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1. 56 500 156 S801 V36 12 360 112 S801 V42 31 420 131 S8014V50 56 500 156 801 V65 203 650 203 S801 V72 225 720 225 S801 V85 265 850 265 S801 V10 312 1000 312 Motor FLA Potentiometer Values Potentiometer Setting Catalog Number Ira A B C D Default S801N37 11 19 27 37 11 S801N66 20 35 50 66 20 801R10 32 56 80 105 32 801R13 42 73 104 135 42 S801T18 56 97 138 180 56 S801T24 75 130 185 240 75 801T30 95 164 233 304 95 801U36 112 194 276 360 12 S801U42 131 221 323 420 31 S801U50 156 270 384 500 56 S801V36 112 194 276 360 12 S801V42 131 22 323 420 31 S801V50 156 270 384 500 56 S801V65 203 352 501 650 203 S801V72 225 390 555 720 225 S801V85 265 460 655 850 265 S801V10 320 547 773 1000 320 Note Mtr Nameplate FLA potentiometer is adjustable to any point within its range The thermal overload is designed to protect the motor from overheating caused by excessive current If the motor is overloaded the current drawn rises and heats the motor The FLA sets the trip threshold and the trip class 5 to 30 is set with the Ovrld Trip Class potentiometer If the device trips on a thermal overload an internal timer is started which inhibits a reset for three minutes After this timer expires the device may be reset and the thermal fault is cleared At this point another internal timer is started this
2. EMA75 CIM for Standard Unit S801 EMA71 801 Soft Starter MN03900002E November 2012 www eaton com 35 Appendix A Parameters Appendix A Parameters Soft Start Config S801 N3S Standard Soft Start Config Line Connected Motor Units Minimum Maximum Default Notes Overld Trip FLA S801 N37 Amps 11 37 11 Motor FLA parameter must be set to motor S8014N66 Amps 20 66 20 nameplate FLA to achieve proper overload protection S801 R10 Amps 32 105 32 S801 R13 Amps 42 135 42 S801 T18 Amps 56 180 56 S801 T24 Amps 75 240 75 S801 T30 Amps 9 304 9 S801 U36 Amps 112 360 112 S801 U42 Amps 131 420 131 S801 U50 Amps 156 500 156 S801 V36 Amps 112 360 112 S801 V42 Amps 131 420 131 S801 V50 Amps 156 500 156 S8014V65 Amps 203 650 203 S801 V72 Amps 225 720 225 S8014V85 Amps 265 850 265 S801 V10 Amps 312 1000 312 Overload On Disable On Jam On Disable On Stall On Disable On Phase Loss On Disable On Phase Reversal On Disable On Reset Mode Manual Auto Manual Ramp Start Current Limit Ramp Current Ramp Kick Start Torque 96 0 85 0 Kick Start Time Seconds 0 2 0 Initial Torque 96 0 85 45 Ramp Time Seconds 0 5 180 20 Ovrld Trip Class 5 30 20 Soft Stop Time Seconds 0 60 0 36 S801 Soft Starter MN03900002E November 2012 www eaton com Protections
3. EML26 S801 U 4 1 0 MCM 2 250 28 3 EML22 2 4 0 500 MC 1 250 28 3 EML23 4 0 500 MCM 20 250 28 3 EML24 2 0 300 MCM 1 225 25 5 EML25 2 0 300 MCM 2 225 25 5 EML26 801 V 4 0 500 MCM 26 250 28 3 EML28 2 4 0 500 MC 10 250 28 3 EML30 4 0 500 MC 606 250 28 3 EML32 2 0 300 MCM 4 225 25 5 EML33 Notes CSA approved 350 500 MCM G Requires special lug cover Note S801 T S801 U and S801 V units are supplied standard without lugs One kit consists of required hardware to make connections for three 3 phases on either line or load side of the soft starter S801 Soft Starter MN03900002E November 2012 www eaton com Installation 11 Installation 801 V10 Installation Requirements 1 Install the device in a minimum enclosure size 30 ft3 2 Two 2 forced air ventilation fans with a minimum 500 ft3 min at a location for air in bottom right or left corner and air out opposite upper right or left corner RD circuit breaker 4 For power wiring Use four 4 500 kcmil cables for each phase between RD circuit breaker and soft starter OPTIONAL Two 2 3 in x 1 4 in bus with a 1 4 in spacer per terminal Note See the figure below for alternative layouts 5 Line and load service entrance wiring must not cross in the enclosure Line Service 4 350 kcmil Terminal RD Circuit Breaker Power Wiring Alternatives RD Circuit Breaker 6
4. Fault Codes To obtain the fault flash codes from the CIM hold the RESET button located below the CIM down or apply 24 Vdc to terminal 4 and count the number of times all the LEDs on the CIM flash For example if you see three flashes and then two more flashes after a short pause the flash code is 32 The CIM can provide multiple flash codes if more than one error condition caused a stop Once you see the same flash code repeated you have seen all the flash codes for the error conditions that caused the stop For example if you see three flashes a pause then two flashes a slightly longer pause then four flashes a pause then one flash the flash codes are 32 and 41 If you then see three flashes a pause then two flashes you are seeing the first code again This means you have seen all the flash codes for this stop You may now release the RESET button or remove 24 Vdc from Control terminal Block Terminal 4 Note f an overload trip has occurred 24 Vdc power must be applied to allow the overload thermal memory to reset Depending on the overload history prior to the latest trip this may be as long as 9 minutes A list of flash codes and the faults they represent is shown below Fault Codes Fault Code Fault 11 Thermal Overload 12 Motor Stall LED 13 Motor Jam LED 14 Phase Reversal LED 15 Pole Over temperature 16 SCR Failed to fire
5. not recommended Unit compares voltage drop across the SCRs to conclude if the SCRs are shorted When a Start command is issued with no load connected there is no voltage drop as there is no current flow S801 Soft Starter MN03900002E November 2012 www eaton com 51 General Information S801 Fault Codes continued Code Fault Condition Solution 33 Motor Under Load Current drawn by the motor is below trip Repair replace failed couplings Disconnect threshold Failed motor coupling Increase load Load engagement device is not operating Motor is not loaded Notes When the internal bypass contactors are closed the average value of the 3 phase currents is monitored as a 96 of FLA 34 SCR Instantaneous Over Excessive SCR Current during the start Increase Soft Start Time and or Initial Torque potentiometers Current ramp Only active when Stall Fault is disabled Reduce starting load Verify S801 is properly rated for current Notes The maximum RMS value of the three phase currents is monitored The SCR Over Current Trip threshold is 3X FLA 41 Low Control Voltage Voltage at Terminal falls below 17 Vdc Verify power capacity amperage of 24V power supply to close contactors The external 24V power supply voltage is Power supply voltage is intermittent and or drifting Read value on below specifications and or insuff
6. ur ur ur O O O 2 T1 4 T2 6 For each start the length of time the SCRs are conducting current as well as the magnitude of that current determine how hot the SCRs will get Between successive starts the SCRs must cool down to avoid exceeding their thermal limits Appendix C gives the S801 s application ratings for various starting conditions Staying within these specified limits will aid in avoiding over temperature trips Control There is one 1 12 position connector and one 1 RJ45 connector on the face of the S801 soft starter that are used for control circuit functions 1 24 Vdc Control Inputs Soft Starter Permissive Start Reset and Auxiliary Relay control functions 2 Control Interface Module CIM soft starter communication with a user interface device Note Do not apply 120 Vac to any Terminal Block Control Input 120 Vac will permanently destroy the printed circuit board 20 S801 Soft Starter MN03900002E November 2012 www eaton com Functional Description Starting Stopping Options The following starting options are available in the S801 4 Soft Starter Voltage Ramp Start This is the most commonly used mode of soft starting speed prior expiration of the Start Ramp time it quickly Starting at an initial value set by the nitial Torque parameter completes the voltage ramp and closes the bypass the voltage applied to the motor is gradually increased at a contactor s i
7. 2012 www eaton com Thermal Memory e At 100 Thermal memory the soft starter will stop with This parameter is not the same as Thermal Overload a RED status LED At 99 thermal Memory a START command will be allowed BUT as soon as 100 is again reached as it will be during the start sequence the soft starter will again stop Cycling 24 Vdc control power will not reduce the Thermal Memory value e Fault Occurrence Categories Immediately when START command is issued During the START ramp before the internal bypass contactors close During the Internal Bypass Contactor closure event Anytime during the RUN operation During the STOP SOFT STOP command e Status LED Indication Conditions RED Active fault is present cannot RESET GREEN Not responding to START command from field wiring LEVEL Sense Insufficient voltage at Terminal P Insufficient voltage at Terminal 1 EDGE Sense Cycle 24 Vdc at Terminal 1 Insufficient voltage at Terminal P Insufficient voltage at Terminal 1 OFF AII Check for loss of 24 Vdc control power and or less than 17 Vdc Check Terminal Block for condition and security Verify 24 Vdc at appropriate terminals Verify proper operation and capacity of control power supply General Information e START Command Troubleshooting From the Terminal Block S801 Soft Starter Verify that Terminal P is energized continuously Ver
8. 5 Auxiliary relays 3 amps at 120 Vac or 24 Vdc 10 amps max resistive switching 16 S801 Soft Starter MN03900002E November 2012 www eaton com Basic Connection Diagram for 2 Wire Pushbutton Us 24 Vdc Us 2 A o gt gt Er 2 Aux Relays 3 0 9 SI VY Fag rae a ea vut p 412 3 t 14 05 os sa Ferrite EStop Start Run T pos E hr r1 L 4d Local a 4 FT Reset Maintained _L 7 Momentary Notes 1 A minimum wire of 14 AWG 2 5 mm should be used between the control power supply and the control terminal block See Using an Auxiliary Relay section below if it is desired to use a relay instead of an indicating lamp for terminals 13 14 95 96 and 98 120 Vac may be applied to terminals 13 14 95 96 and 98 Add ferrite Fair Rite 40446176451 to DC Power Leads and Control I O Leads all through one ferrite at S801 Auxiliary relays 3 amps at 120 Vac or 24 Vdc 10 amps max resistive switching S801 Soft Starter MN03900002E November 2012 www eaton com Installation 17 Installation 24 Vdc Control Power Requirements The S801 Soft Starter requires 24 Vdc control power The sealed in and inrush characteristics of the S801 Soft Starter are summarized in the table below Control Power Requirements Suit Siaran Sealed Inrush Frame Amps Watts Amps Watts Durat
9. Connection Severe Duty 30 Second Ramp and or 45096 Current Limit at 50 C Inline Connection Maximum Power LOSS accio ATE RR de er Appendix E Troubleshooting S801 Fault CodeS sies deu eee bu a EE ud ud 36 37 37 38 38 39 41 42 43 48 S801 Soft Starter S801 Soft Starter MN03900002E November 2012 www eaton com vii 8014 Soft Starter Safety Definitions and Symbols A WARNING This symbol indicates high voltage It calls your attention to items or operations that could be dangerous to you and other persons operating this equipment Read the message and follow the instructions carefully A This symbol is the Safety Alert Symbol It occurs with either of two signal words CAUTION or WARNING as described below A WARNING Indicates a potentially hazardous situation which if not avoided can result in serious injury or death A CAUTION Indicates a potentially hazardous situation which if not avoided can result in minor to moderate injury or serious damage to the product The situation described in the CAUTION may if not avoided lead to serious results Important safety measures are described in CAUTION as well as WARNING Hazardous High Voltage A WARNING Motor control equipment and electronic controllers are connected to hazardous line voltages When servicing drives and electronic controllers there may be exposed components
10. Details 46 If the Status led is RED the soft starter is in a fault condition and will not recognize a START command If a reset attempt is unsuccessful the fault is still present and must be corrected If the soft starter appear s to have tripped but the Status LED is GREEN and there is no new Fault code in memory verify that the soft starter has not stopped due to a STOP command Terminal P permissive must be energized maintained to enable operation but will not prevent a fault from being reset The Status LED can be GREEN without a signal at the P terminal Terminal 1 is energized momentary or maintained to issue a START command Signal duration must be a minimum of 500ms for the Soft Starter to recognize the START command Terminal P is de energized to issue a STOP command S801 Soft Starter e LEVEL Sense Most commonly used Start Control parameter setting Maintained Terminal 1 energized START command is present when Terminal P is energized maintained START command is present when any fault clears and is then RESET RESET function may be either AUTO or MANUAL MPORTANT NOTE If the LEVEL sense parameter AND the AUTO RESET parameters are selected a motor START command will exist if a 24 Vdc signal is present on Terminal P and Terminal 1 and remains energized when the fault condition clears After a transient fault this condition may cause the motor to start une
11. FLA is settable from 32 100 of the S801 s rated current frame size The overload s trip class default 2 20 is set with the Overload trip Class DIP switches Thermal Overload may be disabled during the Voltage Ramp or Current Limit start ramps default Enabled by providing a 24 Vdc signal to Terminal 3 on the Control Terminal block prior to the START command Disabling this protection parameter is not recommended Additional details on the Thermal Overload can be found in Appendix B 8014 Operating Configuration Soft Start Configuration Application Notes a Voltage Ramp Start Configuration Default values may be used for Start Time and initial Torque Kick Start Torque 0 fans and pumps 75 high breakaway loads Kick Start Time 0 sec fans and pumps 1 sec high breakaway loads Start the motor and determine the worst case starting conditions Adjust Initial Torque for smooth start without hesitation Motor rotation should begin within 2 seconds If Stall Faults occur at the end of the ramp time increase Initial Torque Kick Start Torque and Time and or Soft Start Time to get into bypass before the Soft Start Time elapses Also verify that the motor is not overloaded b Current Limit Start Configuration Initial settings Initial Torque 50 Soft Start Time 60 sec Kick Start Torque 0 Kick Start Time 0 sec disabled c Start the motor and determine the worst case starting conditions A
12. Number Amps Watts Amps Watts Voltage Vac PSG240E 10 240 15 360 85 264 PSG240F 10 240 15 360 320 575 PSG480E 20 480 30 720 85 264 PSG480F 20 480 30 720 320 575 18 S801 Soft Starter MN03900002E November 2012 www eaton com Control Wiring Application Notes A CAUTION Only apply 24 Vdc to the control terminal block Control wiring is 22 12 AWG 0 33 4 0 mm Failure to follow this caution may result in damage to the control circuit 1 Connect 24 Vdc Supply positive to Terminal using a minimum wire of 14 AWG 2 5 mm2 non 2 Connect 24 Vdc Supply negative to Terminal minimum wire of 14 AWG 2 5 mm2 using a 3 24 Vdc Control voltage must not exceed 30 Vdc to prevent hardware damage 4 24 Vdc Control voltage must not fall below 18 Vdc Installation Using a Supplemental Line Contactor In some installations it may be necessary to use an electromagnetic contactor in series with the soft starter In this case it is recommended that the contactor be placed on the load side of the soft starter The contactor must be closed prior to starting the soft starter and remain closed until the Soft Starter has been stopped to ensure proper soft starter and system operation If an electromagnetic contactor is used on the line side of the soft starter additional control circuitry must be supplied by the user when using edge control to ensure the line power is supplied to the soft starter before control power is a
13. See the Edge and Level Sensing sections on Page 23 for additional details If the AUTO Reset Mode setting is used with level sensing CAUTION must be exercised to assure that any restart occurs in a safe manner Motor restart may occur immediately and unexpectedly after any fault condition has cleared Terminal 2 Jog Application of 24 Vdc power to the Jog terminal will initial a momentary Start command for as long as the signal is present The S801 will perform a Start ramp in accordance with Start parameters If the motor achieves synchronous speed the internal bypass contactors will not close When the 24 Vdc signal is removed the soft starter will perform a coast stop irrespective of any Soft Stop parameter values Terminal 3 Overload on Start Momentary application of 24 Vdc to Terminal 3 prior to a start raises the overload fault trip point to 12596 of the maximum rating of the frame size for the next start only Functional Description Terminal 4 Reset Application of 24 Vdc power to the Reset terminal will reset the soft starter after all fault conditions are cleared and no active fault is present If the Fault LED is not able to be reset a fault condition still exists and must be corrected Level or Edge Sensing Level or Edge Sensing determines how the soft starter reacts to Start control commands after a fault trip has occurred It is important to be aware if the Start command is a momentary or maintained signal I
14. Starter Table of Contents SAFETY Definitions and Symbols o oooooooooooo kaa ga nitan guira niani viii Hazardous High Voltage 2 0 eee viii Warnings and Cautions aa viii INTRODUCTION OVEDIIEW iot sms tte edite A A BETES pe 1 General Appearance NOtes_ ccc eee 1 Standards and Certifications ciiin 2 CE CONTOMMAN EE tee a tA epe eI v a a t epo ed 2 RF Susceptibility Statement eee 2 TECHNICAL DATA AND SPECIFICATIONS Environmental xen ee CERT eo a EAR RISE S uns 3 PhySIGal bici roce eie p A eg adis edt 3 RECEIPT UNPACKING Generals uda vates eoo IR e PE b eI IRE 5 Unpacking TETTE 5 SIOTadOe s ie im taces on etat natch e ear ann esten eaaet tud 5 SHIPPING sera sun eter tpe qos nen ceded son gage totale Dana eens tea P aves 5 INSTALLATION MOUNTING srt pt ato asks aloe wad dot eia o Pe wae anda eu 6 DIMENSIONS sai ce opto doe d en I UR aule ced Ue eat ode RU ped 7 POWELANIFING sean Erano ln i tae e EUR ada rS E Ene 10 Line and Load Power Wiring 000 cece ses 10 S801 V10 Installation Requirements 000 0000 cee 12 Lug Installation S801 N and S8OI R GG 13 Lug Installation S801 T S801 U and S801 V Frames 13 Control Wiring INPUTS st s tex rete OMe ati 13 DIP SWitehr cti oA ber orte et keene ee elegy IR 13 Control Wiring Terminal Blocks 2 000 ccc cee 14 S801 Control Terminal Block Wiring sls 14 Control Ter
15. after a power outage without operator intervention In the AUTO RESET MODE CAUTION must be exercised to assure that any restart occurs in a safe manner S801 Soft Starter MNO3900002E November 2012 www eaton com 23 Functional Description Edge Sensing Edge sense means that the 24 Vdc signal at the Start terminal must be removed if maintained and reapplied after a fault trip has occurred If the Start signal is momentary no further action is required to restart the motor The cycling of 24 Vdc power to the Start terminal before starting is required regardless of the setting of the Reset Mode parameter Edge sensing will allow a motor restart when Fault condition is cleared e The Permissive terminal is supplied with 24 Vdc e The Reset Mode parameter is set to AUTO or MANUAL e 24 Vdc power to the Start terminal is reapplied Start command momentary Edge sensing will allow a motor restart when e Fault condition is cleared e The Permissive terminal is supplied with 24 Vdc e The Reset Mode parameter is set to AUTO or MANUAL e 24 Vdc power to the Start terminal is removed then reapplied Start command maintained This control configuration can be used when restarting of the motor after a stop command or fault must be supervised manually or as a part of a control scheme AUTO RESET Reset Mode Two 2 modes of resetting Fault Trips are available 0 Manual Requires pressing Reset button on CIM pres
16. as it dissipates the energy stored in the relay coil This delay is often long enough to compensate for the potential effects of a mechanical shock opening the control contact A typical suppression diode is a 1N4001 24 Vdc Control eem 13 Pa Bypass 24V DC 95 Supply EE as Ready u one Fault AN AH es S801 Soft Starter MN03900002E November 2012 www eaton com 15 Installation Typical Control Wiring Diagrams Each diagram illustrates a typical wiring scheme for the options described The additional components shown on the diagrams are not included but may be purchased from Eaton Basic Connection Diagram for 3 Wire Pushbutton Us 24 Vdc Us 2 E o gt gt E to 8 3 Aux Relays o ny So Ae Tapes I E Je alela uo vo os losos Ferrite CA Stop 4 FT 1 Start D L Maintained rp TT Reset Momentary Notes 1 A minimum wire of 14 AWG 2 5 mm should be used between the 24 Vdc control power supply and the control terminal block 2 See Using an Auxiliary Relay section below if it is desired to use a relay instead of an indicating lamp for terminals 13 14 95 96 and 98 3 120 Vac may be applied to terminals 13 14 95 96 and 98 4 Add ferrite Fair Rite 40446176451 to DC Power Leads and Control I O Leads all through one ferrite at S801
17. be 6796 of the above values or 132 26 amps to 149 02 amps respectively Note The current in the motor circuit will be subject to the total impedance of the motor circuit so actual values may be slightly different than calculated values 30 S801 Soft Starter MN03900002E November 2012 www eaton com Troubleshooting General In this section of the manual we present a procedure you can follow to diagnose a problem with your S801 While many potential situations are outlined in this section it is possible you may run into a problem that is not covered here If you have worked through the following troubleshooting procedure and find that you require further assistance please contact Eaton Please have the following information ready when you call Order Number Catalog Number Style Number Serial Number Before You Begin to Troubleshoot A WARNING Make sure you read and understand the procedures in this manual before you attempt to set up or operate the equipment A WARNING HIGH VOLTAGE Do not work on energized equipment unless absolutely required If the troubleshooting procedure requires equipment to be energized all work must be performed by properly qualified personnel following appropriate safety practices and precautionary measure We highly recommend that you read this entire section of the manual before you begin to troubleshoot the S801 Soft Starter You may want to obtain the f
18. have multiple contactors fails to seal electrically of if the contactors opens during operation If the firmware detects that the bypass contactor s have failed to close as measured by the voltage drop across the power poles the firmware will command the contactors to release open and then reapply the signal to the coil of the contactor s this process may repeat for 30 seconds If after 30 seconds and the bypass contactor s have failed to close electrically the firmware will discontinue the signal to close the contactors and the soft starter will rum utilizing the SCRs Bypass contactors may open during the motor run from excessive shock or 24 Vdc control voltage sag insufficient voltage and or current to maintain contact closure If the soft starter is running continuously on the SCRs or in JOG mode an S S Trip fault may occur after a period of time If the fault occurs after the STOP command it is likely that one or more contactors did not seal electrically during the START ramp and the unit has been running on the SCR s 24 Instantaneous Over Current Excessive starting current Reduce starting load Excessive load Increase soft starter capacity be sure model ratings can handle current demands Notes During the Start Ramp Time the maximum RMS value of the 3 phase current s are monitored Instantaneous Over Current Trip threshold is 6X catalog FLA Catalog FLA refers to the maximum continuous line current capacity of the S801 soft
19. in Minimum 12 in 4 500 kcmil or Distance Minimum 2 3 x 1 4 in Bus Isolation Distance with 1 4 in Contactor Space Terminal 6 in Minimum Distance S801 V10 S801 V10 Soft Starter Soft Starter Line Service 4 350 kcmil Terminal 12 S801 Soft Starter MN03900002E November 2012 www eaton com Lug Installation S801 N and S801 R Wire the appropriate line and load conductors to the Soft starter in accordance with federal and local codes Torque fasteners per table on Page 11 Lug Installation S801 T S801 U and S801 V Frames 1 Remove line and load terminal lug covers by removing the screws that hold each cover onto the soft starter 2 With screws removed slide the covers off the unit 3 Position lugs and install lug mounting hardware according to the instructions included in the kit Tighten lug mounting hardware included in the kit to 120 Lb in 13 6 Nm 4 Install line and load conductors and torque hardware in accordance with table on Page 11 5 Slide the line and load lug covers back into their original positions 6 Secure with the screws previously removed 801 V Shown with Terminal Cover Removed and EML30 Lug Kit Installed on Load Side Installation Control Wiring Inputs Control wiring is connected to the S801 by one 1 terminal block and one 1 RJ12 connection located at the front of the unit Control Terminal Block A 12 position connector is utilized t
20. in determining the appropriate corrective action during the various run phases of operation Note If no fault codes are present during an unexpected trip of the soft starter verify that the soft starter did not receive a STOP command Detailed information describing fault codes and corrective action may be found in Appendix E Suggested Corrective Action 24 Vdc permissive signal lost investigate control system Check control wiring for security Check 24 Vdc power source for correct sizing and circuit connections Change Reset Mode to Manual to capture fault condition Inspect external control devices for proper operation Inspect external devices for condition and proper operation Possible device fatal error Status LED is RED Fault condition exists Fault not reset from previous trip Reset Mode set to Manual Protection Operation parameters not set to proper values Determine Fault condition from the Fault Codes Adjust Protection parameter values to prevent recurring fault trips Correct problems with mains voltages and or phase conditions Attempt to reset fault the fault will not reset if the fault condition exists Set Reset Mode to Manual to retain soft starter in fault condition for troubleshooting Correct fault condition and change Reset Mode to Auto if desired Set Protection parameters to Warning Reset Mode set to Manual and no Reset signal was sent to the soft starter Reset soft starter o
21. some faults are routinely experienced in one category The following information is intended to be a reference guide to quickly move through the process to achieve or restore operational status of the Soft Starter New Applications Checklist During Commissioning Note It is not unusual for the S801 Soft Starter to trip in the process of being commissioned as it is likely that one or more parameter s setting are not appropriate 24 Vdc control power applied e Sufficient minimum wattage and voltage value and inrush capacity Mains applied All circuit breakers closed fuses installed no open fuses e All isolation devices closed e Verify continuity of mains power to soft starter Load connected All isolation devices closed Reversing contactors if used in proper position Continuity of circuit from soft starter to the motor Parameter Setup Operation Mode Motor FLA A Motor Nameplate FLA value Default frame size minimum e Motor Rated Voltage Default 480V e Start Method Voltage Ramp or Current Limit Default Voltage Ramp e Start Time As required Default 20 seconds e Initial Torque As required Default 45 96 e Auto Reset Mode As Required Default Manual Parameter Setup Protection Mode Overld Trip Class As Required Default 20 e Start Control As Required Default Level Appendix E Troubleshooting Guide The following Fault Codes may
22. starter NOT the motor rated FLA 25 Phase Imbalance The voltage or current imbalance of the Correct imbalance problem with mains incoming phases exceeds the trip threshold Disable the fault if the other issues cannot be resolved Notes Phase imbalance may be impacted by voltage issues and or current issues 26 Internal NV Memory Internal memory error Component failure on printed circuit board Contact EatonCare for service 31 Voltage Zero Cross Lost Mains voltage lost Restore mains or lost phases Phase L1 or L3 lost Verify that the load is connected and any disconnect devices are properly engaged Load disconnected Contact EatonCare for service Notes The SCRs are unable to fire if there is no source voltage or load on the unit Verify that all mains control devices are properly connected and powered prior to initiating a START command 32 Shorted SCR SCR is shorted Test resistance of each phase Internal bypass contactor welded shut Contact EatonCare for service No load on the SCRs when START command is issued motor disconnected Notes Shorted SCRs are the most common mode of SCR failure With power completely removed from the unit measure the resistance of each pole line to load If the resistance is near zero less than 5 ohms it is most likely that the SCR is shorted Resistance of a serviceable SCR is approximately 10k ohms Resistance typically moves to a lower value as the SCR ages This feature may be disabled
23. timer is 26 x 3 or 48 minutes If another trip occurs before this timer expires the reset inhibit time is increased to 6 minutes 38 S801 Soft Starter MN03900002E November 2012 www eaton com Once the trip level reaches level 3 it will take 144 minutes to go back to level 2 then 96 minutes to get back to level 1 To get from level 3 to a reset thermal overload at level 1 it takes 240 minutes without a trip A reset thermal overload at level 1 means the next thermal overload trip will have a 3 minute reset inhibit as in the table below Thermal Motor Overload Times Trip Reset Time to Previous Level Preset Inhibit Time Trip Level 1 3 minutes N A 2 6 minutes 96 minutes 3 9 minutes 144 minutes Total 240 minutes to reset to level 1 Cycling power on the device will NOT clear the thermal trip The thermal memory and the reset inhibit time are saved to the non volatile memory These values are reloaded when the device boots and the timer is restarted at the full reset time This means if the 3 minute inhibit timer has been running two minutes cycling power will require the user to wait the full three minutes before a reset can clear the overload fault If the device is shut down when the overload fault is tripped the temperature is also saved to the non volatile memory If the device is left to cool and then powered the temperature read from the sensor is compared to the saved temperature If the current temperatur
24. with housings or protrusions at or above line potential Extreme care should be taken to protect against shock Stand on an insulating pad and make it a habit to use only one hand when checking components Always work with another person in case an emergency occurs Disconnect power before checking controllers or performing maintenance Be sure equipment is properly grounded Wear safety glasses whenever working on electronic controllers or rotating machinery Warnings and Cautions This manual contains clearly marked cautions and warnings which are intended for your personal safety and to avoid any unintentional damage to the product or connected appliances Please read the information included in cautions and warnings carefully A CAUTION Unit may weigh up to 103 pounds Use suitable lifting device A WARNING Hazardous voltage can cause electric shock and burns To avoid shock hazard disconnect all power to the controller motor or other control devices before any work is performed on this equipment Failure to do so will result in personal injury death or substantial property damage Do not apply a disconnect device on the output of the S801 soft starter unless a means to turn off the soft starter when disconnect switch is open is used Opening disconnect while the soft starter is operating may cause a malfunction Closing disconnect switch while the soft starter is operating will result in a soft starter failure and pote
25. 03900002E November 2012 www eaton com E T N Powering Business Worldwide Eaton is dedicated to ensuring that reliable efficient and safe power is available when it s needed most With unparalleled knowledge of electrical power management across industries experts at Eaton deliver customized integrated solutions to solve our customers most critical challenges Our focus is on delivering the right solution for the application But decision makers demand more than just innovative products They turn to Eaton for an unwavering commitment to personal support that makes customer success a top priority For more information visit www eaton com electrical Eaton Corporation Electrical Sector 1111 Superior Avenue Cleveland OH 44114 USA Eaton com 2012 Eaton Corporation Eaton is a registered trademark of All Rights Reserved Eaton Corporation Printed in USA Publication No MNO3900002E Z12488 All other trademarks are property November 2012 of their respective owners
26. 1 3 5 Lb in 0 4 Nm The S801 Soft Starter has the following control terminal block control input and aux relay functions Terminal Block Functions Position Function Notes 24 Vdc power Power supply negative 24 Vdc power Power supply positive P Permissive Hardwired STOP command 1 Start Hardwired START command 2 Jog Jog 3 Overload Disable on START 4 Reset Fault reset 13 Relay NO contact Changes state when unit achieves internal bypass mM operation 95 Fault relay Changes state when unit fault trips 96 98 non n and Control Power Connect power supply negative to pin and to system ground Connect 24 Vdc output to pin Verify that the 24 Vdc control power source has the recommended capacity Minimum control voltage is 18 Vdc Note To avoid voltage drop during bypass contactor inrush a minimum of 14 AWG 2 5 mm wire should be used between the power supply and the and inputs at the S801 terminal block non P Permissive Control Input 24 Vdc only maintained Permissive must be energized 24 Vdc to enable START or RUN operation of the unit from any source If power is removed from the permissive circuit at any time the unit will begin a STOP command If a soft stop is selected the soft stop will begin and run to time out 1 START Control Input 24 Vdc only momentary input with 3 wire control maintained for 2 wire control App
27. 14R HFD HKD HMCP 600 10kA 150 300 S8014T HLD HMCP 600 18kA 600 S8014U HLD HMCP 600 18kA 600 S801 V HND RD HMCP 600 35kA 42kA 1000 2000 Note For more details on short circuit protector selections and enclosure sizing please refer to the linked spreadsheet on UL s website at http www ul com global documents offerings industries buildingmaterials industrialcontrolpanels shortcut Eaton xls Note Suitable for use on a circuit capable of delivering not more than 100 000 rms symmetrical amperes 600 volts maximum when protected by Class RK5 fuses Note Suitable for use on a circuit capable of delivering not more than 65 000 rms symmetrical amperes 480 volts maximum when protected by a circuit breaker 4 S801 Soft Starter MN03900002E November 2012 www eaton com Receipt Unpacking General Upon receipt of the unit verify that the catalog number and unit options stated on the shipping container match those stated on the order purchase form Inspect the equipment upon delivery Report any crate or carton damage to the carrier prior to accepting the delivery Have this information noted on the freight bill Eaton is not responsible for damage incurred in shipping Unpacking Carefully remove the unit from the shipping container Check the unit for any signs of shipping damage If damage is found after unpacking report it to the freight company Retain the packaging materials for carrier to review Verify t
28. 2 Phase Loss Incoming phase disconnected Repair broken connection Open fuse or breaker Replace fuse Phase imbalance exceeds specifications or Inspect system for phase imbalance conditions trip parameter Severe voltage phase imbalance Notes Phase loss is a severe condition of phase imbalance even momentarily In cases of severe imbalance causing nuisance trips this feature may be disabled not recommended Phase performance should be monitored for an appropriate length of time to ensure that the phase is not dropping just long enough for the soft starter to detect the condition 50 S801 Soft Starter MN03900002E November 2012 www eaton com General Information S801 Fault Codes continued Code Fault Condition Solution 23 Bypass Failure Internal bypass contactor s not closed and Verify all bypass contactor s close audible noise Measure voltage or electrically sealed after ramp time drop line to load Contactor s opened in bypass Verify all bypass contactor s not opening during run cycle due to excessive vibration and or shock Reduce levels of vibration and or shock Starter is being operated continuously in Verify control power and wire size meet specifications JOG mode Verify that the control power supply meets the 24 Vdc voltage and current requirements of the IT soft starter Notes This fault may occur even if just one contactor larger soft starters
29. 22 Phase loss LED 23 Internal bypass contactor dropout 24 SCR Contactor overcurrent 25 Phase imbalance 26 Non volatile memory error 31 Zero voltage cross failure 32 Shorted SCR Phase loss Load disconnect 33 Load disconnect 34 SCR instantaneous overcurrent 41 24V power supply low 42 Timer system fault 43 Watchdog reset occurred 44 PLL DSP fault 45 Illegal address DSP Appendix A Parameters S801 Soft Starter MN03900002E November 2012 www eaton com 37 Appendix B Overload Protection Appendix B Overload Protection Thermal Overload The S801 Soft Starter features an electronic motor overload protection feature This is intended to protect the motor and power wiring against overheating caused by excessive current for extended periods of time Note Short circuit protection must be applied on the line side of the soft starter Enter the motor full load current rating by adjusting the FLA potentiometer on the face of the CIM It is adjustable from 32 100 of the unit s rated current Overload Adjustment Range Inline Connected Catalog Number Min Max Default Notes S801 N37 11 37 11 Motor FLA potentiometer BOUND 2 2 a dde Hato hae S801 R10 32 105 32 proper overload S8014R13 42 135 42 pretegiion S801 T18 56 180 56 S801 T24 75 240 75 S801 T30 95 304 95 S801 U36 12 360 112 801 U42 31 420 131 801 U50
30. 801 V42 9 41 4 6 57 420 8 05 280 6 7 39 187 8 801 V50 9 A 6 57 420 8 05 280 6 71 38 187 8 S801 V65 9 41 4 6 57 420 8 05 280 6 71 38 187 8 S801 V72 9 41 4 6 57 420 8 05 280 6 7 39 187 8 S8014V85 9 41 4 6 57 420 8 05 280 6 71 38 187 8 801 V10 9 41 4 6 57 420 8 05 280 6 7 39 187 8 S801 Soft Starter MN03900002E November 2012 www eaton com 3 Technical Data and Specifications Short Circuit Ratings Component Frame Size Fuses Circuit Breaker Voltage SCCR Rating A S801 N J HFD 600 10 kA S8014R RK5 J HFD HKD 600 10 kA S8014T RK5 J HLD 600 18 kA S801 U RK5 J HLD 600 30 kA S801 V L HND RD 600 42 kA Short Circuit Ratings Enclosed Control Fuses SCCR Switch Frame Size Fuses Voltage Rating A Size max A Switch Type S801 N J 600 100 kA 100 K S8014R RK5 J 600 100 kA 200 K S8014T RK5 J 600 100 kA 600 K S8014U RK5 J 600 100 kA 600 K S801 V36 RK5 J 600 100 kA 600 K S801 V42 L 600 100 kA 800 K S801 V50 L 600 100 kA 800 K S801 V72 L 600 100 kA 1200 ND S801 V85 L 600 100 kA 1200 ND S801 V10 L 600 100 kA 2000 K Short Circuit Ratings Enclosed Control Breaker Thermal Magnetic Motor Circuit SCCR Max Size Frame Size Circuit Breaker Protector Voltage Rating A breaker A S801 N HFD HMCP 600 10kA 150 S80
31. Description Inline Connected Sont Stamens nee IAN es RR EA NIE Mee ete eden ER 20 Voltage Ramp Stalins retra m rec Mar Redeem odd ale anak Beene 21 Current lE 4 28 ose one tea hal Sn Bas det desto oder ete fot ee s 22 SOM STOP ee ot c uet t i Med MR A AE DUM b Gb A Y 22 S801 Operating Configuration Control Interface Module CIM priae kerah a a E e 25 Troubleshooting Start Command Troubleshooting Flow Chart 2 0 000000 cece eee 32 Local Control Troubleshooting Flow Chart GG 34 Appendix B Protection Overload Irip Gur Ves sea veo BES VERTS en EN E 40 S801 Soft Starter MN03900002E November 2012 www eaton com v 8014 Soft Starter List of Tables Introduction EMC Conformance Technical Data and Specifications Environmental Specifications Unit Weight and Dimensions Short Circuit Ratings Component ooo Short Circuit Ratings Enclosed Control Fuses 0 000 cee eee ee Short Circuit Ratings Enclosed Control Breaker o o ooooooooo Installation Required Mounting Hardware isses Line and Load Power Wiring Line and Load Power Wiring Terminal Block Wiring Capaci S801 N and S801 R 2 0 0 0 000000 0000 S801 T S801 U and S8014V PARCEL Terminal Block Functions o oooo eee Control Power Requirements Eaton Recommended 24 Vdc Power Supplies 0 000000 a ee Operating Configuration FLA Potentiome
32. N CARE 386 2273 8 00 a m 6 00 p m EST FAX 800 752 8602 After Hours Emergency 800 543 7038 6 00 p m 8 00 a m EST If you are in the U S or Canada and have Ol or PLC questions you can take advantage of our toll free line for technical assistance with hardware and software product selection system design and installation and system debugging and diagnostics Technical support engineers are available for calls during regular business hours Technical Resource Center Voice 877 ETN CARE 386 2273 8 00 a m 5 00 p m EST FAX 828 651 0549 e mail TRC Eaton com European PanelMate Support Center This engineering company located in Zurich Switzerland provides high level quality support and repair assistance for your PanelMate products You will receive technical and application support For Customers in Europe contact BFA Solutions Ltd Voice 41 1 806 64 44 9 00 a m 5 00 p m CET e mail gk bfa ch www bfa ch Repair and Upgrade Service Additional support is also available from our well equipped Repair and Upgrade Service department If you have questions regarding the repair or upgrade of an Ol product contact your local distributor Repair and Upgrade Service support for Ol Voice 877 ETN CARE 877 386 2273 8 00 a m 5 00 p m EST 414 449 7100 8 00 a m 5 00 p m EST FAX 614 882 3414 e mail TRC eaton com ii S801 Soft Starter MN03900002E November 2012 www eaton com S801 Soft
33. ROUBLESHOOTING New Applications Checklist During Commissioning Existing Install ations Cheecklist in session General Informations c eb oC Aoc TEM ebd ees iv S801 Soft Starter MN03900002E November 2012 www eaton com 31 31 31 32 35 35 36 38 41 43 44 44 44 44 44 44 44 45 45 46 S801 Soft Starter List of Figures Eaton S80 i SON Staten s s casn vene pL epo E cU EA DW UNES LOS eS 1 Installation Mounting and Dimensions SOOT EIN mx oboe ga RIS RS Ge Petey A cea te mae ose he cep 7 SBOTHR En wae Bout an ones Vow Send eut ed nents wade Nobb ud en Ya dez 7 No P siete ars ents E AS Raa ed wae ae Ree eee el oles AS 8 A ed eor tad a th p quc bug dde oes ett Lh og 8 SOTEN S ar dud cies den ees wed os Gen DU LEES p dee niet ei eh ESTE 9 Power Wiring Inline Connected Soft Starter Power Wiring Diagram S801 N3S 10 Power Wiring Alternatives llli len 12 S801 V Shown with Terminal Cover Removed and EML30 Lug Kit Installed on Load Side 2 ee 13 Control Wiring Control Terminal Block trac am ec Ie ete sek la neh ete d de 13 BIPSSWILCH eh a a ie at ag an Ro an nen DG pa b rc etx a aoi train ea Bars 13 ZO NAC CONO d m tibt os D rS t ebur dites Cae a ge 15 DAN gc COMEOM so toch IR Ete trt tis tal 15 Basic Connection Diagram for 3 Wire Pushbutton 0000 00000 16 Basic Connection Diagram for 2 Wire Pushbutton 00000 cae 17 Functional
34. S801 Soft Starter User Manual Effective November 2012 New Information Mie Ji HT E AANA 4A 44444 ETN Powering Business Worldwide S801 Soft Starter Disclaimer of Warranties and Limitation of Liability The information recommendations descriptions and safety notations in this document are based on Eaton Corporation s Eaton experience and judgment and may not cover all contingencies If further information is required an Eaton sales office should be consulted Sale of the product shown in this literature is subject to the terms and conditions outlined in appropriate Eaton selling policies or other contractual agreement between Eaton and the purchaser THERE ARE NO UNDERSTANDINGS AGREEMENTS WARRANTIES EXPRESSED OR IMPLIED INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY OTHER THAN THOSE SPECIFICALLY SET OUT IN ANY EXISTING CONTRACT BETWEEN THE PARTIES ANY SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF EATON THE CONTENTS OF THIS DOCUMENT SHALL NOT BECOME PART OF OR MODIFY ANY CONTRACT BETWEEN THE PARTIES In no event will Eaton be responsible to the purchaser or user in contract in tort including negligence strict liability or otherwise for any special indirect incidental or consequential damage or loss whatsoever including but not limited to damage or loss of use of equipment plant or power system cost of capital loss of power additio
35. SA 22 2 14 1995 e IEC 60947 4 2 e CCC GB14048 WE RF Susceptibility Statement It is possible in the presence of strong RF fields and at specific RF frequencies that this device could indicate an increase of up to 40V in the measured line voltages in the 370 to 420 kHz frequency range or an increase of up to 1096 FLA of the measured load currents in the 111 to 132 MHz and 152 to 155 MHz frequency range Should this occur and affect the functions of the required motor protection settings refer to the troubleshooting section of this manual CE Conformance EMC Conformance Immunity Electrostatic Discharge IEC 61000 4 2 Severity Level 4 kV contact discharge 8 kV air discharge Electromagnetic Field 10 V m IEC 61000 4 3 80 1000 MHz 2 angles Fast Transient Bursts IEC 61000 4 4 2 kV 5 kHz rep 2 min intervals 1 2 50 uS to 8 20 uS Surges IEC61000 4 5 2 kV Line to earth 1 kV Line to Line 1 minute intervals Conducted RF 10 V rms EC 61000 4 6 0 15 to 80 MHz 50 Hz Magnetic Field N A EC 61000 4 8 Voltage dips 3096 dip at 10 mS nterrupt 60 dip at 100 mS EC 61000 4 11 10096 dip at5 S Emissions Radiated EN 55011 Class A Conducted EN 55011 Class A 1 The 24 Vdc power supply must be grounded 2 Add ferrite Fair Rite 40446176451 to DC Control Power Leads and Control I O Leads all through one ferrite at S8014 2 S801 S
36. This trip condition may not be immediately reset depending on the overload condition If the unit cannot be reset until a period of time has elapsed strongly suggests that an actual overload condition occurred rather than a device or component failure In a true overload condition a period of time may be required before the unit is able to be RESET Initiating another START after a reset may result in another overload trip due to retained thermal memory 48 S801 Soft Starter MN03900002E November 2012 www eaton com General Information S801 Fault Codes continued Code Fault Condition Solution 11 Overload Fault Motor overloaded for an extended period of Reduce the motor s load time Thermal Memory is over 10096 Verify the Overld Trip FLA and or Ovrld Trip Class for proper adjustment Note Exceeding nameplate ratings will shorten equipment life Fault during motor start Verify system is not exceeding the specified maximum starts per hour Increase the initial torque and or reduce ramp time to bring the motor up to speed faster Increase Trip Class setting 30 maximum and or reduce ramp time setting Notes Higher than normal thermal memory may indicate an abnormal operating condition and signal an impending Overload fault 12 Motor Stall Motor not at rated RPM at end of start ramp Lengthen Soft Start Time and or increase Initial Torque time and or current is in excess of 2X FLA potentiomete
37. all the flash codes for this stop You may now release the RESET button or remove 24 Vdc from Control terminal Block Terminal 4 Note If an overload trip has occurred 24 Vdc power must be applied to allow the overload thermal memory to reset Depending on the overload history prior to the latest trip this may be as long as 9 minutes A list of flash codes and the faults they represent is shown below Fault Codes Fault Code Fault Thermal Overload Motor Stall LED Motor Jam LED Pole Over temperature 1 2 3 4 Phase Reversal LED 5 6 SCR Failed to fire 22 Phase loss LED 23 Internal bypass contactor dropout 24 SCR Contactor overcurrent 25 Phase imbalance 26 Non volatile memory error 31 Zero voltage cross failure 32 Shorted SCR Phase loss Load disconnect 33 Load disconnect 34 SCR instantaneous overcurrent 41 24V power supply low 42 Timer system fault 43 Watchdog reset occurred 44 PLL DSP fault 45 Illegal address DSP 28 S801 Soft Starter MN03900002E November 2012 www eaton com Thermal Overload The S801 Soft Starter features an electronic motor overload protection feature It is designed to protect the motor and power wiring against overheating caused by operating at excessive current levels for extended periods of time Adjusting the FLA potentiometer to the motor nameplate Full Load Amps FLA programs the overload The
38. amp Time Seconds 0 5 180 20 Ovrld Trip Class 5 30 20 Soft Stop Time Seconds 0 60 0 S801 Soft Starter MN03900002E November 2012 www eaton com 27 8014 Operating Configuration FLA Potentiometer Setting Values Potentiometer Setting Catalog Number Iria A B C D Default S801N37 11 19 27 37 11 S801N66 20 35 50 66 20 S801R10 32 56 80 105 32 S801R13 42 73 104 135 42 S801T18 56 97 138 180 56 S801T24 75 130 185 240 75 801T30 95 164 233 304 95 801U36 12 194 276 360 112 801U42 31 227 323 420 131 S801U50 56 270 384 500 156 S801V36 12 194 276 360 112 S801V42 31 22 323 420 131 801V50 56 270 384 500 156 S801V65 203 352 501 650 203 S801V72 225 390 555 720 225 S801V85 265 460 655 850 265 S801V10 320 547 773 1000 320 Protection Parameters In addition to motor overload protection the S801 has many programmable features designed to protect the motor e Incoming Line Phase Reversal Loss Imbalance Over Voltage and Under Voltage trips e Selectable Overcurrent trip levels e Stall and Jam trips A Phase Reversal Fault is a likely fault condition on new installations It can be addressed by disabling phase rotation monitoring or removing Mains power and switching the incoming line connections at L1 and L2 of the S801 Apply the Mains voltage and verify that no fault is present The 801 indicates fa
39. ation S801 It is suggested that the S801 4 Soft Starter be configured before applying the line voltage Before applying the Line voltage apply 24 Vdc to the Supply connections of the S801 s control terminal block Set the Operating Parameters to the desired values These settings assume the motor has a 1 15 Service Factor N3S Standard 8014 Operating Configuration Soft Start Config Line Connected Motor Units Minimum Maximum Default Notes Overld Trip FLA S801 N37 Amps 11 37 11 Motor FLA parameter must be set to motor S8014N66 Amps 20 66 20 nameplate FLA to achieve proper overload protection S801 R10 Amps 32 105 32 S801 R13 Amps 42 135 42 S801 T18 Amps 56 180 56 S8014T24 Amps 75 240 75 S8014T30 Amps 95 304 95 S801 U36 Amps 12 360 12 S801 U42 Amps 31 420 31 S801 U50 Amps 56 500 56 S801 V36 Amps 12 360 12 S801 V42 Amps 31 420 31 S801 V50 Amps 56 500 56 S8014V65 Amps 203 650 203 S801 V72 Amps 225 720 225 S801 V85 Amps 265 850 265 S801 V10 Amps 312 1000 312 Overload On Disable On Jam On Disable On Stall On Disable On Phase Loss On Disable On Phase Reversal On Disable On Reset Mode Manual Auto anual Ramp Start Current Limit Ramp Current Ramp Kick Start Torque 0 85 0 Kick Start Time Seconds 0 2 0 Initial Torque 0 85 45 R
40. be experienced during commissioning of a new installation or a new soft start into an existing application Verify all connections and settings with test equipment as appropriate Common Commissioning Fault Codes e FC11 Overload e FC12 Motor Stall Fault e FC13 Jam e FC14 Motor Voltage Phase Reversal e FC16 SCR Not Firing e FC22 Phase Loss e FC25 Phase Imbalance Existing Installations Checklist External Circuit Components Issues e 24 Vdc control power undersized and or failed e solation contactors open or damaged Mains power faulty Load disconnected e Load failure e Line Load Control circuits not restored after component replacement Verification of Recent Maintenance Functions All disconnected connections restored e solation devices restored to proper operating positions Proper selection of replacement components Verify suitability of added or modified components to circuitry Fault Code Verification Use of test equipment to confirm refute validity of fault code e Determine if the fault can be reset Determine if the fault is continuous or intermittent e Note operating conditions at time of fault if possible Common Fault Codes e FC11 Overload e FC13 Jam e FC15 Power Pole Over Temperature e FC16 SCR Not Firing e FC22 Phase Loss e FC25 Phase Imbalance e FC31 Voltage Zero Cross e FC32 Shorted SCR S801 Soft Starter MN03900002E November 2012 www
41. contactors and starters In this method the motor is constructed with all six leads brought out to connect the unit in a wye configuration This allows about 5896 of the current 3396 starting torque to be applied during start up A timer is used to control the circuit and switch to the delta configuration as the unit approaches full speed In this case wire the six lead motor in a standard delta configuration The soft starter is then used to control the voltage and motor torque without the need for additional circuitry An inline disconnect means should be installed per local code The S801 Soft Starter must be wired into the three phase line feeding the three main motor input leads as would be done for normal across the line starting It must not be wired internally between motor windings in an inside the delta configuration Part Winding Motor The part winding motor is another design created to help achieve a soft start to the load A part winding motor is constructed of two separate but parallel windings When using a traditional starter the first winding would receive full voltage This winding supplies as much as 400 of the motors FLA about 4596 starting torque in a delta configuration for motor startup After a timed delay full voltage is applied to the second winding The second winding acts in parallel with the first to provide for normal running current Part winding motors are available in both a wye and delta configurat
42. djust nitial Torque for smooth start without hesitation Rotation should begin within 2 seconds and the motor should smoothly accelerate to full speed d If Stall Faults occur increase nitial Torque and or Soft Start Time to get into bypass before the Soft Start Time elapses Also verify that the motor is not overloaded Verify that the motor is not in a stall condition A stall condition will be noted when the motor does not continue to accelerate during the start ramp e After suitable performance has been achieved determine the starting time to bypass and set Soft Start Time at 1 25 times this time For example if it takes 10 seconds to accelerate the motor and go into bypass set the Soft Start Time for 12 5 seconds Adjust the Soft Stop Time for the desired stopping time f The Initial Torque setting is adjusted to achieve motor rotation within 2 seconds of motor energization The Initial Torque value also determines the upper limit of applied current during a Current Limit start S801 Soft Starter MN03900002E November 2012 www eaton com 29 8014 Operating Configuration The table below notes the values of Initial Torque settings as Code Letters a percentage of Locked Rotor Current das Kilovolt Ampere per hp with Locked Rotor Initial Torque Settings Letter Minimum Maximum Torque Current as A 0 3 14 Setting Locked Rotor Initial M
43. due to line power limitations or other considerations During a Current Limit Start the S801 applies a constant voltage to the motor resulting in limited current flowing through the motor s windings The level of current is set by the nitial Torque parameter See below Current Limit Kick 4 Start Torq Initial Torque 100 Current sof Start Time gt gt Bypass Speed kick Start Time le Start Note Current Limit Starts are not recommended on variable torque load applications like fans and pumps Attempting starts with the Current Limit set to a value of 20 Initial Torque or lower are not recommended as the motor may not develop adequate torque to accelerate properly Lm Start gt Run gt Time Seconds Soft Stop The Soft Stop feature is used for applications that require a controlled ramp extended stop It is designed for high frictional loads that tend to stop suddenly when voltage to the motor is removed During Soft Stop the voltage is ramped to zero in the time set by the Soft Stop Time parameter Note The Soft Stop mode is not an electronic brake function and will not stop a motor any faster than it would normally take to coast to a stop under load Speed 22 S801 Soft Starter MN03900002E November 2012 www eaton com Time Seconds Soft Stop Coast to Stop 100 Spe
44. e motor winding configuration chosen must be appropriate for the available line voltage The soft starter must also be selected on the basis of the configuration chosen Power Factor Correction Capacitors Power factor correction capacitors should be installed on the line side of the soft starter It is recommended that at least 10 feet of cable be between the capacitor and the soft starter The power factor correction capacitors can be Switched with a separate contactor NEMA ICS2 1988 Part 2 210 81 01 provides recommendations for when a separate contactor should be used to switch the power factor correction capacitor including high inertia loads reversing motors frequently jogged motors and multi speed motors It is not recommended that the power factor correction capacitors be used on the load side of the soft starter If used on the load side the overload relay will measure the combination of capacitor and motor current causing the overload relay to not function correctly 44 S801 Soft Starter MN03900002E November 2012 www eaton com Appendix E Troubleshooting Guide This guide is intended to provide the information necessary to successfully troubleshoot issues that may occur during the operation of the S801 Soft Starter The troubleshooting sequence and fault codes FC are identified below in two basic groups New Applications and Existing Installations While any fault may occur in either category experience has shown that
45. e Connection Three Phase Motors kW Rating 50 Hz hp Rating 60 Hz Maximum 230V 380 400V 440V 200V 230V 460V 575 690V Catalog Current 1 0SF 1 0SF 1 0SF 1 0SF 115SF 1 0SF 115SF 1 0SF 115SF 1 0SF 115SF Number Frame Size N 22 5 5 10 11 5 5 75 5 15 10 20 15 S801 N37 42 11 18 5 22 10 10 15 10 30 25 40 30 S801 N66 Frame Size R 65 15 30 33 15 15 20 15 50 40 50 50 S801 R10 80 22 40 45 25 20 30 25 60 50 75 60 801 R13 Frame Size T 115 33 59 63 30 30 40 30 75 75 100 100 S8014T18 150 45 80 90 50 40 50 50 100 100 150 125 S801 T24 192 55 100 110 60 50 75 60 150 125 200 150 S8014T30 Frame Size U 240 75 110 147 75 60 75 75 200 150 200 200 801 U36 305 90 160 185 100 75 100 100 250 200 300 250 801 U42 Frame Size V 240 75 110 147 75 60 75 75 200 150 200 200 801 V36 305 90 160 185 100 75 100 100 250 200 300 250 801 V42 365 110 185 220 125 100 150 125 300 250 350 300 801 V50 420 129 220 257 150 125 150 150 350 300 450 350 801 V65 480 147 257 295 150 150 200 150 400 350 500 450 801 V72 525 160 280 335 150 150 200 150 450 350 500 450 S8014V85 575 172 303 370 200 150 250 200 500 450 600 500 S8014V10 Notes 1 0SF 1 0 Service Factor 1 15SF 1 15 Service 42 Factor S801 Soft Starter MN03900002E November 2012 www eaton com Power Losses Appendix C Ratings Cooling and Power Losses Inline The following table lists t
46. e dae Ane oo Sees eee ae eae eee ae Initial Configuration jasa aki a EKA Eng eee Protection Parameters ooo Fate TD Sige sa it Er rotura ira EE durer ade INI US TERR Fault Codes so ett oe id Nhbe rmal wverload c endete a mane ome dua eu Soft Start Configuration Application Notes 222 2 TROUBLESHOOTING General ar ed bey Aa ahnen Mas de da na edidere na dae c I do d Before You Begin to Troubleshoot ag ANG NE lees Raul GODS Sie tina m edes tette t na ep eet deo De Cap tede s Detine the Problem i utes cta ctr Ita ote ACCESSORIES Eug KES a ra orsa eer Sedes Mie Mao ed t soo A Te em Optional Accessory Kits 2 0 0 0 000 eee Replacement Parts 0 0000 en APPENDIX A PARAMETERS Parameters Ku a EX Seat ha SG See ee Ser a BS Ma ds Ana APPENDIX B OVERLOAD PROTECTION ThiertmalOverlodd sico m met ciated behets a APPENDIX C RATINGS COOLING AND POWER LOSSES INLINE Power RatihgS A au dett en t edet Nass bo eee a ct ened na tached Power LOSSES x ausm ce md eat dee qoid AD UR epa te cta lee aes APPENDIX D MOTOR APPLICATION CONSIDERATIONS Squirrel GageMOtOFL 5 aiite setae etos Rate Wye D lt Motor 22i 22 428320 a aa Aet Te e Bet Part Winding Motor erat ot ct ses d pe led ta Dual Voltage Motor ssia eina na eaae eee M lti SpeedMOtOF t etre GPa Et Ged area Other Winding Configurations llle Power Factor Correction Capacitors_ eee APPENDIX E T
47. e is 8796 or less of the saved temperature a full thermal memory reset is initiated S801 Soft Starter Appendix B Overload Protection MN03900002E November 2012 www eaton com 39 40 Appendix B Overload Protection Overload Trip Curves Time Seconds 10000 0 115 mem Class 5 1000 0 LOTH EEE EE NA NA IS IS A S U Class 10 M Class 20 Class 30 Y N k Y X a IN Y NER N N N N IN s 100 0 n ix KN NK M x A T N N M IN f E Class 30 4 M M x yn MT x M gt AN N Is Class 10 N i Class 20 s yr Class Pas x TE EN he SI N T T N NG MN Sl ML Class 5 P 1 x J 10 0 f Pe T N Ph Sy A Th Tsk Md Sl mb eo PLI 1 0 0 100 200 300 400 500 600 700 800 900 Percent FLA S801 Soft Starter MN03900002E November 2012 www eaton com Appendix C Ratings Cooling and Power Losses Inline Appendix C Ratings Cooling and Power Losses Inline Power Ratings Standard Duty 15 Second Ramp 300 Current Limit at 40 C Inline Connection Three Phase Motors
48. e opposite direction upon soft restarts The time required for slowing the motor to a stop and then ramping up to speed in the opposite direction adds to the overall starting time This condition will also impact the overload protection setting See the Motor Application Considerations in Appendix D for information on typical motor winding configurations Inline Connected Soft Starter Power Wiring Diagram S801 N3S 1lL1 3112 513 O ar ur ur Line and Load Power Wiring S801 N and S801 R soft starters utilize box lugs to accomplish line and load power wiring Refer to the table below for wire sizing requirements Line and Load Power Wiring S801 N and S801 R Catalog Conductor Number of Torque Number Size O Conductors Lb in Nm S801 N 2 AWG 1 50 5 6 4 6 AWG 45 5 0 8 AWG 40 4 5 10 14 AWG 35 4 0 S801 R 14 8 AWG 1 90 100 10 1 11 3 6 4 AWG 3 3 0AWG 6 4 AWG 3 3 0 AWG Note Wire sizes Cu 75 C only 10 S801 Soft Starter MN03900002E November 2012 www eaton com Line and Load Power Wiring S801 T S801 U and S801 V Catalog Conductor Number of Torque Kits Number Size Conductors Lb in Nm Lug Kit Required S801 T 4 1 0 MCM 2 250 28 3 EML22 2 4 0 500 MCM 1 250 28 3 EML23 4 0 500 MCM 20 250 28 3 EML24 2 0 300 MCM 1 225 25 5 EML25 2 0 300 MCM 2 225 25 5
49. e to match incoming sequence If an upstream reverser is used disable Phase Rev Fault not recommended This fault is not uncommon in new installations In the event of a blown fuse prior to a START command this fault may occur as the unit is not able to determine phase rotation with one open fuse If motor rotation requires exchange of phases exchange the cables between the soft starter and the motor S801 Soft Starter MN03900002E November 2012 www eaton com 49 General Information S801 Fault Codes continued Code Fault Condition Solution 15 Power Pole Over SCR temperature is above limits Ventilate to specified maximum temperatures Temperature Operating environment above specified Clear obstructions maximum temperature Ventilation holes blocked Verify fans are operational Fans are not operational Verify system is not exceeding the specified maximum starts per hour Starts hour exceed specifications Verify bypass contacts are closing at the end of ramp time Sensor failure on power pole Reduce excessive cabinet temperature Bypass contactor s failed to close Soft Starter running continuously in JOG mode Notes Any power pole temperature in excess of 100 C will cause a fault trip The soft starter will attempt to close the bypass contactors at the end of the ramp time or if the motor is up to synchronous speed for 30 seconds If the bypass contactors close then o
50. eaton com 45 General Information General Information 24 Vdc Control Power Terminal Block Connections Run Enable 24 Vdc applied to Terminal P This 24 Vdc input must be maintained continuously during RUN operation from either the terminal block or a network START Command enable from Terminal Block gt Voltage applied to terminal 3 of the control power terminal block When a 120 Vac signal is applied to the Comms Select terminal START control from the terminal block will not be recognized START Command with 24 Vdc applied to Terminal P7 apply 24 Vdc to Terminal 1 The signal requirement is momentary but maintained is acceptable Terminals P and 1 may be tied together for 2 wire control START STOP commands STOP Command Remove 24 Vdc from Terminal P Terminals P and 1 may be tied together for 2 wire control START STOP commands Wire size minimum 14 AWG to all Terminal Block connections Wire should have no stands missing or damaged during wire stripping The use of terminal ferrules is recommended to maintain connection integrity Control Power Supply Requirements Must meet or exceed steady state and inrush capacity requirements Steady State sealed 25 Watts 24 Vdc Outrush 240Watts 24 Vdc for 150 ms minimum Minimum supply voltage 24 Vdc measured at the Terminal Block Maximum allowable voltage drop measured at the Terminal Block 5 Vac Fault Reset
51. ed Soft Stop Ramp Voltage Soft Hx Stop Time He Run gt lt Soft Stop 1 Time Seconds Control Functions Local Control S801 Local Control consists of Permissive Start Jog Disable Overload on Start and Reset 24 Vdc control commands to the Terminal Block The Control Terminal Block utilizes five b functions to control the S801 4 soft starter Terminal P Permissive run enable Must be energized with 24 Vdc to enable operation of the S801 soft starters If power is lost or removed from Permissive terminal at any time the unit will initiate a coast Stop or Soft Stop in accordance with the setup parameter selections Terminal 1 Start If 24 Vdc is present at the Permissive terminal momentary application of 24 Vdc to the Start terminal will initiate a Voltage Ramp or Current Limit start for the S801 soft starter Application of 24 Vdc may be maintained Note With level sensing control if 24 Vdc is lost or removed from the Permissive terminal at any time the unit will initiate a stop in accordance with setup parameter selections A restart may occur when 24 Vdc is restored or reapplied if a 24 Vdc is present on the Start terminal maintained and b the S801 shows a Ready LED not faulted status If the starter has faulted and the fault condition clears AND the Auto Reset Mode parameter in the Operation Mode list is set to AUTO the starter will restart
52. etting Values Potentiometer Setting Catalog Number Ira A B C D e RR y s OVLD EN 20 30 Overload Trip Class S801N37 11 19 27 37 o es CLASS Full Load Amps FLA S801N66 20 35 50 66 tea 801R10 32 56 80 105 stop Ramp Time S801R13 42 73 104 135 Se S801T18 56 97 138 180 S801T24 75 130 185 240 Start Torque and Time S801T30 95 164 233 304 Kick Start Torque and Time 801U36 112 194 276 360 S801U42 131 227 323 420 Control Interface Module CIM S801050 156 770 384 500 The S S trip LED indicates the operating status of the S801V36 112 194 216 360 38014 S801V42 131 227 323 420 e S S Trip S801V50 156 270 384 500 e General fault Fault codes S801V65 203 352 501 650 ON S801V72 225 390 555 720 ale S801V85 265 460 655 850 Protections S801V10 320 547 773 1000 e Overload Jam Stall Phase loss Phase reversal S801 Soft Starter MN03900002E November 2012 www eaton com 25 8014 Operating Configuration Setup and Starting Before You Begin Be Aware of the Following 1 The Permissive terminal must have 24 Vdc applied to ENABLE start or run commands from any source 2 Toinitiate a Stop remove the 24 Vdc Permissive terminal input 3 For 2 wire local control jumper Permissive and Start terminal inputs together 4 After an Overload Trip the S801 Soft Starter cannot be restarted until the pre
53. f the Start control signal is momentary then either Edge or Level Sensing may be selected and S801 operation will be the same as in either case only a momentary signal is placed on the Start terminal If the Start control signal is maintained then the signal must be removed then reapplied to initiate a start if Edge Sensing is selected Level or Edge Sensing is selected with the S1 DIP switch located on the face of the S801 Level Sensing Level sense means that the 24 Vdc signal at the Start terminal may be continuous and does not require voltage to be removed and reapplied after a fault trip has occurred Level sensing will result in an automatic motor restart after a fault when e Fault condition is cleared e The Permissive terminal is supplied with 24 Vdc e The Reset Mode parameter is set to AUTO e There is 24 Vdc power to the Start terminal Start command maintained Level sensing will allow a motor restart after a fault when All faults remain cleared or reset e The Permissive terminal is supplied with 24 Vdc e The Reset Mode parameter is set to AUTO or MANUAL e 24 Vdc power to the Start terminal is again applied Start command momentary This control configuration can be used where it is desirable to restart a motor after a fault without additional manual or automatic control An example of this condition would be on a remote pumping station where it is desirable to automatically restart a pump
54. g device It is intended to provide three phase induction motors with a smooth start both mechanically and electrically The S801 Soft Starters utilize six SCRs connected in a full wave power bridge Varying the SCR conduction period controls the voltage applied to the motor This in turn controls the torque developed by the motor After the motor reaches speed internal contacts are closed to bypass the SCRs General Appearance Notes Eaton S801 Soft Starter Line Input sempe FTN OVERLOAD ON IBI ois sane ou d one STALL 9 on ES oisasie PH LOSS on BRM DISABLE PH REV on EM oisas e MANUAL RESET BEM auto RESET Introduction The S801 Soft Starter utilizes a Control Interface Module CIM that allows the user to configure the device and evaluate fault codes for troubleshooting The S801 is designed to fulfill the industrial service requirements for applications such as Chillers Pumps and Machine Tools that require less than 100 of the motor s rated starting torque for worst case starting condition The S801 meets all relevant specifications set forth by UL 508 CSA 22 2 14 1995 IEC 60947 4 2 and CCC GB14048 Mounting Base Base Control Interface aii Module CIM DIP Switch S1 Load Output A o Factory Use Only Detachable 12 Pin Locking Control Terminal Block S801 Soft Starter MN03900002E November 2012 www eaton com 1 Introduction Standards and Certifications UL 508 e C
55. hat the unit s catalog number and options match those stated on the order purchase form A CAUTION Unit may weigh up to 103 pounds Use suitable lifting device S801 Soft Starter MN03900002E November 2012 www eaton com Receipt Unpacking Storage It is recommended that the unit be stored in its original shipping box crate until it is to be installed The unit should be stored in a location where The ambient temperature is 58 to 158 F 50 to 70 C e The relative humidity is 0 9596 non condensing e The environment is dry clean and non corrosive The unit will not be subjected to shock in excess of 15g s and or vibration exceeding 3g in any direction Shipping S801 Soft Starters are to be shipped in packaging that adequately protects the unit S801 units installed in an OEM system as a mounted assembly in a cabinet or panel in enclosed control systems are to be adequately secured and shipped via Air Ride carrier to prevent damage from excessive shock or vibration during shipment Installation Installation Mounting The S801 does not require any special tools for mounting operations To aid with panel layout refer to the dimension drawings on Pages 7 9 Drill holes per mounting hole location as shown Mounting hardware may utilize either tapped holes in the panel or lock washers and nuts to secure the soft starter To mount the unit use all the hardware specified in the table below Required M
56. he maximum power loss for each S801 Soft Starter when it is operating in bypass at the maximum frame size current These losses should be used in conjunction with the losses of another cabinet mounted device to determine the enclosure size and any cooling requirements Maximum Power Loss Catalog FLA Current Power Loss Number Range Inline Watts 801 N37 11 37 amps 30 S801 N66 20 66 amps 33 S801 R10 32 105 amps 4 801 R13 42 135 amps 55 S801 T18 56 180 amps 37 S801 T24 75 240 amps 40 S801 T30 95 304 amps 45 801 U36 12 360 amps 76 801 U42 31 420 amps 92 801 U50 56 500 amps 116 S801 V36 12 360 amps 56 801 V42 31 420 amps 64 801 V50 56 500 amps 78 801 V65 203 650 amps 109 S801 V72 225 720 amps 127 S801 V85 265 850 amps 164 S801 V10 312 1000 amps 215 S801 Soft Starter MN03900002E November 2012 www eaton com 43 Appendix D Motor Application Considerations Appendix D Motor Application Considerations Squirrel Cage Motor This is the most common application The motor is configured with three motor leads available In this case wire the motor to the soft starter with one lead per phase observing proper phase rotation An in sight disconnect means should be installed per code requirements Wye Delta Motor The wye delta motor is a traditional way of achieving a reduced voltage start using regular
57. icient Monitoring Menu c rrent capacity Verify correct wire size 14 gage minimum used to connect power supply to S801 Inspect for wire damage or corrosion Check voltage drop between power supply and Terminal Possible internal hardware failure Notes Only voltage at Terminal is monitored for condition that may generate this fault Inspect control voltage circuit for proper configuration If the 24 Vdc control voltage is lost at Terminal P just prior to the voltage loss at Terminal the soft starter will recognize this condition as a STOP command This condition would cause a shutdown of the soft starter without logging FC41 Suspect source voltage should be monitored for the appropriate length of time to determine if the voltage drifts more than 0 1 Vdc from nominal or if the voltage is intermittent When selecting a power supply ensure that the outrush capacity of the power supply meet or exceed 240 watts at 24 Vdc for 100ms minimum 42 Firmware Incompatibility or Hardware failure Failed unit Contact EatonCare for service information Hardware failure 43 nternal Communications Communications to DSP have been Firmware is not communicating internally interrupted Possible hardware failure Cycle 24 Vdc control voltage power to attempt to clear problem 44 nternal CPU Firmware Incompatibility or Hardware failure on the printed circuit board PCB and or the firmware is corrupted Hardware failure Contact EatonCare for s
58. ify that 24 Vdc is applied to Terminal 1 to issue START command If Terminals P and 1 are tied together verify that both Terminals receive 24 Vdc START signal If Start Control parameter is set to EDGE verify that 24 Vdc has been cycled removed then reapplied after faults have been reset MN03900002E November 2012 www eaton com 47 General Information S801 Fault Codes Code Fault Condition Solution S S Trip LED General Fault Occurs when any dedicated LED and or Check for presence of dedicated LEDs Fault Code is logged into the S801 memory Check for presence of fault codes Note Fault codes are not time stamped Verify that the code is a recent occurrence rather than an old code Notes The most common occurrences of faults may be Overtemperature High operating temperature T setting Ramp time too long Hardware failure Load disconnect Insufficient motor load These faults may be corrected by the appropriate actions If the RVSS has stopped and the S S Trip LED is not illuminated verify that a STOP command was not errantly received by the unit Failure to note the validity of a STOP command and failing to note an old fault code may result in needless troubleshooting activities JAM LED Jam Soft Starter in Bypass Motor below rated Remove obstruction FC13 RPM and or current exceeds 3X FLA Verify proper FLA setting on FLA p
59. ion dependent upon the manufacturer Refer to the motor nameplate for the correct wiring information In this case wire the two windings in parallel The soft starter is then used to control the current applied to the motor An in sight disconnect means should be installed per code requirements Dual Voltage Motor A dual voltage motor should be wired into the appropriate configuration for the line voltage it is being applied to Refer to the motor nameplate for the correct wiring information The soft starter must be selected for the appropriate line voltage Multi Speed Motor Some motors have multiple windings to allow operation at different base speeds The multiple speeds are sometimes utilized for soft starting and other times for a process requirement of the machine to which it is attached If only one speed is required the motor should be wired for that speed If multiple speeds are required the appropriate contactors will need to be connected to the output of the Soft Starter The contactors must be in the selected speed position before the soft starter is started The motor must be stopped and the soft starter turned off before the speed selection contactors are changed Other Winding Configurations Motors with other winding configurations designed for specific characteristics should be wired in a fashion consistent with their intended use The motor nameplate contains information on the available configurations Th
60. ion ms S801 N 1 0 25 10 240 150 S8014R 1 0 25 10 240 150 S8014T 1 0 25 10 240 150 S8014V 1 0 25 10 240 150 S8014U 1 0 25 10 240 150 For applications where one starter is used with one power Formulas to calculate control power requirements are as supply the power supply selected must be equal to or greater than both the sealed in and inrush requirements of the starters e Max Steady State for the power supply gt Sealed In Power of the Starter Outrush for the power supply 2 Inrush Power of the Starter Multiple starters can be used with one power supply If the application requires the starters to start at the same time the power supply must be sized for the sum of the sealed in and inrush power for each starter e Max Steady State for the power supply gt Sum of the Sealed In Power of all the Starters e Outrush for the power supply gt Sum of the Inrush Power of all the Starters Eaton Recommended 24 Vdc Power Supplies follows e Definitions SI 2 Sum of Seal Incurrent LS Largest Seal Incurrent LI 2 Largest Inrush Needed TS Total Seal Incurrent Needed LO Largest Outrush Needed e TS SI LS LO TS LI Max Steady State for the power supply gt SI e Outrush for the power supply gt LO The voltage on the S801 Control Power Supply and Control Input terminals must be 24 Vdc 10 to provide proper operation of the soft starter Sealed Inrush Catalog Primary
61. ip this may be as long as 9 minutes A list of flash codes and the faults they represent is shown below Fault Codes Fault Code Fault 1 Thermal Overload 2 Motor Stall LED 3 Motor Jam LED 4 Phase Reversal LED 5 Pole Over temperature 6 SCR Failed to fire 22 Phase loss LED 23 Internal bypass contactor dropout 24 SCR Contactor overcurrent 25 Phase imbalance 26 Non volatile memory error 31 Zero voltage cross failure 32 Shorted SCR Phase loss Load disconnect 33 Load disconnect 34 SCR instantaneous overcurrent 41 24V power supply low 42 Timer system fault 43 Watchdog reset occurred 44 PLL DSP fault 45 Illegal address DSP S801 Soft Starter MN03900002E November 2012 www eaton com 31 Troubleshooting Define the Problem 1 If the S801 Soft Starter fails to respond in any way to a start command look at the Control Interface Module of the S801 Soft Starter and determine the fault status of the unit The following troubleshooting flowcharts provide a logical sequence to determine issues and suggest probable solutions to each problem Start Command Troubleshooting Flow Chart Check 24 Vdc Ys Are any Power LEDs Lit Is the Fault LED Lit Check Protection LEDs and fault code and attempt to clear Supply 24 Vdc Power Troubleshooting S801 Does not START Yes y Check 24V Permissi
62. kW Rating 50 Hz hp Rating 60 Hz Maximum 230V 380 400V 440V 200V 230V 460V 575 690V Catalog Current 1 0SF 1 0SF 1 0SF 1 0SF 115SF 1 0SF 115SF 1 0SF 115SF 1 0SF 115SF Number Frame Size N 37 10 18 5 18 5 10 10 10 10 25 20 30 30 S801 N37 66 18 5 30 37 20 15 20 20 50 40 60 50 S801 N66 Frame Size R 105 30 55 59 30 25 40 30 75 60 100 75 801 R10 135 40 63 80 40 30 50 40 100 75 125 100 801 R13 Frame Size T 180 51 90 110 60 50 60 60 150 125 150 150 S801 T18 240 75 110 147 75 60 75 75 200 150 200 200 801 T24 304 90 160 185 00 75 100 00 250 200 300 250 S801 T30 Frame Size U 360 10 185 220 25 00 150 25 300 250 350 300 S801 U36 420 29 220 257 50 2 175 50 350 300 450 350 801 U42 500 50 257 300 50 50 200 50 400 350 500 450 801 U50 Frame Size V 360 10 185 220 25 00 150 25 300 250 350 300 S801 V36 420 29 220 257 50 2 175 50 350 300 450 350 S801 V42 500 50 257 300 50 50 200 50 400 350 500 450 801 V50 650 200 355 425 250 200 250 20 500 450 600 500 801 V65 720 220 400 450 300 25 600 500 700 600 S801 V72 850 257 475 500 350 30 700 600 900 700 S801 V85 1000 271 525 500 400 35 800 700 900 800 S801 V10 Notes 1 0SF 1 0 Service Factor 1 15SF 1 15 Service Factor Consult factory S801 Soft Starter MN03900002E November 2012 www eaton com 41 Appendix C Ratings Cooling and Power Losses Inline Severe Duty 30 Second Ramp and or 450 Current Limit at 50 C Inlin
63. ll recessed RESET button on the face of the soft starter and by applying e face of the soft starter is a sub miniature will feel a slight detent when the switch closes Pressing the switch beyond this point does not increase your he switch If the detent cannot be felt when pushing the button proper t can be RESET by applying 24 Vdc to Run without CIM CIM is non functional or intermittent installed Soft Starter may be run wi th existing parameters without the CIM CIM may be reinstalled an d control power applied initialization process will recognize CIM To run the soft starter without the CIM simply disconnect the CIM prior to a START command To reinstall a CIM that has been removed remove 24 Vdc control power reinstall the CIM then restore 24 Vdc control power Notes All mains and control power connections must be completed and voltage applied prior to a START command Failure to make all connections will result in one or more faults S801 Soft Starter All isolation and or reversing contactors must be staged prior to any START commands Manipulating contactors after the START command will result in one or more faults MN03900002E November 2012 www eaton com 53 General Information 54 S801 Soft Starter MN03900002E November 2012 www eaton com General Information S801 Soft Starter MNO3900002E November 2012 www eaton com 55 General Information 56 S801 Soft Starter MN
64. lying 24 Vdc to terminal 1 while P is energized will initiate a START command As shipped from the factory this input is level sensitive 2 JOG Control Input 24 Vdc only momentary Input 2 is JOG Applying 24 Vdc to this input while P is energized will initiate a JOG JOG will follow the selected ramp profile as long as the signal remains present The unit will not close the internal bypass contactors 3 Disable OL on Strt Momentary application of 24 Vdc to Terminal 3 prior to a start raises the overload fault trip point to 12596 of the maximum rating of the frame size for the next start only 4 RESET Fault RESET Control Input 24 Vdc only momentary Input 4 is Fault RESET Energizing this input will reset a fault only if no active faults are present 14 S801 Soft Starter MN03900002E November 2012 www eaton com Using Auxiliary Contacts Often these contacts are used as shown in the illustrations on this page with indicating lamps In some installations the user may wish to use an electromagnetic relay for indication of the status at a remote location for use by a programmable controller PLC or in a 120 Vac control circuit If the S801 Soft Starter is subject to mechanical shock during operation it is possible that these contacts may momentarily open causing nuisance fault tripping of down stream devices When used with an indicating lamp a momentary contact opening would not be observed In order to assure pr
65. minal Block Descriptions 0 0 200005 14 Using Auxiliary Contacts ca ud cae a Sow tole x acte en ar 15 Typical Control Wiring Diagrams isses 16 24 Vdc Control Power Reguifremenis_ o 18 Control Wiring Application Notes 0002s 19 Using a Supplemental Line Contactor_ sls 19 FUNCTIONAL DESCRIPTION FPOWOL X frat a ay ga tu to du ed c io a i e ud n ER E 20 Contro ar o diseno A eS Pini a ter E uli EE Ed gutes du 20 Starting Stopping Options iius s mar er era 21 Voltage Ramp Start o e xum epe eR ea gt ee A SR dd 21 Kiek Starts s thei ded eed heii A a a a a a 21 Curren limit Stake sce Ta eo e RE Ru CIR DRE RS 22 SOP SOP stu da eti ated etat wake aay suns op tex oer e sex pov op ux 22 Control Funetions er mes SER Goa oe Re eo ao el a p ut 23 Local Control a E ed hI a oe let E 23 Level or Edge Sersihng cs ne ad RYE ea ee AED ek 23 Level SEHSING ata a i oa ENG AT ad em eet amete 23 Edge SENSING exec een Ree teer idee eser ee ot 24 S801 Soft Starter MN03900002E November 2012 www eaton com 8014 Soft Starter Table of Contents continued S801 OPERATING CONFIGURATION Introduction uta ku ERE a ak A aio Meee a USER Interface z vus ss A E ER Control Interface Module CIM 0 00002 cee ee eee SetUPsaMGStartlag ue prre ee Ra GE vp Wb ease Be Before You Begin i xiu Ive rane e Rd ee OX Nat n Be Aware of the Following 0c cee eee eee SETUP ec sick ee oe e wa
66. nal expenses in the use of existing power facilities or claims against the purchaser or user by its customers resulting from the use of the information recommendations and descriptions contained herein The information contained in this manual is subject to change without notice Cover Photo S801 Soft Starters S801 Soft Starter MN03900002E November 2012 www eaton com i 8014 Soft Starter Support Services The goal of Eaton is to ensure your greatest possible satisfaction with the operation of our products We are dedicated to providing fast friendly and accurate assistance That is why we offer you so many ways to get the support you need Whether it s by phone fax or e mail you can access Eaton s support information 24 hours a day seven days a week Our wide range of services is listed below You should contact your local distributor for product pricing availability ordering expediting and repairs Web Site Use the Eaton Web site to find product information You can also find information on local distributors or Eaton s sales offices Web Site Address www eaton com electrical EatonCare Customer Support Center Call the EatonCare Support Center if you need assistance with placing an order stock availability or proof of shipment expediting an existing order emergency shipments product price information returns other than warranty returns and information on local distributors or sales offices Voice 877 ET
67. nd of th rt Ram fige dn Nip a EE a in P It should be noted that a lightly loaded motor takes less increases the motor develops torque that accelerates the torque and thus lower voltage and time to accelerate to full load toward full speed When the S801 senses that the speed For this case the S801 will go into bypass before the motor has achieved synchronous ramp reaches full voltage In other words the S801 may go into bypass before the Soft Start Time has elapsed Voltage Ramp Start Bypass Bypass voltage AW Rated l amp Voltage 10096 f Kick Start Torq 3 3 S 2 e E Initial l Torque ae Start Time ir Start gt lt Run gt Start gt lt Run gt Time Seconds Time Seconds Kick Start The Kick Start feature works in both the Voltage Ramp Start and Current Limit Start modes By momentarily applying up to a two 2 second pulse of current to the motor it provides an initial boost in torque to overcome the static friction or high inertial loads common in some applications The level of torque boost is set by the Kick Start Torq parameter and the duration of the kick is set by the Kick Start Time Setting the Kick Start Time to O effectively disables this feature S801 Soft Starter MN03900002E November 2012 www eaton com 21 Functional Description Current Limit Start This mode is typically used when it is necessary to limit the maximum current during start up
68. not start verify that the Start input terminal is at 24 Vdc 2 It is often useful in determining the nature of the fault condition by noting when the trip occurs during operation of the S801 soft starter The operation of the S801 may be categorized into the following periods The S801 amp Soft Starter trips Immediately when the START command is issued The S801 amp Soft Starter trips during the START ramp and never reaches bypass The S801 Soft Starter trips when the bypass contactors are closing The S801 4 Soft Starter trips during running operation while bypass contactors are closed The S801 Soft Starter trips after the Stop command is received The S801 amp Soft Starter stops sooner than expected during a soft stop If the Soft Stop Time is set too long for the motor loading high loads the motor will begin to stall when delaying SCR firing reduces the voltage The S801 Soft Starter will detect this stalling due to the increase in current flow and end the stop immediately and not indicate any faults Troubleshooting S801 Stopped or Faulted Condition Possible Problem Status LED is GREEN Stop command received Terminal block wiring not secure Loss of 24 Vdc control power Transient fault when Reset Mode set to AUTO External control device failure External mains device failure or trip condition Control board failure Troubleshooting Refer to the flowchart on Page 34 to aid
69. ntial equipment damage and personnel hazard A CAUTION Only apply 24 Vdc to Control Terminal Block All control wiring is 22 12 AWG 0 33 2 5 mm A CAUTION If the AUTO Reset mode setting is used CAUTION must be exercised to assure that any restart occurs in the safe manner A CAUTION If the AUTO Reset mode setting is used with level sensing CAUTION must be exercised to assure that any restart occurs in a safe manner Motor restart may occur immediately and unexpectedly after any fault condition has cleared viii S801 Soft Starter MN03900002E November 2012 www eaton com A CAUTION In the AUTO Reset mode CAUTION must be exercised to assure that any restart occurs in a safe manner A WARNING Make sure you read and understand the procedures in this manual before you attempt to set up or operate the equipment A WARNING Do not work on energized equipment unless absolutely required If the troubleshooting procedure requires equipment to be energized all work must be performed by properly qualified personnel following appropriate safety practices and precautionary measures S801 Soft Starter S801 Soft Starter MN03900002E November 2012 www eaton com ix 8014 Soft Starter x S801 Soft Starter MN03900002E November 2012 www eaton com Introduction Overview The Eaton S801 Soft Starter from Eaton s electrical business is an electronic self contained panel or enclosure mounted motor soft startin
70. o make connections for 24 Vdc control power soft starter control function commands and Auxiliary Relay functions A 3 position screw connector utilized to make connections for factory use only and is not utilized with S801 operations User Interface Module Terminal Block An RJ12 connection utilized to make the connection to the Control Interface Module CIM Control Terminal Block Se EN f s DIP Switch Switch S1 selects Edge ON or Level OFF sense detection on the Run1 input on control block Terminal 1 default Switch S2 is not functional on the S801 4 Switches 32 1 are not functional on the S801 DIP Switch gi m mmm a a Additional information on Level and Edge Sensing may be found in Functional Description starting on Page 23 S801 Soft Starter MN03900002E November 2012 www eaton com 13 Installation Control Wiring Terminal Blocks A CAUTION Only apply 24 Vdc to Control Power Terminal Block All control wiring is 22 12 AWG 0 33 2 5 mm A CAUTION Do not apply 120 Vac to Control Power Terminal Block 801 Control Terminal Block Wiring Control Terminal Block Descriptions A CAUTION Do not apply 24 Vdc to Network communications Terminal Block Terminal Block Wiring Capacity Number of Wire Size Conductors Torque Requirements 22 14 AWG 0 33 2 5 mm 2 3 5 Lb in 0 4 Nm 14 12 AWG 2 54 0 mm
71. oft Starter MN03900002E November 2012 www eaton com Technical Data and Specifications Environmental Environmental Specifications Description Specification Technical Data and Specifications Temperature range Operating 40 to 122 F 40 to 50 C Storage 58 to 158 F 50 to 70 C Elevation Up to 6600 ft 2000m above 6600 ft 2000m derate 0 5 per 330 ft 100m Humidity Functional to 95 noncondensing Operating orientation Pollution degree IEC 60947 1 Shock resistance 15g in any direction Vibration resistance Operating 3g in any direction Non Operating 3g in any direction Physical Unit Weight and Dimensions Product Size Inches mm Catalog Number Unit Weight Lbs kg Length Width Height 801 N37 58 2 6 7 37 187 2 2 66 67 6 6 45 163 9 S801 N66 58 2 6 7 37 1872 2 66 67 6 6 45 163 9 801 R10 10 5 4 8 792 2012 438 111 3 6 64 168 6 801 R13 10 5 4 8 792 2012 438 111 3 6 64 168 6 S801 T18 4 18 6 241 322 9 765 1944 6 47 1644 S801 T24 4 18 6 241 322 9 765 1944 6 47 1644 801 T30 4 18 6 241 322 9 765 1944 6 47 1644 S801 U36 4 8 6 2 472 323 1 7713 196 3 7 46 196 3 801 U42 4 18 6 2 72 323 1 7713 196 3 7 46 196 3 801 U50 4 8 6 2 72 323 1 773 196 3 7 46 196 3 S801 V36 9 41 4 6 57 420 8 05 280 6 7 39 187 8 S
72. ollowing equipment to aid you in troubleshooting e Multimeter e Clamp on ammeter Always assume the S801 has high voltage applied and take proper precautions while troubleshooting the soft starter and associated equipment Read all precautions at the front of this manual before starting the troubleshooting process Troubleshooting Fault Codes To obtain the fault flash codes from the CIM hold the RESET button located below the CIM down or apply 24 Vdc to terminal 4 and count the number of times all the LEDs on the CIM flash For example if you see three flashes and then two more flashes after a short pause the flash code is 32 The CIM can provide multiple flash codes if more than one error condition caused a stop Once you see the same flash code repeated you have seen all the flash codes for the error conditions that caused the stop For example if you see three flashes a pause then two flashes a slightly longer pause then four flashes a pause then one flash the flash codes are 32 and 41 If you then see three flashes a pause then two flashes you are seeing the first code again This means you have seen all the flash codes for this stop You may now release the RESET button or remove 24 Vdc from Control terminal Block Terminal 4 Note If an overload trip has occurred 24 Vdc power must be applied to allow the overload thermal memory to reset Depending on the overload history prior to the latest tr
73. onnections 2 0 to 300 kcmil cable EML26 Lug Kits S801 V Description Part Number 2 cable connections 4 0 to 500 kcmil cable EML28 4 cable connections 4 0 to 500 kcmil cable EML30 6 cable connections 4 0 to 500 kcmil cable EML32 2 cable connections 2 0 to 300 kcmil cable EML33 Optional Accessory Kits Accessory Kits Accessory Kit Description S801 Frame Part Number Panel Mounting Kit 3 ft cable S801 EMA69A Panel Mounting Kit 5 ft cable S801 EMA69B Panel Mounting Kit 8 ft cable 8014 EMA69C Panel Mounting Kit 10 ft cable S801 EMA69D Mounting Plate S801 N S801 N EMM13N Mounting Plate S801 R S801 R EMM13R Mounting Plate S801 T S801 T EMM13T Mounting Plate S801 U S8014U EMM13T Mounting Plate S801 V S801 V EMM13V Vibration Plate S801 N S801 N EMM14N Vibration Plate S801 R S801 R EMM14R Vibration Plate S801 T S801 T EMM14T Vibration Plate S801 U S801 U EMM14T Vibration Plate S801 V S801 V EMM14V P20 Kit S801 N S801 N SS IP20 N P20 Kit S801 R S801 R SS IP20 R P20 Kit S8014T S8014T SS IP20 TU P20 Kit S801 U S8014U SS IP20 TU P20 Kit S801 V S801 V SS IP20 V Fan Kit S801 EMM18 Replacement Parts Replacement Parts Accessories Replacement Description S801 Frame Part Number Control Wire Connector S801
74. oper application it is suggested that the following recommendations be implemented PLC Interface It is suggested that a 20 ms delay be programmed to assure the contact status before a change of status is indicated The application and the environmental issues will determine the exact requirements 120 Vac Signal Control When a relay is used in conjunction with an electronic control it is highly recommended that a noise suppressor be used across the relay coil In the case of an AC coil the noise suppressor is made up of a series connected resistor and capacitor as shown in the figure below Usually the delay in the relay opening is very small so if the system is subject to shock a delay should be added in the external control before the contact change of state is recognized The resistor is rated 100 ohms at 0 5 watts The capacitor is 0 25 uF at 250 Vac 120 Vac Control EAS 13 WN Bypass OH u H 120V AC idi Supply THE Ds Ready RH S He Fault 98 Installation 24 Vdc Signal Control When a relay is used in conjunction with an electronic control it is highly recommended that a noise suppression snubber diode be placed across the relay coil as shown below This diode offers two benefits First the suppression of any electrical noise generated when the relay coil is de energized Second the diode delays the opening of the relay slightly
75. otentiometer Jam Fault can be disabled if trips occur during normal operation Notes The Jam Fault may be disabled not recommended The maximum RMS value of the 3 phase currents is monitored when the internal bypass contactors are closed The Jam Fault Trip threshold is 3X Motor FLA and is not user settable Jam Trip Delay is 1 5 seconds and is not user settable STALLLED Unit railed to reach Motor failed to reach synchronous speed Clear application of the cause of the Stall condition FC12 synchronous speed 90 motor rpm or greater prior to the CERE RT expiration of the START time Verify ramp time is sufficient for the application Verify the Initial Torque setting is appropriate for the application Notes Motor rotation should begin within 2 seconds of energization If motor rotation does not begin within 2 seconds increase Initial Torque or utilize the Kick Start feature to initialize motor rotation PH Loss LED One or more phase voltages One or more phase voltages not present Verify that all connections are correct and tight and voltage is of the FC22 not present proper value Phase voltages and or currents have Verify continuity of fuses or breakers disconnects or isolation significant imbalance contactors Verify all connections are correct and tight Verify that imbalance is within limits during Run operation in bypass Notes Verify fuse integrity by using the proper test methods Performing a resistance test with an ohmmeter ac
76. otor Torque B 3 15 354 85 92 Maximum C 3 55 3 99 7196 84 D 4 0 4 49 5696 7596 E 45 4 99 45 67 Default Value F 5 0 5 59 3696 6096 G 5 6 6 29 3396 57 Wye Delta Equivalent H 6 3 7 09 2196 5296 J 7 1 7 99 19 44 Current Limit Minimum K 80 8 99 14 37 L 90 9 99 1 10 Minimum M 10 0 11 19 The National Electrical Code requires that all alternating N 112 12 49 current motors of 1 2 horsepower and higher must have P 12 5 13 99 code letters on the data plate indicating motor current in a R 140 1599 locked rotor condition This code denotes the i Kilovolt Ampere per horsepower of the motor S 16 0 17 99 The KVAhp value is obtained from NEMA and or NEC l mp 19 93 publications The table below is provided as a reference U 20 0 22 39 Locked rotor current of a three phase motor may be V 22 4 gt 22 41 calculated using the following formula Horsepower x KVAhp x 1000 Ex 1 73 Locked Rotor Current Example To calculate the locked rotor current range of a 50 horsepower motor operating at 460 volts with a code letter B proceed as follows Locked Rotor 50x3 15x 1000 Current minimum 160x173 197 91 Amps Locked Rotor 50 x 3 54 x 1000 E Current maximum 460 x 173 222 42 Amps To determine the expected Initial Current value of the above example apply the corresponding current reduction value base on the initial Torque setting of the soft starter Using the default Initial Torque value of 4596 the expected current will
77. ounting Hardware Length Quantity Torque Frame Size Bolt Dia Minimum Grade Minimum Lb in Nm S801 N 310 32 0 5 5 4 15 1 7 S8014R 1 4 in 0 625 5 4 25 2 8 S8014T 1 4 in 0 625 5 6 30 3 4 S8014U 1 4 in 0 625 5 6 30 3 4 S8014V 1 4 in 1 50 8 8 50 5 6 Note See Page 3 for Weight Support Requirements 6 S801 Soft Starter MN03900002E November 2012 www eaton com Dimensions Approximate Dimensions in inches mm S801 N 7 37 187 2 9 2 66 67 6 3 32 84 4 Y 6 45 163 9 o S801 R 0 L2_3 20 0 27 4X 6 64 168 6 6 8 S801 Soft Starter MN03900002E November 2012 www eaton com 7 92 1 2 24 Vdc ONLY 4 38 111 3 ml Installation 13 14 95 9698 00000 191234 13 14959638 5 54 140 7 6 08 154 5 Installation Approximate Dimensions in inches mm S801 T 6 47 164 4 E D 06 eo if 00 8 0000 lo aE 11 77 299 0 e 06 eo Y S801 U S801 Soft Sta
78. ous voltage can cause electric shock and burns To avoid shock hazard disconnect all power to the controller motor or other control devices before any work is performed on this equipment Failure to do so will result in personal injury death or substantial property damage Do not apply a disconnect device on the output of the S801 Soft Starter unless a means to turn off the soft starter when disconnect switch is open is utilized Opening a disconnect while the Soft Starter is operating may cause a malfunction Closing a disconnect switch while the Soft Starter is operating will result in a soft starter failure and potential equipment damage and personnel hazard Note Short circuit protection must be applied on the line side of the soft starter The S801 is wired in an inline configuration By factory default the S801 is to be connected with an ABC phase rotation on the incoming power wiring If the motor turns in the incorrect direction upon energization exchange two phases at the motor terminal box or at the output terminals of the soft starter Changing the input wiring may cause a voltage phase reversal trip N IMPORTANT A reversing contactor must never be switched while the soft starter is operating In order to gain the full benefit of the S801 with a reversing contactor the S801 needs to be OFF when switching the direction of the motor The soft starter control settings must account for catching a motor spinning in th
79. pen then close etc several times the contactor s may be failing to seal electrically A common report of this condition is chattering of the soft starter After the 30 second time period the unit will discontinue attempting to close the bypass contactors and will continue to run on the SCRs At some point in the future the unit will very likely overheat due to insufficient cooling of the power poles If the soft starter is run continuously in the JOG mode the starter will use the normal start parameters BUT the bypass contactors will not close Running continuously on the SCRs will generate more heat than can be dissipated by the internal fans resulting in an over temperature fault trip 16 SCR Not Firing SCR is not conducting when gated SCR failure Incoming phase lost Special application undersized or high Re apply lost phase impedance motor Load disconnected Review S801 application Circuitry damaged by megger testing Contact EatonCare for service Notes Verify that both mains and load lines are connected and secure Verify that any isolation and or reversing contactors are properly engaged prior to the soft starter receiving a START command If the current draw is significantly less than the frame size of the soft starter less than 1 16 of motor FLA not enough current may be flowing to allow the SCRs to fire If this fault occurs immediately when the START command is issued isolation contactors may be open and or in transition 2
80. pplied If this sequence is not followed the soft starter will fault on either a phase loss or zero voltage crossing fault If it is desired to place an electromagnetic contactor on the line side of the soft starter Eaton recommends using level sense option With level sense no additional control circuitry is required A start can be completed when the line power is supplied to the unit after the control power providing the Reset Mode parameter is set to AUTO and the unit has a Ready light status with 24 Vdc on the Start terminal If the AUTO Reset Mode setting is used CAUTION must be exercised to assure that any restart occurs in the safe manner S801 Soft Starter MN03900002E November 2012 www eaton com 19 Functional Description Functional Description Power The S801 Soft Starter controls the voltage applied to a three phase induction motor in order to control the starting torque and provide a smooth starting characteristic Within the soft starter are three power poles each of which includes a set of anti parallel SCRs thyristors in parallel with a contact During a start the conduction periods of the SCRs are continuously adjusted to apply a gradually increasing voltage to the motor resulting in gradually increasing torque and a smooth start As the motor reaches its rated speed the power pole contacts are closed bypassing the SCRs for the most efficient operation Inline Connected Soft Starter L1 ol 5 L3 O O
81. r change Reset Mode to AUTO No status LEDs illuminated No Control Power supply CIM display dark Device failure Provide 24 Vdc to Control power terminal block Check Control Power for proper value and reliability S801 Soft Starter MN03900002E November 2012 www eaton com 33 Troubleshooting Local Control Troubleshooting Flow Chart Is the Check protection Fault LED LEDs fault code and Lit attempt to cleat Stop Command received Yes Is Reset Check basis Mode set for STOP to AUTO Command wv Possible Check for Transient fault external set Reset Mode device to Manual failures nit trips Yes fault code present No Y Correct fault condition y Contact Eaton Support End 34 S801 Soft Starter Consuit Manual to diagnose Fault Code Fault Code repeats No Yes y VerifyFault condition does not exist y Contact b d Fault Condition not Present MN03900002E November 2012 www eaton com Accessories Lug Kits Lug Kits S801 T U Description Part Number 2 cable connections 4 AWG to 1 0 cable EML22 1 cable connection 4 0 to 500 kcmil cable EML23 2 cable connections 4 0 to 500 kcmil cable EML24 1 cable connection 2 0 to 300 kcmil cable EML25 2 cable c
82. ross a fuse may not necessarily produce accurate measurements This fault may also be triggered by an excessive degree of phase imbalance Imbalance may be generated by degraded connections due to loose hardware loose connections cracked or damaged connections hardware degraded contacts in isolation contactors and loose connections in junction boxes Ph REV LED Phase rotation is not ABC Improper phase connections Exchange any two phase in the line connections of the soft starter FC14 Phase loss Correct phase loss and or current imbalance conditions Notes In new applications phase connections may not be proper when setting the correct direction of rotation of the motor In existing applications momentary phase loss and or current imbalance may trigger phase reversal as with only 2 phases present the unit cannot determine the direction of phase rotation OVLD Trip Motor Overload Motor is operating in excess of rated FLA Verify motor load is within specs LED FLA setting not correct FLA potentiometer not set correctly Verify that the FLA potentiometer is set correctly for the application FC11 Improper Trip class Trip class potentiometer not set correctly Verify that the trip class potentiometer is set correctly for the application Failed current sensor RVSS Hardware failure Possibly current sensor failure contact EatonCare for service Notes Verify that the service factor has been accommodated in the FLA potentiometer setting
83. rs Bypass contactors not closed at the end of Loads that are heavily loaded high inertia during a start such as fans the start time start current low ramp time will often need an initial torque setting much greater than the factory short default Set Kick Start parameters Notes Motor rpm is monitored for a synchronous speed condition A Motor Stall fault will occur at the end of the ramp time default is 20 seconds if the motor is not at synchronous speed and the current is in excess of 2X FLA This feature is not user settable Verify that the motor is properly sized for the load 13 Jam Soft Starter in Bypass Motor below rated Remove obstruction RPM and or current exceeds 3X FLA Verify proper FLA setting in Protections Menu Jam Fault can be disabled if trips occur during normal operation Over Current Fault will provide protection at a higher current threshold of 4X catalog FLA Notes The Jam Fault may be disabled not recommended The maximum RMS value of the 3 phase currents is monitored when the internal bypass contactors are closed The Jam Fault Trip threshold is 3X Motor FLA and is not user settable 14 Motor Voltage Phase Incoming line phase rotation sequence Exchange two incoming mains phases Reversal opposite of device setting One phase missing and or open fuse or Verify that all circuit breakers are closed or fuses are serviceable breaker Notes If mains leads need to be changed swap incoming leads and set Phase Sequenc
84. rter MNO3900002E November 2012 www eaton com 7 65 194 4 A 5 95 151 1 5 40 137 3 Y Y ln TE Ed lt 6X 0 28 295 5 91 150 0 7 1 75 0 7 73 196 3 66 0 dn Hd 1 Uu La La 154 8 C o Area 2 60 5 20 132 0 Approximate Dimensions in inches mm S801 V MAN fl g 000 0 15 63 397 0 6 79 172 5 3 05 9 84 250 0 11 05 280 6 E AL PERASA EEEE 4 7 39 6 50 187 8 165 1 Y Y 0 2650 AD 6731 S801 Soft Starter MN03900002E November 2012 www eaton com Installation 16 57 420 8 Installation Power Wiring Using the wiring diagrams in below as guides connect the Line and Motor wiring in accordance with appropriate local and national codes Note To provide optimum motor protection the Line and Motor power wiring should be tightly bundled and run perpendicular to the orientation of the S801 A WARNING Hazard
85. scribed cool down time has elapsed Review the START Inhibit times noted in Appendix B Cycling 24 Vdc control power does not reset the timer If control power is removed the soft starter will retain the remaining time and will resume the cool down timing when power is again reapplied 5 When the S801 internal bypass contactor s close a sound similar to contactor chatter may be heard This sound is the result of multiple contactors in some models closing one after the other in a very short period It is normal operation intended to reduce the surge current requirements of your power supply During normal operation the S801 will cycle the internal bypass contactors at random intervals to clean the contacts During this operation the contactors may be heard to release then pull in again as described above Setup After all power and control connections have been made and you have read and understood the different operating modes and protection features of the soft starter set the Operations and Protection potentiometers for your application In many cases only the Motor FLA potentiometer requires adjustment to the proper value and all other settings may be used with the default values for the initial Start Review the Protection Options of the S801 Appendix A and Appendix B adjust as required 26 S801 Soft Starter MN03900002E November 2012 www eaton com Initial Configuration 1 Operating Parameters Soft Start Configur
86. sing Reset button on the face of the S801 or by providing a signal to Input Control Terminal 4 1 AUTO The S801 firmware attempts to clear any active Fault Trips 24 S801 Soft Starter MN03900002E November 2012 www eaton com 8014 Operating Configuration S801 Operating Configuration Introduction The S801 has a wide range of operation and protection parameters to enable coordinated motor and load protection Several protections options and Ramp Start Current Limit start profiles may be selected on the Control Interface Module CIM The unit is supplied with default settings that accommodate general induction motor applications that provide very basic motor protection The user should adjust the parameters to their specific application User Interface A Control Interface Module CIM is used to configure all e Fault Reset Method MODE Selb oat e Ramp Start Current Limit Selection Control Interface Module CIM e Ramp Start or Current Limit Start Ramp Time and Initial Torque Potentiometers E TM i S S TRIPC 5 5 Trip e Kick Start Ramp Time and Kick Start Torque OVERLOAD ON DISABLE Potentiometers ue Gale Be ei Protections Enable e Soft Stop Ramp Time Potentiomet ren Bde oft Stop Ramp Time Potentiometer PH REV O ON DISABLE e Overload Class DIP Switches MANUAL RESET AUTO RESET Reset Mode Start Profile Motor Full Load Amps FLA Setting RAMP START FLA Potentiometer S
87. ter Setting Values 0 2 0 0 a Operating Parameters Soft Start Configuration S801 N3S Standard FLA Potentiometer Setting Values 0 0 0 Paul Codes 5a MR eet O Pe ath ee ell PM oe oe Y Aute des Initial Torque Settings unse o see mA be oe May pore amaze ee Cose Letters a dama ede ata Brin eta Dt adds Troubleshooting Fault Codes net ns nde epe ot eS tete e table dae td d Troubleshooting S801 Does not START nananana anaana Troubleshooting S801 Sto Accessories Lug Kits Sgot Wess ioc ce Sk gles acd RA ep RR E Da LUG Kits S80T EW ise al dept dt ge der tne to ted be da baee eia ACCESSORIES css eh e ET ue SER hu Ur Sere vi Replacement Parts S801 Soft Starter pped or Eaulted ticos att ee anda bed eed MN03900002E November 2012 www eaton com 52500 10 11 14 14 18 18 25 27 28 28 30 30 31 32 33 35 35 35 35 List of Tables continued Appendix A Parameters Soft Start Config S801 N3S Standard anaana aaa Protections cox Saw BE Ane he ea OS Re Ge ae BE eR Fak E0d amp 83 Her m baee debe cedes bee ole dece ri Appendix B Overload Protection Overload Adjustment Range Inline Connected Motor FLA Potentiometer Values lee Thermal Motor Overload Times ess Appendix C Ratings Cooling and Power Losses Inline Standard Duty 15 Second Ramp 30096 Current Limit at 40 C Inline
88. ults with a Flash Code on the CIM When a Fault Trip occurs the S S Trip LED will illuminate along with the corresponding dedicated LED if applicable If the Fault is no longer active the S801 may be Manually reset by pressing the reset button on the face of the soft starter Fault Trips The S801 is configured from the factory with all protection parameters enabled It is recommended that all appropriate protection parameters are enabled for proper operation and protection of the soft starter and the load Fault Codes For additional details on troubleshooting fault codes and fault conditions please refer to Troubleshooting and Appendix E To obtain the fault flash codes from the CIM hold the RESET button located below the CIM down or apply 24 Vdc to terminal 4 and count the number of times all the LEDs on the CIM flash For example if you see three flashes and then two more flashes after a short pause the flash code is 32 The CIM can provide multiple flash codes if more than one error condition caused a stop Once you see the same flash code repeated you have seen all the flash codes for the error conditions that caused the stop For example if you see three flashes a pause then two flashes a slightly longer pause then four flashes a pause then one flash the flash codes are 32 and 41 If you then see three flashes a pause then two flashes you are seeing the first code again This means you have seen
89. upport 45 nternal Program Memory Corrupted firmware or memory Cycle 24 Vdc control power to the S801 Contact EatonCare for service CIM LEDs Non functional Control Interface Module failure Replace the CIM to restore operation Notes There is only one model CIM part number EMA71 for all S801 soft starters All operating parameters for the soft starter are stored in non volatile memory on the printed circuit board so the CIMs may be exchanged between all models sizes of soft starters if a replacement CIM is not available The S801 may be operated without the CIM installed by simply removing the control prior to energizing the unit 24 Vdc 52 S801 Soft Starter MN03900002E November 2012 www eaton com S801 Fault Codes continued Code Fault Condition Cannot RESET fault Fault condition still exists Solution General Information Troubleshoot fault and correct defective condition Soft Starter has not received RESET signal Attempt alternate methods of RESET Notes The RESET signal can be applied 24 Vdc to terminal 4 of the Con switch mounted on the PCB You trol Voltage Terminal Block The chances of clearing a fault but m ay cause permanent damage to operation of the switch is suspec Terminal Block 4 the push butt If the soft starter cannot be RE on switch is damaged small recessed RESET button on th SET with the Reset push button bu from any one of two locations the sma
90. ve Yes v Check 24V Start Signal Start Source Attempted Suggested Corrective Action Control Interface Module Verify that the Status LED is GREEN prior to the Start attempt Terminal Block Verify that the S S Trip or Status LED is not RED Verify that the 24 Vdc Permissive signal is at the proper voltage Verify that the 24 Vdc Start signal is at the proper voltage If the Start Control parameter is set to Edge verify that the 24 Vdc Start signal is transitioned from 0 Vdc after a fault trip Network Determine if the S801 can be started locally from TB1 Verify tha Verify tha the Status LED is GREEN the 24 Vdc Permissive signal is at the proper voltage a With the Status LED illuminated RED the device will not start Attempt to reset the S801 Soft Starter by pressing the S801 s RESET button for one second If the Status LED remains RED use the Control Interface Module CIM to determine the fault and fault code and go to the Troubleshooting Fault Table in Appendix E to find the corrective action for the fault 32 S801 Soft Starter MN03900002E November 2012 www eaton com b If the Status LED is GREEN the S801 4 Soft Starter is ready to start Determine the Start source in table above to aid in determining the appropriate corrective action Verify that the Permissive input terminal is at 24 Vdc Then start the S801 the Control Input terminal block If the S801 does
91. xpectedly e Momentary Terminal 1 energized START command is present when Terminal P is energized maintained START command is not present when any fault clears and is then RESET Terminal 1 must be again energized to issue a START command e EDGE Sense Maintained Terminal 1 energized After a fault has been RESET the 24 Vdc signal must be removed from the Terminal 1 to enable a START command After a fault has been RESET re energizing Terminal 1 maintained or momentary will issue a START command Momentary Terminal 1 energized f Terminal 1 is energized momentary by the soft starter control system the START signal must be reapplied after the RESET has been accomplished e n either case above Terminal 1 must be de energized momentarily if the RESET parameter is in either MANUAL or AUTO to enable a START command e Thermal Overload After an Overload trip no restart is allowed until the prescribed time period has elapsed Trip Rest Time Periods 1st Trip 3 minute RESET inhibit 2nd Trip within 48 minutes of 1st Trip 2 6 minute RESET inhibit 96 minutes to restore 3 minute inhibit level 3rd Trip within 48 minutes of 2nd Trip 9 minute RESET inhibit 144 minutes to restore 6 minute inhibit level 240 minutes to restore 3 minute inhibit level Cycling 24 Vdc control power does not reset the inhibit times MN03900002E November

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