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PF Softstarters User manual 5A to 1250A

1. 635 2 50 32 74 m E F i 1 29 67 48 ay WD 11 89 Oo L3 5 ce Fe L 22 5 DETAIL A 1 89 Mi2x 1 75 SCALE 1 000 8 32 UNC 2B 30 5 1 20 12 522 49 5 2765 10 89 i A 6 AN MM 104 5 l 0275 4 11 B j at 1 08 O O oj UNA 178 938 2005 LO 7 04 10 26 tul va ae SEE DETAIL A p 5 WU Z 600 fo L 23 62 80 3 15 18 539 18 Y 1 21 23 t9 1 8 g B Terz T48 T540 Ch 177 938 o o 7 01 21 O li 103 5 1 4 07 a gt Q 56 E NS 2 20 Y Tim Ta 1 13 022 i 51 200 T D 7 87 n 290 A 11 42 Height Ship Wt 317 480A mm 290 600 2765 200 539 18 182 25 104 5 555 103 5 45 8 kg Controller in 11 42 23 62 10 89 7 87 2123 718 411 219 407 101 Ib All dimensions are approximate and are not intended for manufacturing purposes Chapter 2 9 Chapter 2 Installation Figure 2 7 Dimensions 625 780 A Controllers 400 1016 200 1508 J8 198 120 305
2. A832 UNC2B 3X DETAIL A I 100 5 i 3 11778 1 12095 1 17621 735 275 6981 NUT 4 1 T g Ed SEE DETAIL A __ Il PU izimi 7 1 L E 11 5 L T 41 00 110414 1 3845 19766 1 29 02 1737 T 1954 14963 1 L L 25 051 2169 15509 1 2350 T 15969 1 un emo comm o e 625 780 A 179 kg Controller 235 410 1363 2169 2339 846 789 395 Ib All dimensions are approximate and are not intended for manufacturing purposes Consult your local Sprecher Schuh representative for complete dimension drawings Chapter 2 10 Chapter 2 Installation Figure 2 8 Dimensions 970 1250 A Controllers 39 10 1 9531 318 32 UNC 2B 13 49 3X DETAIL A 7 00 8 25 C 4X 300 177 8 209 5 13 63 AX 275 8462 69 8 X 25 s 6 4 F IN SEE DETAIL A TN ds i Bee 970 1250A Controller All dimensions are approximate and are not intended for manufacturing purposes Consult your local Sprecher Schuh representative for complete dim
3. PF Softstarter as By using the controller as shown in Figure 3 37 a soft start characteristic can be a Bypass to an AC provided in the event that an AC drive is nonoperational Drive Note A controlled acceleration can be achieved with this scheme but speed control is not available in the bypass mode Figure 3 37 Typical Application Diagram of a Bypass Contactor for an AC Drive OL g a 9 V PARC 3 Phase CR VFD M Input Power ry me M il i r NI I un io VFD Branch Protector L1 1 1 2 L2 3 T2 4 L3 5 T3 6 IC IC PF Softstarter Mechanical interlock required Q Customer supplied amp Many VF drives are rated 15096 FLA Because the PF Softstarters can be used for a 60096 FLA starting separate branch circuit protection may be required Overload protection is included as a standard feature of the PF Softstarter Chapter 3 36 Chapter 3 Wiring PF Softstarter with a Motor Winding Figure 3 38 Typical Application Diagram of a PF Softstarter with a Motor Winding Heater Heater L1 1 T1 2 3 Phase 12 3 T2 4 Input Power 13 5 T3 6 PF Softstarter Motor Winding Heater Customer supplied Overload protection is included as a standard feature of the PF Softstarter Chapter 3 37
4. 1 Softstarter Figure3 5 Ic Ii X 1 6 13 10 T5 ic l kl a2 M 3 8 4 ll X um 272 I 12 T6 Chapter 3 4 Power Lugs Chapter 3 Wiring Power lugs are required for devices rated 108 1250 A In some cases these lugs are sold in kits Each kit contains three lugs The number and type of lugs required is listed in the following tables Table 3 C lists the recommended lugs for the PF Softstarter when configured as a line connection Table 3 D lists the recommended lugs when using the PF Softstarter with a delta connection Note that devices rated 625 1250 A require use of a power distribution block when used with a delta connection Terminal covers are available for units rated 108 480 A which can make the product deadfront IP2X safe See A ppendix D for the appropriate catalog numbers for ordering Table 3 C PF Softstarter 5 1250 A Line Connection Lug Information PF Lug Kit Wire Strip Conductor Max No Lugs Pole Tightening Torque Rating Cat No Length Range Line Side Load Side Wire Lug Lug Busbar 5 85A 18 20 mm 2 5 85 mm 11 3 Nem 14 3 0 AWG 100 Ib in 31 Nem 23 Nem 108 135A PNX 1120 18 20mm 16 120 mm 6 250 2751b in 200 Ib in 201 251A PNX 1120 18 20mm 16 120 mm 23 Nem 6 250 200 Ib in 28 Nem 250 Ib in 2 68 Nem 400 Ib in 600 Ib in 1 45 Nem 68 Nem 400 Ib
5. Soft Stop Pump Control Option Control Options M odes of Operation Pump Control rm M odes of Operation Braking Control nen nen an SMB Smart M otor Braking en Accu Stop Option Slow Speed with Braking option MP NO ne a Mle Protection and Diagnostics Overload zi sisien ee es u a ee ee a Undervolage nt tet ale wa ar teats ae Overvoltage Unbalance Stall Protection and Jam Detection GROUT Ground Fault TID erregen Ground Fault A larm Thermistor PTC Protection PTC Trip Excessive Starts H our Overtemperature ann sar ann ee sn ut ee sn at ste se nn a rr re teri s OpenGate ea nee Ne Linie Faultszi Ri Metering S12 una er erh Status Iii cation Table of Contents 1 1 1 1 1 2 1 2 1 2 1 3 1 3 1 4 1 4 1 5 1 6 1 7 1 8 1 8 1 8 1 9 wa 119 1 10 1 10 1 11 1 11 1 13 1 13 1 14 1 15 1 16 ma 1 16 pi i ite del 1 18 1 18 1 18 1 18 1 19 1 19 1 20 Chapter 2 Installation Chapter 3 Wiring Degregof PFOLGCHOff sera Es ie Receiving Unpacking E CE UI Storing Lifting General Precautions Heat Dissipation ee ee er rin a duda i Enclosures une nee dee tle ae M ounting Dimensions Power Factor Correction Capacito
6. sprecher schuh Divisional Headquarters Sprecher Schuh US Division Headquarters 15910 International Plaza Dr Houston TX 77032 Tel 281 442 9000 Fax 800 739 7370 Sprecher Schuh Canadian Division 3610 Nashua Dr Unit 10 Mississauga Ontario LV4 112 Tel 905 677 7514 Fax 905 677 7663 www sprecherschuh com Publication No LIT MAN PF 311 03 2011 SS P N 40055 230 01 3
7. CONTROLLER WARNING WHEN NOT USING AN ISOLATION CONTACTOR HAZARDOUS VOLTAGES ARE PRESENT AT THE LOAD TERMINALS OF THE 16 124 mr 15 10 3 CONTROLLER EVEN WHEN THE CONTROLLER IS TURNED OFF 11 25 72 43 13 6 1 1 1 TO WYE DELTA MOTOR 12 LEAD DUAL VOLTAGE MOTOR CONNECTIONS STARTER TERMINALS T1 2 12 4 13 6 T6 12 14 8 15 10 JOIN MOTOR TERMINAL LOW VOLTAGE 1 amp 7 2 amp 8 3 amp 9 6 amp 20 4 amp 10 5a MOTOR TERMINAL 4 amp 7 HIGH VOLTAGE 1 2 3 12 10 5 amp 8 6 amp 9 76 22 111 2 16 12 11 2 13 6 15 10 MOTOR TERMINAL 6 LEAD WYE DELTA MOTOR MOTOR TERMINAL MOTOR TERMINAL HIGH VOLTAGE LOW VOLTAGE 12 LEAD DUAL VOLTAGE WYE DELTA MOTOR Chapter 3 27 Chapter 3 Wiring Sequence of Figure 3 27 through Figure 3 32 show the different operation sequences for the Operation Soft Stop Preset Slow Speed Pump Control SM B Smart M otor Braking A ccu Stop and Slow Speed with B raking options Figure 3 27 Soft Stop Sequence of Operation 100 mm Coast to rest Soft Stop Motor Speed Start Run Soft Stop Time seconds Push Buttons Start Closed Open Sto Closed Open st Soft Stop Closed Open Auxiliary Contacts E If Soft Stop Selected Normal Closed Open Up to speed N If Coast to rest Selected Closed Open Attention The user is responsibl
8. Contacts 4 Nor Closed B Op 4 J osed 1 tto rest tad Open Attention The user is responsible for determining which stopping mode is best suited to the application and will meet applicable standards for operator safety on a particular machine Chapter 3 33 Chapter 3 Wiring Special Application Use of Protective Modules Considerations A protective module see Figure 3 35 containing metal oxide varistors OV 5 can be installed to protect the power components from electrical transients and or electrical noise The protective modules clip transients generated on the lines and prevent such surges from damaging the SCRs Figure 3 35 Protective Module There are two general situations that may occur which would indicate the need for using the protective modules 1 Transient spikes may occur on the lines feeding the PF Softstarter controller or feeding the load from the PF Softstarter controller Spikes are created on the line when devices are attached with current carrying inductances that are open circuited The energy stored in the magnetic field is released when the contacts open the circuit Examples of these are lightly loaded motors trans formers solenoids and electromechanical brakes Lightning can also cause spikes 2 The second situation arises when the PF Softstarter controller is installed on a system that has fast rising wavefronts present although not necessarily high peak voltages
9. Ground Input Input Fault Aux 2 Aux 3 Aux 4 Customer supplied Q Refer to the controller nameplate to verify the rating of the control power input voltage For units rated 625 1250 A terminals 11 amp 12 are factory pre wired from terminal block CP1 terminals 1 amp 4 Chapter 3 21 Chapter 3 Wiring Soft Stop Figure 3 21 through Figure 3 23 show the different wiring for the Soft Stop Pump Control Pump Control and SMB Smart otor Braking options and SMB Smart Motor Braking rm Control Power Figure 3 21 Typical Wiring Diagram Stop Start Option Stop EIE 11 12 13 14 15 16 17 18 19 20 21 22 PF Softstarter l Control Terminals Aux 1 23 24 25 26 27 28 29 30 31 32 33 34 kn TACH Ground Aux 2 Aux 3 Aux 4 Input Input Fault Customer supplied Q Soft Stop Pump Stop or Brake Refer to the controller nameplate to verify the rating of the control power input voltage For units rated 625 1250 A terminals 11 amp 12 are factory pre wired from terminal block CP1 terminals 1 amp 4 Note Refer to Chapter 3 for typical power circuits Chapter 3 22 Chapter 3 Wiring Figure 3 22 Typical Retrofit Wiring Diagram 1 mo 0 OL Option Stop 09 199 EEE
10. Power Factor Overvolt F Lvl Aux1 Config Mtr Therm Usage Overvolt Diy Aux3 Config Motor Speed Overvolt A Lvl Aux4 Config PF Option Overvolt A Aux Config Motor Connection Unbalance F Lvl Language Line Voltage Unbalance F Dly Timed Start Starting Mode Unbalance A Lvl I Shut Off Level Ramp Time Unbalance A Dly UTS Level Initial Torque Jam F Lvl Parameter Mgmt Cur Limit Start Jam F Dly Backspin Timer Reserved Jam A Lvl VShut Off Level Kickstart Time Jam A Dly OL Reset Level Kickstart Level Stall Delay Ambient Temp Option Input 2 Gnd Fit Enable Notch Position Starting Mode 2 Gnd Fit Level Notch Maximum Ramp Time 2 Gnd Fit Delay Start Delay Initial Torque 2 Gnd Fit Inh time By pass Delay Cur Limit Level 2 Gnd Fit A Enable Fault 1 Reserved Gnd Fit A Level Fault 2 Kickstart Time 2 Gnd Fit A Delay Fault 3 Kickstart Level 2 PTC Enable Fault 4 Stop Mode Phase Reversal Fault 5 Stop Time Start Per Hour Ramp Time E Pump Pedestal Restart Attempts Ramp Time 2E Braking Current Restart Delay Stop Time E Braking Time Line Fault Disable Option Input 1 Load Type Emergency Run Stop Input High Eff Brake Current Loss Slow Speed Sel Logic Mask Slow S
11. 549 e 25 H 2 95 I 4 63 105 9 H PLACES kl L 117 7 L D Fe 168 is Tias 6 l A l 7 4 188 6 NOTE 1 DIMENSIONS IN INCHES MILLIMETERS 2 DIMENSIONS ARE NOT INTENDED TO BE USED FOR MANUFACTURING PURPOSES Approx a Ship Wt 5 85 A 150 1 307 FI 120 119 8 5 7 kg Controller 5 91 12 09 4 72 1 s 4 72 12 6 Ib Chapter 2 6 All dimensions are approximate and are not intended for manufacturing purposes Chapter 2 Installation Figure 2 4 Dimensions 108 135 A Controllers 5 10 237 129 5 160 3 ae 51 48 r a m f i msi lt S E a e __ n o SER 16 57 1420 8 E 53 8 43 214 15 58 2 1445 1895 81 267 9 B 14 07 1857 5 15 32 389 ID Zr 17 47 443 7 lo n 300455785222 A A A oe os u 21 l 1 123 fed Momo Her 2 13 EN 2 13 MEE 1 56 54 54 39 5 5 10 4 25 129 5 108 8 35 6 56 121 1 C peso D Height Ship Wt 108 135 A
12. 2286 90 1829 72 508 20 1250 2286 90 1829 72 508 20 970 1250 rated devices are only available as Type 1 and require door mounted fan capable of delivering 240 7 Enclosed Type Line Connected Controllers Continued Approximate Dimensions Appendix A Controller Disconnect IP65 Type 4 12 Rating A Rating A B Height A Width C Depth Combination Controllers with Fusible Disconnect 5 30 A J 610 24 508 20 254 10 25 30 A J 610 24 508 20 254 10 43 60 A J 610 24 508 20 254 10 60 100 A J 610 24 508 20 254 10 85 100 A J 610 24 508 20 254 10 108 200 A J 914 36 762 30 406 16 135 200 A J 914 36 762 30 406 16 201 400 A J 1219 48 914 36 406 16 251 400 A J 1219 48 914 36 406 16 317 600 A J 1524 60 914 36 406 16 361 600 A J 1524 60 914 36 406 16 480 600 A J 1524 60 914 36 406 16 800 A L 2286 90 508 20 508 20 625 2286 90 1829 72 508 20 780 2286 90 1829 72 508 20 970 2286 90 1829 72 508 20 1250 2286 90 1829 72 508 20 Combination Controllers with Circuit Breaker 5 15A 610 24 508 20 254 10 25 30A 610 24 508 20 254 10 43 80A 610 24 508 20 254 10 60 100A 610 24 508 20 254 10 85 125A 610 24 508 20 254 10 108 175 A175 A Plug 914 36
13. 4 4 Sr Y Y Y Table 3 G Heatsink Fan Control Power PF Rating Heatsink Fan VA 5 135 A 20 201 251 A 40 317 480 A 60 625 780 A 150 970 1250 A 150 Internally Wired Chapter 3 10 Chapter 3 Wiring Control Terminal As shown in Figure 3 10 the PF Softstarter contains 24 control terminals on the Designations front of the controller Figure 3 10 PF Softstarter Control Terminals gan A EM AE bi eo Pies Description Velia Description 11 Control Power Input DO 23 PTC Input 12 Control Power Common DG 24 PTC Input 13 Controller Enable Input 25 Tach Input 14 Control Module Ground 26 Tach Input 15 Option Input 2 O 27 Ground Fault Transformer Input 16 Option Input 1 28 Ground Fault Transformer Input 17 Start Input DD 29 Aux Contact 2 0 18 Stop Input DD 30 Aux Contact 2 O 19 Aux Contact 1 OD 31 Aux Contact 3 0 20 Aux Contact 1 0 32 Aux Contact 3 DD 21 Not Used 33 Aux Contact 4 0 22 Not Used 34 Aux Contact 4 0 RC Snubbers are required on loads connected to auxiliary Do not connect any additional loads to these terminals These parasitic loads may cause problems with operation which may result in false starting and stopping External Bypass operates an external contactor and overload relay once the motor reaches full speed The PF Softstarter overload functionality diagnostics and metering are disabled when the external bypass is activated
14. Appendix A Short Circuit Protection Type 1 SCCR Performance 200 600V Non Time Delay Fuse Circuit Breaker Time Delay Fuse SCCR List Max Std Max Std Max Std Max Circuit Max High Max Fuse Available Fault Fuse A Available Fault Breaker A Fault A Line Device Operational Current Rating A 5 5 kA 20 5 kA 20 70 kA 10 25 5 100 5 100 70 kA 50 43 10 kA 150 10 kA 150 70 kA 90 60 10 kA 225 10 kA 225 70 kA 125 85 10 kA 300 10 kA 300 70 kA 175 108 10 kA 400 10 kA 300 70 kA 200 135 10 kA 500 10 kA 400 70 kA 225 201 18 kA 600 18 kA 600 70 kA 350 251 18 kA 700 18 kA 700 70 400 317 30 kA 800 30 kA 800 69 kA 500 361 30 kA 1000 30 kA 1000 69 kA 600 480 42 kA 1200 42 kA 1200 69 kA 800 625 42 kA 1600 42 kA 1600 74 1600 780 42 1600 42 2000 74 1600 970 85 2500 85 2500 85 2500 1250 85 kA 3000 85 kA 3200 85 kA 3000 Delta Device Operational Current Rating A 8 7 5 kA 35 5 kA 35 70 kA 18 43 5 150 5 150 70 kA 90 74 10 kA 300 10 kA 300 70 kA 150 104 10 kA 400 10 kA 400 70 kA 200 147 10 kA 400 10 kA 400 70 kA 200 187 10 kA 600 10 kA 500 70 kA 300 234 10 kA 700 10 kA 700 70 kA 400 348 18 kA 1000 18 kA 1000 70 kA 600 435 18 kA 1200 18 kA 1200 70 kA 800 549 30 kA 1600 30 kA 1600 69 kA 1000 625 30 kA 1600 30 kA 1600 69 kA 1200 831 42 kA 1600 30 kA 1600 69 kA 1600 850 42 kA 1600 42 kA 2000 74 1600 900 42kA 1600 42 kA 2000 74 kA 1600 1200 85 kA 3000 85 kA 3200
15. Provides the theoretical model of motor heating as a percentage value At 100 MTU the controller will fault on overload This model is based on the motor thermal overload calculation Metering Motor Speed 0 100 B 1 Indicates the operating percentage of motor base speed when linear ramp is selected and an external tachometer is used Group Basic Set Up Basic Set Up Basic Set Up Basic Set Up Basic Set Up Basic Set Up Basic Set Up Basic Set Up Basic Set Up Basic Set Up Basic Set Up Parameter Name PF Option Motor Connection Line Voltage Starting Mode Ramp Time Initial Torque Cur Limit Start Level Reserved Kickstart Time Kickstart Level Option Input 2 Table B 1 Parameter List Continued Parameter Number 14 20 21 22 23 24 Units Volt Secs LRT FLC Secs LRT Min Max Standard Brake Pump Control Line Delta 0 10000 Full Voltage Current Limit Soft Start Linear Speed Pump Start 50 600 0 0 2 0 0 90 Disable Preset Slow Speed Dual Ramp Fault Fault NC Network Clear Fault B 2 Default Settings Line 480 Soft Start 10 70 350 0 0 Disable Appendix B Parameter Description This a read only parameter that identifies to the user the type of control module installed This parameter allows the user the ab
16. Linear Speed Acceleration Preset Slow Speed e Soft Stop Protection and Diagnostics Power loss line fault voltage unbalance excessive start hour phase reversal undervoltage overvoltage controller temp stall jam open gate overload underload communication fault Metering A V kW kWH elapsed time power factor motor thermal capacity usage Alarm Contact Overload underload undervoltage overvoltage unbalance jam stall and ground fault Status Indication Stopped starting stopping at speed alarm and fault Auxiliary Contacts Four fully programmable contacts as normal up to speed external bypass fault alarm network N O N C Optional Features Pump Control Helps reduce fluid surges in centrifugal pumping systems during starting and stopping period Starting time is adjustable from 0 30 seconds Stopping time is adjustable from 0 120 seconds Braking Control SMB Smart Motor Provides motor braking without additional equipment for applications that require the motor to Braking option stop quickly Braking current is adjustable from 0 400 of the motor s full load current rating Accu Stop Provides controlled position stopping During stopping braking torque is applied to the motor until it reaches preset slow speed 7 or 15 of rated speed and holds the motor at this speed until a stop command is given Braking torque is then applied until the motor reaches zero speed Braking current is programmable from 0 450 of full
17. Multiples of FLC Multiples of FLC 1 2 3 4 5678910 E M 2 Multiples of FLC 3 45678910 Multiples of FLC Approximate trip time for 3 phase balanced condition from hot start Approximate trip time for 3 phase balanced condition from cold start Figure 1 14 Restart Trip Curves after Auto Reset 100000 Class 10 Class 15 1000 m Class 20 m Class 30 Auto Reset Times Class 10 90s Class 15 135s Class 20 180s Class 30 270s 100 Seconds 10 E 100 1000 Percent Full Load Current Setting Chapter 1 12 Chapter 1 Product Overview Undervoltage Utilizing the undervoltage protection of the PF Softstarter motor operation can be halted if a sudden drop in voltage is detected The PF Softstarter provides an adjustable undervoltage trip setting from 0 99 of the programmed motor voltage Trip delay time can be adjusted from 0 99 seconds An alarm pre fault indication level can be programmed to indicate the unit is getting close to faulting The alarm modification information is displayed through the LCD and alarm contact closing Overvoltage Utilizing the overvoltage protection of the PF Softstarter motor operation can be halted if a sudden increase in voltage is detected The PF Softstarter provides an adjustable overvoltage trip setting from 0 19996 of the programmed motor voltage Trip delay
18. PF Softstarter Control Terminals Aux 1 BIEIGIEIEIEIEIEIEIEIENEN Ww TACH Ground Aux 2 Aux 3 Aux 4 Input Input Fault Customer supplied Overload protection should be disabled in the PF Softstarter Refer to the controller nameplate to verify the rating of the control power input voltage For units rated 625 1250 A terminals 11 amp 12 are factory pre wired from terminal block CP1 terminals 1 amp 4 Soft Stop Pump Stop or Brake Aux 4 should be set to normal operation Note Refer to Chapter 3 for typical power circuits Chapter 3 23 Chapter 3 Wiring Figure 3 23 Typical Wiring Diagram for Applications Requiring an Isolation Contactor Control Power Stop ka O Option Stop VA EEE PF Softstarter Control Terminals Aux 1 WH WH PTC TACH Ground Aux 2 Aux 3 Aux 4 Input Input Fault Customer supplied Q Refer to the controller nameplate to verify the rating of the control power input voltage For units rated 625 1250 A terminals 11 amp 12 are factory pre wired from terminal block CP1 terminals 1 amp 4 Soft Stop Pump Stop or Brake Aux 4 should be set to normal operation Note Refer to Chapter 3 for typical power circuits Chapter 3 24 Preset Slow Speed Chapter 3 Wiring Figure 3 24 show the different wiring for the Preset Slow Speed Figure 3 24 Typical Wiring Dia
19. factory default settings can still be re initialized Display Memory Storage Reset to Defaults Electrically Erasable Programmable Read only Memory EEPROM The PF Softstarter provides a non volatile area for storing user modified parameter values in the EEPROM Chapter 4 6 Chapter 4 Programming Parameter All parameters are modified using the same method The basic steps to Modification performing parameter modification are described below Notes 1 Parameter values modified while the motor is operating are not valid until the next time that operation occurs 2 If the password is set parameters cannot be adjusted without logging in 3 Use the Sel key to highlight a single digit Description Action Display E Amps vot 1 Press the ESC key to go from the status display to the Main menu 2 Scroll with the Up Down keys Main Menu until the Parameter option is G Memory Storage highlighted 3 the Enter key to access the GP File Parameter menu Set Up 4 Scroll with the Up Down keys GP File until the option you want to use O e ne Monitoring Motor Protection Motor Protection etc is highlighted For this example Set Up will be used 5 Press Enter to select the Set Up group 6 Scroll to Basic Set Up and press FEF Group Enter O amp Basic Set Up 7 Scroll to the Starting Mode FG Parameter parameter
20. sity of the braking current applied to the motor form slow speed operation 0 400 of full load current All braking stopping current settings in the range of 1 100 will provide 100 braking current to the motor Chapter 4 12 Chapter 4 Programming Option Parameter Range Slow Speed PF Option Braking Control with Braking This parameter identifies the type of control present and is not user programmable Slow Speed Select Allows the user to program the slow speed that best fits the application Low 7 High 15 Slow Accel Current Allows the user to program the re quired current to accelerate the motor to slow speed operation 0 450 of full load current Slow Running Current Allows the user to program the re quired current to operate the motor at the slow speed setting 0 450 of full load current Braking Current Allows the user to program the inten sity of the braking current applied to the motor Chapter 4 13 0 400 of full load current All braking stopping current settings in the range of 1 100 will provide 100 braking current to the motor Basic Set Up Chapter 4 Programming The Basic Set Up programming group provides a limited parameter set allowing quick start up with minimal adjustment If the user is planning to implement some of the advanced features e g Dual Ramp or Preset Slow Speed then the Setup programming group should be selec
21. 751 VA recommended 800 VA Heatsink Fan s A 5 135 A 20 VA 201 251 A 40 VA 317 480 A 60 VA 625 1250 A 150 VA Steady State Heat Dissipation with Control and Fan Power W Controller Rating A 5 25 43 60 85 108 135 201 251 317 361 480 625 780 970 1250 70 70 81 97 129 91 104 180 198 225 245 290 446 590 812 1222 Auxiliary Contacts 19 20 Aux 1 e 29 30 Aux 2 e 31 32 Aux 3 e 33 34 Aux 4 Type of Control Circuit Electromagnetic relay Number of Contacts 1 Type of Contacts programmable N O N C Type of Current Rated Operational Current 120V AC 1 5 A 240V Conventional Thermal Current Ith 5A Make Break VA 3600 360 Utilization Category AC 15 DC PTC Input Ratings Response Resistance 3400 150 Q Reset Resistance 1600 Q 100 Q Short Circuit Trip Resistance 25Q 10Q Max Voltage at PTC Terminals R 4 lt 7 5V Max Voltage at PTC Terminals Rp open 30V Max No of Sensors 6 Max Cold Resistance of PTC Sensor Chain 1500 Q Response Time 800 ms Tach Input 0 5V DC 4 5V DC 100 Speed For devices rated 5 480 A heatsink fans can be powered by either 110 120V AC or 220 240V AC For devices rated 625 1250 A heatsink fan power is sourced internally based on supplied power A 4 Environmental Mechanical Appendix A Operating Temperature R
22. 85 108A 135A 201A 251A 317A 361A 480A 625A 700A 970A 1250A 70 70 81 97 129 91 104 180 198 225 245 290 446 590 812 1222 Chapter 2 3 Chapter 2 Installation The open style design of the PF Softstarter requires that it be installed in an enclosure The internal temperature of the enclosure must be kept within the range of 0 50 C Enclosures For Type 12 IP54 enclosures the following guidelines are recommended to limit the maximum controller ambient temperature T here should be a clearance of at least 15 cm 6 in above and below the controller This area allows air to flow through the heatsink Table 2 B Minimum Enclosure Size Controller IP65 Type 4 12 Rating A B Height A Width C Depth Non Combination Controller 5 610 24 508 20 254 10 25 610 24 508 20 254 10 43 610 24 508 20 254 10 60 610 24 508 20 254 10 85 610 24 508 20 254 10 108 760 30 610 24 305 12 135 760 30 610 24 305 12 201 914 36 762 30 406 16 251 914 36 762 30 406 16 317 1524 60 914 36 406 16 361 1524 60 914 36 406 16 480 1524 60 914 36 406 16 625 2286 90 1829 72 508 20 780 2286 90 1829 72 508 20 970 2286 90 1829 72 508 20 1250 2286 90 1829 72 508 20 Combination Controllers with Fusible Disconnect 5 610 24 508 20 254 10 25 610 24 508 20 254 10 43 610 24 508 20
23. Lightning strikes can cause this type of response A dditionally if the PF Softstarter controller is on the same bus as other SCR devices AC DC drives induction heating equipment or welding equipment the firing of the SCRs in those devices can cause noise Note protective modules may be placed on the line load or both sides of the softstarter H owever protective modules must NOT be placed on the load side of the softstarter when using inside the delta motor connections or with pump linear speed or braking control Chapter 3 34 Multi motor Applications 3 Phase Input Power Chapter 3 Wiring The PF Softstarter controller will operate with more than one motor connected to it To size the controller add the total nameplate amperes of all of the connected loads The stall and jam features should be turned off Separate overloads are still required to meet the National Electric Code NEC requirements Note The PF Softstarter controller s built in overload protection cannot be used in multi motor applications Figure 3 36 Multi Motor Application L1 1 T1 2 X J K aa Motor L2 3 T2 4 e f X J n No iu sk L3 5 T3 6 aw Br Overload Branch Relay O L Protection PF Softstarter py ANC E a DS po Motor CustomeSupplied AS No 2 ZA yA HENA Se Der AJ m Overload Relay O L Chapter 3 35 Chapter 3 Wiring
24. Note Depending on the application the Braking options SMB Smart M otor Braking Accu Stop and Slow Speed may cause some vibration or noise during the stopping cycle This may be minimized by lowering the braking current adjustment If this is a concern in your application please consult the factory before implementing these options Chapter 8 1 Chapter 8 Troubleshooting The following flowchart is provided to aid in quick troubleshooting Figure 8 1 Troubleshooting Flowchart YES Fault Displayed Define Nature of Trouble Motor will not start no output voltage to motor Motor rotates but does not accelerate to full speed Motor stops while running Miscellaneous situations See Table 8 A See Table 8 B See Table 8 C Table 8 A PF Fault Display Explanation See See Table 8 D Table 8 E Display Fault Code Possible Causes Possible Solutions Line Loss 1 2 3 Missing supply phase e Check for open line i e blown fuse with phase e Motor not connected properly e Check for open load lead indication Consult the factory Shorted SCR 4 5 amp 6 Shorted Power Module Check for shorted SCR replace power module if necessary Open Gate 7 8 amp 9 Open gate circuitry Perform resistance check replace power module if with phase necessary indication Loose gate lead Check gate lea
25. Overview Keypad Description Programming Menu Chapter 4 Programming This chapter provides a basic understanding of the programming keypad built into the PF Softstarter This chapter also describes programming the controller by modifying the parameters The keys found on the front of the PF Softstarter are described below Escape Exit a menu cancel a change to a parameter value or acknowledge a fault alarm Lang Select Select a digit select a bit or enter edit mode in a o parameter screen Will get to menu to change the language being displaved Up Down Scroll through options increase decrease a value or A e Arrows toggle a bit Enter Enter a menu enter edit mode in a parameter screen or e save a change to a parameter value Note For ease of programming values after using the Enter key to edit use the Sel key to jump to the digit that needs to be modified then use the arrow keys to scroll through the digits Parameters are organized in a three level menu structure for straightforward programming Figure 4 1 details the programming menu structure and the three level hierarchy In order to change parameters the controller must be in the STOP mode and the control voltage must be present Chapter 4 1 Chapter 4 Programming Figure 4 1 Menu Structure Hierarchy Power up and Status Display Lang o Select language being displayed Choose Mode OPERATION L
26. Y ji 0 0 if On 11 Appendix D Appendix D 625 780 A 100 Ib in 11 3 Nem 140 Ib in 970 1250A 15 8 N m 625 780 A 970 1250A D 4 D 4 Accessories Appendix E Description Description Used With Catalog No Protective Modules 5 85 A 480V PFP 0085 480V 108 480 A 480V PFP 0480 480V 5 85 A 600V PFP 0085 600V 108 480 A 600V PFP 0480 600V Terminal Lugs 108 251 A PNX 1120 317 480 A PNX 1240 625 1250 A CA6 L630 CA6 L860 IEC Terminal Covers 108 135 A PFT 0135 201 251 A PFT 0251 317 480 A PFT 0480 E 1 AC AC Contactor Ambient Temperature American Wire Gauge AWG Block Transfer BIR BIW Buffer Contactor Reversing Cursor Cycle Glossary Alternating current An alternating current AC contactor is designed for the specific purpose of establishing or interrupting an AC power circuit Ambient temperature is the temperature of air water or a surrounding medium where equipment is operated or stored A standard system used for designing the size of electrical conductors Gauge numbers have an inverse relationship to size larger numbers have a smaller cross sectional area However a single strand conductor has a larger cross sectional area than a multi strand co
27. in 600 Ib in i 68 Nem 625 780A CA6 L630 32mm 64 mm 70 240 mm 2 0 500 MCM 970A CA6 L860 26mm 48mm 120 240 mm 4 0 500 MCM sa 2 2 a 317 480A PNX 1240 18 25 mm 25 240 mm 2 4 500 2 x 7 CA6 L630 32 64 mm 70 240 mm 1250A 2 0 500 MCM 1 1 1 1 6 1860 26 48 120 240 mm 1 400 600 Ib in 4 0 500 The 1250 A device requires one 1 each of the CA6 L630 and CA6 L860 Chapter 3 5 Chapter 3 Wiring Table 3 D PF Softstarter 108 1250 A Delta Connection Lug Information for inside the Delta applications PF Softstarter Suggested Lug Conductor Max No Lugs Pole Tightening Torque Rating Cat No Range Line Side Wire Lug Lug Busbar 108 135A 1494R N15 25 240 mm 1 42 Nem 23 Nem 4 500 AWG 375 Ib in 200 Ib in 201 251 A 1494R N14 50 120 mm 2 31 Nem 23 Nem 1 0 250 AWG 275 Ib in 200 Ib in 317 480 A 150 LG5MDC 95 240 mm 1 33 9 Nem 28 Nem 3 0 500 AWG 300 Ib in 250 Ib in 625 780 A 42 Nem N A 25 240 mm 4 500 AWG 375 Ib in 970 1250 A 25 240 mm 4 42 Nem N A 4 500 AWG 375 Ib in For 625 1250 A inside the delta connections terminal blocks are required for line side connections Required terminal blocks are as follows Part 1492 BG 625 780 A 2 per phase 970 125
28. 1250 A Chapter 3 3 Chapter 3 Wiring Failure of solid state power switching components can cause overheating due to a single phase condition in the motor To prevent injury or equipment damage the fol lowing is recommended Use of an isolation contactor shunt trip type circuit breaker on the line side of the PF This device should be capable of interrupting the motor s lock rotor current Connection of this isolation device to an auxiliary contact on the PF Softstarter The auxiliary contact should be programmed for the normal condition See Chapter 4 for additional information on programming Line Connected The PF Softstarter by default is programmed to be connected to a line controlled motor as shown in Figure 3 4 These motors typically have 3 leads and must be rated between 1 1250 amps An optional isolation contactor can be added to the circuit to provide galvanic isolation of the motor and final electro mechanical removal of power Figure 3 4 NEC ko SII u K X Us diu Delta Connected The PF Softstarter can be programmed and connected to a delta controlled mo tor as shown in Figure 3 5 These motors typically have 6 or 12 leads and must be rated between 1 8 1600 amps It is recommended that an isolation contactor be added to the circuit to provide galvanic isolation of the motor and final electro mechanical removal of power
29. 18 14 AWG Tightening torque 14 7 Nem 130 Ib in Wire strip length 18 20 mm 0 22 0 34 in One M10 x 1 5 diameter hole per power pole Two M10 x 1 5 diameter holes per power pole Two M12 x 1 75 diameter holes per power pole Two 13 5 mm 0 53 in diameter holes per power pole NEMA CENELEC EN50 012 M 3 screw clamp clamping yoke connection Other Appendix A EMC Emission Conducted Radio Frequency Emissions Class A Levels Radiated Emissions Class A EMC Immunity Electromagnetic Discharge 8 kV Air Discharge Levels Radio Frequency Per EN IEC 60947 4 2 Electrostatic Field Fast Transient Per EN IEC 60947 4 2 Surge Transient Per EN IEC 60947 4 2 Overload Current Range Line Delta Characteristics 5 1 5 1 7 9 25 5225 8 6 43 43 8 6 43 14 8 75 60 12 60 20 8 104 85 17 85 29 4 147 108 27 108 47 187 135 34 135 59 234 201 67 201 116 348 251 84 251 145 435 317 106 317 183 549 361 120 361 208 625 480 160 480 277 831 625 208 625 283 850 780 260 780 300 900 970 323 970 400 1200 1250 416 1250 533 1600 Trip Classes 10 15 20 and 30 Trip Current Rating 117 of Motor FLC Number of Poles 3 Certifications Open Type Controllers CE Marked Per Low Voltage Directive UL 73 23 EEC 93 68 EEC Listed File No E195687 A 6 Appendix A Approximate Open Type Controllers Dimensions and Shipping Weights Dimensions are in millimeters inc
30. 762 30 406 16 135 225 N225 A Plug 914 36 762 30 406 16 201 300 A 300 A Plug 1219 48 914 36 406 16 251 400 A 400 A Plug 1219 48 914 36 406 16 317 600 A 500 A Plug 1524 60 914 36 406 16 361 600 A 600 A Plug 1524 60 914 36 406 16 480 800 A 800 A Plug 1524 60 914 36 406 16 625 2286 90 1829 72 508 20 780 2286 90 1829 72 508 20 970 2286 90 1829 72 508 20 1250 9 2286 90 1829 72 508 20 Use this row for 460V 58 and 575V 59 Q Use this row for 460V 59 and 575 60 and 61 970 1250 rated devices are only available as Type 1 and require a door mounted fan capable of delivering 240 cfm These dimensions are to be considered the recommended minimal enclosure dimensions and do not represent actual Sprecher Schuh assembled product dimensions Consult your local Sprecher Schuh representative for details A 8 Parameter Information Group Parameter Name Table B 1 Parameter Number Parameter List Units Min Max Default Settings Parameter Description Appendix B User Settings Metering Volts Phase A B Volt Provides the three phase to phase supply voltage measurements at all times including bypass operation Metering Volts Phase B C Volt Provides the three phase to phase supply voltage measurements at all times including bypass operation Metering Volts Phase C A Volt Provides the t
31. 85 PFB 0085 600V B PFB PFL 0085 600V 108 PFB 0108 600V B PFB PFL 0108 600V 135 PFB 0135 600V B PFB PFL 0135 600V 24V AC DC 200 480V AC 5 PFB 0005 480V 024 B PFB 024 PFL 0005 480V 25 PFB 0025 480V 024 B PFB 024 PFL 0025 480V 43 PFB 0043 480V 024 B PFB 024 PFL 0043 480V 60 PFB 0060 480V 024 B PFB 024 PFL 0060 480V 85 PFB 0085 480V 024 B PFB 024 PFL 0085 480V 108 PFB 0108 480V 024 B PFB 024 PFL 0108 480V 135 PFB 0135 480V 024 B PFB 024 PFL 0135 480V 200 600V AC 5 PFB 0005 600V 024 B PFB 024 PFL 0005 600V 25 PFB 0025 600V 024 B PFB 024 PFL 0025 600V 43 PFB 0043 600V 024 B PFB 024 PFL 0043 600V 60 PFB 0060 600V 024 B PFB 024 PFL 0060 600V 85 PFB 0085 600V 024 B PFB 024 PFL 0085 600V 108 PFB 0108 600V 024 B PFB 024 PFL 0108 600V 135 PFB 0135 600V 024 B PFB 024 PFL 0135 600V C 3 Appendix Control Control Line Am Originally Ordered as Series Control Module Power Poles Type Voltage Voltage peres Catalog Number Catalog Number Catalog Number Braking 100 240V 200 480V AC 5 PFD 0005 480V B PFD 0085 PFL 0005 480V Control 25 PFD 0025 480V B PFD 0085 PFL 0025 480V 43 PFD 0043 480V B PFD 0085 PFL 0043 480V 60 PFD 0060 480V B PFD 0085 PFL 0060 480V 85 PFD 0085 480V B PFD 0085 PFL 0085 480V 108 PFD 0108 480V B PFD 0251 PFL 0108 480V 135 PFD 0135 480V B PFD 0251 PFL 0135 480V 200 600V AC 5 PFD 0005 600V B PFD 0085 PFL 0005 600V 25 PFD
32. Current Transformer Catalog Number 1411 126 252 Ratio 2500 5 Figure 1 17 Ground Fault Wiring Branch Protection L1 1 T1 2 3 Phase go L 2 3 T 2 4 Input Power L3 5 T 3 6 PF Softstarter Controller 11 12 13 14 15 17 18 19 SHIELD PF Softstarter Control Terminals Customer supplied Cat No 825 CBCT or Cat No 1411 126 252 Note When connecting the ground fault sensors the secondary of the CT should be shorted until the connection to the PF control module is complete Chapter 1 15 Chapter 1 Product Overview Ground Fault Trip The PF Softstarter will trip with a ground fault indication if No other fault currently exists Ground fault protection is enabled GF Inhibit Time has expired e GF Current is equal to or greater than the GF Trip Level for a time period greater than the GF Trip Delay Parameter 75 Gnd Flt Inh Time allows the installer to inhibit a ground fault trip from occurring during the motor starting sequence and is adjustable from 0 250 seconds Parameter 74 Gnd F It Delay allows the installer to define the time period a ground fault condition must be present before a trip occurs It is adjustable from 0 1 250 seconds Parameter 73 Gnd F It Level allows the installer to define the
33. High 7 Low Time seconds 10 Low x N Start Run T y 20 High Reverse Attention Slow speed running is not intended for continuous operation due to reduced motor cooling Chapter 1 5 Chapter 1 Product Overview Linear Speed Acceleration The PF Softstarter has the ability to control the motor speed during starting and stopping maneuvers A tach input 0 5V DC is required to perform this start mode The start time is selectable from 0 30 seconds and determines the time the motor will ramp from 0 speed to full speed K ickstart is available with this option Figure 1 7 Linear Speed Acceleration Percent Speed 100 m Start gt Stop Time seconds Kickstart is also available with Linear Speed Acceleration Attention Linear Stop is not intended to be used as an emergency stop Refer to the applicable standards for emergency stop requirements The Linear Stop does not need to be set up even if the linear start has been programmed The Linear Stop can not brake the motor load and reduce the stopping time Chapter 1 6 Chapter 1 Product Overview Soft Stop This option can be used in applications that require an extended stop time The voltage ramp down time is user adjustable from 0 120 seconds and is adjusted independently from the starting time The load will stop when the output voltage drops to a point where the load tor
34. Hr feature Power Loss with 35 36 Missing supply phase as indicated Check for open line i e blown line fuse phase indication amp 37 Hall ID 38 Incorrect power module has been installed Check power module and replace NVS Error 39 Data entry error Check user data and perform a User Store function Replace control module Reset default values Line Loss 41 42 43 e Line distortion Check supply voltage for capability to start stop motor High impedance connection Check for loose connections on line side or motor side of power wires Prestart fault indication Chapter 8 3 Chapter 8 Troubleshooting Table 8 B Motor Will Not Start No Output Voltage to the Motor Display Fault displayed Possible Causes See fault description Possible Solutions See Table 9 A addressing fault conditions Display is blank Stopped 0 0 Amps Control voltage is absent Failed control module Pilot devices PF Enable input is open at terminal 13 Input terminals are not wired correctly Start Stop control has not been enabled for the human interface module Control voltage Failed control module Check control wiring and correct if necessary Replace control module Cycle control power Check wiring Check wiring Check wiring Follow the instructions on pg 7 4 7 6 to enable control capability Check control voltage Replace control mod
35. Proper sizing of the contactor and overload is required Control power on units rated 625 1250 A is pre wired internally from terminal block CP1 Chapter 3 11 Chapter 3 Wiring Standard Figure 3 11 through Figure 3 20 show typical wiring for the Controller Wiring PF Softstartercontroller Diagrams Figure 3 11 Typical Wiring Diagram for Standard Controller 3 Phase Input Power D Branch Protection PF Softstarter Control Terminals Aux 1 u d UY PTC TACH Ground Input Input Fault Aux 2 Aux 3 Aux 4 Customer supplied Refer to the controller nameplate to verify the rating of the control power input voltage For units rated 625 1250 A terminals 11 amp 12 are factory pre wired from terminal block CP1 terminals 1 amp 4 Chapter 3 12 Chapter 3 Wiring Figure 3 12 Typical Wiring Diagram for Two Wire Control with Stopping Control 3 Phase Input Power Two Wire _ Device Y 2 EEEE EEEE PF Softstarter Control Terminals Aux 1 EIEIEIEIEZEIEIEIEIEIEIEN 7 ka PTC TACH Ground Aux 2 Aux 3 Aux 4 Input Input Fault Customer supplied Q Refer to the controller nameplate to verify the rating of the control power input voltage For units rated 625 1250 A terminals 11 amp 12 are factory pre wired from terminal block CP1 terminals 1 amp 4 Notes 1 Programmable controller interfacing in this diagram refers to hard wiring between
36. Vues Neg Des PTC TACH Ground Aux 2 Aux 3 Aux 4 Input Input Fault Network inputs can be obtained through proper programming of Option 1 and Option Input 2 Chapter 1 20 Chapter 2 Installation Installation Degree of The PF soft starters have an IPOO or IP2X protection rating depending on the size Protection Taking into account the ambient conditions the device must be installed in IP54 Type 2 switchgear cabinets M ake sure that no dust liquids or conductive parts can enter the soft starter Soft starter operation produces waste heat heat loss See Table 2 A or Specifications on page A 1 for details It is the user s responsibility to thoroughly inspect the equipment before accept ic ing the shipment from the freight company Check the item s received against the Receiving purchase order If any items are damaged it is the responsibility of the user not to accept delivery until the freight agent has noted the damage on the freight bill Should any concealed damage be found during unpacking it is again the respon sibility of the user to notify the freight agent The shipping container must be left intact and the freight agent should be requested to make a visual inspection of the equipment Remove all packing material wedges or braces from within and around the controller Unpacking After unpacking check the item s nameplate catalog number against the purchase order Inspecting The controller should
37. applications the standard profile will work sufficiently Adjusting this parameter should really only be used when some type of problem during braking is being encountered This parameter is used to extend the SMB braking time by a percentage of the typical stopping time The need to adjust this parameter can occur when braking is applied to high efficiency motors and relates to the counter EMF produced by these motors This setting should never really exceed 50 Nuisance overload faults will likely occur is set incorrectly Settings This parameter is not viewable without entering a special password in Firmware versions 4 001 or earlier Contact Sprecher Schuh technical support if you have Version 4 001 firmware or earlier and need to access this parameter B 4 Appendix B Table B 1 Parameter List Continued Group Parameter Name Parameter Units Min Max Default Parameter Description User Number Settings Settings When this option is used this parameter provides the user the ability to select between Hees Slow Speed Sel 39 d SS High the Low and High settings for both the 9 Preset Slow Speed and Accu Stop control options Provides the user the abilitv to program the motor s direction of rotation Note that with the Preset SS SS FWD Preset Slow Speed option the controller has the Accu Stop Sow Speed Dir SS REV SSFWD capability to operate the motor in the reverse direction during slow speed opera
38. be read and understood The controller contains ESD electrostatic discharge sensitive parts and assemblies Static control precautions are required when installing testing servicing or repairing the assembly Component damage may result if ESD control procedures are not followed If you are not familiar with static control procedures refer to applicable ESD protection handbooks An incorrectly applied or installed controller can damage components or reduce product life Wiring or application errors such as undersizing the motor incorrect or inad equate AC supply or excessive ambient temperatures may result in malfunction of the system Only personnel familiar with the controller and associated machinery should plan or implement the installation start up and subsequent maintenance of the system Failure to do this may result in personal injury and or equipment damage H azardous voltages that can cause shock burn or death are present on L1 L2 L3 T1 T2 T3 T4 T5 and T6 Power terminal covers can be installed to prevent inadvertent contact with terminals Disconnect the main power before servicing the motor controller or associated wiring Heat Dissipation The following table provides the maximum heat dissipation at rated current for the controllers For currents lower than rated value heat dissipation will be reduced Table 2 A Maximum Heat Dissipation PF Rating Max Watts 25 43A 60
39. by using the Up Down O e StaringiMade Ramp Time keys and press Enter 8 Press Enter to select the option 17 Scroll to the option of your O e e EI ml choice by using the Up Down keys For this example we will choose Current Limit 9 Press the Enter key to accept the new setting FG P 18 Ramp Time Secs 10 Scroll to the next parameter by using the Down key Continue the process until all desired settings are entered 900 The PF Option advises the user if any control option i e Pump Control is resident This parameter is factory set and cannot be modified by the user display will indicate that the second line is now active by highlighting the first character If the LCD display does not provide a highlighted cursor then the controller is in the display mode Chapter 4 7 Current Limit Start Chapter 4 Programming The following parameters are specifically used to adjust the voltage ramp supplied to the motor Parameter Option Starting Mode This must be programmed for Soft Start SES Ramp Time 0 30 s This programs the time period that the controller will ramp the output voltage up to full voltage from the Initial Torque level programmed Initial Torque The initial reduced output voltage level for the voltage ramp to the motor is established and adjusted with this parameter 0 90 locked rotor tor
40. e Renewal Part Instructions 41053 345 01 5 85 41053 346 01 108 135 A 41053 347 01 201 480A 41053 385 01 625 1250A Description The PF Softstarter controller offers a full range of starting modes as standard Soft Start with Selectable K ickstart e Current Limit with Selectable K ickstart e Dual Ramp Start with Selectable Kickstart Full Voltage Start e Preset Slow Speed Linear Speed Acceleration with Selectable K ickstart requires Tach feedback e Soft Stop Other features that offer further user benefit include e Expanded protective features e Metering e 1 0 Innovative starting and stopping options provide enhanced performance e Pump Control e Braking Control SMB Smart Motor Braking Accu Stop Slow Speed with Braking These modes features and options are further described in this chapter Latest revision Chapter 1 1 Chapter 1 Product Overview Operation The PF Softstarter can operate standard squirrel cage induction motors rated 1 1250 or Star delta wye delta type motors rated 1 8 1600 A up to 600V AC 50 60 Hz Depending upon the controller type ordered control power input can range from 100 240V AC or 24V AC DC Please verify voltage on a prod uct before applying power Modes of Soft Start Operation This mode has the most general application The motor is given an initial torque Standard setting which is user adjustable from 0 90 of locked rotor torque Fr
41. firmware or earlier and need to access this parameter B 9 Appendix B Table B 1 Parameter List Continued Group Parameter Name Parameter Units Min Max Default Parameter Description User Number Settings Settings Allows the user the ability to assign a specific identification number to a motor and controller combination This can be useful for network Motor Data Motor ID 104 0 65535 0 1 applications where you may need to locate a specific motor controller based on a network address Sets the proper current ratio when an external Motor Data CT Ratio 105 1 1500 current transformer is used for Medium Voltage applications Motor Data MV Ratio 106 1 10000 Sets the proper feedback scaling when used for Medium Voltage applications Normal Normal NC Up To Speed Up To Speed NC Basic Set Fault Allows the user the ability to configure each Up Aux1 Config 107 Fault NC Normal Auxiliary relay contact for a specific operation Alarm Note Normal PF in RUN Alarm NC Network Network NC External Bypass Normal Normal NC Up To Speed Up To Speed NC Basic Set Fault Allows the user the ability to configure each Up Aux3 Config 108 Fault NC Alarm Auxiliary relay contact for a specific operation Alarm Note Normal PF in RUN Alarm NC Network Network NC External Bypass Normal Normal NC Up To Speed Up To Speed NC Basic Set Fault Allows the user the ability to configure each Up Aux4 Config 109 Fault NC Normal Auxiliary relay c
42. input voltage For units rated 625 1250 A terminals 11 amp 12 are factory pre wired from terminal block CP1 terminals 1 amp 4 Aux 4 should be set for normal operation Chapter 3 15 Chapter 3 Wiring Figure 3 15 Typical Wiring Diagram for Isolation Applications I 3 Phase t 12 3 Input Power Isolation a Contactor PF Softstarter dnd IC Controller a PF Softstarter Aux 1 Control Terminals EINEIEIEIEIEIEIEIEIEIEN wo TACH Ground Aux 2 Input Aux 3 Aux 4 Input Fault Customer supplied Refer to the controller nameplate to verify the rating of the control power input voltage For units rated 625 1250 A terminals 11 amp 12 are factory pre wired from terminal block CP1 terminals 1 amp 4 Aux 4 should be set for normal operation Chapter 3 16 Chapter 3 Wiring Figure 3 16 Typical Wiring for Shunt Trip Applications L1 1 3 Phase m T2 4 L3 5 T3 6 Input Power Branch Protection PF Softstarter Controller DOOR PF Softstarter Control Terminals BIEIEIEIEIEIEIEIEIEIEIEN 8 PTC TACH Ground Aux 2 Aux 3 Aux 4 Input Input Fault Customer supplied Refer to the controller nameplate to verify the rating of the control power input voltage For units rated 625 1250 A terminals 11 amp 12 are factory pre wired from terminal block CP1 terminals 1 amp 4 Aux 2 should
43. load current Slow Speed with Braking Used on applications that require slow speed in the forward direction for positioning or alignment and also require braking control to stop A 1 Appendix A Electrical Ratings IEC Power Circuit Rated Operation Voltage 480V 200 480V AC 200 415V 15 10 600V 200 600V AC 200 500V 15 10 Rated Insulation Voltage 480V N A 500V 600V 500V Related Impulse Voltage 480V E N A 6000V Dielectric Withstand 480V Repetitive Peak Inverse Volt 480V 1400V age Rating 600V 1600V il Operating Frequency All 47 63 Hz Utilization Category 5 480 A AC 53B 3 0 50 1750 625 1250A AC 53B 3 0 50 3550 Protection Against 5 85 A IP20 108 480 A IP2X with terminal covers 625 1250 A N A IPOO open Device DV DT Protection 480V amp 600V RC Snubber Network 690V None Transistent Protection 480 V amp 600V Metal Oxide Varistors 220 Joules Control Circuit Rated Operation Voltage 5 480A 100 240V AC or 24V AC DC 625 1250 A 110 120V AC or 230 240V AC Rated Insulation Voltage All N A 240V Rated Impulse Voltage All N A 3000V Dielectric Withstand All 2000V AC Operating Frequency All 47 63 Hz Logic input on state voltage minimum 85V AC 19 2V DC 20 4V AC Logic input on state current 20 mA Q120V AC 40 mA Q 240V AC 7 6 mA Q 24V AC DC Logic input off state voltage maximum 50V AC 10V DC 12V AC Logic input off site current input off state 10 mA AC 3 mA DC voltage
44. parameter is not viewable without entering a special password in Firmware versions 4 001 or earlier Contact Sprecher Schuh technical support if you have Version 4 001 firmware or earlier and need to access this parameter B 6 Appendix B Table B 1 Parameter List Continued Group Parameter Name Parameter Units Min Max Default Parameter Description User Number Settings Settings Allows the user to set a voltage of line Voltage under Undervolt A Lvl 57 V 0 99 0 that will cause an Alarm when the voltage falls below voltage this value A zero value is the off setting Allows the user the ability to prevent some nuisance Under Undervolt A Dly 58 Secs 0 99 0 Alarms by entering a delay period that provides voltage a window that the voltage condition must persist within for the controller to Alarm Allows the user to set a voltage of line Voltage Over voltage Overvolt F Lvl 59 V 0 199 0 that will cause a fault when the voltage falls above this value A zero value is the off setting Allows the user the ability to prevent some nuisance faults by entering a delay period that provides a window that the voltage condition must persist within for the controller to fault Over voltage Overvolt F Dly 60 Secs 0 99 0 Allows the user to set a voltage of line Voltage Over voltage Overvolt A Lvl 61 V 0 199 0 that will cause an Alarm when the voltage falls above this value A zero value is the off
45. programmed Overload Protection Overload protection is enabled in the Motor Protection group by programming the Overload class Overload reset Motor FLC Service factor Refer to Chapter 5 for more information on Motor Protection Phase Reversal Phase reversal is indicated when the incoming power to the PF Softstarter is in any sequence other than ABC This pre start protective feature can be disabled Network Network faults are faults generated on the network external to the PF Softstarter and are annunciated on the LCD display Ground Fault Ground faults are based on feedback from the user supplied 825 CT 5 480A devices only detecting ground fault currents Ground fault parameters of level and time delay must be pro grammed for proper operation Excess Starts Hour Excess starts hour is displayed when the number of starts in a one hour period exceeds the value programmed Power Loss Power loss indicates that an input power phase is not present The controller s LCD display will identify the missing phase If all three phases are absent when a start command is issued the LCD will display Starting without motor rotation Line Loss F41 F42 F43 During expected SCR gate periods the power pole voltage and currents are monitored If the SCR conduction is discontinuous a fault is indicated Phase loss overvoltage and undervoltage protection are disabled during bra
46. remain in its shipping container prior to installation If the l equipment is not to be used for a period of time it must be stored according to the Storing following instructions in order to maintain warrantv coverage Storeinaclean dry location Store within an ambient temperature range of 20 C to 75 C 4 F to 167 F Store within a relative humidity range of 0 to 95 noncondensing Do not store equipment where it could be exposed to a corrosive atmosphere Do not store equipment in a construction area Chapter 2 1 Chapter 2 Installation Lifting For controllers rated 625 1250 A the device should only be lifted from designated lifting points T he lifting points are designed to accept a 1 2 13 threaded hoist ring capable of lifting 2500 pounds These points are identified in Figure 2 1 Avold equipment damage Holst at proper lift points Refer to User Manual for lifting procedure Figure 2 1 Lifting Points Lifting Points o 0 9 0 0 8 8 RO Kose o o KOF 9 oo0 o 9 PE o o oo Chapter 2 2 Chapter 2 Installation General In addition to the precautions listed throughout this manual the following Precautions statements which are general to the system must
47. setting Allows the user the ability to prevent some nuisance Alarms by entering a delay period that provides a window that the voltage condition must persist within for the controller to Alarm Over voltage Overvolt A Dly 62 Secs 0 99 0 Allows the user to set a percentage of line to line Unbalance Unbalance F Lvl 63 V 0 25 0 Voltages that will cause a fault when the voltage falls above this value A zero value is the off setting Allows the user the ability to prevent some nuisance faults by entering a delay period that provides a window that the voltage unbalance condition must persist within for the controller to fault Unbalance Unbalance F Dly 64 Secs 0 99 0 Allows the user to set a percentage of line to line Voltages that will cause an Alarm when the voltage falls above this value A zero value is the off setting Unbalance Unbalance A Lvl 65 V 0 25 0 Allows the user the ability to prevent some nuisance Alarms by entering a delay period that provides a window that the voltage unbalance condition must persist within for the controller to Alarm Unbalance Unbalance A 01 66 Secs 0 99 0 Allows the user to set an instantaneous over current Jam Jam F Lvl 67 FLC 0 1000 0 level of line FLC that will cause a fault A zero value is the off setting Allows the user the ability to prevent some nuisance faults by entering a delay period that provides a window that the motor over current condi
48. short conductor with which you connect two points Liquid crystal display which is a reflective visual readout device commonly used in digital watches and laptop computers The minimum torque that a motor will develop at rest for all angular positions of the rotor with rated voltage applied at rated frequency A selected method of operation Example run test or program A set of contacts on a relay or switch that are closed when the relay is de energized or the switch is de activated They are open when the relay is energized or the switch is activated A set of contacts on a relay or switch that are open when the relay is de energized or the switch is de activated They are closed when the relay is energized or the switch is activated 1 A programmable controller 2 A programmable controller with a name that includes the letters PLC See Programmable Controller F 2 Port Power Factor Preset Speed Programmable Controller Protocol Remote 1 0 RS 232 C RS 422 RS 485 Scrolling Serial Service Factor S F Silicon Controlled Rectifier SLCTM Controller Glossary On a communication link the logic circuitry or software at a station that determines its communication parameters for a particular communication channel A measurement of the time phase difference between the voltage and current in an AC circuit It is represented by the cosine of the angle of this phase difference Power factor is t
49. the up to speed condition during the current limit starting mode the internal bypass contactor will be pulled in Figure 1 3 Current Limit Start 600 Percent Full Load Current 50 Start Ti d Kickstart is also available with Current Limit Start Ime se ongs Chapter 1 3 Chapter 1 Product Overview Dual Ramp Start This starting mode is useful on applications that have varying loads and therefore varying starting torque requirements Dual Ramp Start allows the user to select between two separate start profiles with separately adjustable ramp times and initial torque settings Figure 1 4 Dual Ramp Start Dual Ramp Start is available only with the standard controller Full Voltage Start This starting mode is used for applications requiring across the line starting The output voltage to the motor will reach full voltage within 1 4 second Figure 1 5 Full Voltage Start 100 Percent Voltage Time seconds Chapter 1 4 Chapter 1 Product Overview Preset Slow Speed This option can be used in applications that require a slow speed jog for general purpose positioning Preset Slow Speed provides either 7 of base speed low or 15 of base speed high settings in the forward direction Reverse can also be programmed and offers 10 of base speed low and 20 of base speed high settings Figure 1 6 Preset Slow Speed 100 pF Motor Speed gt 15
50. up to speed condition this parameter can be modified to compensate Rule of thumb is this number should be increased on up to high efficiency motors experiencing problems speed Ifthe is detecting the up to speed condition too late or not at all this number should be decreased on very low efficiency motors Note Be careful when adjusting this level Improper adjustment can cause the PF to start at full voltage Linear List UTS Level 114 Allows the user to load factory default values for all parameters Ready All Parameter Mgmt 115 Load Default Ready Only available with the Pump Control option Backspin Timer 116 Secs 0 999 0 Ensures that a specific amount of time passes between a stop and start sequence Basic Set Up This parameter is not viewable without entering a special password in Firmware versions 4 001 or earlier Contact Sprecher Schuh technical support if you have Version 4 001 firmware or earlier and need to access this parameter B 11 Group Linear List Linear List Linear List Linear List Linear List Linear List Linear List Linear List Linear List Parameter Name V Shut Off Level OL Reset Level Ambient Temperature Notch Position Notch Maximum pump control Start Delay By pass Delay Fault 1 Fault 2 Table B 1 Parameter List Continued Parameter Units Min Max Default Number Settings 117 9o V 0 100 25
51. 0 A 4 per phase Short Circuit Protection Fuses Cooper Bussmann Part 16504 2 625 780 A 1 per phase 970 1250 A 2 per phase Short Circuit Protection Circuit breaker Load side lug information for inside the delta applications is contained in Table 3 C Control Power Control Wiring Refer to the product nameplate for control terminal wire capacity and tightening torque requirements Each control terminal will accept a maximum of two wires Refer to the product nameplate prior to applying control power Depending on the specific application additional control circuit transformer VA capacity may be required Controllers rated 5 480 Amps The PF Softstarter controllers rated 5 480 amps accept control power input of 100 240V AC or 24V AC DC 10 15 single phase 50 60 Hz A control power source of 125 VA is required The control power requirement for the control module is 75VA The control power requirement for the fans is 20 or 50 VA The control module and fans are separately wired The control module requirements are shown in Table 3 E The fans require additional power as defined in Table 3 G Table 3 E Control Module Requirements 120 240V AC 75 VA 24V AC 130 VA Inrush Current 5A 250 ms ait sow 500 ms 24W 1606 XLP50E Chapter 3 6 Chapter 3 Wiring Controllers rated 625 1250 Amps For controllers rated 625 1250 A common control is required for proper operation Control power is connected to the
52. 0025 600V B PFD 0085 PFL 0025 600V 43 PFD 0043 600V B PFD 0085 PFL 0043 600V 60 PFD 0060 600V B PFD 0085 PFL 0060 600V 85 PFD 0085 600V B PFD 0085 PFL 0085 600V 108 PFD 0108 600V B PFD 0251 PFL 0108 600V 135 PFD 0135 600V B PFD 0251 PFL 0135 600V 24V AC DC 200 480V AC 5 PFD 0005 480V 024 B PFD 0085 024 PFL 0005 480V 25 PFD 0025 480V 024 B PFD 0085 024 PFL 0025 480V 43 PFD 0043 480V 024 B PFD 0085 024 PFL 0043 480V 60 PFD 0060 480V 024 B PFD 0085 024 PFL 0060 480V 85 PFD 0085 480V 024 B PFD 0085 024 PFL 0085 480V 108 PFD 0108 480V 024 B PFD 0251 024 PFL 0108 480V 135 PFD 0135 480V 024 B PFD 0251 024 PFL 0135 480V 200 600V AC 5 PFD 0005 600V 024 B PFD 0085 024 PFL 0005 600V 25 PFD 0025 600V 024 B PFD 0085 024 PFL 0025 600V 43 PFD 0043 600V 024 B PFD 0085 024 PFL 0043 600V 60 PFD 0060 600V 024 B PFD 0085 024 PFL 0060 600V 85 PFD 0085 600V 024 B PFD 0085 024 PFL 0085 600V 108 PFD 0108 600V 024 B PFD 0251 024 PFL 0108 600V 135 PFD 0135 600V 024 B PFD 0251 024 PFL 0135 600V C 4 Appendix D Contactor Attention Remove all power to the unit before proceeding with Replacement replacement procedures Installation Instructions for 625 1250 A units Prior to beginning the following steps the front cover must be removed 1 Note Cover is removed D 1 Appendix D x Sy Qy
53. 1180 0 99 75 119 0 60 50 120 40 0 100 0 87 5 121 50 70 70 122 Sec 0 30 0 123 Sec 0 15 0 124 0 255 125 0 255 Appendix B Parameter Description This parameter provides the user with the abilitv to manually adjust the level for the controller s voltage shut off detection Since this parameter has the potential to modifv the SCR control scheme it is important that adjustments be made with the help of Technical Support It is important that you do not disable both parameter 113 and this one at the same time otherwise SCR firing instability can occur Sets the level at which the motor overload is allowed to be reset Once the TCU has dropped below the program level the device can be reset manually or will auto reset if programmed for auto reset operation Provides the ability to compensate for a lower or higher ambient temperature condition The ambient temperature programmed should be representative of the actual nominal temperature or worst case condition since improper programming can result in nuisance tripping or SCR damage due to true SCR overheating This parameter allows for the starting control algorithm to be manually modified It is recommended that you do not make changes to this parameter without specifically talking with Technical Support This parameter allows for the pump stopping control algorithm to be manually modified It is recommended that you do not make change
54. 196 4 4437 2122 166 6 129 5 15 kg Controller 17 47 14 45 33 Ib All dimensions are approximate and are not intended for manufacturing purposes Chapter 2 7 Chapter 2 Installation Figure 2 5 Dimensions 201 251 A Controllers 49 r 135 980 531 4 ig ma moxi lt c i NS 1 3 5 m 48 32 UNC 2B DETAL SCALE 1 000 197 H 1776 9115 453 276 5 i 1 f 91 189 D 3 59 0215 6 18225 1 083 7 18 o 164 126 16 46 E oo N_ r 685 NUS s SEE DETAIL AA 25 B Ben 6 560 e 122 047 i 41 937 gig I ro 889000 m Ly PF Softstarter i Terz 152 749 6 01 SS N Z 1 40 9 Ld fis A LELI Width Height Ship Wt 201 251 A mm 225 560 2538 150 5041 157 25 91 189 44 311 79 811 30 4 kg Controller in 8 858 22 047 9 992 5 906 19847 62 359 174 3 14 67 Ib All dimensions are approximate and are not intended for manufacturing purposes Chapter 2 8 Chapter 2 Installation Figure 2 6 Dimensions 317 480 A Controllers
55. 254 10 60 610 24 508 20 254 10 85 610 24 508 20 254 10 108 914 36 762 30 406 16 135 914 36 762 30 406 16 201 1219 48 914 36 406 16 251 1219 48 914 36 406 16 317 1524 60 914 36 406 16 361 1524 60 914 36 406 16 480 1524 60 914 36 406 16 2286 90 508 20 508 20 625 2286 90 1829 72 508 20 780 2286 90 1829 72 508 20 9700 2286 90 1829 72 508 20 1250 2286 90 1829 72 508 20 Combination Controllers with Circuit Breaker 5 610 24 508 20 254 10 25 610 24 508 20 254 10 43 610 24 508 20 254 10 60 610 24 508 20 254 10 85 610 24 508 20 254 10 108 914 36 762 30 406 16 135 914 36 762 30 406 16 201 1219 48 914 36 406 16 nn nn 460V 58 251 1219 48 914 36 406 16 Q Use this row for 460V 59 17 124 Em m 2 m Ar and 575V 60 and 61 60 16 970 1250 rated devices are w 1524 60 914 36 10616 B 625 2286 90 1829 72 508 20 only available as Type 1 and 780 2286 90 1829 72 508 20 require a door mounted fan capable of delivering 240 cfm 970 2286 90 1829 72 508 20 1250 2286 90 1829 72 508 20 Chapter 2 4 Chapter 2 Installation Mounting All units are fan cooled It is important to locate the controller in a position t
56. 85 kA 3000 1600 85 kA 3000 85 kA 3200 85 kA 3000 SCCR Performance 690V Type 1 SCCR List Max Std Available Fault Max Ampere Tested Max Ampere Tested North American Style European Style i i 6 9 gRB 73xxx400 Maximum FLC Device Rating A 108 70 kA A070URD33xxx500 6 xg XXX 135 70 kA A070URD33xxx500 8 URD3300600 XXXI 201 70kA A070URD33xxx700 5 9 gRB 73Xxxi 251 70 kA A070URD33xxx700 8 SURD3300700 XXX 317 70 kA A070URD33xxx900 5 73XXX 361 70 kA A070URD33xxx900 480 70 A070D33xxx1250 9 URD 73xxx1250 A100URD73xxx1250 6 6URD33xxx1250 625 70 A070URD33xxx1400 6 6URD33xxx1400 780 70kA A070URD33xxx1400 6 6URD33xxx1400 2 fuses in parallel 2 fuses in parallel an SKA AO7OURD3300 250 G GURDIJOXI250 uses in paralle uses in paralle 1250 mM 4070003301250 6 608033001250 Consult local codes for proper sizing of short circuit protection Non time delay fuses Class K5 5 480 8 7 831 A devices Class L 625 1250 850 1600 A devices High capacity fault rating when used with time delay class CC J or L fuses A 3 Appendix A Power Requirements Control Module 1 480 A 120 240V AC Transformer 75 VA 24V AC Transformer 130 VA 24V DC Inrush Current 5A Inrush Time 250 ms Transistent Watts 60 W Transistent Time 500 ms Steady State Watts 24W Minimum Allen Bradley 1606 XLP50E Power Supply Control Module 625 1250 A
57. B PFS PFL 0135 600V 24V AC DC 200 480V AC 5 PFS 0005 480V 024 B PFS 024 PFL 0005 480V 25 PFS 0025 480V 024 B PFS 024 PFL 0025 480V 43 PFS 0043 480V 024 B PFS 024 PFL 0043 480V 60 PFS 0060 480V 024 B PFS 024 PFL 0060 480V 85 PFS 0085 480V 024 B PFS 024 PFL 0085 480V 108 PFS 0108 480V 024 B PFS 024 PFL 0108 480V 135 PFS 0135 480V 024 B PFS 024 PFL 0135 480V 200 600V AC 5 PFS 0005 600V 024 B PFS 024 PFL 0005 600V 25 PFS 0025 600V 024 B PFS 024 PFL 0025 600V 43 PFS 0043 600V 024 B PFS 024 PFL 0043 600V 60 PFS 0060 600V 024 B PFS 024 PFL 0060 600V 85 PFS 0085 600V 024 B PFS 024 PFL 0085 600V 108 PFS 0108 600V 024 B PFS 024 PFL 0108 600V 135 PFS 0135 600V 024 B PFS 024 PFL 0135 600V C 2 Appendix C Control Control Line Amperes Originally Ordered as Series Control Module Power Poles Type Voltage Voltage Catalog Number Catalog Number Catalog Number Pump 100 240V 200 480V AC 5 PFB 0005 480V B PFB PFL 0005 480V Control 25 PFB 0025 480V B PFB PFL 0025 480V 43 PFB 0043 480V B PFB PFL 0043 480V 60 PFB 0060 480V B PFB PFL 0060 480V 85 PFB 0085 480V B PFB PFL 0085 480V 108 PFB 0108 480V B PFB PFL 0108 480V 135 PFB 0135 480V B PFB PFL 0135 480V 200 600V AC 5 PFB 0005 600V B PFB PFL 0005 600V 25 PFB 0025 600V B PFB PFL 0025 600V 43 PFB 0043 600V B PFB PFL 0043 600V 60 PFB 0060 600V B PFB PFL 0060 600V
58. EVEL ey MAIN MENU or Memor f Parameter gt gt Preferences Diagnostics Storage 117 Monitoring Reset to Defaults Change Password Enter Password Alarms Set up User Dspl Line Faults Motor Protection User Dspl Time Device Revision Utility User Dspl Video Linear List Reset User Display GROUP MENU Parameter menu continued in Figure 4 2 The PF Softstarter does not support EEPROM Link Process or Start up modes Steps back one level Only displayed if password other than 0 is entered Chapter 4 2 Chapter 4 Programming Figure 4 2 Parameter Menu Structure Depending upon PF option selected some parameters may not appear in product display Q Steps back one level For further information on parameters see Appendix B For further information on parameter management see page 4 7 Chapter 4 3 Volts Phase A B Table 4 A Parameter Linear List OL Trip Enable Disable Chapter 4 Programming Data Out A2 Volts Phase B C Overload A Lvl Data Out B1 Volts Phase C A Underload F Lvl Data Out B2 Current Phase A Underload F Dly Data Out C1 Current Phase B Underload A Lvl Data Out C2 Current Phase C Underload A Dly Data Out D1 Watt Meter Undervolt F Lvl Data Out D2 Kilowatt Hours Undervolt F Div Motor ID Elapsed Time Undervolt A Lvl CT Ratio Meter Reset Undervolt A Dly MV Ratio
59. Minimum spacing between different wire groups in the same tray should be 16 cm 6 in Wireruns outside an enclosure should be run in conduit or have shielding armor with equivalent attenuation Different wire groups should be run in separate conduits Minimum spacing between conduits containing different wire groups should be 8 cm 3 in Foradditional guidelines please refer to Wiring and Ground guidelines publication DRIV ES IN 001A EN P Additional Requirements e f linear acceleration is used a separate conduit or wire way should be used for the tachometer leads Wire earth ground to control terminal 14 Useshielded wire for PTC Tachometer and ground fault input Terminate shielded wires to terminal 14 Ground fault CT must be inside or within 3 m of metal enclosure Chapter 2 14 Chapter 3 Wiring Terminal Locations ThePF Softstarter wiring terminal locations are shown in Figure 3 1 and Figure 3 2 Make wiring connections as indicated in the typical connection diagrams incoming three phase power connections are made to terminals L 1 1 L2 3 and L3 5 Load connections to Line motors are made to T 1 2 T 2 4 and T 3 6 while load connections to Wye Delta motors are made to T 1 2 T 2 4 T 3 6 T 4 8 T 5 10 and T 6 12 Figure 3 1 Wiring Terminal Locations 5 85 A eoooo DERRE PF Softstarter 225272722322 O 00000000000 000000000004 00 55sUS 22 Table 3 A Wir
60. Speed options For general purpose positioning the A ccu Stop option provides a brake from full speed to the preset slow speed setting then brakes to stop Figure 1 11 Accu Stop Option 100 Motor Speed 7 or 15 Slow Speed Braking Coast to rest Brake Slow Speed l Slow Start Run Speed Time seconds Attention Accu Stop and Slow Speed with Braking are not intended to be used as an emergency stop Refer to applicable standards for emergency stop requirements Slow Speed with Braking Option The Slow Speed with Braking option provides a job speed for process set up and braking to stop atthe end of the cycle Figure 1 12 Slow Speed with Braking Option 100 Motor Speed 7 15 Slow Start Run Stop Time seconds Chapter 1 10 Chapter 1 Product Overview Protection and Diagnostics The PF Softstarter provides the protective and diagnostic features described be low Overload The PF Softstarter meets applicable requirements as a motor overload protective device Thermal memory provides added protection and is maintained even when control power is removed The built in overload controls the value stored in Pa rameter 12 M otor Thermal Usage an Overload Fault will occur when this value reaches 100 The programming parameters below prov
61. TROL MODULE CONTACTOR FAN INPUT 230 VAC Chapter 3 8 iring W Chapter 3 Internal Wiring and 120V Control Connection Diagram for 625 1250 A Devices Figure 3 8 F JFN z 9 nr FAN B L EAA PF SOFTSTARTER CONTROL MODULE CONTACTOR FAN INPUT 120 VAC Chapter 3 9 Fan Power Chapter 3 Wiring Control Wire Specifications Table 3 F provides the control terminal wire capacity the tightening torque requirements and the wire strip length Each control terminal will accept a maximum of two wires Table 3 F Control Wiring and Tightening Torque Wire Size Wire Strip Length 0 75 2 5 mm 18 14AWG 0 6 Nem 5 Ib in 5 6 8 6mm 0 22 0 34 in Controllers rated 5 1250 A have heatsink fans Refer to Table 3 G for the control power VA requirements of the heatsink fans Fan Terminations See Figure 3 1 3 2 and 3 3 for fan power connection locations Attention e The fan jumpers have been factory installed for 110 120V AC input Refer to Figure 3 9 for 220 240V AC fan wiring 5 480A devices only Figure 3 9 Power Terminations 625 1250A Control Power 5 480 A Fan Terminations Fan Terminations 1 110 120 VAC or Factory Set Optional 230 240 VAC 110 120 VAC 20200 50 60 Hz ONLY i i 1 1 ili 4 To To To 2 1 Supply 2 Supply 2 LI Supply Jumpers Jumper jumpers 3 3 a
62. User Dspy lines To complete the programming process re enter the Main Menu mode to log out This will eliminate unauthorized access to the programming system Note f you lose or forget the password contact your local Sprecher Schuh representative Chapter 4 5 Chapter 4 Programming Parameter Management Before you begin programming it s important to understand how the controller memory 15 structured within the PF Softstarter used on power up and during normal operation Refer to Figure 4 3 and the explanations below Figure 4 3 Memory Block Diagram EEPROM gt RAM ROM Random Access Memory RAM This is the work area of the controller after itis powered up The PF Softstarter uses an A uto Store feature when programming parameters W hen parameters are modified in the program mode the new values are stored immediately in RAM and then in EEPROM once the enter key has been pressed these values will be lost When the device first powers up the values from the EEPROM area of memory are copied into RAM Read only Memory ROM The PF Softstarter comes with factory default parameter values T hese settings are stored in non volatile ROM and are displayed the first time you enter the Program mode At any time you can restore defaults by accessing the memory storage menu Description Recalling Defaults After parameter values have been modified
63. a sliding window for the one hour time period Q The 625 780 970 and 1250 A units the min max is 5 0 25 and the default value is 5 0 Amps B 8 User Settings Appendix B Table B 1 Parameter List Continued Group Parameter Name Parameter Units Min Max Default Parameter Description User Number Settings Settings Allows the user to enable the PF Softstarter to auto restart for up to 5 attempts other than an SCR Restart Restart Attempts 82 dos 0 overtemp or motor overload fault The start signal must remain active for a restart to occur Restart Restart Delay 83 Secs 0 60 0 Provides a delay time between restart attempts to allow for the condition to be removed This parameter gives the user the ability to selectively disable specific fault codes such as F1 F2 F3 and F41 F42 F43 These faults are used 0 Disable to detect problems with incoming power and the 1 Disable F1 detection of appropriate zero crosses 1 or the Linear List Line Fault Disable MS 2 Disable F41 firing of the SCRs based the current and voltage 3 Enable characteristics associated with the SCR turning off F41 These faults can only occur during starting or stopping and are usually related to the incoming power condition This parameter defeats all running faults and is 0 Disable only effective in the run mode It will not override Linear List Emergency Run 859 n Disable faults prior to starting i e s
64. ad from tripping during slow speed pump stopping and braking maneuvers Motor Thermal Usage MTU continues to increment during these maneuvers Setting this parameter to disable can result in motor overheating or potential damage Allows the user to set an overload level of motor thermal usage that will cause an alarm when the level exceeds the setting Allows the user to set a current of line FLC that will cause a fault when the motor current falls below this value A zero value is the off setting Allows the user the ability to prevent some nuisance faults by entering a delay period that provides a window that the motor current condition must persist within for the controller to fault Allows the user to set a current of line FLC that will cause an Alarm when the motor current falls below this value A zero value is the off setting Allows the user the ability to prevent some nuisance Alarm conditions by entering a delay period that provides a window that the motor current condition must persist within for the controller to Alarm Allows the user to set a voltage of line Voltage that will cause a fault when the voltage falls below this value A zero value is the off setting Allows the user the ability to prevent some nuisance faults by entering a delay period that provides a window that the voltage condition must persist within for the controller to fault User Settings This
65. age Viewing To access the metering information follow the procedure below Metering Data Description Action Display Amps Volt MTU Main Menu Parameter Memory Storage 1 Press any of the following keys to access the Main Menu O e 2 Scroll with the Up Down keys until e inni Parameter the Parameter option is shown Memory Storage 3 the Enter key to select the Parameter option e 4 Scroll with the Up Down keys until GP File the Monitoring option is displayed Set Up 5 Press the Enter key to access the Monitoring group 6 Press the Enter key to access the e FOR Grou Metering group Refer to Metering on page 1 19 or Figure 4 2 on page 4 3 for details on the metering functions Chapter 6 1 Chapter 6 Metering Description Display 7 Scroll through the Metering PET parameters with the Up Down keys to access the desired information Press the Enter key to view that parameter d ar see Volt FG Peg ser l Voll FG Pra vn Amps FG Pes 26 Amps FG Pre wen Amos r6 PBT u Kw FG Pas KWH FG LAE Hour F er 10 Na FG Pali ee FG Pe 12 ss SATU The metering values that are displayed on the PF Softstarter can be modified to show your desired values by accessing M ain M enu Preferences Chapter 6 2 Overview Fault Display Clear Fau
66. ange 5 50 C 23 122 F open 5 40 C 23 104 F enclosed Storage and Transportation Temperature Range 20 75 C Altitude 2000 m 6560 ft Humidity 5 95 non condensing Pollution Degree 2 The product s allowable operational ambient temperature must be derated by 3 C 27 F per 1000 m 3280 ft Maximum operating altitude is 7000 m 23 000 ft Current rating of the PF Softstarter does not change for altitudes that require a lower maximum ambient temperature Resistance to Operational Vibration Non Operational Resistance to Operational Shock Non Operational Construction Power Poles Control Modules Metal Parts Terminals Power Terminals All 5 480 A 625 1250 A 5 85 A 108 480 A 625 1250 A 5 85 A 108 480 A 625 1250 A 5 85 108 1250 A 5 85 108 135 A 201 251 A 317 480 A 625 1250 A Power Terminal Markings Control Terminals A 5 1 0 G Peak 0 15 mm 0 006 in displacement 2 5 G 0 38 mm 0 015 in displacement 1 0 G 0 15 mm 0 006 in displacement 15G 5 56 46 306 25 6 126 Heatsink thvristor modular design Heatsink hockev puck thyristor modular design Thermoset and Thermoplastic Moldings Plated Brass Copper or Painted Steel Cable size Line Upper 2 5 95 mm 14 3 0 AWG Line Lower 0 8 2 5 mm 18 14 AWG Load Upper 2 5 50 mm 14 1 AWG Load Lower 0 8 2 5 mm
67. at is repeated regularly 2 The time it takes for one sequence of operations to occur 1 DH 485 Link Disable Duty Cycle Enable Fault G File Gate Jogging Jumper LCD Locked Rotor Torque Mode Normally Closed Contacts Normally Open Contacts PLC Controller Glossary Data Highway 485 link An Allen Bradley token passing baseband link for a local area network based on the RS 485 standard To inhibit logic from being activated The relationship between the operating and rest times or repeatable operation at different loads To allow an action or acceptance of data by applying an appropriate signal to the appropriate input Any malfunction that interferes with normal system operation G File configuration is based on the devices that you have on the RIO link G File configuration consists of setting logical device starting addresses and the logical device image size of each physical device adapter with which the scanner communicates The control element of an SCR silicon controlled rectifier commonly referred to as a thyristor When a small positive voltage is applied to the gate momentarily the SCR will conduct current when the anode is positive with respect to the cathode of the SCR Current conduction will continue even after the gate signal is removed Jogging is a means of accomplishing momentary motor movement by repetitive closure of a circuit using a single push button or contact element A
68. ata be entered as it appears on the motor nameplate Motor Data Entry In the Program mode enter the correct values into the Overload group Parameter Option Display Overload Class Disable 10 F cma 44 The Factory default setting is 10 15 20 30 Overload Class Service Factor 0 01 1 99 Enter the value from the motor s nameplate F Gl Pit 45 Service Factor Motor FLC 1 0 2200A Enter the value for the motor s nameplate 46 Motor FLC ug Amps Overload Reset Manual Auto Allow s the user to select either a manual or FcR P 47 Overload Reset auto reset after an overload fault Motor Connection Line Delta F Gi P 15 Enter the type of motor being connected to Kater PF Softstarter Line or Delta Line Voltage 1 10 000V Enter the system voltage in this parameter F dg This must be done to ensure optimum mo Line Voltage tor performance and correct operation of undervoltage and overvoltage protection Refer to the PF Softstarter nameplate for maximum ratings Exceeding these could result in damage to the controller Q Found in Overload programming group Only one location needs to be programmed Found in Basic Set Up programming group Chapter 5 1 Chapter 6 Metering Overview Whilethe PF Softstarter operates your motor it also monitors several different parameters providing full function metering pack
69. ate motor stress caused by repeated starting over a short time period Overtemperature The PF Softstarter monitors the temperature of the SCRs and Bypass by using internal thermistors W hen the power poles maximum rated temperature is reached the unit will shut down and restart is inhibited An over temperature condition can indicate inadequate ventilation high ambient temperature overloading or excessive cycling After the temperature is reduced to allowable levels the fault can be cleared Open Gate An open gate fault indicates that improper SCR firing typically caused by an open SCR gate has been detected on one of the power poles Before the controller shuts down it will attempt to start the motor a total of three times Line Faults The PF Softstarter continually monitors line conditions for abnormal factors Pre start protection includes Line Fault with phase indication Line voltage loss Missing load connection Shorted SCR Running protection includes Line Fault no phase indication Line voltage loss Missing load connection Phase Reversal protection can be toggled either On or Off Phase Reversal protection is functional only at pre start Chapter 1 18 Chapter 1 Product Overview Metering Power monitoring parameters include Three phase current Three phase voltage Power in kW Power usage in KWH Power factor M otor thermal capacity usage Elapsed time Notes 1 Vol
70. ayed through the LCD and alarm contact closing Jam detection allows the user to determine the jam level up to 100096 of the motor s FLC rating and the delay time up to 99 0 seconds for application flexibility Figure 1 16 Jam Detection oo Percent Full Load User Programmed Trip Level Current 100 Running Jam Time seconds Jam detection is disabled during slow speed and braking operation Q Unit will self protect in a jam condition Chapter 1 14 Chapter 1 Product Overview Ground Fault In isolated or high impedance grounded systems core balanced current sensors are typically used to detect low level ground faults caused by insulation break downs or entry of foreign objects Detection of such ground faults can be used to interrupt the system to prevent further damage or to alert the appropriate personnel to perform timely maintenance The PF Softstarter s ground fault detection capabilities require the use of external sensor Installation of this sensor allows the option of enabling Ground Fault Trip Ground FaultA larm or both For the 5 480 Amp devices the recommended sensor is a Cat No 825 CBCT core balance current transformer for 1 5A core balanced ground fault protection For the 625 1250 A devices the recommended sensor is shown below and provides 5 25A core balanced ground fault protection M anufacturer Rockwell A utomation Description 600Volt Rated
71. be set to fault operation Chapter 3 17 Chapter 3 Wiring Figure 3 17 Typical Wiring Diagram for Single Speed Reversing Applications L i f B f 1 L1A 3 Phase lii 4 14123 Input Power Po r1LZ i M L3 5 Branch Protection t 4 x T24 1 T 3 6 PF Softstarter T 1 OFF FOR REV E Stop dil alo al M 8 4 Due x dm X L zN F R 1 tT F l r n n2 13 14 15 16717118 19 2 21 22 PF Softstarter Control Terminals Auer 23 24 25 z 27 28 29 20 31 32 33 34 Baum wy ll TACH Ground AUX 2 Input Fault PTC Input Customer supplied L U Li l AUX 3 AUX 4 Refer to the controller nameplate to verify the rating of the control power input rating For units rated 625 1250 A terminals 11 amp 12 are factory pre wired from terminal block CP1 terminals 1 amp 4 No braking maneuver allowed in wiring diagram Maintained pushbutton Notes 1 Minimum transition time for reversing direction is 1 2 second 2 Phase Reversal protection must be disabled in reversing applications Chapter 3 18 Chapter 3 Wiring Figure 3 18 Typical Wiring Diagram for Two speed Applications Two Speed Motor Starter 1 ee
72. between two Start settings The parameters below are available in the Set Up programming mode To obtain Dual Ramp control Ramp 1 is located in the Basic Set Up and Ramp 2 is located in the Option 2 Input Dual Ramp Parameter Set Up The user must select the Set Up programming mode to obtain access to the Dual Ramp parameters Option Basic Set Up Starting Mode Set Up as stated in previous pages Option 2 Input Dual Ramp This allows the user the option to choose between two Soft Start profiles defined by 1 Start Mode Ramp Time Initial Torque and 2 Start Mode 2 Ramp Time 2 Initial Torque 2 When this feature is turned on the ramp time initial torque combination is deter mined by a hard contact input to terminal 15 When this input signal is low ramp time initial torque are selected When this input is high ramp time 2 initial torque 2 are selected Once the Option 2 Input has been set to Dual Ramp you must ESC back to the Parameter File menu Re enter into the Set Up menu to show both Basic Set Up and Dual Ramp Basic Set Up Start Mode 2 This selects the start mode for option 1 Basic Set Up Ramp Time This programs the time period during which the controller will ramp the output volt age up to full voltage for the first Start setup 0 30 s Basic Set Up Initial Torque This parameter establishes and adjusts the initial reduced output voltage level for the first Soft Start setup 0 90
73. d Slow Speed with Braking DEMETRII Sequence of Operation Special A pplication Considerations Use of Protective M odules M ulti motor Applications PF Softstarter as a Bypass to an AC Drive PF Softstarter with aM otor Winding Heater 5 3 25 3 26 nn 3 28 s 3 34 s 3 34 uie 3 22 s 3 36 3 37 Table of Contents Chapter 4 Overview ED Programming K eypad Description Programming Menu ine Password PER EEE Parameter Management ETE EUER ESTE TT eI AMORE UT Random Access Memory RAM Be Read only Memory ROM 6 Electrically Erasable Programmable Read only emory EEPROM es 4 6 Parameter M odification usi tetas ee een ET SOLES EAN ta ec duct res Rod a d o re Current Limit Star occ eo ed Bes ra dg Duat Ramp Starta teie sos sip c Wer aks Dok pete cg Full Voltage Start nn ann trie ctun Rex ted ana a 210 Linear Speedi hee ire I por ivre t m ae da etat folds 10 Programming Parameters unse ea os 1 11 een M otor Protection re ee Example Settings nassen 10 Lindervoltag ae een leo ele we jeddu Aiea ee Iu EMT A Kinder odd ants ate i cani dab da u Missa Motor Information Motor Data Entry tet nee tee tee eee eee e nn nn n nn Metering Viewi
74. d A 16 No Load 40 No Load B 17 Line Loss A 410 No Load C 18 Line Loss B 42 Line Imbalance 19 Line Loss C 430 Overvoltage 20 V24 Loss 45 Undervoltage 21 V Control Loss 46 Overload 22 Input 1 48 Underload 23 Input 2 49 Jam 24 System Faults 128 209 See Table 7 B for definition Fault and Alarm Auxiliary contacts can be programmed for Fault or Alarm N O or N C Auxiliary Indication indication Parameter setup can be found in the Parameter M otor Protection y group when modifying parameters in the Program M ode for Fault or Alarm Chapter 7 2 Fault Definitions Chapter 7 Diagnostics Table 7 B shows the fault definitions for the PF Softstarter Table 7 B Fault Definitions Fault Description Line Loss F1 F2 F3 The PF Softstarter can determine if a line connection has been lost and will indicate this accordingly Shorted SCR Shorted SCRs will be detected and starting will be prohibited by the PF Softstarter Open Gate Open gate indicates that an abnormal condition that causes faulty firing e g open SCR gate has been sensed during the start sequence The PF Softstarter will attempt to start the motor a total of three times before the controller shuts down Power Pole PTC and SCR The power pole temperature in each phase is monitored If the temperature rises above the Overtemperature predetermined level the unit will fault to protect the power pole A reset can be performed once the te
75. d connections to the control module PTC Power Pole 10 amp 11 Controller ventilation blocked Check for proper ventilation Controller duty cycle exceeded Check application duty cycle Fan failure Replace fan Ambient temperature limit exceeded Wait for controller to cool or provide external cooling Failed thermistor Replace power module SCR Overtemp Failed control module Replace control module Motor PTC 12 Motor ventilation blocked Check for proper ventilation Motor duty cycle exceeded Check application duty cycle Wait for motor to cool or provide external cooling PTC open or shorted Check resistance of PTC Chapter 8 2 Table 8 A PF Fault Display Explanation Continued Display Open Bypass 13 14 amp 15 Control voltage is low Inoperable power module bypass Chapter 8 Troubleshooting Possible Solutions Check control voltage power supply Replace power module e Check control module TB2 TB4 and TB5 TB7 for secureness Check Aux 1 2 3 4 configurations are not set to External Bypass No Load 16 17 18 Loss of load side power wiring Check all load side power connections and amp 40 motor windings Line Unbalance 19 Supply unbalance is greater than the user Check power system and correct if necessary programmed value The delay time is too short for the application Extend the delay time to match the application requirements Overvoltage 20 Supp
76. e for determining which stopping mode is best suited to the application and will meet applicable stan dards for operator safety on a particular machine Chapter 3 28 Figure 3 28 100 Motor Speed Push Buttons Start Stop Slow Speed Auxiliary Contacts Normal Up to speed Chapter 3 Wiring Preset Slow Speed Sequence of Operation Closed Open Closed Open Closed Open Closed Open Closed Open Coast to rest Soft Stop SlowSpeed m Start Run Coast Time seconds Chapter 3 29 Figure 3 29 Pump Control Sequence of Operation 100 Motor Speed Push Buttons Start Stop Pump Stop Auxiliary Contacts Normal Up to speed Closed Open Closed Open Closed Open Closed Open Closed Open Chapter 3 Wiring Coast to rest m Pump Start Run Time seconds Pump Stop m Pi If Pump Stop Selected If Coast to rest Selected The user is responsible for determining which stopping mode Chapter 3 30 is best suited to the application and will meet applicable standards for operator safety on a particular machine Chapter 3 Wiring Figure 3 30 SMB Smart Motor Brake Sequence of Operation 100 Motor Speed Push Buttons Start Stop Smart Motor Braking Auxiliary Co
77. emperature rating the PTC sensor s resistance transitions from a low to high value Since PTC sensors react to actual temperature enhanced motor protection can be provided to address such conditions as obstructed cooling and high ambient temperatures The following table defines the PF Softstarter PTC thermistor input and response ratings Table 1 A PTC Input Ratings Response resistance 3400 Q 150 Q Reset resistance 1600 Q 100 Q Short circuit Trip Resistance 25 100 Maximum Voltage at PTC Terminals R 4 lt 7 5V Maximum Voltage at PTC Terminals R Open 30V Maximum Number of Sensors 6 Maximum Cold Resistance of PTC Sensor Chain 1500 Q Response Time 800 ms The following figure illustrates the required PTC sensor characteristics per IEC 34 11 2 Figure 1 18 PTC Sensor Characteristics per IEC 34 11 2 4000 F 1330 l 550 250 100 20 1 10 e 20 C TNF 20K 15 C _ TNF 5K TNF 5K TNF PTC Trip The PF Softstarter will trip with a PTC indication if No other fault currently exists PTC protection is enabled The resistance across terminals 23 and 24 is either greater than the relay s response resistance or less than the short circuit trip resistance Chapter 1 17 Chapter 1 Product Overview Excessive Starts Hour The PF Softstarter allows the user to program the allowed number of starts per hour up to 99 This helps elimin
78. ension drawings Chapter 2 11 Chapter 2 Installation Power Factor The controller can be installed on a system with power factor correction PFC Correction capacitors The capacitors must be located on the line side of the controller This must be done to prevent damage to the SCRs in the PF Softstarter Capacitors W hen discharged a capacitor essentially has zero impedance For switching sufficient impedance should be connected in series with the capacitor bank to limit the inrush current One method for limiting the surge current is to add inductance in the capacitor s conductors This can be accomplished by creating turns or coils in the power connections to the capacitors 250V 15 6 in diameter coil 6 loops 480 600V 15 cm 6 in diameter coil 8 loops Take care in mounting the coils so that they are not stacked directly on top of each other stacking will cause a cancelling effect Also mount the coils on insulated supports away from metal parts so they will not act as induction heaters If an isolation contactor is used put capacitors in front of contactor Note For further instructions consult the PFC capacitor vendor Figure 2 9 Typical Wiring Diagram for Power Factor Correction Capacitors 1 T1 2 3 Phase i J 1 L2 3 T2 4 Input Power i J L3 5 T3 6 E iei uade Branch KO PF Softstarter Protection o 9 A 5 Cust
79. er 4 10 Chapter 4 Programming Programming Parameters The following table provides the option specific parameters that are provided with each control option These parameters are in addition to those already discussed in the Basic Set Up and M etering groups Diagrams supporting the options described below are shown later in this chapter Option Parameter Range Standard Soft Stop PF Option Standard This parameter identifies the type of control present and is not user programmable Soft Stop Time 0 120 s Allows the user to set the time period for the Soft Stopping function Preset Slow PF Option Standard Speed This parameter identifies the tvpe of control present and is not user programmable Slow Speed Select Allows the user to program the slow speed that best fits the application Low 790 forward 10 reverse High 1590 forward 2090 reverse Slow Speed Direction This parameter programs the slow speed motor rotational direction Forward Reverse Slow Accel Current Allows the user to program the re quired current to accelerate the motor to slow speed operation 0 450 of full load current Slow Running Current Allows the user to program the re quired current to operate the motor at 0 450 of full load current the slow speed setting Chapter 4 11 Option Parameter Chapter 4 Programming Range Pump Control Pump Control PF Opti
80. es for successive parts When used on a motor nameplate a number which indicates how much above the nameplate rating a motor can be loaded without causing serious degradation i e a motor with 1 15 S F can produce 15 greater torque than one with 1 0 S F to adjust measured loads in an attempt to compensate for conditions which are difficult to measure or define A solid state switch sometimes referred to as a thyristor The SCR has an anode SCR cathode and control element called the gate The device provides controlled rectification since it can be turned on at will The SCR can rapidly switch large currents at high voltages They are small in size and low in weight A programmable controller with a name that includes the letters SLC See Programmable Controller F 3 Status Surge Protection Toggle Transient UL Glossary The condition at a particular time of any numerous entities within a system These conditions may be represented by values in a status line The process of absorbing and clipping voltage transients on an incoming line or con trol circuit MOVs Metal Oxide Varistors and specially designed R C networks are usually used to accomplish this To switch alternately between two possible selections A momentary deviation in an electrical or mechanical system Underwriters Laboratories a third party safety certification agency F 4 Notes
81. gram for the Preset Slow Speed Control Power Option Command GG PF Softstarter Control Terminals Aux 1 BIEEIEIEZEIEIEIEIEIEN wo PTC TACH Ground Aux 2 Aux 3 Aux 4 Input Input Fault Customer supplied Q Refer to the controller nameplate to verify the rating of the control power input voltage For units rated 625 1250 A terminals 11 amp 12 are factory pre wired from terminal block CP1 terminals 1 amp 4 Slow Speed Note Refer to Chapter 3 for typical power circuits Chapter 3 25 Slow Speed with Braking Chapter 3 Wiring Figure 3 25 Typical Wiring Diagram for the Slow Speed with Braking with an Isolation Contactor Control Power rl TSSTeTS SE TT De DT PF Softstarter Control Terminals Aux 1 CIEIEIEJEIEIEIEIEREIETES ae kd PTC TACH Ground Aux 2 Aux 3 Aux 4 B Input Input Fault Customer supplied Refer to the controller nameplate to verify the rating of the control power input voltage For units rated 625 1250 A terminals 11 amp 12 are factory pre wired from terminal block CP1 terminals 1 amp 4 Aux 4 should be set to normal operation Note Refer to Chapter 3 for typical power circuits Chapter 3 26 Chapter 3 Wiring Figure 3 26 Inside the Delta Power and Motor Connections For 6 and 12 Lead Wye Delta Motors INCOMING POWER LI L2 L3 uA L2 3 L3 5 PF PCS SERIES
82. ground fault current at which the PF Softstarter will trip It is adjustable from 1 0 5 0 or 5 0 25 A depending on the service size Important The ground fault inhibit timer starts after the maximum phase of load current transitions from 0 A to 30 of the device s minimum F LA Setting or the GF Current is greater than or equal to 0 5 A The PF Softstarter does not begin monitoring for a ground fault condition until the Gnd F It Inh Time expires Ground Fault Alarm The PF Softstarter will indicate a Ground FaultA larm if No warning currently exists Ground fault alarm is enabled GF InhibitTime has expired e GF Current is equal to or greater than the Gnd FItA Lvl Parameter 77 Gnd FItA Lvl allows the installer to define the ground fault current at which the PF Softstarter will indicate a warning It is adjustable from 1 0 5 0 or 5 0 25 A depending on the service size Parameter 78 Gnd FItA Dly allows the installer to define the time period a ground fault alarm condition must be present before a trip occurs It is adjustable from 0 1 250 seconds Chapter 1 16 Chapter 1 Product Overview Thermistor PTC Protection The PF Softstarter provides terminals 23 and 24 for the connection of positive temperature coefficient PTC thermistor sensors PTC sensors are commonly embedded in motor stator windings to monitor the motor winding temperature W hen the motor winding temperature reaches the PTC sensor s t
83. hat allows air to flow vertically through the power module The controller must be mounted in a vertical plane and have a minimum of 15 cm 6 in free space above and below the controller W hen drilling or installing near the softstarter make sure that adequate measures are taken to protect the device from dust and debris See Figure 2 2 Figure 2 2 PF Softstarter Mounting Protection Chapter 2 5 Chapter 2 Installation Dimensions Figure 2 3 Dimensions 5 85 A Controllers l C je 4 72 l 6 64 120 _ 1164 H 3 15 80 fit 2 B 42 220 e 12 56 2 PLACES I 1 59 T 40 3 1 39 315 35 4 181 HL 48 m a l ia p Q Lm 12 3 135 p 1B P 25 5 gt gt 2 PLACES 250 6 35 4 PLACES wa B E 12 64 321 1 kJ PF Softstarter 2452327523225 000000000000 109459089222 o 0 295 M IT d Db 315 N 2 T2 4 E 1 39 B T T1 TT 7 Y 35 4 LH Y I 2 16 i 250
84. he ratio of Real Power kW to total kVA or the ratio of actual power W to apparent power volt amperes Preset speed refers to one or more fixed speeds at which the drive will operate A solid state system that has a user programmable memory for storage of instructions to implement specific functions such as 1 0 control logic timing counting report generation communication arithmetic and data file manipulation A controller consists of a central proces sor input output interface and memory A controller is designed as an industrial control system A set of conventions governing the format and timing of data between communication devices 1 0 connected to a processor across a serial link With a serial link remote 1 0 can be located long distances from the processor An EIA standard that specifies electrical mechanical and functional characteristics for serial binary communication circuits in a point to point link An EIA standard that specifies electrical characteristics of balanced voltage digital interface circuits in a point to point link An EIA standard that specifies electrical characteristics of balanced voltage digital interface circuits in a multi point link The vertical movement of data on a display screen caused by the dropping of one line of displayed data for each new line added at the opposite end Pertaining to time sequential transmission of storage of or logic operations on data using the same faciliti
85. hes Dimensions are not intended for manufacturing purposes Approximate Controller Rating A Height Width Depth Shipping Weight 5 85 321 150 203 5 7 kg 12 6 5 9 8 0 12 6 Ib 108 135 443 7 196 4 205 2 15 0 kg 17 47 7 74 8 08 33 Ib 201 251 560 225 253 8 30 4 kg 22 05 8 86 9 99 67 Ib 317 480 600 290 276 5 45 8 kg 23 62 11 42 10 89 101 Ib 625 780 1041 1 596 9 346 2 179 kg 41 0 23 5 13 63 395 Ib 970 1250 1041 1 596 9 346 2 224 kg 41 0 23 5 13 63 495 Ib Enclosed Type Line Connected Controllers Factory installed options may affect enclosure size requirements Exact dimensions can be obtained after order entry Consult your local Sprecher Schuh representative B Y Controller Disconnect IP65 Type 4 12 Rating A Rating A B Height A Width C Depth Non Combination Controller 5 610 24 508 20 254 10 25 610 24 508 20 254 10 43 610 24 508 20 254 10 60 610 24 508 20 254 10 85 610 24 508 20 254 10 108 762 30 610 24 305 12 135 762 30 610 24 305 12 201 914 36 762 30 406 16 251 914 36 762 30 406 16 317 1524 60 914 36 406 16 361 1524 60 914 36 406 16 480 1524 60 914 36 406 16 625 2286 90 1829 72 508 20 780 2286 90 1829 72 508 20 9700
86. horted SCR This 1 Enable l n parameter is reset to off disable when control power is recycled 0 Disable This parameter allows the user to override a Linear List Current Loss 86 Enable current loss fault This is indicative of the typical 1 Enable F failure mode of a damaged CT Allows the user to enable or disable control from various serial interface ports DPI with a 0 boram Logic Mask 87 8 bit binary 0 setting If a port is set to 1 the port will be Maske allowed to control the PF and will produce a comm fault if disconnected DataLinks Data In A1 88 0 16 bit Datalink DataLinks Data In A2 89 0 16 bit Datalink DataLinks Data In B1 90 0 16 bit Datalink DataLinks Data In B2 91 0 16 bit Datalink DataLinks Data In C1 92 0 16 bit Datalink DataLinks Data In C2 93 0 16 bit Datalink DataLinks Data In D1 94 0 16 bit Datalink DataLinks Data In D2 95 0 16 bit Datalink DataLinks Data Out A1 96 0 16 bit Datalink DataLinks Data Out A2 97 0 16 bit Datalink DataLinks Data Out B1 98 0 16 bit Datalink DataLinks Data Out B2 99 0 16 bit Datalink DataLinks Data Out C1 100 0 16 bit Datalink DataLinks Data Out C2 101 0 16 bit Datalink DataLinks Data Out D1 102 0 16 bit Datalink DataLinks Data Out D2 103 0 16 bit Datalink This parameter is not viewable without entering a special password in Firmware versions 4 001 or earlier Contact Sprecher Schuh technical support if you have Version 4 001
87. hree phase to phase supply voltage measurements at all times including bypass operation Metering Current Phase A Amps Provides the three phase motor current measurement This measurement is always line current regardless of the motor connection Wye or Delta Metering Current Phase B Amps Provides the three phase motor current measurement This measurement is always line current regardless of the motor connection Wye or Delta Metering Current Phase C Amps Provides the three phase motor current measurement This measurement is always line current regardless of the motor connection Wye or Delta Metering Watt Meter KW MW Provides the power usage of the connected motor This value is calculated from the voltage current and power factor measurements Metering Kilowatt Hours KWH MWH Provides the power usage over time of the connected motor Metering Elapsed Time Hours Indicates the total time of motor operation in hours The accumulated time is updated continuously during run time Metering Meter Reset NO ETM Reset KWH Reset NO Provides the user the capability to reset the value stored in the elapsed time 9 and kilowatt hours 8 meters to zero Metering Power Factor 0 00 0 99 Provides the operational displacement power factor measurement of the connected motor Metering Mtr Therm Usage MTU 0 100
88. ide application flexibility and easy setup Parameter Range Overload Class Off 10 15 20 30 Overload Reset Manual Auto Motor FLC 1 0 2200 A Service Factor 0 01 1 99 Notes 1 The factory default setting for Overload Class which is 10 enables overload protection The motor s full load current rating must be programmed to properly set overload protection 2 Automatic reset of an overload fault requires the start input to be cycled in a 2 wire control scheme The trip rating is 117 of the programmed FLC Figure 1 13 and Figure 1 14 provide the overload trip curves for the available trip classes Underload Utilizing the underload protection of the PF Softstarter motor operation can be halted if a sudden drop in current is sensed The PF Softstarter provides an adjustable underload trip setting from 0 99 of the programmed motor full load current rating Trip delay time can be adjusted from 0 99 seconds Underload protection is disabled during slow speed and braking operations Chapter 1 11 Chapter 1 Product Overview Figure 1 13 Overload Trip Curves 1000 0 100 0 Approximate Trip Time seconds Class 10 10000 0 1000 0 100 0 Approximate Trip Time seconds Class 15 Approximate Trip Time seconds 10000 0 1000 0 100 0 e Class 20 10000 0 1000 0 100 0 Approximate Trip Time seconds Class 30 1 0 3 4 5678910 1 2 4 5678910 1 2
89. ility to select the power wiring configuration of the attached motor WYE or DELTA A fault controlled means of disconnecting the line should always be use in the DELTA mode This parameter sets the base voltage for the under over voltage protective features For medium voltage applications the controller has internal capabilities set of multipliers that correspond to the line voltage dividers Allows the user to select the type of start provided with controller configuration Allows the user to program the time 0 30 s that the controller performs the starting maneuver The starting maneuver will automatically transition to bypass and full voltage if the controller senses that the motor has reached full speed prior to the ramp time completion Also refer to Parameter 129 When using the soft start mode this parameter allows the user to adjust the initial torque level applied to the motor at the beginning of the start maneuver When using the current limit starting mode this parameter allows the user to adjust the current level applied to the motor during the start maneuver Reserved When programmed with a non zero value this parameter provides a torque pulse for the programmed time period at the beginning of the starting maneuver 0 0 2 0 s When the Kickstart Time is programmed this parameter provides the user with the ability to set the level of the torque pulse applied to the motor approx 0 90 Pro
90. ing Terminal Locations 1 Incoming Line Termination Line Motor Connections Delta Motor Connections oo Control Terminations Fan Terminations IP20 protective covers on Delta termination must be removed when connecting in a Delta configuration Chapter 3 1 Chapter 3 Wiring Figure 3 2 Wiring Terminal Locations 108 480 A Table 3 A Wiring Terminal Locations 1 Incoming Line Termination 2 Line Motor Connections 3 Delta Motor Connections 4 Control Terminations 5 Fan Terminations Chapter 3 2 Chapter 3 Wiring Figure 3 3 Wiring Terminal Locations 625 1250 A Table 3 B Wiring Terminal Locations 1 Incoming Line Termination 2 Line Motor Connections 3 Terminal Block CP1 Control Power Connections Fans Contactors and Control Modules Power Structure The PF Softstarter product has an integrated mechanical run contactor on each phase of the motor to minimize heat generation during run time T hese contacts are pulled in sequentially in the 108 1250 A units In the 5 85 A units these contacts are pulled in all at once The PF Softstarter product also has a Current Transformer CT built in on each phase of the motor to provide current readings Power Wiring Refer to the product nameplate or U ser M anual for power lug termination information including Lug wire capacity e Tightening torque requirements e Lug kit catalog numbers 108
91. ing option is installed this parameter allows the user the ability to adjust the braking current level applied to the motor Smart Motor Braking and Accu Stop has the capability to apply braking current to the motor from the at speed condition With Smart Motor Braking the braking maneuver continues until the motor comes to rest at which point the controller automatically ceases braking action Note that high braking currents can introduce excessive vibration to the motor couplings and or gearing and additional heating in the motor This parameter provides the ability to over ride the SMB function zero speed detection and set an exact time in which the braking current is applied to the motor This can be used for applications where detecting zero speed is difficult or when the purpose is to reduce the number of overload trips associated with driving the motor to a complete stop Setting this to a specific value will turn off the braking at a set time each time a stopping maneuver is performed An ideal setting can be accomplished through trial and error and should always allow for some small coast time Setting this value to long will cause braking current to be applied to a stopped motor and likely result in overload trips Allows the user the ability to modify the braking profile to match a particular load type This parameter is designed to only be used with the SMB algorithm and not with timed brake For the majority of
92. king operation Jam detection and underload protection are disabled during slow speed and braking operation Chapter 7 3 Introduction Chapter 8 Troubleshooting For safety of maintenance personnel as well as others who might be exposed to electrical hazards associated with maintenance activities follow the local safety related work practices for example the NFPA 70E Part II in the United States M aintenance personnel must be trained in the safety practices procedures and requirements that pertain to their respective job assignments Hazardous voltage is present in the motor circuit even when the PF Softstarter is off To avoid shock hazard disconnect main power before working on the controller motor and con trol devices such as Start Stop push buttons Procedures that require parts of the equipment to be energized during trouble fied personnel using appropriate local safety work practices shooting testing etc must be performed by properly quali and precautionary measures Disconnect the controller from the motor before measuring insulation resistance IR of the motor windings Voltages used for insulation resistance testing can cause SCR failure Do not make any measurements on the controller with an IR tester megger Note The time it takes for the motor to come up to speed may be more or less than the time programmed depending on the frictional and inertial characteristics of the connected load
93. locked rotor torque Dual Ramp Start Mode 2 This selects the start mode for option 2 Dual Ramp Ramp Time 2 This programs the time period during which the controller will ramp the output voltage up to full voltage for the second Start setup Dual Ramp lnitial Torque 2 The initial reduced output voltage level for the second Start setup is established and adjusted with this parameter The Dual Ramp feature is available on the standard controller Kickstart can be programmed for both start modes Chapter 4 9 0 30 s 0 90 locked rotor torque Full Voltage Start Linear Speed Chapter 4 Programming The PF Softstarter may be programmed to provide a full voltage start output voltage to the motor reaches full voltage within 1 4 second with the following programming Parameter Option Starting Mode Full Voltage The PF Softstarter provides the user the ability to control the motor speed during starting and stopping maneuvers A tach input is required as specified in Linear Speed Acceleration on page 1 6 Parameter Option Starting Mode Linear Speed Ramp Time 0 30 This programs the time period that the controller will ramp from 0 speed to full speed Kickstart Time 0 0 2 2 s A boost of current is provided to the motor of the pro grammed time period Kickstart Level 0 90 locked rotor torque Adjusts the amount of current applied to the motor during the kickstart time Chapt
94. lt Fault Buffer Chapter 7 Diagnostics This chapter describes the fault diagnostics of the PF Softstarter Further this section describes the conditions that cause various faults to occur Protection Programming any of the protective features available with the PF Softstarter can be enabled and adjusted through the programming parameters provided For further details on programming refer to the M otor Protection section in Chapter 4 Programming The PF Softstarter comes equipped with a built in three line 16 character LCD The LCD displays the unit has faulted on the first line the fault number on the second line and the fault code on the third line Figure 7 1 Fault Display Faulted Fault 1 Line Loss A Note The fault display will remain active as long as control power is applied If control power is cycled the fault will be cleared the controller will re initialize and the display will show a status of Stopped Note You can hit Esc to get to another programming diagnostic list but the PF Softstarter will still be in a faulted state Important Resetting a fault will not correct the cause of the fault condition Corrective action must be taken before resetting the fault You can clear a fault using any of several methods Program the PF Softstarter for a Clear Fault which can be found in Main M enu Diagnostics Faults e If a RESET push button is present the N O push button auxiliary contact ca
95. ltage Fault Level Undervoltage Fault Delay Undervoltage Alarm Level Undervoltage Alarm Delay Overvoltage Determines the trip level as a percentage of line voltage and delay period Overvoltage Fault Level Overvoltage Fault Delay Over voltage Alarm Level Overvoltage Alarm Delay Unbalance Allows the user to set the current unbalance trip level and delay period Unbalance Fault Level Unbalance Fault Delay Unbal ance Alarm Level Unbalance Alarm Delay Jam Determines the trip level as a percentage of motor full load current and delay period Jam Fault Level Jam Fault Delay Jam Alarm Level Jam Alarm Delay Stall Stall Delay Allows the user to set the stall delay time Ground Fault Ground Fault Enable Ground Fault Level Ground Fault Allows the user to enable the ground fault level in amps delay time and inhibit time Delay Ground Fault Inhibit Time Ground Fault Alarm Enable Ground Fault Alarm Level Ground Fault Alarm Delay Motor PTC Allows the user to connect a PTC to the PF and enable a fault when it becomes active PTC Enable Phase Reversal Determines the proper orientation of line connections to the PF If Enabled and phases are out of sequence a fault will be indicated Phase Reversal Restarts Allows the user to determine the maximum number of restarts per hour the unit can experience and delay time between consecutive starts See details in Ground Fault
96. ly voltage is greater than user programmed value Check power system and correct if necessary Correct the user programmed value Undervoltage 21 Supply voltage is less than user programmed value The delay time is too short for the application Check power system and correct if necessary Correct the user programmed value Extend the delay time to match the application requirements Overload 22 Motor overloaded Check motor overload condition Overload parameters are not matched to Check programmed values for overload class and motor FLC the motor Underload 23 Broken motor shaft Repair or replace motor Broken belts toolbits etc Pump cavitation e Check machine Check pump system Jam 24 Motor current has exceeded the user programmed jam level Correct source of jam Check programmed time value Stall 25 Motor has not reached full speed by the end of the programmed ramp time Correct source of stall Phase Reversal 26 Incoming supply voltage is not in the expected ABC sequence Check power wiring Ground Fault 33 Ground fault current level has exceeded programmed value Check power system and motor correct if necessary Check programmed ground fault levels to match application requirements Excess Starts Hr 34 Number of starts in a one hour period has exceeded the value programmed Wait an appropriate amount of time to restart e Turn off the Starts
97. m T1 2 12 3 T2 4 Input Power m L3 5 T3 6 Branch PF Softstarter Protection Controller PF Softstarter Aux 1 Control Terminals 23 24 25 26 27 28 29 30 31 32 33 34 ws TACH Ground Aux 2 Aux 3 Aux 4 Input Input Fault Customer supplied Two speed consequent pole installations Refer to the controller nameplate to verify the rating of the control power input voltage For units rated 625 1250 A terminals 11 amp 12 are factory pre wired from terminal block CP1 terminals 1 amp 4 Overload must be disabled in PF Softstarter Chapter 3 19 Chapter 3 Wiring Figure 3 19 Typical Wiring Diagram for PF Off Bypass Control PF Softstarter Control Terminals Aux 1 V M PTC TACH Ground input input Fault Aux 2 Aux 4 Customer supplied Q Refer to the controller nameplate to verify the rating of the control power input voltage For units rated 625 1250 A terminals 11 amp 12 are factory pre wired from terminal block CP1 terminals 1 amp 4 Chapter 3 20 Chapter 3 Wiring Figure 3 20 Typical Wiring Diagram for Hand Off Auto Control with Stop Option and Start Stop Buttons Control Power L Stan f H A G Stop e e 2 roe s vo rj vo 19 20 zn 2 PF Softstarter Control Terminals Aux 1 wu
98. me beyond the initial start maneuver for the motor to be at speed A setting of zero means that the stall detection feature is disabled Enables ground fault protection when used with an external core balanced ground fault sensor Allows the user to set a current core balance current that will cause a fault when the current is above this value Allows the user the ability to prevent some nuisance faults by entering a delay period that provides a window that the ground fault condition must persist within for the controller to fault Allow the user the ability to disable inhibit ground fault protection for a selected time when starting Enables a ground fault protection Alarm when used with an external core balanced ground fault sensor Allows the user to set a current core balance current that will cause an Alarm when the current is above this value Allows the user the ability to prevent some nuisance Alarms by entering a delay period that provides a window that the ground fault condition must persist within for the controller to Alarm Enables PTC based over temperature protection when used with external PTC sensors Allows the user to prevent starting if the incoming line phase sequence is not correct The incoming power lines are expected to be in an ABC sequence The controller will fault if power lines are out of the ABC sequence Limits the number of starts that can occur in a one hour period This feature includes
99. mperature falls below this level Motor PTC A motor PTC can be connected to terminals 23 and 24 If the PTC parameter is enabled and the PTC trips the PF Softstarter will trip and indicate a Motor PTC fault Open Bypass Power pole bypass contacts are monitored for proper operation In the event that a contact closure is not sensed the PF Softstarter will indicate an Open Bypass fault No Load The PF Softstarter can determine if a load connection has been lost and No Load fault will be indicated Line Unbalance Voltage unbalance is detected by monitoring the three phase supply voltages The formula used to calculate the percentage voltage unbalance is as follows Vu 100 V V Vu Percent voltage unbalance Maximum voltage deviation from the average voltage V Average voltage The controller will shut down when the calculated voltage unbalance reaches the user programmed trip percentages Overvoltage and Under voltage Protection Overvoltage and undervoltage protection are user defined as a percentage of the programmed line voltage The PF Softstarter continuously monitors the three supply phases The calculated average is then compared to the programmed trip level Underload 2 Underload protection is available for undercurrent monitoring The controller will shut down when the motor current drops below the trip level This trip level a percentage of the motor s full load current rating can be
100. n be connected to Option Input 2 terminal 15 Option Input 2 must be programmed for Clear Fault Cycle control power to the PF Softstarter Important An overload fault cannot be reset until the M otor Thermal U sage parameter 12 value is below 7596 See Protection and Diagnostics on page 1 11 for further details The PF Softstarter stores in memory the five most recent faults Display the fault buffer by selecting the View Faults Queue and scrolling through the fault buffer parameters T he information is stored as fault codes and fault descriptions A fault code cross reference is provided in Table 7 A Chapter 7 1 Chapter 7 Diagnostics Fault Codes Table 7 A provides a complete cross reference of the available fault codes and corresponding fault descriptions Table 7 A Fault Code Cross reference Fault Code Fault Code Line Loss A 1 Stall 25 Line Loss B 2 Phase Reversal 26 Line Loss C 3 Coms Loss P2 27 Shorted SCR A 4 Coms Loss P3 28 Shorted SCR B 5 Coms Loss P5 29 Shorted SCR C 6 Network P2 30 Open Gate A 7 Network P3 31 Open Gate B 8 Network P5 32 Open Gate C 9 Ground Fault 33 PTC Pwr Pole 10 Excess Starts 34 SCR Overtemp 11 Power Loss A 35 Motor PTC 12 Power Loss B 36 Open Bypass A 13 Power Loss C 37 Open Bypass B 14 Hall ID 38 Open Bypass C 15 NVS Error 39 No Loa
101. nductor of the same gauge so that they have the same current carrying specification Block Transfer is the method used by a PLC to transfer data that does not require continuous updates To perform this function the module provides a status word to the PLC during normal discrete transfer scan This status word occupies the first module group in the PLC I O image table for the designated rack The status word is then used by the PLC program to control the BTW and BTR functions of the PLC A PLC Block Transfer Read instruction A PLC Block Transfer Write instruction 1 In software terms a register or group of registers used for temporary storage of data to compensate for transmission rate differences between the transmitter and receiving device 2 In hardware terms an isolating circuit used to avoid the reaction of one circuit with another A method of reversing motor rotation by the use of two separate contactors one of which produces rotation in one direction and the other produces rotation in the opposite direction The contactors are electrically and mechanically interlocked so that both cannot be energized at the same time This instruction copies data from one location into another It uses no status bits If you need an enable bit program a parallel output using a storage address The intensified or blinking element in a video display A means for indication where data entry or editing occurs 1 A sequence of operations th
102. ng M etering Data SE en Diagnostics Protection Programming ee er kura Gel p apio Worse Ep Clear Fault ues ette cime ea Fault Buffer re ie ewige Pid Fault Codes i cath Ber dun tdt iti Fault and A larm A uxiliary Indication for Fault or Alarm iji aiuti ede wen a ML He Dd Fault Def nlt oec ee ri exa etr ca taie Raus Chapter 8 Introduction Troubleshooting Power Module Check rrr Table of Contents Appendix A Functional Design Specifications sa a Specifications Electrical Ratings re Environmental Per EN Mechanical haurrei TT a en a ee ee Approximate Dimensions and Shipping Weights Open Type Controllers ats ai e tle Doer tinens Enclosed Line Connected Controllers gt gt gt gt gt gt gt gt lt H Appendix Parameter Information er ee Del Parameter Information Appendix C Renewal Pan een aod antena Renewal Parts Appendix D Contactor Replacement Installation Instructions for 625 1250A units D 1 Accessories Appendix E PRE COSSOR OG S fa E sa Al al Od o a e at eels iste Bel Accessories Chapter 1 Product Overview Other Related PF Softstarter Installation Guide Documents Publication TQG PF 4119
103. ntacts Normal Up to speed Closed Open Closed Open Closed Open Closed Open Closed Open Start Run Brake Time seconds DE Speed Z If Brake Selected If Coast to rest Selected The user is responsible for determining which stopping mode is best suited to the application and will meet applicable standards for operator safety on a particular machine Chapter 3 31 Chapter 3 Wiring Figure 3 31 Accu Stop Sequence of Operation M y f Speed v p t to res f v Spee f K M Slow Star ji A 5 Spee Time n Push Butlor Start hosed Ope a gt Sto Close T l bau D Accu Stog Closed Open ow Auxiliary s p Spe ed Braking 4 mal l A to Fa Up to speed Se amp When Accu Stop push button is closed start stop function is disabled The user is responsible for determining which stopping mode is best suited to the application and will meet applicable standards for operator safety on a particular machine Chapter 3 32 Chapter 3 Wiring Figure 3 32 Slow Speed with Braking Sequence of Operation 100 N Coast to Stop Motor Spee Braking Ls W 4 km Star Run a me seconds Push Buttons Start Closed On 1 Closed Oper Siow S Closed Oper Brake Closed 1 L l Bra
104. o select between an auto and Set Up Overload Reset 47 Manual Overload Auto manual reset mode for all Overload faults Devices rated 625 1250 Amps are only programmable to the whole digit ampere There are no decimal points for any current based parameters B 5 Group Linear List Linear List Overload Underload Underload Underload Underload Under voltage Under voltage Parameter Name OL Shunt Time OL Trip Enable Disable Overload A Lvl Underload F Lvl Underload F Dly Underload A Lvl Underload A Dly Undervolt F Lvl Undervolt F Dly Table B 1 Parameter List Continued Parameter Number 480 499 50 51 52 53 54 55 56 Units Sec MTU FLC Secs FLC Secs V Secs Min Max 0 999 0 Disable 1 Enable 0 100 Default Settings Enable Appendix B Parameter Description This parameter prevents the overload from accumulating or incrementing the Motor Thermal Usage MTU during the programmed shunt time This function is allowable under some electrical codes for loads which have long acceleration times i e High inertia As a general rule of thumb this time should never exceed the programmed start time Setting this parameter longer than necessary can result in motor overheating that is not being accounted for in the thermal model This parameter disables the overlo
105. om the initial torque level the output voltage to the motor is steplessly increased during the acceleration ramp time The acceleration ramp time is user adjustable from 0 30 seconds If the PF Softstarter senses that the motor has reached the up to speed condition during the voltage ramp operation the internal bypass contactor will be pulled in Figure 1 1 Soft Start Percent Voltage 100 Initial Torque Start ai Run gt Time seconds Kickstart is also available with Soft Start Chapter 1 2 Chapter 1 Product Overview Selectable Kickstart This feature provides a boost at startup to break away loads that require a pulse of high torque to get started This is intended to provide a pulse of current that is selectable from 0 90 of locked rotor torque Selectable kickstart is user adjust able from 0 0 2 0 seconds Figure 1 2 Selectable Kickstart Percent Voltage Selectable Kickstart 100 Sr nue Coast to rest Soft Stop Initial r Torque Start el Run gt Soft Stop Time seconds Current Limit Start This starting mode provides a true current limit start it is used when limiting maximum starting current is necessary The Current Limit level is user adjustable from 50 600 of the motor full load ampere rating and the current limit time is user adjustable from 0 30 seconds If the PF Softstarter senses that the motor has reached
106. omer Supplied Overload protection is included as a standard feature of the PF Soft Starter Power Factor Correction Capacitors Figure 2 10 Typical Wiring Diagram for Power Factor Correction Capacitors and Contactor L1 T1 2 3 Phase L2 3 T2 4 Input Power L3 5 T3 6 l toe ono Branch Protection Softstarter N Customer Supplied Overload protection is included as a standard feature of the PF Softstarter controller Power Factor Energize 1 2 second before start command to PF Softstarter Correction Capacitors Open contactor after stopping method is complete Alternate Energize contactor after up to speed amp Open contactor before initiating a stop Chapter 2 12 Chapter 2 Installation Protective Modules Protective modules containing metal oxide varistors M OV s can be installed on Motor Overload Protection controllers rated 5 1250 A and 200 600V to protect the power components from electrical transients The protective modules clip voltage transients generated on the lines to prevent such surges from damaging the SCRs W hen installing or inspecting the protective module make sure that the controller has been disconnected from the power source T he protective module should be inspected periodically for damage or discoloration Replace if necessary Thermal motor overload protection is provided as s
107. on This parameter identifies the type of control present and is not user programmable Pump Control Pump Stop Time Allows the user to set the time period for the pump stopping function 0 120 s Starting Mode Allows the user to program the PF Softstarter for the type of starting that best fits the application Pump Start Soft Start Current Limit Start Braking Control SMB Smart Motor Braking PF Option This parameter identifies the type of control present and is not user programmable Braking Control Braking Current Allows the user to program the inten sity of the braking current applied to the motor 0 400 of full load current Accu Stop PF Option This parameter identifies the type of control present and is not user programmable Braking Control Slow Speed Select Allows the user to program the slow speed that best fits the application Low 7 High 15 Slow Accel Current Allows the user to program the re quired current to accelerate the motor to slow speed operation 0 450 of full load current Slow Running Current Allows the user to program the re quired current to operate the motor at the slow speed setting 0 450 of full load current Braking Current 0 Allows the user to program the inten sity of the braking current applied to the motor 0 400 of full load current Stopping Current Allows the user to program the inten
108. on of terminal 15 Option Input 2 Disable Slow Speed Dual Ramp Fault Fault NC Network Clear Fault Stop Mode Allows the user to program the PF Softstarter for the type of stopping that best fits the application Disable Soft Stop Linear Speed Stop Time This sets the time period which the controller will ramp the voltage during a stopping maneuver 0 0 120 s Overload Class Disable 10 15 20 30 Service Factor 0 01 1 99 s Motor FLC 1 0 2200 OL Reset Auto Manual Aux1 Config Normal Up to speed Fault Alarm Network Contact is provided as standard with the PF Softstarter This contact is located at terminals 19 and 20 Aux Contacts 1 allows the user to configure the operation of the contacts Control External Bypass N O N C Aux2 Config Contact is provided as standard with the PF Softstarter This contact is located at terminals 29 and 30 Aux Contacts 2 allows the user to configure the operation of the contacts Normal Up to speed Fault Alarm Network Control External Bypass N O N C Aux3 Config Contact is provided as standard with the PF Softstarter This contact is located at terminals 31 and 32 Aux Contacts 3 allows the user to configure the operation of the contacts Normal Up to speed Fault Alarm Network Control External Bypass N O N C Aux4 Config Contact is provided as standard with the PF Softstarter This contact is located at terminal
109. on page 1 15 See details in Thermistor PTC Protection on page 1 16 eoo Chapter 4 15 Restarts Per Hour Restart Attempts Restart Delay The delay time must be set to a value greater than zero when Undervoltage Overvoltage and Unbalance are enabled For Jam and Underload detection to function the Motor FLC must be programmed in the Motor Protection group See Chapter 5 for instructions Example Settings Chapter 4 Programming Undervoltage With Line Voltage programmed for 480V and the U ndervoltage level programmed for 80 the trip value is 384V Overvoltage With Line Voltage programmed for 240V and the Overvoltage level programmed for 115 the trip value is 276V Jam With Motor FLC programmed for 150 A and the J am level programmed for 400 the trip valueis 600A Underload With M otor FLC programmed for 90A and the Underload level programmed for 6096 the trip valueis 54A The average value of the three phase to phase voltages is utilized The largest value of the three phase currents is utilized The PF Softstarter will self protect Chapter 4 16 Chapter 5 Motor Information Overview The Basic Set Up and Overload programming group allows the user to set pa rameters indicating to the controller the motor that is connected It is important to correctly input the data to achieve the best performance from your controller Attention For overload protection it is critical that the d
110. ontact for a specific operation Alarm Note Normal PF in RUN Alarm NC Network Network NC External Bypass B 10 Appendix B Table B 1 Parameter List Continued Group Parameter Name Parameter Units Min Max Default Parameter Description User Number Settings Settings Normal Normal NC Up To Speed Up To Speed NC Fault Allows the user the ability to configure each Aux2 Config 110 Fault NC Fault Auxiliary relay contact for a specific operation Alarm Note Normal PF in RUN Alarm NC Network Network NC External Bypass Basic Set Up English French Spanish German Portuguese Mandarin Allows the user to change the text display to one English of the available options Language Language 111 This parameter can be used to force the starting 0 Disable profile to complete its entire time period and Linear List Timed Start 1126 1 Enable Disable ignore an early up to speed detection The default is set to Disabled so that the PF can determine when the motor is at speed This parameter adjusts the level of current at which the PF determines that the SCR has turned off Since this parameter has the Linear Hist l Shut off MS current 0 37 0 potential to modify the SCR control scheme it is important that adjustments be made with the help of Technical Support The PF has the ability to automatically determine if the motor is up to speed If there is a problem with detecting the
111. peed Dir Data In A1 Slow Accel Cur Data In A2 Slow Running Cur Data In B1 Stopping Current Data In B2 Overload Class Data In C1 Service Factor Data In C2 Motor FLC Data In D1 Overload Reset Data In D2 OL Shunt Time Data Out A1 Chapter 4 4 Elapsed Time 2 Chapter 4 Programming Password The PF Softstarter allows the user to limit access to the programming system through password protection This feature is disabled with a factory set default of 0 To modify the password complete the procedure below 1 Press the ESC key to go from the nn Menu iagnostics status display to the Main menu 2 Scroll with Up Down keys until the M i beni Preferences Preferences option is highlighted Diagnostics 3 Press the Enter key to access the Preferences Change Password Preferences menu User Dspy lines 4 Scroll with Up Down keys until the Preferences Change Password Change Password option is highlighted User Dspy lines 5 Press the Enter key 6 Scroll with Up Down keys to enter the desired number If you are modifying Prefs Password the password make a note of it as New Code displayed Use the Sel key to highlight Verity a single digit 7 Verification of the new password is required Press the enter key Preferences 8 Press the Enter key after you have Charge Password completed modifying the password
112. peration Loose connections Shut off all power to controller and check for loose connections Accelerates too fast Accelerates too slow e Starting time Initial torque Current limit setting Kickstart e Starting time Initial torque Current limit setting Kickstart Increase starting time Lower initial torque setting Decrease current limit setting Lower kickstart time or turn off Decrease starting time Increase initial torque setting Increase current limit setting Increase kickstart time or turn off Fan does not operate Wiring Failed fan s Check wiring and correct if necessary Replace fan module Motor stops too quickly Time setting Verify the programmed stopping time and correct if with Soft Stop option necessary Motor stops too slowly Stopping time setting Verify the programmed stopping time and correct if with Soft Stop option Misapplication necessary The Soft Stop option is intended to extend the stop ping time for loads that stop suddenly when power is removed from the motor Fluid surges with pumps Still occur with the Soft Stop option Motor overheats Misapplication Duty cycle Soft Stop ramps voltage down over a set period of time In the case of pumps the voltage may drop too rapidly to prevent surges A closed loop system such as Pump Control would be more appropriately suited Preset Slow Speed and Acc
113. product through terminal block CP1 at terminals 1 and 4 This single connection point feeds the control module contactors and fans Control power must be supplied as 110 120 VAC or 230 240 VAC 50 60 Hz only A control power source of at least 800 VA is required The control power requirements include the control module 75 VA bypass contactors 526 VA max and fan power 150 VA Depending on the specific application additional control circuit transformer VA capacity may be required Figure 3 6 230V Control Undervoltage Relay Settings for 625 1250 A Devices SEE NAMEPLATE FOR STATUS O PICK UP NOMINAL VOLTAGE TIME DELAY NOMINAL PICK UP VOLTAGE 10 208 SEC 95 0 1 TIME DELAY DROP OUT DROP OUT i PICKUP 0 GENERAL NOTES 1 SET ALL RELAY POTENTIOMETERS PER ILLUSTRATION Chapter 3 7 Chapter 3 Wiring Figure 3 7 Internal Wiring and 230V Control Undervoltage Relay Connection Diagram for 625 1250 A Devices 1 1 AT 1 AF 1 lT M it Ore k aal L L L IL l FAL I b TT l l l l B 14L 22 14 14 L 1 LT l l l REN J SER I Ezczoccececcc J nn PF SOFTSTARTER CON
114. que Kickstart Time A boost of current is provided to the motor of the pro grammed time period Kickstart Level Adjusts the amount of current applied to the motor during the kickstart time 0 0 2 0 0 90 locked rotor torque Ifthe controller senses that the motor has reached full speed before completing the Soft Start it will automatically switch to providing full voltage to the motor To apply a current limit start to the motor the following parameters are provided for user adjustment Parameter Option Starting Mode Current Limit This must be programmed for Current Limit Ramp Time 0 30 This programs the time period that the controller will hold the fixed reduced output voltage before switching to full voltage Current Limit Level This parameter provides adjustability for the reduced output voltage level provided to the motor 50 600 full load current Kickstart Time A boost of current is provided to the motor for the programmed time period Kickstart Level Adjusts the amount of current applied to the motor during the kickstart time 0 0 2 0 s 0 90 locked rotor torque Ifthe controller senses that the motor has reached full speed before completing the current limit start it will automatically switch to providing full voltage to the motor Chapter 4 8 Dual Ramp Start Chapter 4 Programming The PF Softstarter provides the user with the ability to select
115. que is greater than the developed motor torque Figure 1 8 Soft Stop Percent Voltage Selectable Kickstart 100 secs EE MB Coast to rest Soft Stop Initial Torque Soft Stop Start Time seconds Soft Stop is not intended to be used as an emergency stop Refer to the applicable standards for emergency stop requirements Chapter 1 7 Chapter 1 Product Overview Control Options Modes of Operation Pump Control The PF Softstarter offers the control options described below Important The options listed in this section are mutually exclusive and must be specified when ordering An existing controller may be upgraded to another control option by replacing the control module Consult your local Sprecher Schuh representative Pump Control Option This option reduces surges during the starting and stopping of a centrifugal pump by smoothly accelerating and decelerating the motor The microprocessor analyzes the motor variables and generates commands that control the motor and reduce the possibility of surges occurring in the system The starting time is programmable from 0 30 seconds and the stopping time is programmable from 0 120 seconds Figure 1 9 Pump Control Option 10096 ERE Motor Speed Pump Start Pump Stop Time seconds Kickstart is also available with Pump Control Attention Pump stopping is not intended to be u
116. rovides the user with the ability Dual Ramp Kickstart Level2 31 LRT 0 90 0 to set the level of the torque pulse applied to the motor approx 0 to 90 for ramp profile 2 Soft Stop Basic Set Linear Speed Allows the user to select the type of stop provided Up Stop Mode a Smart Brake Soft Stop with the installed controller Accu Stop Basic Set Stop Time 33 Secs 0 120 0 Allows the user to select the length of stopping Up time when a stopping mode is selected Only available with Pump Control option Allows the ability to manually adjust the pump algorithm slightly for different applications The purpose of Linear List Pump Pedestal 34 this parameter is to allow the pump stop algorithm to be more aggressive earlier in the ramp If experiencing overload trips during stopping either reduce the stopping time or try increasing this by units of 5 Try not to exceed a value of 40 B 3 Group Parameter Name Table B 1 Parameter List Continued Parameter Units Min Max Default Appendix B User Parameter Description Basic Set Up Accu Stop Linear List Linear List Linear List Braking Current Braking Time SMB Load Type SMB High Eff Brake SMB Number 35 36 370 38 FLC Sec of Stopping Time 0 400 0 999 0 Standard 1 Hi Inertia 2 Hi Friction 3 Ramp 89 Settings 0 Standard When the Smart Motor Brak
117. rs TR vive NE en Protective M odules Motor Overload Protection UELLE Two speed M otors M ulti motor Protection TON TEQUE Electromagnetic Compatibility EM C m Enclosure Wiring Additional Requirements FEM ost a UP Terminal uu tetto Biase eee REO a anh Power Structure et itn dove en lee head erc de een POW er MENTRE een Bi eM near da l ine Connected usse ee re CU RE E Ta Dei hee D elta onnected sue rum eres decus uos etr N Power Eds zs cod eric ct shy ao tee Do Tt ves ER d ca eS NS Control Power Control Wiring Controllers rated 5 480 Amps olg era Serer AT A Controllers rated 625 1250 Amps nn ae Control Wire Specifications ze ne oet Per te e pe dan mse met ak nn Fan Power Fan Terminatlons uei Ses decade deeded ne hind eden de t PRO deen ag Control Terminal Designations sen sse skrase Dese Bes Standard Controller Wiring Diagrams Soft Stop Pump Control and Smart M otor Braking Typical Wiring Diagram Typical Retrofit Wiring Diagram Table of Contents 2 1 2 1 2 1 2 1 2 1 2 2 2 3 2 3 2 4 2 5 2 6 2 12 2 13 2 13 2 13 2 13 2 14 214 2 14 2 14 3 1 3 3 3 3 3 4 3 4 3 5 3 6 3 6 3 6 3 7 3 10 3 10 3 10 3 11 mn 3 12 22 ehe 227 3 23 Typical Wiring Diagram for Applications Requiring a an n Isolation Contactor ME 3 24 Preset Slow Spee
118. s 33 and 34 Aux Contacts 4 allows the user to configure the operation of the contacts Normal Up to speed Fault Alarm Network Control External Bypass N O N C Parameter Mgmt Recall of factory default parameter values Chapter 4 14 Ready Load Default Starting Mode must be programmed to Soft Start to obtain access to the Initial Torque parameter Q Starting Mode must be programmed to Current Limit to obtain access to the Current Limit Level parameter Motor Protection Chapter 4 Programming For overload protection it is critical that the data be entered as it appears on the motor nameplate While the Basic Set Up group allows the user to get started with a minimum number of parameters to modify the M otor Protection group allows full access to the PF Softstarter s powerful parameter set Following is a listing of the additional setup parameters provided Note The majority of parameters have a Fault and an Alarm setting Parameter Option Overload Trip Class Service Factor Motor FLC Overload Reset Allows the user to select the operation of the overload Overload Alarm Level Underload Underload Fault Level Underload Fault Delay Under Determines the trip level as a percentage of the motor s FLA and the delay period load Alarm Level Underload Alarm Delay Undervoltage Determines the trip level as a percentage of the line voltage and the delay period Undervo
119. s to this parameter without specifically talking with Technical Support An internal on delay timer Ensures that a subsequent start can not be initiated for a preset amount of time For applications that routinely see fast spikes of current or overload conditions more than 125 of the PF s frame rating this parameter can be used to reduce the cycling between SCR and by pass This time delay parameter will allow the PF to stay under SCR control for the duration of time programmed Fault buffer 1 allows display of the current fault A value of 0 indicates that there is no current fault Fault buffer 2 represents fault history of the device with fault 1 being the current fault and fault 5 being the oldest fault kept in memory User Settings This parameter is not viewable without entering a special password in Firmware versions 4 001 or earlier Contact Sprecher Schuh technical support if you have Version 4 001 firmware or earlier and need to access this parameter B 12 Appendix B Table B 1 Parameter List Continued Group Parameter Name Parameter Units Min Max Default Parameter Description User Number Settings Settings Fault buffer 3 represents fault history of the device with Linear List Fault 3 126 0 255 fault 1 being the current fault and fault 5 being the oldest fault kept in memory Fault buffer 4 represents fault history of the device with Linear List Fault 4 127 0 255 fault 1 being the c
120. sed as an emergency stop Refer to the applicable standard for emergency stop requirements Pump stopping may cause motor heating depending on the mechanical dynamics of the pumping system Therefore select the lowest stopping time setting that will satisfactorily stop the pump Chapter 1 8 Chapter 1 Product Overview Modes of Operation SMB Smart Motor Braking Option Braking Control This option can be used in applications that require reduced stopping times The PF Softstarter incorporates a microprocessor based system that applies braking current to a motor without any additional equipment This option offers a user adjustable braking current setting from 0 to 400 of the motor s full load current rating Further it provides automatic shut off at zero speed detection Figure 1 10 SMB Smart Motor Braking Option 100 a lt Smart Motor Braking Motor Speed Coast to rest EN m ka Start Run Automatic Zero Speed Time Seconds Shut off Note All braking current settings in the range of 1 100 will provide 100 braking current to the motor Attention SMB Smart M otor Braking Option is not intended to be used as an emergency stop Refer to applicable standards for emergency stop requirements Chapter 1 9 Chapter 1 Product Overview Accu Stop Option This option combines the benefits of the SMB Smart Motor Braking and Preset Slow
121. sion 4 001 firmware or earlier and need to access this parameter B 13 Appendix C Renewal Parts Catalog Number Description PF Rating For units rated 200 600V AC 24V AC DC Control Modules Al PFS PFS 024 Al PFB PFB 024 Catalog Number Description PF Rating Line Voltage 200 600V Power Poles ABs PFRL00548 G PFL 0005 600V res mem esi One piece provided per part number Q Three phase power pole structure provided per part no See Appendix D for special installation instructions C 1 Appendix Control Control Line Amperes Originally Ordered as Series Control Module Power Poles Type Voltage Voltage Catalog Number Catalog Number Catalog Number Standard 100 240V 200 480V AC 5 PFS 0005 480V B PFS PFL 0005 480V 25 PFS 0025 480V B PFS PFL 0025 480V 43 PFS 0043 480V B PFS PFL 0043 480V 60 PFS 0060 480V B PFS PFL 0060 480V 85 PFS 0085 480V B PFS PFL 0085 480V 108 PFS 0108 480V B PFS PFL 0108 480V 135 PFS 0135 480V B PFS PFL 0135 480V 200 600V AC 5 PFS 0005 600V B PFS PFL 0005 600V 25 PFS 0025 600V B PFS PFL 0025 600V 43 PFS 0043 600V B PFS PFL 0043 600V 60 PFS 0060 600V B PFS PFL 0060 600V 85 PFS 0085 600V B PFS PFL 0085 600V 108 PFS 0108 600V B PFS PFL 0108 600V 135 PFS 0135 600V
122. sprecher schuh PF Softstarters 5A 1250A User Manual For Series B February 2011 Important User Information Because of the variety of uses for the products described in this publication those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements including any applicable laws regulations codes and standards The illustrations charts sample programs and layout examples shown in this guide are intended solely for purposes of example Since there are many variables and requirements associated with any particular installation Sprecher and Schuh does not assume responsibility or liability to include intellectual property liability for actual use based upon the examples shown in this publication Rockwell Automation publication SGI 1 1 Safety Guidelines for the Application Installation and Maintenance of Solid State Control available from your local Sprecher Schuh office describes some important differences between solid state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication Reproduction of the contents of this copyrighted publication in whole or part without written permission of Rockwell Automation is prohibited Throughout this manual we use notes to make
123. tage measurement is not available during the braking operation of the SM B Smart M otor Brake Accu Stop and Slow Speed with Braking control options 2 The elapsed time and KWH values are automatically saved to memory every 12 hours 3 Motor thermal capacity usage is determined by the built in electronic thermal overload A n overload fault occurs when this value reaches 100 1 0 The PF Softstarter has the ability to accept up to two 2 inputs and four 4 outputs controlled over a network The two inputs are controlled at terminal 16 Option Input 1 and terminal 15 Option Input 2 For these two inputs see Chapter 4 for the parameter settings By using these two terminals as inputs the Stop Input will need to be programmed to meet the desired stop functionalitv The four 4 outputs are A ux 1 Aux 2 Aux and A ux 74 All auxiliary contacts are programmable to the function found on page 4 15 Chapter 1 19 Chapter 1 Product Overview Status Indication Four programmable hard contact outputs are provided as standard All auxiliary contacts are programmable for the following states e Normal N O N C Up to Speed N O N C Alarm N O N C Fault N O N C Network Control N O N C External Bypass N O Figure 1 19 Control Terminals PP PE EPP TS IST Te T Stop Input Opt PF Softstarter Input 1 Control Terminals Opt Start Input 2 Input Aux 1 sTsTeTe Te Te Te T S TSTST
124. tandard with the PF Softstarter If the overload trip class is less than the acceleration time of the motor nuisance tripping may occur Overload protection should be properly coordinated with the motor Two applications require special consideration two speed motors and multi motor protection Two speed Motors The PF Softstarter has overload protection available for single speed motors When the PF Softstarter is applied to a two speed motor the Overload Class parameter must be programmed to OFF and separate overload relays must be provided for each speed Multi motor Protection If the PF Softstarter is controlling more than one motor individual overload protection is required for each motor Chapter 2 13 Chapter 2 Installation Electromagnetic Com bil Attention This product has been designed for Class A equipment Use of the product in domestic environments may cause radio EMC interference in which case the installer may need to employ additional mitigation methods The following guidelines are provided for EMC installation compliance Enclosure Install the product in a grounded metal enclosure Wiring Wire in an industrial control application can be divided into three groups power control and signal The following recommendations for physical separation between these groups is provided to reduce the coupling effect Different wire groups should cross at 90 inside an enclosure
125. ted It provides all the Basic Set Up parameter set plus the advanced set Parameter Option PF Option Standard Displays the type of controller This is factory set and not adjustable Motor Connection Line or Delta Displays the motor type to which the device is being connected Line Voltage Displays the system line voltage to which the unit is connected Starting Mode Soft Start Current Limit Full Voltage Linear Allows the user to program the PF Softstarter for the type of starting that best fits the application Speed Ramp Time This sets the time period during which the controller will ramp the output voltage 0 30 s Initial Torque The initial reduced voltage output level for the voltage ramp is established and adjusted with this parameter 0 90 locked rotor torque Current Limit Level The current limit level that is applied for the Ramp Time selected 50 600 FLC Kickstart Time 0 0 2 0 s A boost current is provided to the motor for the programmed time period Kickstart Level 0 90 locked rotor torque Adjusts the amount of current applied to the motor during kickstart Stop Input Coast Stop Option Allows the user to select the operation of terminal 18 Stop Input Option 1 Input Allows the user to select the operation of terminal 16 Option Input 1 Disable Coast Stop Option Fault Fault NC Network Option 2 Input Allows the user to select the operati
126. the PLC s output contacts and the PF Softstarter s control terminals 2 The OFF state leakage current for a solid state device must be less than 6 mA Chapter 3 13 Chapter 3 Wiring Figure 3 13 Typical Wiring Diagram for Dual Ramp Applications 3 Phase L2 3 T2 4 L3 5 T3 6 Input Power Branch Protection Ramp 1 Ramp 2 oj PF Softstarter Control Terminals Aux 1 STIS TIn To Ts Te N oe TACH Ground Aux 2 Aux 3 Aux 4 Input Input Fault Customer supplied Refer to the controller nameplate to verify the rating of the control power input voltage For units rated 625 1250 A terminals 11 amp 12 are factory pre wired from terminal block CP1 terminals 1 amp 4 Note The Dual Ramp feature is available only with the standard control version Chapter 3 14 Chapter 3 Wiring Figure 3 14 Typical Wiring Diagram for Retrofit Applications Race he A IE 3 Im 123 T2 4 Input Power L X An uis T3 6 Existing Motor Branch Starter D Protection PF Softstarter Controller Stop Start __ Q Q O O M D JM DEISDEIDEIEIEIEIES PF Softstarter Control Terminals Aux 1 1 A U PTC TACH Ground Aux 2 Aux 3 Aux 4 4 Input Input Fault Customer supplied Overload protection should be disabled in the PF Softstarter Refer to the controller nameplate to verify the rating of the control power
127. time can be adjusted from 0 99 seconds alarm pre fault indication level can be programmed to indicate the unit is getting close to faulting The alarm modification information is displayed through the LCD and alarm contact closing Unbalance The PF Softstarter is able to detect an unbalance in line voltages M otor operation can be halted if the unbalance is greater than the desired range The PF Softstarter provides an adjustable unbalance setting from 0 2596 of the line voltages Trip delay time can be adjusted from 0 99 seconds An alarm pre fault indication level can be programmed to indicate the unit is getting close to faulting The alarm modification information is displayed through the LCD and alarm contact closing Undervoltage overvoltage and voltage unbalance protection are disabled during braking operation Chapter 1 13 Chapter 1 Product Overview Stall Protection and Jam Detection The PF Softstarter provides both stall protection and jam detection for enhanced motor and system protection Stall protection is user adjustable from 0 0 10 0 seconds in addition to the ramp time programmed Figure 1 15 Stall Protection 600 Percent Full Load Current Programmed Start Time Stall gt Time seconds An alarm pre fault indication level can be programmed to indicate the unit is getting close to faulting The alarm modification information is displ
128. tion must persist within for the controller to fault Jam Jam F Dly 68 Secs 0 99 0 B 7 Group Jam Jam Stall Ground Fault Ground Fault Ground Fault Ground Fault Ground Fault Ground Fault Ground Fault PTC Phase Reversal Restart Parameter Name Jam A Lvl Jam A Dly Stall Delay Gnd Fit Enable Gnd Fit Level Gnd Fit Delay Gnd Fit Inh Time Gnd Fit A Enable Gnd Fit A Lvl Gnd Fit A DIV PTC Enable Phase Reversal Starts Per Hour Table B 1 Parameter List Continued Parameter Number 69 70 71 72 73 74 75 76 77 78 79 80 81 Units FLC Secs Secs Amps Secs Secs Amps Secs Min Max 0 1000 0 0 10 0 Disable Enable 1 0 5 0 9 0 1 250 0 0 250 Disable Enable 1 0 5 0 9 0 250 Disable Enable Disable Enable 0 99 Default Settings Disable 250 0 5 10 Disable 200 Disable Disable Appendix B Parameter Description Allows the user to set an instantaneous over current level of line FLC that will cause an Alarm A zero value is the off setting Allows the user the ability to prevent some nuisance Alarms by entering a delay period that provides a window that the motor over current condition must persist within for the controller to Alarm This feature allows the user to program the amount of ti
129. tion without the use of a reversing contactor Provides the user the ability to program the Preset SS current to slow speed operation for both the Accu Stop PIU CER Cur i AFLG 0 Preset Slow Speed and Accu Stop control options This setting is typically load dependent Provides the user the ability to program the Preset SS operating current of slow speed operation for Slow Running Cur 42 FLC 0 450 0 both the Preset Slow Speed and Accu Stop Accu Stop A ee control options This setting is typically load dependent Provides adjustment capability for the braking Y intensity from slow speed operation to the Recursion Stopping Current 33 AFLE 0 400 stopped condition for the Accu Stop control option Disa Allows the user to select the time to trip for the Basic Class 10 M Pie built in overload This selection is based on the Set Up Overload Class 44 Class 15 Class 10 BE oa type of motor being used and the application it Overload Class 20 is bein anpiled tno Class 30 g app l Basic This motor nameplate value is used to determine Set Up Service Factor 45 0 01 1 99 1 15 the ultimate overload trip current Overload Sets the base current for use with all the current Basic based protection features jam over under Set Up Motor FLC 46 Amps 1 0 2200 0 1 0 load motor overload The motor nameplate Overload FLA is to be used regardless of the configuration WYE or DELTA Bach Manual Allows the user t
130. u Stop options Extended operation at slow speeds reduces motor cooling efficiency Consult motor manufacturer for motor limitations SMB Smart Motor Braking option Check duty cycle Consult motor manufacturer for motor limitations Motor short circuit Winding fault dentify fault and correct Check for shorted SCR replace if necessary Ensure power terminals are secure Chapter 8 5 Chapter 8 Troubleshooting Power Module If apower module needs to be checked use the applicable procedure Check that follows To avoid shock hazard disconnect main power before work ing on the controller motor or control devices such as Start Stop push buttons ake sure that wires are properly marked and programmed parameter values are recorded A A Shorted SCR Test 1 Using an ohmmeter measure the resistance between the line and load terminals of each phase on the controller L1 T1 L2 T2 amp L3 T3 The resistance should be greater than 10 000 ohms Chapter 8 6 Appendix A Specifications Functional Design Specifications Standard Features Installation Power Wiring Standard squirrel cage induction motor or a Wye Delta six lead motor Control Wiring 2 and 3 wire control for a wide variety of applications Setup Keypad Front keypad and backlit LCD display Starting and Stopping Modes e Soft Start e Current Limit Start e Dual Ramp Full Voltage
131. ule Starting Two or three power phases are missing Check power system Table 8 C Motor Rotates but does not accelerate to full speed Display Possible Causes Possible Solutions Fault displayed See fault description See Table 8 A addressing fault conditions Starting Mechanical problems Check for binding or external loading and correct Inadequate Current Limit setting Failed control module Table 8 D Motor Stops While Running Display Fault displayed Possible Causes See fault description Check motor Adjust the Current Limit Level to a higher setting Replace control module Possible Solutions See Table 9 A addressing fault conditions Display is blank Control voltage is absent Failed control module Check control wiring and correct if necessary Replace control module Stopped 0 0 Amps Pilot devices Failed control module Check control wiring and correct if necessary Replace control module Starting Two or three power phases are missing Failed control module Chapter 8 4 Check power system Replace control module Table 8 E Miscellaneous Situations Situation Motor current and voltage fluctuates with steady load Possible Causes Motor Erratic Load Chapter 8 Troubleshooting Possible Solutions Verify type of motor as a standard squirrel cage induc tion motor Check load conditions Erratic o
132. urrent fault and fault 5 being the oldest fault kept in memory Fault buffer 5 represents fault history of the device with Linear List Fault 5 128 0 255 fault 1 being the current fault and fault 5 being the oldest fault kept in memory This parameter provides the user with the ability to extend the ramp time beyond the initial range of 0 30 Linear List Ramp Time E 129 99 pet 0 999 0 seconds To use this parameter parameter 18 must be setto 0 Linear List Ramp Time 2E 1300 Sec 0 999 0 Allows for the second ramp time to also be extended To use this parameter parameter 26 must be set to 0 Allows the stop time be extended beyond the limit of Linear List Stop Time E 131 Sec 0 999 0 120 seconds Parameter 33 must be set to 0 for this parameter to be active Disable Coast Basic Set Stop Option Stop Provides the user with the ability to define the function of Up Option Input 1 192 Fault Option option Input 1 Fault NC Network Basic Set Coast Provides the user with the ability to define the function of Up Stop Input Stop Option Coast the stop input This is an additional Elapsed Time Meter that cannot be Linear List Elapsed Time 2 134 9 Hours 0 0 3000 0 reset by the user It increments exactly as the Elapsed Time but cannot be reset This parameter is not viewable without entering a special password in Firmware versions 4 001 or earlier Contact Sprecher Schuh technical support if you have Ver
133. vides the user with the ability to define the function of option Input 2 disable coast stop option fault fault N C network User Settings Appendix B Table B 1 Parameter List Continued Group Parameter Name Parameter Units Min Max Default Parameter Description User Number Settings Settings Full Voltage Current Limit When the dual ramp mode is selected this Dual Ramp Starting Mode 2 25 Soft Start Soft Start parameter allows the user to select the type of Linear Speed ramp mode used for the second ramp profile Pump Start When the dual ramp mode is selected this parameter allows the user to program the time Dual Ramp Ramp Time 2 26 Secs 0 30 10 0 30 s that the controller performs the starting maneuver for profile 2 Also refer to Parameter 130 When using the soft start mode for profile 2 this parameter allows the user to adjust the initial Dual Initial Torque 2 2r gal nm torque level applied to the motor at the beginning of the start maneuver When using the current limit starting mode for Dual Ramp Cur Limit Level 2 28 50 600 350 profile 2 this parameter allows the user to adjust the current level applied to the motor during the start maneuver Dual Ramp Reserved 29 Reserved This parameter provides a torque pulse for the Dual Ramp Kickstart Time 2 30 Secs 0 0 2 0 0 0 programmed time period at the beginning of the starting maneuver for ramp profile 2 This parameter p
134. you aware of safety considerations Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attention statements help you to e identify a hazard avoid a hazard recognize the consequences Important Identifies information that is critical for successful application and understanding of the product European Communities EC Directive Compliance If this product has the CE mark it is approved for installation within the European Union and EEA regions It has been designed and tested to meet the following directives EMC Directive This product is tested to meet the Council Directive 89 336 EC Electromagnetic Compatibility EMC per EN IEC 60947 4 2 This product is intended for use in an industrial environment Low Voltage Directive This product is tested to meet Council Directive 73 23 EEC Low Voltage per EN IEC 60947 4 2 This equipment is classified as open equipment and must be mounted in an enclosure during operation to provide safety protection Chapter 1 Product Overview Other Related Documents eene nn gee KEE ne gee nn age DIESER ee E RD Soft Start Operation ee M odes of Operation Standard SelectableKickstarE sue GUrrentEIMIESEATE A oec D alRamp Start i i E E E N Full Voltage Start Preset Slow Speed len Re en

PF Softstarters User manual 5A to 1250A

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