Cutler-Hammer Intelligent Technology ( ) S801 Soft Starter

Cutler-HammerIntelligent Technology (S801 Soft StarterUser ManualThe Cutler-Hammer Intelligent Technology Soft StarterPub 49003Catalog No. S801USERMANRev. L)

Important Notice – Please ReadThe product discussed in this literature is subject to terms and conditions outlined inappropriate Cutler-Hammer selling policies. The sole source governing the rights andremedies of any purchaser of this equipment is the relevant Cutler-Hammer selling policy.NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OFFITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, ORWARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF TRADE,ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS ANDDESCRIPTIONS CONTAINED HEREIN. In no event will Cutler-Hammer be responsibleto the purchaser or used in contract, in tort (including negligence), strict liability orotherwise for any special, indirect, incidental or consequential damage or loss whatsoever,including but not limited to damage or loss of use of equipment, plant or power system,cost of capital, loss of power, additional expenses in the use of existing power facilities, orclaims against the purchaser or user by its customers resulting from the use of theinformation, recommendations and descriptions contained herein.2 Soft Starter User Manual

Table of ContentsSafety . 5The Meaning of Safety Statements .5IT. Soft Starter Safety Statements.6Introduction . 7General Appearance Notes .7Inspection . 8General.8Unpacking.8Storage .8Mounting . 9Size .9Required Mounting Hardware .11Weight Support Requirements.11Environmental Requirements .11Mounting Instructions for Models S801N, S801R and S801T .12Mounting Instructions for Model S801V.13Safety Notices.14Lugs for T and V Frame .15Lug Installation.16Control Wiring.16Motor/Application Considerations . 17Using MOVs.17Squirrel Cage Motor .17Wye-Delta Motor.17Part Winding Motor.17Dual Voltage Motor.18Multi-Speed Motor .18Other Winding Configurations .18Power Factor Correction Capacitors.18Control Wiring Inputs.19Using an Auxiliary Relay .21Edge & Level Sensing .22Using a Supplemental Line Contactor .23Providing Control Power .25Set Up / Software . 27General.27Starting Options .27Soft Stop .29Protective Features. 30Thermal Overload.30Jam Detection .31Stall Detection .32Phase Loss/Current Unbalance Detection & Load Disconnect.32Phase Reversal Detection.32Protective Features Review.33Thermal Motor Overload .33Programming Settings . 34General.34Trip Class.34Overload Trip Curves .35Manual/Auto Fault Reset .36Special Function S.F.36Programming the Start .37Programming the Kick Start Sequence .37Programming the Ramp Start Sequence .38Soft Starter User Manual 3

Ramp Start. 38Programming the Current Limit Start .39Programming the Soft Stop.40Procedure For Starting . 41Line Power.41Jog.41Troubleshooting. 42General.42Before You Begin to Troubleshoot.42Define the Problem .43Status LED Off .44Status LED Green .44Fault Shown on CIM .45Soft Starter Fault Flash Codes Sent to CIM.46Fault Not Shown on CIM.47Excess Noise/Vibration in Motor .47Audible Noise From Soft Starter – Bypass Fails to Close/Chatters.47Unit Will Not Stop.47Other Symptoms Not Listed .48Removing Controller Interface Module (CIM) . 49HP and KW Ratings.5015 Second Ramp, 4 Starts per Hour, 300% Current Limit @ 40oC .50HP and KW Ratings.5125-Second Ramp, 4 Starts per Hour, 300% Current Limit @ 40oC.5115-Second Ramp, 4 Starts per Hour, 300% Current Limit @ 50oC.5250-Second Ramp, 2 Starts per Hour, 300% Current Limit @ 50oC.5315-Second Ramp, 4 Starts per Hour, 450% Current Limit @ 40oC.54HP and KW Ratings (continued).5530-Second Ramp, 4 Starts per Hour, 450% Current Limit @ 40oC.55Severe Duty Ratings .56Cooling .56Short Circuit Ratings .57Special Function Options . 58Pump Control Option.58Adjustment.59Application Notes . 59CE Conformity . 61Customer Service.back cover4 Soft Starter User Manual

SafetyCutler-Hammer has made every effort to provide you with the safest motor starters on themarket. However, we wish to point out how to safely operate and troubleshoot your starter.The Meaning of Safety StatementsYou will find various types of safety information on the following pages and on the labelsattached to the equipment. This section explains their meaning.The Safety Alert Symbol means ATTENTION!BECOME ALERT! YOUR SAFETY IS INVOLVED!Le symbole d’alerte signifie ATTENTION!SOYEZ VIGILANT! VOTRE SECURITE EST EN JEU!DangerDanger means that failure tofollow the safety statement willresult in serious personal injury,death, or substantial propertydamage.WarningWarning means that failure tofollow the safety statementcould result in serious personalinjury, death, or substantialproperty damage.CautionCaution means that failure tofollow the safety statement mayresult in minor or moderatepersonal injury or propertydamage.DangerDanger signifie quel’inobservation de l’énoncérelatif à la sécurité entrainerades blessures corporellesgraves ou mortelles.AvertissementAvertissement signifie quel’inobservation de l’énoncérelatif à la sécurité pourraitentraîner des blessurescorporelles graves ou mortelles,ou des dommages matérielsimportants.AttentionAttention signifie quel’inobservation de l’énoncérelatif à la sécurité peutentraîner des blessurescorporelles mineures oumoderees ou des dommagesmatériels.NoticeAvisNotice means that failure tofollow these instructions couldcause damage to the equipmentor cause it to operateimproperly.Avis signife que l’inobservationdes presentes directivespourrait causer des dommagesa l’equipement ou en provoquerle mauvais fonctionnement.Soft Starter User Manual 5

IT. Soft Starter Safety StatementsThe following safety statements relate to the installation, operation, and troubleshooting ofCutler-Hammer Motor Starters.NoticeMake sure you read andunderstand the installationprocedures in this manualbefore you attempt to operateor troubleshoot the equipment.WarningThe instruction manual shouldbe used for proper installation,operation, and maintenance ofthe equipment. Improperlyinstalling and maintaining theseproducts can result in seriouspersonal injury or propertydamage. Before attemptinginstallation or maintenance, readand understand this entiremanual.Danger High Voltage6 AvisLire et bien comprendre lesmethodes de montage de cemanuel avant de fairefonctionner cet equipement oude proceder au depannage.AvertissementConsulter la notice pourl’installation, le fonctionnementet l’entretien de l’equipement.Use mauvaise installation et unentretien inadequat peuventcauser des blessures graves etdes dommages materials. Avantde proceder a l’installation et al’entretien, bien lire etcomprendre cette notice.Danger (Haute tension)There can be line voltagepotential at the motor loadterminals even with the starter inthe off state. This is due to thepossible leakage across SCRs.Always disconnect input powerbefore servicing starter or motor.Il peut exister une tension deligne aux bornes du côté chargedu moteur bien que le moteursoit arrêté. Cela s’explique dufait de fuites possibles à traversles redresseurs au silicium.Toujours débrancherl’alimentation avant d’effectuerdes travaux sur le démarreur oule moteur.NoticeAvisPower factor capacitors: Do notconnect power factor correctingcapacitors to the load side of thestarter. They will cause thestarter to fail. If capacitors areused, they must be connected tothe line side of the starter, as farupstream as possible.Condensateurs decompensation: ne pas raccorderces appareils du côté charge dudémarreur. Cela entraînera ladéfaillance du démarreur.Raccorder tout condensateur ducôté ligne du démarreur, aussiloin amont que possible.Soft Starter User Manual

IntroductionThe Intelligent Technologies IT. Soft Starter is an electronic, self-contained, panel- orenclosure-mounted motor soft-starting device. It is intended to provide 3-phase inductionmotors with a smooth start, both mechanically and electrically. The IT. line of soft startersutilizes six thyristors connected in a full wave power bridge. Varying the thyristorconduction period controls the voltage applied to the motor. This in turn controls the torquedeveloped by the motor. After the motor reaches speed, contacts are closed to bypass thethyristors.The Intelligent Technologies IT. Soft Starter is designed to fulfill the industrial servicerequirements for applications such as Chillers, Pumps, and Machine Tools that require lessthan 85% if the motor’s rated starting torque for worst case starting condition.The Intelligent Technologies IT. Soft Starter meets all relevant specifications set forth byNEMA ICS 1, ICS 2 and ICS 5, UL 508, IEC 60947-4-2, CE, and CSA.This user manual covers everything you need to know in order to install, set up, operate,troubleshoot and maintain the IT. Soft Starter.However, no publication can take into account every possible situation. If you requirefurther assistance with any aspect of this product, or a particular application, feel free tocontact us. You will find our address, phone number, and other contact information on theback cover of this manual.General Appearance NotesSHOWN WITHLUGS (optional)BASELUGCOVERLINE INPUTCONTROLINTERFACEMODULE(CIM)RESETBUTTONSTATUS LEDLOAD OUTPUTDETACHABLE12-PINTERMINALBLOCKFigure 1: The Cutler-Hammer Intelligent Technologies (IT) Soft Starter The Control Interface Module (CIM) is mounted on the face of the unit. The base supports the soft starter and all internal and external components. The lug cover (T and V frames only) reduces the chance of accidental contact with livecabling. The 12-pin terminal block is detachable for easy wiring.Soft Starter User Manual 7

InspectionGeneralUpon receipt of the unit, verify that the catalog number and unit options stated on theshipping container match those stated on the order/purchase form.Inspect the equipment upon delivery. Report any crate or carton damage to the carrier priorto accepting the delivery. Have this information noted on the freight bill. Cutler-Hammer isnot responsible for damage incurred in shipping.UnpackingRemove all packing material from the unit. Be sure to remove all packing material fromlug locations. Also, make sure no packing material blocks the airflow near the fans. For Vframe units, verify mounting hardware has been included with shipment.Check the unit for any signs of shipping damage. If damage is found after unpacking,report it to the freight company. Retain the packaging materials for carrier to review.Verify that the unit’s catalog number and options match those stated on the order/purchaseform.StorageIt is recommended that the unit be stored in its original shipping box/crate until it is to beinstalled.The unit should be stored in a location where:8 The ambient temperature is between -50 C and 70 C (-58 F and 158 F) The relative humidity is between 0% and 95%, non-condensing The environment is dry, clean, and non-corrosive The unit will not be subjected to high shock or vibration conditionsSoft Starter User Manual

MountingSizePP ,QFKHV@Figure 2: N Frame4 X [6.330]90,0[3.543]PP ,QFKHV@Figure 3: R FrameSoft Starter User Manual 9

Size ,1 [.278]SLOT DIMENSION(6 PLCS)75,0[2.953]158,0[6.221]150,0[5.906]SLOT DIMENSIONPP ,QFKHV@Figure 4: T Frame250,0[9.843]95,0 [3.740]SLOT 5,0[15.157]SLOTDIMENSIONØ7,2[.282]4 X 6,7[.265]SLOT DIMENSION183,7[7.233]PP ,QFKHV@Figure 5: V Frame10 Soft Starter User Manual

Required Mounting HardwareFrameSizeScrewSizeNWasherSize#10 – 32 x 0.5R1/4 – 20 x 0

Soft Starter User Manual 7 Introduction The Intelligent Technologies IT. Soft Starter is an electronic, self-contained, panel- or enclosure-mounted motor soft-starting device. It is intended to provide 3-phase induction motors with a smooth start, both mechanically and electrically. The IT. line of soft starters