digit and scrolls through the history of fault conditions Left Arrow Each keypress shifts the flashing digit to the left one position use to change function number or value Read Enter Selects and stores the value of a function Control power is present Green LEDs Motor is at full speed and power At Speed The SCRs have phased fully on Two or more power poles are shorted and current is passing to the motor while in the off mode For positive motor prote
45. lay 10 00 The date the fault occurred is available in Function F077 The date is expressed as mm dd So if the OLA fault occurred on March 1 F077 would display 03 01 If there are no fault conditions in history the display in FO75 would read 0000 For detailed explanation of Fault Codes Fault Numbers Probable Cause and Solution see Chapter 8 Troubleshooting LED Indications Description Over Current During Decel or Stop Phase Loss During Decel or Stop Over Temperature During Decel or Stop Over Load During Decel or Stop no a NA Phase Imbalance Current During Acceleration wa NA Phase Imbalance During Decel or Stop Motortronics 35 XLD Series Chapter 8 Troubleshooting 8 1 Failure Analysis Over Current D A Fault or Code Description Over Current during Acceleration Start mode Over Current during Constant Speed Run mode Over Current during Deceleration Stop mode Phase Loss during Acceleration Start mode Phase Loss during Constant Speed Run mode Phase Loss during Deceleration Stop mode Over temperature during Acceleration Start mode Over temperature during Constant Speed Run mode Over temperature during Deceleration Stop mode Motor thermal Overload during Acceleration Start mode Motor thermal Overload
46. ltage Ramping is the most reliable starting method since at some point the starter will reach an output voltage high enough to allow the motor to draw full current and develop full torque This method is useful for applications where the load conditions change frequently and significantly enough to require different levels of starting torque Examples where this is effective are material handling conveyers positive displacement pumps drum mixers etc Voltage is increased from a starting point Initial Torque to full voltage over an adjustable period of time Ramp Time To achieve Voltage Ramping set the Ramp Profile F010 to 0001 or 0003 Voltage Ramp and the Maximum Current Limit setting F014 to maximum 60096 Since this is essentially Locked Rotor Current on most motors there will be little or no Current Limit effect on the Ramp profile 2 Voltage Ramping with Current Limit works similarly to the above except adds an adjustable maximum current output Voltage is increased gradually until the Maximum Current Limit setting F014 is reached then held at this level until the motor accelerates to full speed This may be necessary in applications where the electrical power is limited Examples would be portable or emergency generator supplies Utility power near the end of a transmission line Utility starting power demand restrictions Using Current Limit will override the Ramp Time setting if necessary so use
47. ly A three inch high quality dry paint brush is helpful to loosen up the dust prior to using compressed air on the unit 2 6 Power Terminal Wire Range and Tightening Torque Model Max Model Number Wire range Torque Ibs in oo SS a a XLD 48 XLD 39 XLD 48 XLD 62 XLD 78 XLD 92 6 250 kcmil 325 Me _ 2 6 250 325 XLD 120 XLD 360 XLD 150 XLD 180 2 2 250 kcmil XLD 220 XLD 288 XLD 360 XLD 414 XLD 476 XLD 550 ZLD TIS 8 2 600 XLD 1150 1150 35 XLD 120 1200 40 4 300 kcmil 800 kemil XLD 125 1250 450 500 1000 1125 XLD 862 Note All wiring must be sized according to NEC standards UPS IA ojojo WE mola Ma 197 19 n 4 gjejn 1 AIO al 60 E gt IN IN e ojojojo jo O1 XLD 100 1006 300 O1 RIO ojo ABI alo ojo XLD 39 XLD 48 XLD 62 XLD 78 XLD 92 XLD 120 XLD 150 XLD 180 XLD 220 XLD 288 XLD 360 XLD 414 XLD 476 XLD 550 XLD 718 XLD 862 Motortronics 5 XLD Series Digital Solid State Soft Starter 39 1250A 2 7 Dimensions Model Overall Mounting Enclosure Dimensions Number Poon es a i ieee eee er
48. mal Capacity is needed in the motor in order to successfully restart and stores the information at this Function 5 5 7 Relays There are three programmable relays rated 240VAC 5A 1200 VA on the XLD Series They can be programmed for change of state indication for any one of the 18 conditions identified in the chart to the left F050 Aux Relay 1 Factory Setting 1 Run Stop Range 1 18 See list Use to program the desired operation for Relay 1 2051 Aux Relay 2 Factory Setting 2 At Speed Stop Range 1 18 See list Use to program the desired operation for Relay 2 2052 Aux Relay 3 Factory Setting 14 Any Trip Range 1 18 See list Use to program the desired operation for Relay 3 F053 F054 Reserved 5 5 8 Communications The XLD Soft Starter features built in serial communications RS 485 hardware and Modbus RTU protocol software The XLD Soft Starter is a passive communication device which responds and or replies to the commands of active host devices such as personal computers SCADA systems PLCs with ASCII ports DCS and other industrial systems F055 Communications Factory Setting 0 Disabled 1 Enabled Range 0 1 When 2055 1 the XLD Soft Starter will communicate with remote monitoring and control systems F056 Baud Rate Factory Setting 9 6 KB Range 4 8 to 19 2 KB Set value to either 4 8 KB 9 6 KB 14 4 KB or 19 2 KB and matchthe setting of the ho
49. n referred to as a Load Loss Trip and can be used to detect a broken drive shaft or belt In pumping applications this can be used as a Loss of Prime trip Under Current Factory Setting 40 Range 10 90 Use to set the trip level for an under current condition for any phase Percentage is based on FLA F001 setting Under Current Trip Delay Factory Setting 2 seconds Range 1 60 seconds Provides a time delay to prevent nuisance trips from short duration transients Using default settings if the output current of any phase drops below 40 of FLA for more than 2 seconds the starter will trip Coast Down Lockout Timer Back Spin Timer Factory Setting 0 Disabled Range 0 1 When F039 1 this function provides a timer which prevents motor restarts for the number of minutes specified in 2040 This function is useful in applications like pump motor backspin where you need to prevent the pump motor from restarting if it is spinning backwards Coast Down Lockout Time Factory Setting 5 minutes Range z 0 60 minutes Sets a minimum amount of time that a starter must be off before a restart can be completed Used in conjunction with F039 Starts per Hour Lockout Factory Setting 0 Disabled Range 0 1 If F041 1 this feature will count the number of start commands within a 1 hour period If the setting of F042 maximum starts per hour is exceeded starting is prohibited until sufficient
50. ng units under warranty at their option All warranty repairs must be performed by the Company factory or on site by factory authorized ser vice firms or personnel approved by the Company Solid state controls have different operating characteristics from those of electromechanical equipment Because of these differences and the wide variety of applications for solid state controls each application designer must verify that the solid state equipment is acceptable for his application In no event will MOTORTRONICS be liable or responsible for indirect or consequential damages resulting from the use or application of this equip ment The diagrams and illustrations in this document are included solely for illustrative purposes Because of the number of different applications MOTORTRONICS can be responsible or liable for actual use based on the examples or diagrams
51. nth of manufacture Range 1 12 F067 Day Factory Setting Day of manufacture Range 1 31 F068 Hour Factory Setting Actual EST Range 0 23 12 00 midnight is hour 0 2069 Minute Factory Setting Actual EST Range 0 59 F070 Second Factory Setting Actual EST Range 0 59 F071 Reserved for Factory Use F072 F074 Reserved 5 5 10 Fault History and Run Time The fault history will store the three last fault conditions plus the date and time that each fault occurred F075 Fault History 1 Latest Fault Factory Setting 0000 Range NA Displays 2 digit fault number See Chapter 7 F076 Time Stamp Fault 1 Factory Setting 00 00 Range HH MM where HH 00 23 and MM 00 59 Displays time fault in F075 was detected F077 Date Stamp Fault 1 Factory Setting 01 01 Range MM DD where MM 01 12 and DD 01 31 Displays date time fault in F075 was detected 2078 Fault History 2 Previous Fault Factory Setting 0000 Range NA Displays 2 digit fault number See Chapter 7 Motortronics 31 XLD Series F079 F080 F081 F082 F083 F084 F085 Digital Solid State Soft Starter 39 1250A Time Stamp Fault 2 Factory Setting 00 00 Range HH MM where HH 00 23 and MM 00 59 Displays time fault in F078 was detected Date Stamp Fault 2 Factory Setting 01 01 Range MM DD where MM 01 12 and DD 01 31 Displays
52. of the following 1 Current limit setting when the motor is still accelerating or 2 Full output voltage if the Current Limit is set to maximum Increasing the Ramp Time softens the start process by lowering the slope of increase in voltage or current This should be set to provide the softest possible start without stalling unless you have determined that your application has other considerations Applications where this setting should be shorter include Centrifugal Pumps because pump problems may occur as a result of insufficient torque during acceleration through the pump curve Note Ramp Time is affected by the following conditions 1 Current Limit will extend the Ramp Time if the motor does not reach full speed while in current limit mode 2 The Anti Oscillation Circuit will shorten the Ramp Time if the motor reaches full speed before end of ramp Current Limit This Function sets the maximum motor current that the starter allows during Ramping It is active in both the Voltage Ramp and Current Ramp modes As the motor begins to ramp this feature will set a ceiling at which the current draw will be held Current Limit will remain in effect until one of the following two events occur Motortronics 48 XLD Series Digital Solid State Soft Starter 39 1250A 1 The motor reaches full speed as detected by the At Speed detection circuit 2 The Overload Protection trips on Motor Thermal Overload see Ch 3 Once the motor h
53. oft Starter 39 1250A Chapter 9 Wiring Diagram amp Printed Circuit Board Layout 9 1 Typical Wiring Diagram KEYPAD A AS OT A POWER BOARD ot CPU BOARD Factory Settings Power Board X1 ON Phase Loss Enabled Remove to disable SES X2 ON Shorted SCR Enabled Remove to disable Tov X3 ON 60 Hz Operation Remove for 50 Hz d d EP INPUTS H 120 VAC TS Factory Calibrated Do not adjust P1 A Phase Current P2 B Phase Current P3 C Phase Current P4 Phase Loss CPU Board X1 Pins 2 amp 3 shorted X2 Removed X3 Pins 2 amp 3 shorted X4 Pins 2 amp 3 shorted J2 Not installed J3 Not installed NOTE 1 CURRENT TRANSFORMER VALUES VARY IN ACCORDANCE WITH MOTOR HORSEPOWER NOTE 2 TB3 IS LOCATED ON THE OPPOSITE SIDE OF THE POWER BOARD FROM THE SHOWN LOCATION NOTE 3 TB1 AND TB2 CONNECTIONS ARE BROUGHT OUT TO A PANEL MOUNTED TERMINAL BLOCK FOR UNITS RATED 150 AMPS AND ABOVE FOR UNITS RATED 120 AMPS AND BELOW CONNECTIONS ARE MADE AT TB1 AND TB2 ON THE MAIN CONTROL BOARD Optional Jumper Selections amp Settings CPU Board Power Board J1 Analog Signals J3 Digital Signals J2 Serial Comm 12C No connec
54. or controlled acceleration of the load The XLD Series includes solid state electronic overload protection in addition to numerous other protective features It is factory wired for 120 VAC control voltage and two or three wire start stop control Units can also be ordered with 240 VAC control voltage if required Programmable auxiliary contacts and provisions for interlocking are also included 1 2 Specifications and Performance Features Type of Load AC Supply Voltage HP Ratings Unit Overload Capacity Percent of motor FLA Power Circuit SCR Diode Ratings Peak Inverse Voltage Phase Insensitivity Transient Voltage Protection Cooling Bypass Contactor Ambient Condition Design Control Auxiliary Contacts Approvals Motortronics ES Three phase AC induction motor 208 600VAC 10 50 60 Hz 39 1250 Amps 10 1125 HP 125 Continuous 50096 60 seconds 60096 30 seconds 6 SCRs 1600V Unit operates with any phase sequence RC snubber dv dt networks on each phase Convection up to 1804 fan assisted 62 120A Fan ventilated 220 1250A Shunt rated contactor included as standard in all NEMA 12 enclosed units 92A and above Also standard with all NEMA 12 combination starters Line start rated contactor available as an option Chassis units 0 to 50 C 32 to 122 F Enclosed units 0 to 40 C 32 to 104 5 95 relative humidity 0 3300 ft 1000m above sea level witho
55. ord Factory Setting 0 disabled Range 0 999 Password 0123 Enabling Password Protection Provides users with the ability to prevent unauthorized operators from making changes to the programmed functions If you do not need to take advantage ofthis feature do not enter anything into this function The factory default is disabled and no Password is necessary to make changes to the program When any value other than 0 is entered into this Function the Parameter Lock is enabled and that number becomes the User Password From that point forward it will be necessary to enter the User Password in this Function prior to making changes in any programmed function including this one When the Parameter Lock has been enabled attempts to alter the program will result in the display reading Err whenever the READ ENTER key is pressed To be able to alter the program after the Parameter Lock has been enabled go to Function F060 and enter the correct user Password When the READ ENTER button is pressed the display will read PASS indicating that the User Password is correct and the system is unlocked You will have 5 minutes in which to make a change in the program This 5 minute window resets whenever any key is pressed so it floats to give you 5 minutes after the last entry After 5 minutes of no keypad activity the Parameter Lock is reinstated with the current user Password Subsequent changes will re
56. per Hour Timer Value 1 3800 Seconds ny o 855 Stans per Hour Count Vae o 558 Tine Value Bemeen Sens Vewony o 1 1 1 1 Motortronics 18 XLD Series Digital Solid State Soft Starter 39 1250A 5 4 7 Relays t t tti Factor 7 Group Function Setting cr Section Aux Relay 1 nr Speisen 1 18 note2 Aux Relay 3 setting Operation 1 18 Note 2 Auxiliary relays can be programmed for any of the following operations 1 Stop 7 Shunt Trip 13 Under Current Trip 2 At Speed Stop 8 OL Trip 14 Any Trip 5 13 3 At Speed End Decel 9 OT Trip 15 Coastdown Time 4 Start End of Decel 10 Short Circuit Trip 16 Starts Per Hour 5 Short SCR Trip 11 Current Imbalance Trip 17 Time Between Starts 6 Phase Loss Trip 12 Over Current Trip 18 Any Lockout 15 17 5 4 8 Communications Grou Function Adjustment Setting Default p Range Increments Setting 0 Disabled 1 Enabled Modbus Address 12247 0 Disabled 5 4 9 System Settings Adjustment Setting Factory 1 0 Disabled 5 5 9 Section Communications Communications Section Range is 0 999 0 Disabled Any Other Number Password Protected Range is 0 2 0 Disabled 1 Clear Thermal Register and Reset Factory Default Settings Lockout Time
57. pplication Considerations Deceleration Soft Stop is a unique feature of Solid State Soft Starters such asthe XLD It provides a slow decrease in the output voltage accomplishing Coasting Stop a gentle decrease in motor torque during the stopping mode This is the using Electro Mech starter OPPOSITE OF BRAKING in that it will take longer to come to a stop than if the starter were just tuned off The primary use of this function is with centrifugal pumps as a means to reduce the sudden changes in pressure that are associated with Water Hammer and slamming of check valves Decel control in pump applications is often referred to as Pump Control Check Valve Open In a pump system liquid is being pushed uphill The force exerted by gravity on the column of liquid as it goes up hill is called the Head Pressure in the system The pump is sized to provide enough Output Pressure to overcome the Head Pressure and move the fluid up the pipe When the pump is turned off the Output Pressure rapidly drops to zero and the Head Pressure takes over to send the fluid back down the hill A Check Valve is used somewhere in the system to prevent this if necessary by only allowing the liquid to flow in one direction The kinetic energy in that moving fluid is suddenly trapped when the valve slams closed Since fluids can t compress that energy is transformed into a Shock Wave that travels through the piping system looking for an outlet
58. quire re entering the User Password To change the User Password or to disable the Parameter Lock function enter the programmed User Password first then set Function F060 to 0 F060 0 disabling the Parameter Lock If you do not re enter the Password or enter a new user password the Parameter Lock feature will remain disabled If you enter a different number into this Function the new number becomes your new User Password The User Password will not be displayed after being entered or at any other time The number displayed after the READ ENTER key is initially pressed is for reference only Caution DO NOT LOSE YOUR PASSWORD If the password has been lost or forgotten contact Motortronics for assistance in retrieving it with authorization Enabling Password Protection Parameter Lock See Example Start from the Status Display Mode Press the Fn key Press the LEFT arrow to select the second digit from the right Press the UP arrow six times 6x to change the function code to F061 Press the RIGHT arrow to select the first digit from the right Press the DOWN arrow to change the function code to FO60 Press the Read Enter key The display should hide the password Use the UP arrow and the LEFT arrow to display the password you desire Valid range is 0000 to 0999 In this example 0123 has been selected Press the Read Enter key The word END should momentarily display to confirm you have enabled the user password f
59. re abrupt stopping could be damaging to the equipment and or load Note Decelis THE OPPOSITE of braking Enabling the Decel feature will make the motor take LONGER to stop than if it were simply turned off See Appendix 2 at the end of this manual for detailed descriptions of typical applications for the Decel feature F025 Deceleration Ramp Factory Setting 0 Disabled Range 0 2 When 025 0 the deceleration feature is disabled When F025 z 1 the deceleration feature is enabled AND the overload protection feature set with F003 and F004 is enabled Even when the stop command is received the starter continues to apply decel voltage However if an overload trip occurs the starter stops applying voltage and the motor coasts to a stop to prevent additional motor heating and potential motor damage When F025 z 2 the deceleration feature is enabled and deceleration will continue even when an overload condition trips WARNING Setting F025 2 presents significant risk of over heating the motor beyond its design limits which could result in motor damage and fire hazard Do this only in circumstances where the potential for mechanical damage outweighs the risk of motor damage Motortronics 25 XLD Series 30 Over Current Trip Setting 250 FLA Time Over Current Trip F033 z 1 F026 F027 z F028 Digital Solid State Soft Starter 39 1250A Begin Decel Level BDL Factory Setting
60. red white red white The testing procedure for SCRs is comprised of two separate tests The first one tests the anode to cathode integrity of the SCR by performing the following ohm checks Lead Lead Good Consult factory L1Lug T1 Lug Greater than 10K ohm Less than 10K ohm L2 Lug Greater than 10K ohm Less than 10K ohm L3 Lug Greater than 10K ohm Less than 10K ohm The second tests the gate to cathode integrity of the SCR Place the leads of an ohm meter into the receptacle that was unplugged from the main circuit board Ohm the pair of wires on one end of the plug Then ohm the pair of wires on the other end of the plug The chart below indicates good versus bad readings For wire that is color coded black yellow gray and white Lead Lead Good Bad Yellow Between 5 and 90 ohms than 90 ohms Less than 5 or greater Grey White Between 5 and 90 ohms than adem For wire that is color coded red white red and white Between 5 and 90 ohms Less thana or greater than 90 ohms Between 5 and 90 ohms Fess greater than 90 ohms Note If any of the above readings are out of specifications replace the faulty SCR Note The best way to test an SCR is with an SCR Tester and look for leakage current less than the manufacturer specified values Motortronics 40 XLD Series 8 3 8 3 1 Digital Solid State Soft Starter 39 1250A Replacing SCR Devices Two types of SCRs are used in the XLD
61. red for the application It is recommended that you try the factory setting first If possible keep values for F003 and F004 the same Increase F003 above F004 only if nuisance tripping occurs during start See Section 3 2 for details on trip curves Overload Class During Run Factory Setting 10 Class 10 Range 5 30 NEMA UL Class Set value according to the instructions provided by your motor equipment manufacturer This trip curve will not be enabled until the motor has reached full speed Overload Reset Factory Setting 0 Manual Range 0 2 Set value to determine starter behavior overload condition has cleared When set to 0 Manual the operator must press the Reset key before restarting the motor Once the motor windings have cooled sufficiently AND the Reset key is pressed the unit will accept a restart command When set to 1 Automatic mode and once sufficient time has elapsed allowing motor windings to cool the motor will be restarted upon a start command WARNING Setting F005 1 Automatic may present significant operational risk When set to 2 Disabled Overload a separate external thermal overload protection device must be in the circuit F009 Reserved Motortronics 21 XLD Series Digital Solid State Soft Starter 39 1250A 5 5 2 Starting Mode The XLD is capable of several different starting modes but is set from the factory for the most common applications
62. ring Stop mode Run mode Current flowing through any CT when the starter is in the Off mode activates this protection feature to prevent motor damage Probable cause 1 Multiple shorted opposing phases that allow a conduction path through the motor windings Test per section 8 2 and St Shunt Shunt Trip Relay has been repair as necessary N A 116 818 Trip activated 2 Bypass contactor failed to open on 2 or more phases upon stop command Check contactor for mechanical problems or welded contacts and repair 3 Internal short circuit improper device connections across line conductors down stream of the CTs Locate short or connections and remove The differential in current between any 2 phases is greater than the Current Imbalance during programmed percentage F031 for a period that is longer than the time in Acceleration Start mode F032 Probable causes 1 Line voltage imbalance or blown fuse may act faster that Phase Loss trip Check line voltages and fuses Correct problem or adjust sensitivity in 2031 current Imbalance during 2 One or more load conductors is open without shorting or has a high F030 F032 Constant Speed Run mode som resistance connection Check wiring and connections for breaks corrosion or loose devices 3 A line voltage transient has occurred 1 or 2 phases i e a large Shorted SSC SCR Shorted SCR during 14 Constant Speed Run mode Current Imbalanc
63. rotection The Overload Protection feature can be disabled if absolutely necessary When using external devices such as Motor Protection Relays or when the XLD Series is wired downstream from an existing starter this feature can be disabled to prevent conflicts with external overload protection devices When the XLD Series is controlling multiple motors Overload Protection must be disabled Individual thermal overload relays must be installed on the motor leads going to each motor To disable the Overload Protection function use F005 See Section 5 Warning Do NOT disable Overload Protection unless another Thermal Overload Protection device exists in the circuit for all three phases Running a motor without Overload Protection presents serious risk of motor damage or fire 3 1 3 a Manual Reset The factory default setting is Manual Reset This means that when the Overload Trip is activated the starter cannot be restarted without pressing the Reset key The Overload Trip will not reset until the motor cools down The Manual Reset function is also trip free Holding in the Reset key will not prevent the Overload Trip from activating and protecting the motor Note When the Overload Trip activates the Overload LED will glow solid When the motor cools down the LED will begin to flash indicating that the Overload Trip can be reset Motortronics 7 XLD Series Digital Solid State Soft Starter 39 1250A 3 1 3 b Automatic
64. rs 1 5 5 9 2 Reset to Factory Default Settings Motortronics 19 Parameter Lock User Password System Settings XLD Series Digital Solid State Soft Starter 39 1250A 5 4 10 Fault History Run Time Adjustment Setting Factory Group Function Range Increments Setting 0 Section 0 1 27 Fault see Fault code list 0 No fault history uc m sn Fault History 2 0 1 27 Fault see Fault Previous Fault code list 0 No fault history CIIM 5 sso Fault History 3 Oldest Fault x de M NS 5 5 10 sso 000 0 999 9 hours View Only 0 ___ 5 5 10 0000 9999 thousand hours View Only e 5 5 10 F075 Fault History 1 Latest Fault View Only F076 F077 Date Stamp Fault 1 F078 5 5 10 F079 Time Stamp Fault 2 F080 Date Stamp Fault 2 F081 Fault History and Run Time F082 Time Stamp Fault 3 F083 Date Stamp Fault 3 F084 F085 F086 F087 Run Time Hours Run Time K Hours 0000 9999 times View Only 5 5 10 0000 9999 10 thousand times View Only 5 5 10 Run Counts Run Counts 10K times 5 5 Function Descriptions The unit is set at the factory with typical starting characteristics that perform well in most applications Note Customer must program motor FLA F001 for unit to operate 5 5 1 Motor and Overload Function Descriptions 2001 Motor FLA Factory Setting
65. s mode Initial Voltage Current and Ramp Time are set to minimum so the output current jumps to the current limit setting immediately Examples of when to use this mode are applications with a severely limited power supply e when starting a difficult load such as a centrifuge or deep well pump when the motor capacity is barely adequate without stalling or overloading Itis a good choice when other starting modes fail Since ramp times are set to minimum this mode functions in either Voltage Ramp or Current Ramp setting Ramp Parameter Description Initial Torque Initial Voltage or Initial Current This function sets the initial start point of either the Voltage Ramp or Current Ramp as programmed in F010 Every load requires at least some amount of torque to start from a standstill It is not efficient to begin ramping the motor from zero every time since between zero and the WK break away torque level no work is being performed The initial torque level should be set to provide just enough torque to make the motor shaft begin to rotate enabling the softest possible start and preventing torque shock damage to the mechanical components Setting this function too high will not damage the starter but may reduce or eliminate the soft start advantages See Chapter 5 for initial setup procedures Accel Ramp Time This Function sets the maximum allowable time for ramping the Initial voltage or current torque setting to either
66. st device 2057 Modbus Address Factory Setting 1 Range 1 247 The Modbus communications protocol allows each node to have up to 247 connected devices but each must have a unique address Two devices with the same address will result in a communications error Motortronics 29 XLD Series F058 F059 Digital Solid State Soft Starter 39 1250A Remote Starter Control Factory Setting 0 disabled Range 0 1 When 55 1 the start stop control will switch to the remote control system However the start stop button still has the ability to stop the motor Reserved 5 5 9 System Settings F060 F061 Parameter Lock User Password Factory Setting 0 disabled Range 0 999 Provides users with the ability to prevent unauthorized operators from making changes to the programmed functions If you do not need to take advantage of this feature do not enter anything into this function The factory default is disabled and no Password is necessary to make changes to the program See Appendix 3 at the end of this manual for detailed instructions on using and altering the Parameter Lock User Password feature Emergency Clear Reset Factory Setting 0 disabled Range 0 2 This Function serves two purposes It can clear the memory values used for lockouts and overload protection and it can reset all functions to the factory default settings When F061 0 the feature is disabled This
67. successful restart Starter learns and retains this information by monitoring previous successful starts Imbalance Trip Level 5 30 current between any two phases Imbalance Trip Delay 1 20 seconds Trip Level 50 300 of motor FLA Trip Delay 1 20 seconds Under Current Trip Level 10 90 of motor FLA Under Current Trip Delay 1 60 seconds Coast Down Time Range 1 60 minutes Range 1 10 successful starts per hour Time between starts 1 60 minutes between start attempts Programmable Outputs Form C SPST Rated 5 amps 240 VAC max 1200 VA Start Stop or Start End of Decel At Speed Stop or At Speed End of Decel Programmable Ramp Types Voltage or Current Ramp VR or CR Starting Torque 0 10096 of line voltage VR or 0 600 of motor FLA CR Ramp Time 1 to 120 seconds Current Limit 200 60096 VR or CR 4 Options VR1 VR2 VR1 CR2 CR1 CR2 CR1 VR2 Dual Ramp Control Ramp 1 Default Ramp 2 selectable via dry contact input Begin Decel Level 0 100 of line voltage Stop Level 0 to 1 less than Begin Decel Level Decel Time 1 60 seconds Programmable to decel or coast to stop upon overload trip Voltage Jog 5 100 Time of Voltage Jog 1 20 seconds Current Jog 100 500 Kick Voltage 10 100 Kick Time 0 1 2 seconds Shorted SCR Phase Loss Shunt Trip Phase Imbalance Trip Overload Overtemp Overcurrent Short Circuit Load Loss or Any Trip Coast Down Time
68. sword in function F060 See Appendix 4 for details The display of a customer password is encrypted If you do not have a record of the password and need to gain access contact Motortronics Tech Support Be ready to provide the XLD Series serial number and the four digits in the encrypted display If the display reads when the READ ENTER key is pressed the parameter lock is enabled Changing a Function s Set Value Use the UP arrow key to increment the value of the flashing digit Use the DOWN arrow key to decrement the value of the flashing digit Use the LEFT or RIGHT arrow to select the next digit to be altered Values can only be changed within the Adjustment Range of the function parameter Storing the Altered Value of a Function Once the desired value is displayed press the READ ENTER key This stores the value in memory The readout momentarily displays END and then retums to another function code NOTE If the Fn key is pressed BEFORE the READ ENTER key is pressed the XLD Series Starter will not store the selected value in memory Motortronics 15 XLD Series Digital Solid State Soft Starter 39 1250A Setting Motor FLA and Overload Class During Start See Example Setting mFLA During Start Use UP arrow key to go to F001 FOO Read Press Read Enter to display factory setting 0000 Use arrow keys to change 69 1 to actual Motor FLA bus t Press Read Enter gm to accept changes Setting OL Class D
69. tal Solid State Soft Starter 39 1250A Coast Down Lockout Time fe me woms ES ES e ___ mw F045 F049 Display Only me ES ES mm me _____ _ F053 F054 No record required mm mw ET e LE ES mew we me LL CC mm me we LL m sem E LL Ll mm e ese mesmenman _____ ue ET mm me ne rese mowama ___ 2 me me Motortronics 53 XLD Series Digital Solid State Soft Starter 39 1250A Motortronics 54 Warranty Policy MOTORTRONICS warrants its products to be free from defects mate rial and or workmanship for a period of one year from the date of installa tion to a maximum of 18 months from the date of shipment as indicated by the unit s date code Extended warranties are available please contact fac tory for details The Company reserves the right to repair or replace any malfunctioni
70. that Motortronics 42 XLD Series 8 4 Digital Solid State Soft Starter 39 1250A the washer spins freely after clamping Once proper force is reached make sure that the SCR pucks are securely held between the heatsinks and aligned evenly Replace any lugs MOVs snubbers power straps printed circuit boards and associated wiring that was removed in step 4 Use the following chart to verify wiring of J5 J6 and J7 Main Circuit Destination Board Pin Load cathode Output Load Lug Pine Line Cathode After verifying that all wiring is correctly connected test the SCR and then test the unit Replacing the Printed Circuit Board Assembly The printed circuit board assembly is not intended to be field repaired If a board is faulty the entire assembly should be replaced using the following procedure See Chapter 9 for the printed board assembly layout Remove three phase power and control power from the unit and lock out Remove plugs and tag plugs with connector numbers Remove control wires from terminals and tag wires with terminal numbers Remove the mounting screws Remove the old printed circuit board assembly Mount the new printed circuit board assembly Install the mounting screws Install the control wires onto correct terminals per tag sequence Install the plugs Apply power to the unit and test Motortronics 43 XLD Series Digital Solid State S
71. time has expired Maximum Starts per Hour Factory Setting 2 Range 1 10 Consult the motor manufacturer for a Starts per Hour or Starting Duty Cycle rating Larger motors tend to have lower starts per hour ratings Used in conjunction with 2041 When using the Decel function F025 or an electronic braking option count these cycles as additional starts when determining maximum starts per hour Motortronics 27 XLD Series 043 Digital Solid State Soft Starter 39 1250A Time Between Starts Lockout Factory Setting 0 Disabled Range 0 1 If F043 1 the motor cannot be started within the time specified in F044 Time between starts is calculated from the time of the first start command to the next regardless of run time Used in conjunction with F041 Starts Hour Time Bet n Time Between Time Between ime Betwee Starts Starts Starts HEUS Ce sak 9 F044 z F045 z F046 F047 z F048 z Minimum Time Between Starts Factory Setting 15 minutes Range z 1 60 minutes If F043 1 and F044 15 motor will not start within 15 minutes of first start Coast Down Timer Value Factory Setting Not Applicable Range z 1 3600 Seconds Display for information only value cannot be altered by the user Readout only for user s viewing of remaining time value of the Coast Down Lockout Timer Starts per Hour Timer Value Factory Settin
72. tion J4 Analog Signals J3 Serial Comm Asyncsi No Connection J9 Relay Control J4 Relay Control TB4 Digital Inputs J5 Keypad Control Signals TB4 PIN 1 Common J6 Digital Signals TB4 PIN2 Jog TB4 PIN 3 Dual Ramp X1 External Alarm Pins 1 amp 2 shorted X1 Internal Comm Pins 1 amp 3 shorted X2 Program Jumper X3 64K Eprom Pins 1 amp 2 shorted X3 256K Eprom Pins 2 amp 3 shorted Internal Eprom Pins 1 amp 2 shorted X4 External Eprom Pins 2 amp 3 shorted Motortronics 44 Digital Solid State Soft Starter 39 1250A XLD Series L3 L2 L1 2 o T3 T2 T1 Motortronics 45 XLD Series Digital Solid State Soft Starter 39 1250A 9 2 Power Board and CPU Board PC Board Assembly CPU Board x2 0 c Digital Input Control Relays Pin 1 Common Pins 1 through 3 Aux 1 Pin 2 Jog Pins 4 through 6 Aux 2 Pin Dual Ramp Pins 7 through 9 Aux 3 Pins 11 and 12 Optical Output Motortronics 46 XLD Series Digital Solid State Soft Starter 39 1250A Appendix 1 Ramp Profile Details Four Different Ramp Types The XLD Series offers four different types of starting ramp profiles Simply select the one that best matches your motor load requirements Ramp Type Setting F010 Ramp 1 2 Voltage Voltage Profile Selection Voltage Ramp Voltage Ramp 1 Vo
73. tions will increase resistance and cause the unit to function improperly Prior to beginning the installation verify that the motor and XLD unit are rated for the proper amperage and voltage Warning Do not service equipment with voltage applied The unit can be the source of fatal electrical shocks To avoid shock hazard disconnect main power and control power before working on the unit Warning labels must be attached to terminals enclosure and control panel to meet local codes Motortronics 24 XLD Series Digital Solid State Soft Starter 39 1250A 2 5 Mounting and Cleaning When drilling or punching holes in the enclosure cover the electrical assembly to prevent metal filings from becoming lodged in areas which can cause clearance reduction or actually short out electronics After work is complete thoroughly clean the area and reinspect the unit for foreign material Make sure there is sufficient clearance six inches all around the unit for cooling wiring and maintenance purposes To maximize effective air flow and cooling the unit must be installed with its heat sink ribs oriented vertically and running parallel to the mounting surface Warning Remove all sources of power before cleaning the unit In dirty or contaminated atmospheres the unit should be cleaned on a regular basis to ensure proper cooling Do not use any chemicals to clean the unit To remove surface dust use 80 to 100 psi clean dry compressed air on
74. to activate the Jog feature See Section 5 5 3 for setup of the Jog Function The Jog feature can be used for tasks such as lining up machines for blade or bit changes or inching belts along to check tracking See chapter 9 for main control board layout 4 2 9 Enabling the Dual Ramp Feature Closing TB4 Pins 1 and 3 will enable ramp 2 The dual ramp feature is useful in instances where a load changes such as a loaded or unloaded conveyor belt The characteristics for starting an unloaded conveyor can be programmed for ramp 1 The characteristics for starting a loaded conveyor can be programmed for ramp 2 4 3 Interlock Connection TB1 provides a connection point for an external user N C normally closed interlock device between pins 2 and 3 Examples of the use of this interlock connection would be for conditions such as low oil high temperature or excess vibration from user supplied devices A factory installed jumper is provided which allows the XLD unit to operate if external interlocks are not used If this jumper is removed and an interlock is not used the XLD unit will not function Motortronics 12 XLD Series Digital Solid State Soft Starter 39 1250A Chapter 5 Programming 5 1 Introduction is best to operate the motor at its full load starting condition to achieve the proper time torque and ramp settings Initial factory settings are set to accommodate general motor applications and provide basic motor protect
75. uring Start Use arrow keys to go to F003 003 Press Read Enter to display factory OL Setting Class 10 Use arrow keys to change if necessary Press Read Enter to accept changes y 5 3 3 Fault Mode The Fault Display Mode provides information to the operator when a fault occurs or when the operator wishes to review fault history Refer to Section 7 for details Fault codes are three digits in length and are displayed in alpha characters The first and second characters reading left to right are the initials for the applicable English language fault name The third or right most character can be either A C or D to denote when the fault occurred denotes Acceleration C denotes Constant speed D denotes Decel Reading Fault Code See Example PLC Indicates a Phase Loss fault was detected while at Constant Speed The decimal point to the right of the C denotes that this is the most recent fault Reading Fault Code condition Once a fault condition has been corrected pressing the Reset key will return the readout to the Status Display mode Fault History can be accessed during a fault condition While the current fault number is being displayed use the Up and Down Arrow keys to scroll through the Fault History Access Fault History via Functions F075 through F083 Motortronics 16 XLD Series Digital Solid State Soft Starter 39 1250A 5 4 The XLD Function List 5 4 1 Motor FLA Service Factor and Overload
76. ut Load Lug Line Cathode BUSBAR CONNECTION AC CONNECTION Isolated SCR Configuration Motortronics 41 XLD Series Digital Solid State Soft Starter 39 1250A 8 3 2 Changing a Hockey Puck Type SCR Remove both line and control power from unit tag and lock out Warning Failure to remove both line and control power before starting this procedure may cause personal injury or death Motortronics uses two types of clamps with gauges for reading the amount of force on the device The first type of force gauge uses a spin washer When the proper force is applied the washer will be free to spin The second type of gauge uses a step indicator on the end of the lever Before proceeding note the type of clamp used and if the clamp has a step indicator document the position of the indicator before removing the clamp to facilitate proper mounting of the new SCR device Label the location of the wires connected to the SCR Remove any lugs snubbers printed circuit boards refer to section 8 4 and associated wiring that may get in the way of reaching the faulty SCR Document the location and wiring of all parts before removing them to facilitate the reinstallation of the devices later Documentthe position of the indicator on the SCR clamp Then remove the top clamp holding the SCR stack together Remove the top heatsink Use extreme caution when handling the heat sink so it does not become dented or
77. ut derating 2 or 3 wire 120VAC customer supplied Optional 240VAC control voltage and CPTs are available Type Rating Form C SPDT rated 5 Amps 240VAC max 1200VA 3 Programmable Relays Fault Indicator AC triac solid state switch 240VAC 50mA max UL Listed Canadian UL cUL Listed XLD Series Digital Solid State Soft Starter 39 1250A Two Stage Electronic Overload Curves Overload Reset Note 1 Retentive Thermal Memory Dynamic Reset Capacity Phase Current Imbalance Protection 1 OverCurrent Electronic Shear Pin Protection Note 1 Load Loss Trip Protection Note 1 Coast Down Back Spin Lockout Timer Note 1 Starts per hour Lockout Timer Note 1 Type Rating Run Indication At Speed Indication Acceleration Adjustments Dual Ramp Settings Deceleration Adjustments Jog Settings Jog function selected via dry contact closure input Kick Start Settings Note 1 Fault Indications Lockout Indicator 1 2 Specifications and Performance Features Cont d Advanced Motor Protection Starting Programmable for Class 5 through 30 Run Programmable for Class 5 through 30 when At Speed is detected Manual default or automatic Overload circuit retains thermal condition of the motor regardless of control power status Unit uses real time clock to adjust for off time Overload will not reset until thermal capacity available in the motor is enough for a
78. wer Power 1 Connect L1 L2 and L3 to power lines and T1 T2 and T3 to motor TB1 Three Wire Connection 2 Connect control wires and control power 3 Program motor FLA F001 6 1 2 XLD Start up Parameters and Factory Defaults Enti Try the initial presets first and then adjust or enable the more advanced features Contact Bower to meet your specific starting needs Interlock Control Start Power TB1 Two Wire Connection Function Function alternate connection Number Name Factory Setting Description Starter disabled Unit must be set to actual motor FLA Motor Service Factor from motor nameplate NEMA Overload Class Class 10 NEMA Overload Class Class 10 Manual Reset Ramp 1 is voltage ramp with current limit Ramp 2 is voltage ramp with current limit 10 second time duration for Ramp 1 Maximum current limit of Ramp 1 as a percentage 350 Motor Nameplate FLA Motor Service Factor Overload Protection During Start Overload Protection During Run Overload Reset Ramp Profile Initial Torque Current Limit F015 F018 Ramp 2 60 200 10 350 Inactive unless TB4 control circuit is wired Jog 50 10 150 Inactive unless control circuit is wired MOTOR FLA 001 must be programmed for unit to operate See page 20 for more information C NO NC C NC NO NC Programmable Programmable Programmable Fault be Fo22 Fo49 Al See Note
79. xcessive voltage in the control logic circuit and may damage the unit Warning Never connect power factor correction capacitors on the load side of the unit The SCRs will be seriously damaged if capacitors are located on the load side The unit cannot be tested without a motor or other test load connected to the load side of the unit It may be necessary to use a load bank to test the unit without a motor Note that line voltage will appear across the output terminals if there is no motor or load connected to the unit In areas where lightning is a significant problem stationary air gap lightning arrestors should be considered and utilized on the input power source XLD Series Unit DISCONNECT CIRCUIT BREAKER Power Connections Grounding Connect the ground cable to the ground terminal as labeled on the unit Refer to the National Electrical Code for the proper ground wire sizing and be sure that the ground connector is connected to earth ground 4 2 Control Connections 4 2 1 Control Power Connections Separate 120VAC supply is required order 240 VAC if required The control voltage should be connected to pins 1 and 6 of TB1 This control voltage must be customer supplied unless an optional control power transformer see chart has been supplied with the unit The terminal block TB1 is located on the main power board However on units rated 150 Amps and above TB1 is brought out to a duplicate terminal block on the back panel
80. ycled to the starter the initial function 2001 should display with the selected digit flashing If the XLD Soft Starter has been programmed and power to the unit has not been cycled the readout will display the last function viewed or changed To change to a different function use the arrow keys Program Mode F001 The indicates the programmable function 0000 This is the present setting of the applicable function This display may include decimals between digits depending on the function setting s range and incremental step Motortronics XLD Series Digital Solid State Soft Starter 39 1250A Viewing a Function s Set Value See Example NOTE If password protection has been enabled operator will need to obtain password access before function settings can be changed 0000 Indicates that Phase A is 0000 drawing no current Press the Fn key F001 Indicates that this is function 001 Motor FLA To view the F001 s value press Read Enter 200 0306 Indicates that the programmed motor FLA is 306 Amps 0000 Press the Fn key to return to the Viewing Function s function Set Value F001 Press the Fn key again to return to the Status Display Mode Enabling Password Protection Parameter Lock The XLD Series Soft Starter is shipped with the Customer password disabled F060 0 If it is necessary to prevent parameters from being changed inadvertently set the pas

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