SOFTSTARTER

IT.
SMV801 Medium Voltage Soft Starter

User Manual
New Information
September 2004
MN03901001E / Pub 50560
For more information visit: www.EatonElectrical.com
IT. SMV801 Medium Voltage Soft Starter User Manual

September 2004
Important Notice Please Read

The product discussed in this literature is subject to terms and conditions outlined in Eaton
Electrical Inc. selling policies. The sole source governing the rights and remedies of any
purchaser of this equipment is the relevant Eaton Electrical Inc. selling policy.
NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A
PARTICULAR PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE
OF DEALING OR USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION,
RECOMMENDATIONS AND DESCRIPTIONS CONTAINED HEREIN. In no event will Eaton
Electrical Inc. be responsible to the purchaser or user in contract, in tort (including
negligence), strict liability or otherwise for any special, indirect, incidental or consequential
damage or loss whatsoever, including but not limited to damage or loss of use of equipment,
plant or power system, cost of capital, loss of power, additional expenses in the use of
existing power facilities, or claims against the purchaser or user by its customers resulting
from the use of the information, recommendations and descriptions contained herein.
The information contained in this manual is subject to change without notice.
Cover Photo: The Cutler-Hammer Intelligent Technology Medium Voltage Soft Starter
MN03901001E / Pub 50560

September 2004
Table of Contents
ii
LIST OF FIGURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Meaning of Safety Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IT. Soft Starter Safety Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dangers, Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iv
v
vi
vi
vii
viii
CHAPTER 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Appearance Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1-2
CHAPTER 2 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
2-1
2-1
2-1
CHAPTER 3 MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Required Mounting Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weight Support Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Instructions for Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Instructions for Power Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
3-1
3-3
3-3
3-3
3-4
3-4
CHAPTER 4 POWER WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Notices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminal Pads for SMV801A and SMV801B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminal Pad Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4-1
4-4
4-4
4-5
CHAPTER 5 MOTOR/APPLICATION CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . .

Using Lightning Arrestors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Squirrel Cage Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Autotransformer or Reactor Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part Winding Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dual Voltage Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Multi-Speed Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Other Winding Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Factor Correction Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Wiring Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using an Auxiliary Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Edge & Level Sensing Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using a Supplemental Line Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Providing Control Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24V DC Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
5-1
5-1
5-2
5-2
5-2
5-2
5-3
5-3
5-3
5-12
5-13
5-14
5-15
5-16
CHAPTER 6 SETUP/SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Soft Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
6-1
6-1
6-3
MN03901001E / Pub 50560

September 2004
CHAPTER 7 PROTECTIVE FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Thermal Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Jam Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stall Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Phase Loss/Current Unbalance Detection & Load Disconnect . . . . . . . . . . . . . . . . .
Phase Reversal Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protective Features Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1
7-1
7-2
7-3
7-3
7-3
7-4
CHAPTER 8 PROGRAMMING SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trip Class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overload Trip Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protective Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual/Auto Fault Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Function S.F. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Programming the Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Programming the Soft Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1
8-1
8-2
8-3
8-4
8-4
8-4
8-5
8-5
8-9
CHAPTER 9 PROCEDURE FOR STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Line Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Jog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1
9-1
9-1
CHAPTER 10 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before You Begin to Troubleshoot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Define the Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1
10-1
10-1
10-2
CHAPTER 11 REMOVING CONTROLLER INTERFACE MODULE (CIM) . . . . . . . . . . . .

CHAPTER 12 RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Horsepower and kW Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blowers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Short Circuit Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-1
12-1
12-1
12-8
12-8
CHAPTER 13 SPECIAL FUNCTION OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Control Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-1
13-1
CHAPTER 14 ACCESSORIES AND REPAIR PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accessory Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewal Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14-1
14-1
14-2
MN03901001E / Pub 50560
iii

September 2004
List of Figures
Figure 1-1: Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1-2: Power Module Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1-3: Power Module Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3-1: Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3-2: Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3-3: Minimum Enclosure Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4-1: Soft Starter Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4-2: Line Power Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4-3: Power Module Shown with Lug Cover Removed
and EML50 Terminal Kit Installed on Load Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5-1: Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5-2: Elementary Diagram for Soft Starter with START/STOP/RESET/JOG
with 120V AC Alarm and Run Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5-3: Elementary Diagram for Soft Starter with HAND/OFF/AUTO/RESET
with PLC shown with 120V AC Pilot Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
with 24V DC Alarm and Run Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5-5: Elementary Diagram Using 95-96 Trip Contacts for Soft Starter
with START/STOP/JOG with 120V AC Alarm and Run Indication . . . . . . . . . . . . . . .
with 120V AC Alarm and Run Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5-7: Elementary Diagram Using 95-96 Trip Contacts for Soft Starter with
START/STOP/RESET/JOG with 120V AC Alarm and Run Indication . . . . . . . . . . . . .
Figure 5-8: 24V DC Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5-9: 120V AC Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5-10: 24V DC Control with Edge Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6-1: Selectable Kick-Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6-2: Ramp Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6-3: Current Limit Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 6-4: Soft Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-1: Setting Trip Class and
FLA on the CIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-2: Jam Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7-3: Stall Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-1: Soft Start Control Interface Module (CIM) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-2: Setting Trip Class on the CIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-3: Overload Trip Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-4: Kick Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-5: Ramp Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-6: Current Limit Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 8-7: Soft Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-1: Troubleshooting Flowchart #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 10-2: Troubleshooting Flowchart #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 13-1: IT. Soft Starter CIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 13-2: Pump Start Ramp and Soft Pump Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iv
1-2
1-3
1-3
3-1
3-2
3-4
4-1
4-2
4-5
5-3
5-5
5-6
5-7
5-8
5-9
5-10
5-12
5-13
5-14
6-1
6-2
6-2
6-3
7-2
7-2
7-3
8-1
8-2
8-3
8-6
8-7
8-8
8-9
10-2
10-3
13-1
13-2
MN03901001E / Pub 50560

September 2004
List of Tables
Table 3-1: Required Mounting Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 3-2: Weight Support Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 3-3: Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 4-1: Line and Load Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 4-2: Control Power Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 4-3: 12-Pin Terminal Block Wiring Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 5-1: Arrestor Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 5-2: Control Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 5-3: Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 7-1: Short Circuit Protection Adjustment Settings . . . . . . . . . . . . . . . . . . . . . . . .
Table 7-2: Thermal Motor Overload Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 7-3: Thermal Overload Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 8-1: Rotor Torque vs. Equivalent Starting Current . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 10-1: Troubleshooting Status LED OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 10-2: Troubleshooting Status LED Green . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 10-3: Troubleshooting Power Pole +24V DC Green LED OFF . . . . . . . . . . . . . . .
Table 10-4: Troubleshooting Power Pole +24V DC Green LED ON . . . . . . . . . . . . . . . .
Table 10-5: Troubleshooting Power Pole Blower Green LED OFF . . . . . . . . . . . . . . . . .
Table 10-6: Troubleshooting Power Pole Blower Green LED ON . . . . . . . . . . . . . . . . .
Table 10-7: Troubleshooting Power Pole Bypass Contactor Amber LED OFF . . . . . . .
Table 10-8: Troubleshooting Power Pole Bypass Contactor Amber LED ON . . . . . . .
Table 10-9: Troubleshooting Power Pole SCR Gate Trigger Amber LED OFF . . . . . . .
Table 10-10: Troubleshooting Power Pole SCR Gate Trigger Amber LED ON . . . . . . .
Table 10-11: Troubleshooting Fault Shown on CIM . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 10-12: Flash Codes/Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 10-13: Troubleshooting Fault Not Shown on CIM. . . . . . . . . . . . . . . . . . . . . . . . .
Table 10-14: Troubleshooting Excess Noise/Vibration in Motor . . . . . . . . . . . . . . . . . .
Table 10-15: Troubleshooting Audible Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 10-16: Troubleshooting Unit Will Not Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 10-17: Troubleshooting Other Symptoms Not Listed. . . . . . . . . . . . . . . . . . . . . .
Table 12-1: 15 Second Ramp, 4 Starts per Hour, 300% Current Limit @ 40C . . . . . . . . .
Table 12-7: > 30 Second Ramp, > 4 Starts per Hour or >300% Current Limit . . . . . . . . . .
Table 12-8: Maximum Power Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 14-1: SMV801 Accessory Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 14-2: SMV801 Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MN03901001E / Pub 50560
3-3
3-3
3-3
4-3
4-5
4-5
5-1
5-4
5-16
7-1
7-4
7-4
8-6
10-3
10-3
10-4
10-4
10-5
10-5
10-6
10-6
10-6
10-7
10-8
10-9
10-10
10-10
10-10
10-11
10-11
12-1
12-2
12-3
12-4
12-5
12-6
12-7
12-8
14-1
14-2

September 2004
Safety
Eaton has made every effort to provide you with the safest motor starters on the market.
However, we wish to point out how to safely operate and troubleshoot your starter.
The Meaning of Safety Statements

You will find various types of safety information on the following pages and on the labels
attached to the equipment. This section explains their meaning.
!
!
The Safety Alert Symbol means ATTENTION! BECOME ALERT!

YOUR SAFETY IS INVOLVED!
Le symbole dalerte signifie ATTENTION! SOYEZ VIGILANT!
VOTRE SECURITE EST EN JEU!
Danger
Danger means that failure to follow the safety
statement will result in serious personal injury,
death, or substantial property damage.
Danger
Danger signifie que linobservation de lnonc
relatif la scurit entrainera des blessures
corporelles graves ou mortelles.
Warning
Warning means that failure to follow the safety
statement could result in serious personal injury,
death, or substantial property damage.
Avertissement
Avertissement signifie que linobservation de
lnonc relatif la scurit pourrait entraner des
blessures corporelles graves ou mortelles, ou des
dommages matriels importants.
Caution
Caution means that failure to follow the safety

statement may result in minor or moderate
personal injury or property damage.
Attention
Attention signifie que linobservation de lnonc

relatif la scurit peut entraner des blessures
corporelles mineures ou moderees ou des
dommages matriels.
Notice
Avis
Notice means that failure to follow these

Avis signife que linobservation des presentes
instructions could cause damage to the equipment directives pourrait causer des dommages a
or cause it to operate improperly.
lequipement ou en provoquer le mauvais
fonctionnement.
vi
MN03901001E / Pub 50560

September 2004
IT. Soft Starter Safety Statements

The following safety statements relate to the installation, operation, and troubleshooting of
Cutler-Hammer Motor Starters.
Notice
Avis
Make sure you read and understand the

Lire et bien comprendre les methodes de montage
installation procedures in this manual before you de ce manuel avant de faire fonctionner cet
attempt to operate or troubleshoot the equipment. equipement ou de proceder au depannage.
Warning
The instruction manual should be used for proper
installation, operation, and maintenance of the
equipment. Improperly installing and maintaining
these products can result in serious personal
injury or property damage. Before attempting
installation or maintenance, read and understand
this entire manual.
Avertissement
Consulter la notice pour linstallation, le
fonctionnement et lentretien de lequipement.
Use mauvaise installation et un entretien
inadequat peuvent causer des blessures graves et
des dommages materials. Avant de proceder a
linstallation et a lentretien, bien lire et
comprendre cette notice.
Danger High Voltage
Danger (Haute tension)
There can be line voltage potential at the motor

load terminals even with the starter in the off state.
This is due to the possible leakage across SCRs.
Always disconnect input power before servicing
starter or motor.
Il peut exister une tension de ligne aux bornes du

ct charge du moteur bien que le moteur soit
arrt. Cela sexplique du fait de fuites possibles
travers les redresseurs au silicium. Toujours
dbrancher lalimentation avant deffectuer des
travaux sur le dmarreur ou le moteur.
Notice
Avis
Power factor capacitors: Do not connect power

factor correcting capacitors to the load side of the
starter. They will cause the starter to fail. If
capacitors are used, they must be connected to the
line side of the starter, as far upstream as possible.
Condensateurs de compensation: ne pas raccorder

ces appareils du ct charge du dmarreur. Cela
entranera la dfaillance du dmarreur. Raccorder
tout condensateur du ct ligne du dmarreur,
aussi loin amont que possible.
MN03901001E / Pub 50560
vii

September 2004
Dangers, Warnings and Cautions

Dangers
Danger High Voltage
Hazard of Burn or Electrical Shock
Risque de Brulure ou Electriques de Choc
To avoid shock hazard, disconnect all power to the

controller, motor or other control devices before
any work is performed on this equipment. Failure
to do so will result in personal injury, death or
substantial property damage.
Pour viter les chocs lectriques, couper

lalimentation lectrique du contrleur, du moteur
ou autres dispositifs de commande avant dy
effectuer quelque travail. Linobservation de cette
mesure entranera des blessures corporelles, la
mort ou des dommages matriels.
Do not apply a disconnect device on the output of

the IT. Soft Starter unless a means to turn off the
soft starter when disconnect switch is open is
utilized. Opening disconnect while the IT. Soft
Starter is operating may cause a malfunction.
Closing disconnect switch while the IT. Soft Starter
is operating will result in a soft starter failure and
potential equipment damage and personnel
hazard.
Ne pas appliquer un dispositif de sectionnement

sur le dmarreur IT. Soft moins quun moyen
dteindre le dmarreur Soft ne soit utilis lorsque
linterrupteur de sectionnement est ouvert. Le fait
douvrir linterrupteur de sectionnement pendant
le fonctionnement du dmarreur IT. Soft risque de
provoquer un dysfonctionnement. Le fait
dteindre linterrupteur de sectionnement
pendant le fonctionnement du dmarreur IT. Soft
provoquera la dfaillance du dmarreur Soft, des
dommages de lquipement ainsi quun danger
pour le personnel.
Danger High Voltage

Make sure all power is off before wiring.

Sassurer de couper le courant avant de cabler.
Danger High Voltage

Do not work on energized equipment unless
absolutely required. If troubleshooting procedure
requires equipment to be energized, all work must
be performed by properly qualified personnel,
following appropriate safety practices and
precautionary measures.

Ne pas travailler sur de lequipement sous tension
sauf si absolutment necessaire. Si les methodes de
depannage exigent que lequipment soit sous
tension, les travaux doivent etre executes par
personnel qualifie, et les pratiques de securite et
mesures preventives etre observees.
Warnings
Warning
Make sure you read and understand all of the
safety statements in the safety section of this
manual before you begin troubleshooting.
viii
Avertissement
Sassurer de lire et de comprendre tous les
enonces relatifs a la securite de la section securite
de ce manuel avant de proceder au depannage.
MN03901001E / Pub 50560

September 2004
Cautions
Caution
The SMV801A and B soft starter power modules

weigh approximately 138 Lbs. (63 kg). To prevent
personal injury or equipment damage, use proper
lifting equipment (such as a floor crane) to safely
lift and install the soft starter. A lifting eye is
provided at the line end of the soft starter.
Attention
Le dmarreur SMV801A pse environ 63 kg (138

livres). Pour viter les blessures personnelles et
les dommages matriels, utiliser un matriel de
levage appropri (comme un grue roulante
datelier) pour soulever et installer le dmarreur de
faon scuritaire. Un oeillet de levage est prvu du
ct ligne du dmarreur.
Caution
Attention
Never megger a motor while it is connected to the Ne jamais rgler un moteur alors quil est branch
IT. Soft Starter. Disconnect the leads at the IT. Soft au dmarreur IT. Soft. Dbrancher les fils au
Starter before meggering the motor.
dmarreur IT. Soft avant de rgler le moteur.
Caution
Only apply 24V DC to the control terminal block

unless specified otherwise in this manual. All
control wiring is 22 12 AWG. Failure to follow this
caution could result in severe damage to the
controller.
MN03901001E / Pub 50560
Attention
Appliquer une tension de 24 V c.c. aux bornes sauf

avis contraire dans ce manuel. Toute la filerie de
commande est de calibre 0.33 2.5 mm2 (22 12
AWG). Linobservation de cette mesure pourrait
causer des dommages importants au contrleur.
Caution
Soft Stop is not an emergency stop, and cannot

make the load stop faster than its normal coastto-stop time. If removal of control is desired,
additional control is required to open up the
24V DC to terminal +. Using terminal P to initiate
power removal is not recommended.
Attention
Appliquer seulement une tension de 24 V c.c. aux

bornier sauf avis contraire dans ce manuel. Toute
la filerie de commande est de calibre 22 12 AWG.
Linobservation de cette mesure pourrait
causerdes dommages importants au contrleur.
Caution
Only apply 24V DC to the terminal block unless

specified otherwise in this manual. All control
wiring is 22 12 AWG (0.33 2.5 mm2). Failure to
follow this caution could result in severe damage
to the controller.
Attention
Larrt Soft nest pas une commande darrt

durgence et ne peut servir acclrer larrt du
chargement par rapport au temps darrt
programm. Si le retrait de la commande est
souhait, un contrle supplmentaire est requis
pour ouvrir le CC 24 V au plot +. Il nest pas
recommand de commencer couper le courant
partir de la borne P.
ix

September 2004
Cautions, continued
Caution
Soft Stop is not an emergency stop. If a quick stop

is desired, additional control is required to open
up the 24V DC to terminal +. Using terminal P for a
quick stop is not recommended.
Attention
Un arrt tension rduite nest pas un arrt

durgence. Pour un arrt rapide, prvoir un bouton
additionnel afin douvrir le circuit de +24 V c.c. la
borne +. Lutilisation de la borne P comme arrt
rapide nest pas recommande.
Caution
Soft Stop does not provide any braking. It cannot

cause the motor and its load to stop faster than
their normal unpowered coast down time.
Attention
Un arret a tension rduite nassure aucun freinage.

l Il ne peut assurer le freinage du moteur et de sa
charge plug rapidement quen mode dbray.
MN03901001E / Pub 50560

September 2004
Chapter 1 Introduction
The Cutler-Hammer Intelligent Technologies IT. Soft Starter from Eatons electrical business
is an electronic, self-contained, panel- or enclosure-mounted medium voltage motor softstarting device. It is intended to provide three-phase induction motors with a smooth start,
both mechanically and electrically. The IT. line of soft starters utilizes a maximum of 12
series-connected thyristors connected in a full wave power bridge. Varying the thyristor
conduction period controls the voltage applied to the motor. This in turn controls the torque
developed by the motor. After the motor reaches speed, contacts are closed to bypass the
thyristors.
The Intelligent Technologies IT. Soft Starter is designed to fulfill the industrial service
requirements for applications such as Chillers, Pumps and Machine Tools that require less
than 85% of the motors rated starting torque for worst case starting condition.
The Intelligent Technologies IT. Soft Starter meets all relevant specifications set forth by
UL 508 and 347, CSA C22.2 #14.95 TILD 21.
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 require further
assistance with any aspect of this product, or a particular application, feel free to contact us.
MN03901001E / Pub 50560
1-1

September 2004
General Appearance Notes

Base
Cover
Control Interface
Module (CIM)
Reset Button
Status LED
Detachable 12-Pin
Terminal Block
Control Cable
Figure 1-1: Control Module
1-2
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.
Cover reduces the chance of accidental contact with controller circuit board.
The 12-pin control terminal block is detachable for easy wiring.
Control Cable connects the Control Module to the Power Module.
MN03901001E / Pub 50560

September 2004
Power Pole
Functions LEDs
Power Pole Functions
Power Pole
Cooling Air IN
Figure 1-2: Power Module Front
Legend for power pole functions.
Power pole functions LED shows pole operation.
Cooling air IN port.

Cooling Air Exhaust
Pole Cover
Line Lug Cover
Isolation Housing
Base
Load Lug Cover
Control Harness Port
Terminal
Figure 1-3: Power Module Side
Terminal port can accept a 1.5 Inch (38 mm) bus.
Cooling Air Exhaust port requires a 2 Inch (50.8 mm) clearance.
Pole Cover protects the electronics and secures the Line and Load lug covers.
Base supports the ISO-Housing and houses the SCRs.
Isolation Housing contains the isolation components that trigger the SCR gates and
provide the low voltage feedback signals to the controller.
Control Harness Port provides a secured entrance and exit for the control harness.
Provides isolation for the Terminal Pad and houses the forced air cooling blowers.
MN03901001E / Pub 50560
1-3

September 2004
1-4
MN03901001E / Pub 50560

September 2004
Chapter 2 Inspection
General
Upon receipt of the unit, verify that the catalog number and unit options stated on the
shipping container match those stated on the order/purchase form.
Inspect the equipment upon delivery. Report any crate or carton damage to the carrier prior
to accepting the delivery. Have this information noted on the freight bill. Eaton is not
responsible for damage incurred in shipping.
Unpacking
Remove all packing material from the unit. Be sure to remove all packing material from lug
locations. Also, make sure no packing material blocks the airflow near the fans.
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 units catalog number and options match those stated on the order/purchase
form.
Storage
It is recommended that the unit be stored in its original shipping box/crate until it is to be
installed.
The unit should be stored in a location where:
The ambient temperature is -58F 158F (-50C 70C)
The relative humidity is 0% 95%, non-condensing
The environment is dry, clean and non-corrosive
The unit will not be subjected to high shock or vibration conditions
MN03901001E / Pub 50560
2-1

September 2004
2-2
MN03901001E / Pub 50560

September 2004
Chapter 3 Mounting
Size
4.41 (112.1)
3.54 (90.0)
L1 1
L2
L3
7.28
7.83
(185.0) (199.0)
3.02 (76.6)
3.41 (86.8)
Inside of Cabinet Door
.94 (24.0)
Min
.79
(20.1)
Figure 3-1: Control Module

Approximate Dimensions in Inches (mm)
MN03901001E / Pub 50560
3-1

September 2004
12.60 (320.0)
1.57 (40.0)
6.30 (160.0)
Dia.
Rad.
.20 (5.0)
16 Places
.37 (9.3)
Ref.
Dia.
.40 (10.0)
13 Places
.61
(15.4)
23.80
(604.5)
22.00
(358.7)
20.39
(517.9)
3.15
(80.0)
Center
of Plugs
4.74
(120.1)
Center
of Plug
3.43
(87.0)
4.80
(122.0)
5.22
(132.5)
Ref.
6.30 (160.0)
12.60 (320.0)
1.00 (25.4)
1.59 (40.5)
Center of Plug
3.91
(99.4)
17.37 (441.2)
7.39 (187.7)
Ref.
8.45 (214.7)
Ref.
9.81
(249.2)
1.99
(50.5)
1.53
(38.8)
Ref.
1.61
(40.8)
Center
of Plug
Figure 3-2: Power Module

Approximate Dimensions in Inches (mm)
3-2
MN03901001E / Pub 50560

September 2004
Required Mounting Hardware

Table 3-1: Required Mounting Hardware
Quantity
Required
Torque
Required
Standard 1/4 Lockwasher and

Flat Washer
60 Lb-in
(6.8 Nm)
Standard 3/8 Lockwasher, Flat

Washer and Nut
46 Lb-in
(62 Nm)
Module
Screw Size
Washer Size
Control
1/4 20 x 0.625
2.5 kV
Power
Module
Grade 5
3/8 16 x 0.625
Weight Support Requirements

Table 3-2: Weight Support Requirements
Module
Weight of Unit
Control
5.8 pounds (2.6 kg)
SMV801A
(1) 2.5 kV Power Module
150 pounds (68.3 kg) with terminal

pads
138 pounds (62.6 kg) without terminal
pads
SMV801B
(2) 2.5 kV Power Modules
300 pounds (124.6 kg) with terminal

pads
276 pounds (125.2 kg) without
terminal pads
Environmental Requirements
Table 3-3: Environmental Requirements
Item
Specification
Temperature Range
Operating
Storage
-40F 122F (-40C 50C)

-58F 158F (-50C 70C)
Elevation
Up to 6,600 ft. (2000m). Above

6,600 ft. (2000m), derate 0.5% per
330 ft. (100m)
Humidity
Functional to 95% non-condensing
Operating Orientation
Any
Pollution IEC 60947-1
Shock Resistance
Operational
Non-operational
2.5g in any direction

Vibration Resistance
Operational
Non-operational
1g in any direction
MN03901001E / Pub 50560
3-3

September 2004
Mounting Instructions for Control Module

The IT. Soft Starter is easy to mount.
To aid you with panel layout, refer to the dimension drawings in Figures 3-1 and 3-2 of this
manual. Drill and tap holes per mounting hole location as shown.
To mount the unit, use all the hardware specified in Table 3-1 on Page 3-3. Tighten to the
torque specified.
Mounting Instructions for Power Modules
Caution
The SMV801A and B soft starter power module

weigh approximately 138 Lbs. (63 kg). To prevent
personal injury or equipment damage, use proper
lifting equipment (such as a floor crane) to safely
lift and install the soft starter. A lifting eye is
provided at the line end of the soft starter.
Attention
Le dmarreur SMV801A pse environ 63 kg (138

livres). Pour viter les blessures personnelles et
les dommages matriels, utiliser un matriel de
levage appropri (comme un grue roulante
datelier) pour soulever et installer le dmarreur de
faon scuritaire. Un oeillet de levage est prvu du
ct ligne du dmarreur.
Drill the six clearance holes for the 3/8-16 mounting bolts. Thread the three lower middle
screws (with flat washer and lockwasher) through the panel and into the nuts before lifting
the soft starter. These three screws will assist in mounting.
Hook lifting equipment to the soft starter-lifting eye. If you are using a hydraulic crane,
minimize the chain length between the boom and the soft starter. Make sure that the back of
the soft starter is oriented to the panel-mounting surface. Make sure that the lifting
equipment hook is fully engaged with the soft starter lifting eye before lifting.
Slowly lift the soft starter to about 2 inches (5 cm) above the mounting location. Then move it
back against the mounting panel. Carefully lower the soft starter onto the three mounting
screws. Make sure the screws align with the slots on the load end of the soft starter mounting
panel, and that the three washers are between the soft starter panel and the screw head.
Install and tighten the remaining three mounting screws, washers and lockwashers. Then
tighten the three lower screws. Tighten all six screws to 46 Lb-ft (63 Nm).
Disengage and remove the lifting equipment.
Max. Internal Ambient 50C
Minimum Enclosure
Size or Equivalent
48
(1219)
32
(813)
7
(178)
8
(203)
36
(914)
16
(406)
Figure 3-3: Minimum Enclosure Configuration
3-4
MN03901001E / Pub 50560

September 2004
Chapter 4 Power Wiring

Safety Notices
Danger High Voltage
To avoid shock hazard, disconnect all power to the

controller, motor or other control devices before
any work is performed on this equipment. Failure
to do so will result in personal injury, death or
substantial property damage.
Pour viter les chocs lectriques, couper

lalimentation lectrique du contrleur, du moteur
ou autres dispositifs de commande avant dy
effectuer quelque travail. Linobservation de cette
mesure entranera des blessures corporelles, la
mort ou des dommages matriels.
Do not apply a disconnect device on the output of

the IT. Soft Starter unless a means to turn off the
soft starter when disconnect switch is open is
utilized. Opening disconnect while the IT. Soft
Starter is operating may cause a malfunction.
Closing disconnect switch while the IT. Soft Starter
is operating will result in a soft starter failure and
potential equipment damage and personnel
hazard.
Ne pas appliquer un dispositif de sectionnement

sur le dmarreur IT. Soft moins quun moyen
dteindre le dmarreur Soft ne soit utilis lorsque
linterrupteur de sectionnement est ouvert. Le fait
douvrir linterrupteur de sectionnement pendant
le fonctionnement du dmarreur IT. Soft risque de
provoquer un dysfonctionnement. Le fait
dteindre linterrupteur de sectionnement
pendant le fonctionnement du dmarreur IT. Soft
provoquera la dfaillance du dmarreur Soft, des
dommages de lquipement ainsi quun danger
pour le personnel.
SMV801A and SMV801B Configuration

The SMV801A or B Medium Voltage Soft Starters MUST be configured as described below.
The Controller Module always connects to Power Module, Unit #1.
Power Module, Unit #1 always connects to the motor.
Power Unit #2 is connected in series and connects to the LINE.
Line
Unit 2
Power
Unit
Unit 1
Power
Module
Controller
Module
Load
Motor
Figure 4-1: Soft Starter Configuration
MN03901001E / Pub 50560
4-1

September 2004
Center Grounded Star (WYE)

A
Grounded Delta
(Not Intended for Use on Delta Power Systems)
A
B
C
Figure 4-2: Line Power Configuration

The IT. Medium Voltage Soft Starter is to be wired into the three-phase line feeding the three
main motor input leads as would be done for normal across-the-line starting. It must not be
wired internally between motor windings. Refer to the motor nameplate for correct wiring
information for normal across-the-line operation. Contact Eaton if a special motor wiring
requirement exists before wiring your starter.
The IT. Medium Voltage Soft Starter is to be connected to a center grounded star (WYE) line
power configuration as shown above.
The IT. Medium Voltage Soft Starter is to be connected with an ABC phase rotation on the
incoming power wiring. If the motor turns in the incorrect direction upon energization,
exchange two phases at the motor terminal box or at the output terminals of the soft starter.
Do not change the input wiring. Otherwise, a phase reverse trip will occur.
If the input phase rotation to the soft starter is not ABC, correct this first. Then rewire the
motor phases, if needed, for correct rotation.
If the application requires a reversing contactor, it should be connected on the output side of
the soft starter. The contactor must be closed before starting the soft starter. The soft starter
must be off before switching the direction of the reversing contactor. The reversing contactor
must never be switched while the soft starter is operating.
Note that in some situations it may be desired to place the reversing contactor ahead of the
IT. Soft Starter. In one of the directions, the phase rotation will not be ABC and a Phase
Reverse trip will occur. To prevent the trip, the Phase Reverse trip will need to be disabled.
See Page 7-3.
See the Motor/Application Considerations in Chapter 5 of this manual for information on
typical motor winding configurations.
Line and Load power wiring data is shown in Table 4-1.
4-2
MN03901001E / Pub 50560

September 2004
Table 4-1: Line and Load Power Wiring

Terminal
Kit
Number of
Option
Conductors
Wire
Size Cu
Termination 90 C
Type
Only
Tang
Width
Inches
(mm)
SMV801A37
SMV801B37
EML50
Crimp
SMV801A66
SMV801B66
EML50
Crimp
SMV801A10
SMV801B10
EML50
SMV801A13
SMV801B13
EML50
SMV801A18
SMV801B18
Catalog
Number
Bolt
size
Torque
Req.
1.12
(28.5)
3/8-16
216 Lb-in 2
(33.5 Nm) 4
Horz
1.12
(28.5)
3/8-16
216 Lb-in 2
(33.5 Nm) 4
Horz
Crimp
1.12
(28.5)
3/8-16
216 Lb-in 2
(33.5 Nm) 4
Horz
Crimp
1.12
(28.5)
3/8-16
216 Lb-in 2
(33.5 Nm) 4
Horz
EML50
Crimp
1.12
(28.5)
3/8-16
216 Lb-in 2
(33.5 Nm) 4
Horz
SMV801A24
SMV801B24
EML50
Crimp
2/0
1.12
(28.5)
3/8-16
216 Lb-in 2
(33.5 Nm) 4
Horz
SMV801A30
SMV801B30
EML50
Crimp
4/0
1.12
(28.5)
3/8-16
216 Lb-in 2
(33.5 Nm) 4
Horz
SMV801A36
SMV801B36
EML50
Crimp
350
1.12
(28.5)
3/8-16
216 Lb-in 2
(33.5 Nm) 4
Horz
SMV801A42
SMV801B42
EML50
Crimp
350
1.12
(28.5)
3/8-16
216 Lb-in 2
(33.5 Nm) 4
Horz
SMV801AXX
SMV801BXX
EML51
Crimp
1.98
(48)
3/8-16
216 Lb-in Horz

(33.5 Nm)
Horz
SMV801AXX
SMV801BXX
EML51
Bus
3/8-16
216 Lb-in Horz

(33.5 Nm)
Horz
SMV801AXX
SMV801BXX
EML52
Crimp
3/8-16
216 Lb-in Vert

(33.5 Nm)
Vert
SMV801AXX
SMV801BXX
EML52
Bus
3/8-16
216 Lb-in Vert

(33.5 Nm)
Vert
SMV801AXX
SMV801BXX
EML53
Crimp
1/2-13
37 Lb-ft
Horz
(50.0 Nm)
Horz
SMV801AXX
SMV801BXX
EML53
Bus
1/2-13
37 Lb-ft
Horz
(50.0 Nm)
Horz
MN03901001E / Pub 50560
1.56
(39.6)
1.98
(48)
Number Terminal
of Kits
Orientation
4-3

September 2004
Terminal Pads for SMV801A and SMV801B

The SMV801A and SMV801B power modules are supplied standard without terminal pads. If
terminal pads are needed, they can be ordered through your local Cutler-Hammer distributor.
Each terminal pad kit contains three terminal pads, mounting hardware, and instructions for
use on either line or load side of the IT. Soft Starter. Catalog numbers and wire ranges for
terminal pad kits are listed in Table 4-1 above.
Terminal Pad Installation

Danger High Voltage
Make sure all power is off before wiring.

Sassurer de couper le courant avant de cabler.
1. For SMV801A and SMV801B , remove the line and load lug covers by fully
loosening the six (6) top cover screws.
Note: The cover screws are self-contained and will not fall out of the cover screw holes.
2. Remove the cover by moving it away from the soft starter.
3. The lug cover does not have any fasteners holding it into the housing. Lift the lug cover
out of the housing. Caution, if there is a cooling blower in the lug cover, there will be a
cable harness attached to the blower. Secure the lug cover to the housing via the tab
located on the lug cover. If the blower must be removed, unplug the blower from the
harness. Note, there is a locking tab on the harness, which must be depressed before
you can unplug the blower.
4. Position the terminal pads and install the terminal pad mounting screws according to
instructions provided with the kit. Tighten the terminal pad mounting screws provided
with the kit to 120 Lb-in (13.6 Nm).
5. Wire the appropriate line and load connections to the IT. soft starter (as required by the
NEC and local codes based on the device rating).
6. Torque bolts as directed by Table 4-1 on Page 4-3 of this manual.
7. Slide the lug covers back into the housings. Reconnect the blowers if required.
8. Replace the cover and tighten the screws to 8 Lb-in (10.8 Nm).
4-4
MN03901001E / Pub 50560

September 2004
Figure 4-3: Power Module Shown with Lug Cover Removed

and EML50 Terminal Kit Installed on Load Side
Control Wiring
The Control Power Transformers (CPTs) per the table below are only based on the
requirements for the SMV801A or SMV801B soft starters. Any additional control features
must be added to the CPT rating.
Table 4-2: Control Power Transformer
Soft Starter Catalog
Number
CPT Minimum kV
Rating
SMV801A
200
350
SMV801B
Table 4-3 provides the 12-pin terminal block wiring capacity and torque requirements for the
control wiring.
Table 4-3: 12-Pin Terminal Block Wiring Capacity
Number of
Conductors
Torque
Requirements
22 14 AWG
(0.33 2.5 mm2)
3.5 Lb-in (0.4 Nm)
12 AWG
(4.0 mm2)
3.5 Lb-in (0.4 Nm)
Wire Size
MN03901001E / Pub 50560
4-5

September 2004
4-6
MN03901001E / Pub 50560

September 2004
Chapter 5 Motor/Application Considerations

Using Lightning Arrestors
Most utility power systems experience periodic transient voltages. Line or power factor
correction capacitor switching, nearby lightning strikes, utility supply faults, or a user starting
or shutting down a large load such as a motor can cause these voltages. The IT. starter has
been designed to handle transient voltages of up to 7 kV lasting up to 20 S.
If transient voltages of greater magnitude or longer duration than the standard withstand
capability are expected, a lightning arrestor must be installed. The lightning arrestor contains
metal oxide varistors (MOVs). MOVs are devices that remain in a passive state until a
transient voltage occurs. Under the transient condition, the MOV turns on and holds the peak
line voltage down to a level less than the IT. transient voltage rating. When the transient
clears, the lightning aresstor returns to a passive state.
Eaton offers one arrestor kit:
Table 5-1: Arrestor Kit
Catalog
Number
EMS50
Description
20 kV (max) lightning arrestor for SMV801A or
SMV801B Soft Start
The EMS50 is panel mounted.

In situations where a lightning arrestor must be used, the installer may choose to apply a
different transient absorption device, but it must be equivalent to the EMS50. The lightning
arrestors may also be used on the load side of the soft starter where long cables connect the
motor to the Soft Starter or where the cables are located outdoors.
Squirrel Cage Motor

This is the most common application.
The motor is configured with three motor leads available.
In this case, wire the motor to the Soft Starter with one lead per phase, observing proper
phase rotation. An in-sight disconnect means should be installed, per code requirements.
MN03901001E / Pub 50560
5-1

September 2004
Autotransformer or Reactor Motor

The autotransformer or reactor motor is a traditional way of achieving a reduced voltage
start using regular contactors and inductors. In this method, the motor is constructed with all
six leads brought out to connect the unit in a wye configuration. This allows about 58% of the
current (33% starting torque) to be applied during start-up. A timer is used to control the
circuit and switch inductor as the unit approaches full speed.
In this case, wire the six-lead motor in a standard delta configuration. The Soft Starter is then
used to control the voltage and motor torque without the need for additional circuitry. An insight disconnect means should be installed, per local code. The IT. Soft Starter must be wired
into the three-phase line feeding the three main motor input leads as would be done for
normal across-the-line starting. It must not be wired internally between motor windings in
an inside-the-delta configuration.
Part Winding Motor

The part winding motor is another design created to help achieve a soft start to the load. A
part winding motor is constructed of two separate (but parallel) windings. When using a
traditional starter, the first winding would receive full voltage. This winding supplies as much
as 400% of the motors FLA; about 45% starting torque in a delta configuration for motor
start-up. After a timed delay, full voltage is applied to the second winding. The second
winding acts in parallel with the first to provide for normal running current. Part winding
motors are available in both a wye and delta configuration, dependent upon the
manufacturer. Refer to the motor nameplate for the correct wiring information. In this case,
wire the two windings in parallel. The soft starter is then used to control the current applied
to the motor. An in-sight disconnect means should be installed, per code requirements.
Dual Voltage Motor

A dual voltage motor should be wired into the appropriate configuration for the line voltage it
is being applied to. Refer to the motor nameplate for the correct wiring information. The Soft
Starter must be selected for the appropriate line voltage.
Multi-Speed Motor
Some motors have multiple windings to allow operation at different base speeds. The
multiple speeds are sometimes utilized for soft starting and other times for a process
requirement of the machine to which it is attached. If only one speed is required, the motor
should be wired for that speed. If multiple speeds are required, the appropriate contactors
will need to be connected to the output of the Soft Starter. The contactors must be in the
selected speed position before the Soft Starter is started. The motor must be stopped and the
Soft Starter turned off before the speed selection contactors are changed.
5-2
MN03901001E / Pub 50560

September 2004
Other Winding Configurations

Motors with other winding configurations, designed for specific characteristics, should be
wired in a fashion consistent with their intended use. The motor nameplate contains
information on the available configurations. The motor winding configuration chosen must
be appropriate for the available line voltage. The Soft Starter must also be selected on the
basis of the configuration chosen.
Power Factor Correction Capacitors

Power factor correction capacitors must never be connected on the load side of the IT. Soft
Starter or at the motor terminal box. To do so will result in soft starter failure. If you choose to
use individual motor capacitors, they must be wired on the line input side of the IT. Soft
Starter as far upstream as possible.
Caution
Attention
Never megger a motor while it is connected to the Ne jamais rgler un moteur alors quil est branch
IT. Soft Starter. Disconnect the leads at the IT. Soft au dmarreur IT. Soft. Dbrancher les fils au
Starter before meggering the motor.
dmarreur IT. Soft avant de rgler le moteur.
Control Wiring Inputs
Caution
Only apply 24V DC to the control terminal block

unless specified otherwise in this manual. All
control wiring is 22 12 AWG. Failure to follow this
caution could result in severe damage to the
controller.
Attention
Appliquer seulement une tension de 24 V c.c. aux

bornier sauf avis contraire dans ce manuel. Toute
la filerie de commande est de calibre 22 12 AWG.
Linobservation de cette mesure pourrait
causerdes dommages importants au contrleur.
Figure 5-1: Terminal Block
MN03901001E / Pub 50560
5-3

September 2004
The IT. Soft Starter has the following control inputs:

Table 5-2: Control Inputs
Terminal Block
Designation
Default
Input
Negative
24V DC nominal
(see Page 5-16 for sizing)
P (24V DC only)
Hardwired
STOP
24V DC only (maintained

input)
1 (24V DC only)
START
24V DC only (momentary

input)
2 (24V DC only)
JOG

input)
3 (24V DC only)
Overload
Disable

input)
4 (24V DC only)
Fault RESET

input)
13
Relay close connects to 14
3 Amps, @ 120V AC/24V DC,

10 Amps, Max (Resistive)
Switching
95
Form C Common for 96 and

98
96

Switching
98

Switching
14

13 and 14 Closed when in bypass. Contact is normally open.

95 and 96 Closed System OK, Opened Fault.
95 and 98 Opened System OK, Closed Fault
See Using an Auxiliary Relay section, on Page 5-12.

Pins 95, 96, and 98 are a Form C contact. 95 acts as common. 96 is a normally closed contact,
and 98 is a normally open contact. On any fault that trips the unit or causes it not to start,
96 opens and 98 closes.
The control wiring is connected to the soft starter by a 12-pin removable terminal block
located on the front of the unit. Each terminal is capable of holding one or two 22 14 AWG
(0.33 2.5 mm2) wires, or one 12 AWG (4 mm2) wire. The terminals should be tightened to
3.5 Lb-in (0.4 Nm).
5-4
MN03901001E / Pub 50560

September 2004
Each diagram illustrates a typical wiring scheme for the options described. The terminal
block represents the soft starter. The additional Cutler-Hammer items shown on the diagrams
are not included, but they may be purchased from Eaton.
Protection
Means
Disconnection
Means
SMV801A Soft Starter

L3/5
T3/6
ISO
Incoming
Line
Note:
Center Grounded
WYE Systems ONLY
L2/3
T2/4
L1/1
T1/2
Motor
Isolation
Means
AC
Motor
2,500V AC Max.
OR
SMV801B Soft Starter
2C
1C
CPT
L1
L2
Fuse
(2)
L11
Fuse
L3/5
L12
X1
X2
T3/6
L2/3
2B
1B
T2/4
L1/1
2A
1A
T1/2
5,000V AC Max.
See Manual for

VA Rating
120V AC Supply
N
Power Supply
120V AC 24V DC
+
Red
Black
Int 1 Yellow
Int 2 Yellow
Vn White
ISO
Red
Black
24V DC
Stop
SMV801 Terminal Board

CAUTION:
Applying voltages other than
24V DC to terminals P thru 4
may cause serious damage to
soft-start control board.
+
P
Start
Jog
1
2
Reset
24V Inputs
DC Only
3
4
13
14
Run
Internal
Auxiliary
Contacts
95
96
24V DC
Or
120V AC
98
Pilot Lights
When Used.
DIAG: 284259
Fault

with 120V AC Alarm and Run Indication
MN03901001E / Pub 50560
5-5

September 2004
Protection
Means
Disconnection
Means

L3/5
T3/6
ISO
Incoming
Line
Note:
Center Grounded
WYE Systems ONLY
L2/3
T2/4
L1/1
T1/2
Motor
Isolation
Means
AC
Motor
2,500V AC Max.
OR
2C
1C
CPT
L1
L2
Fuse
(2)
L3/5
L11
Fuse
L12
X1
X2
T3/6
L2/3
2B
1B
T2/4
L1/1
2A
1A
T1/2
5,000V AC Max.
See Manual for

VA Rating
120V AC Supply
N
Power Supply
120V AC 24V DC
+
Red
Black
Int 1 Yellow
Int 2 Yellow
Vn White
ISO
Red
Black
24V DC
Hand
24V
CAUTION:
OFF
Auto
P
PLC
1
2
Reset
24V Inputs
DC Only
3
4
13
14
Run
Internal
Auxiliary
Contacts
95
96
24V DC
Or
120V AC
98
Pilot Lights
When Used.
Fault
DIAG: 284260
Figure 5-3: Elementary Diagram for Soft Starter with HAND/OFF/AUTO/RESET

with PLC shown with 120V AC Pilot Lights
5-6
MN03901001E / Pub 50560

September 2004
Protection
Means
Disconnection
Means

L3/5
T3/6
ISO
Incoming
Line
Note:
Center Grounded
WYE Systems ONLY
L2/3
T2/4
L1/1
T1/2
Motor
Isolation
Means
AC
Motor
2,500V AC Max.
OR
2C
1C
L3/5
120V AC Supply
T3/6
L2/3
2B
1B
T2/4
L1/1
2A
1A
T1/2
5,000V AC Max.
L
N
Power Supply
120V AC 24V DC
+
Red
Black
Int 1 Yellow
Int 2 Yellow
Vn White
ISO
Red
Black
24V DC

CAUTION:
STOP
Start
Jog
P
1
2
Reset
24V Inputs
DC Only
3
4
13
14
Run
Internal
Auxiliary
Contacts
95
96
24V DC
Or
120V AC
98
Pilot Lights
When Used.
Fault
DIAG: 284261

with 24V DC Alarm and Run Indication
MN03901001E / Pub 50560
5-7

September 2004
Protection
Means
Disconnection
Means

L3/5
T3/6
ISO
Incoming
Line
Note:
Center Grounded
WYE Systems ONLY
L2/3
T2/4
L1/1
T1/2
Motor
Isolation
Means
AC
Motor
2,500V AC Max.
OR
2C
1C
CPT
L1
L2
Fuse
(2)
L11
Fuse
L3/5
L12
X1
X2
T3/6
L2/3
2B
1B
T2/4
L1/1
2A
1A
T1/2
5,000V AC Max.
See Manual for

VA Rating
X2
1A
N
Power Supply
120V AC 24V DC
+
Red
Black
Int 1 Yellow
Int 2 Yellow
Vn White
ISO
Red
Black
24V DC

CAUTION:
MX
Jog
Jog
MX
1
2
Reset
24V Inputs
DC Only
3
4
Run
STOP
13
100 .25fd
1/2W 250V AC
Start
MX
14
Run
Internal
Auxiliary
Contacts
95
MX
96
24V DC
Or
120V AC
98
Fault
Jog
Jog
Alarm
DIAG: 284262
with START/STOP/JOG with 120V AC Alarm and Run Indication
5-8
MN03901001E / Pub 50560

September 2004
Protection
Means
Disconnection
Means

L3/5
T3/6
ISO
Incoming
Line
Note:
Center Grounded
WYE Systems ONLY
L2/3
T2/4
L1/1
T1/2
Motor
Isolation
Means
AC
Motor
2,500V AC Max.
OR
2C
1C
CPT
L1
L2
Fuse
(2)
L11
Fuse
L3/5
L12
X1
X2
T3/6
L2/3
2B
1B
T2/4
L1/1
2A
1A
T1/2
5,000V AC Max.
See Manual for

VA Rating
X2
1A
N
Power Supply
120V AC 24V DC
+
Red
Black
Int 1 Yellow
Int 2 Yellow
Vn White
ISO
Red
Black
24V DC

CAUTION:
MX
P
1
2
Reset
24V Inputs
DC Only
3
4
13
Run
14
Run
Internal
Auxiliary
Contacts
95
Hand
MX
Remote
Input
OFF
96
24V DC
Or
120V AC
98
Fault
Auto
Alarm
DIAG: 284263
with 120V AC Alarm and Run Indication
MN03901001E / Pub 50560
5-9

September 2004
Protection
Means
Disconnection
Means

L3/5
T3/6
ISO
Incoming
Line
Note:
Center Grounded
WYE Systems ONLY
L2/3
T2/4
L1/1
T1/2
Motor
Isolation
Means
AC
Motor
2,500V AC Max.
OR
2C
1C
CPT
L1
L2
Fuse
(2)
L3/5
L11
Fuse
L12
X1
X2
T3/6
L2/3
2B
1B
T2/4
L1/1
2A
1A
T1/2
5,000V AC Max.
See Manual for

VA Rating
X2
1A
L
+
N
Power Supply
120V AC 24V DC
+
Red
Black
Int 1 Yellow
Int 2 Yellow
Vn White
ISO
Red
Black
24V DC

CAUTION:
MX
Jog
Jog
1
MX
1
2
Reset
4
3
4
13
Run
14
Start
STOP
2
24V Inputs
DC Only
Run
Internal
Auxiliary
Contacts
95
3
MX
MX
+
(Diode)
Jog
96
96
24V DC
Or
120V AC
98
Fault
Jog
Alarm
+
(Diode)
DIAG: 284264
Figure 5-7: Elementary Diagram Using 95-96 Trip Contacts for Soft Starter with
START/STOP/RESET/JOG with 120V AC Alarm and Run Indication
5-10
MN03901001E / Pub 50560

September 2004
Notes:
1. A minimum of wire of 14 AWG (2.5 mm2) should be used between the power supply and
the 24V DC + and - terminals.
2. See Using an Auxiliary Relay section on Page 5-12 if it is desired to use a relay instead of
an indicating lamp for terminals 13, 14, 95, 96 and 98.
3. If an isolation or reversing contactor is used upstream of the SMV801, Eaton
recommends the standard level sensing control which ends with a B.
MN03901001E / Pub 50560
5-11

September 2004
Using an Auxiliary Relay

The IT. Soft Starter contains one Form A and one Form C set of auxiliary contacts to indicate
its status. A contact between terminals 13 and 14 indicates when the IT. is in bypass. The
contacts between terminals 95 and 96 and 95 and 98 indicate the IT. is in a normal or tripped
state. Often these contacts are used as shown in Figures 5-2, 5-3, and 5-4 with indicating
lamps. In some installations the user may wish to use an electromagnetic relay for indication
of the status at a remote location for use by a programmable controller (PLC), or in a 120V AC
or 24V DC control circuit.
If the IT. Soft Starter is subject to mechanical shock during operation, it is possible that these
contacts may momentarily open, causing nuisance fault tripping of down stream devices.
When used with an indicating lamp, a momentary contact opening would not be observed. In
order to assure proper application, it is suggested that the following recommendations be
followed:
PLC Interface
It is suggested that a 20 mS delay be programmed to assure the contact status before a
change of status is indicated. The application and the environmental issues will determine
the exact requirements.
24V DC Control
When a relay is used in conjunction with an electronic control, it is highly recommended that
a noise suppression/snubber diode be placed antiparallel to the relay coil as shown in Figure
5-8. This diode offers two benefits. The first is the suppression of any electrical noise
generated when the relay coil is de-energized. The second is that the diode delays the
opening of the relay slightly as it dissipates the energy stored in the relay coil. This delay is
often long enough to compensate for the potential effects of a mechanical shock opening the
control contact. A typical suppression diode is a 1N4001.
13
Bypass
R
+
14
95
24V DC
Supply
Ready
96
98
Fault
Figure 5-8: 24V DC Control
5-12
MN03901001E / Pub 50560

September 2004
120V AC Control
When a relay is used in conjunction with an electronic control, it is highly recommended that
a noise suppressor be used across the relay coil. In the case of an AC coil, the noise
suppressor is made up of a series connected resistor and capacitor as shown in Figure 5-9.
Usually the delay in the relay opening is very small, so if the system is subject to shock, a
delay should be added in the external control before the contact change of state is
recognized. The resistor is rated 100 ohms at 0.5 watts. The capacitor is 0.25 F at 250V AC.
13
Bypass
R
+
14
95
120V AC
Supply
Ready
96
98
Fault
Figure 5-9: 120V AC Control
Edge & Level Sensing Control

Edge Sensing (Optional)
Edge sensing Consult Factory.
Edge sensing requires +24V DC power be momentarily applied to pin 1 (with terminal P at
+24V DC) to initiate a start under all conditions. After a stop or fault occurs, the +24V DC must
be removed, then reapplied to pin 1 before another start can occur. This control configuration
should be used when restarting of the motor after a fault or stop must be supervised
manually or as a part of a control scheme. The cycling of +24V DC power to terminal 1 before
starting is required regardless of the position of the auto reset switch on the CIM.
Level Sensing (Standard)
Level sensing is denoted with an S in the last character of the Catalog Number. Example:
SMV801B30N3S.
Level sensing will enable a motor to restart after a fault is cleared without cycling +24V DC
power to terminal 1 as long as:
Terminal P is supplied with +24V DC,
The Auto reset switch on the CIM is set to enabled,
All faults have been reset.
This control configuration should be used where it is desirable to restart a motor after a fault
without additional manual or automatic control. An example of this condition would be on a
remote pumping station where it is desirable to automatically restart a pump after a power
outage without operator intervention.
If the auto-reset feature is used, CAUTION must be exercised to assure that any restart
occurs in a safe manner.
MN03901001E / Pub 50560
5-13

September 2004
Using a Supplemental Line Contactor

In some installations, the customer may dictate the use of an electromagnetic contactor in
series with the soft starter.
If an electromagnetic contactor is used, it is recommended that the contactor be placed on
the load side of the Soft Starter. The contactor must be closed prior to starting the Soft
Starter and remain closed until the Soft Starter has been stopped.
If an electromagnetic contactor is used on the line side of the soft starter, additional control
circuitry must be supplied by the user when using edge level control to ensure the line power
is supplied to the Soft Starter before control power (24V DC) is applied. If this sequence is not
followed, the Soft Starter will fault on either a phase loss or zero voltage-crossing fault. This
control scheme is illustrated in Figure 5-10.
START
STOP
120V AC
X
T
X
(Side Adder #1)
Soft-Starter
24V
PP
24V DC
T
(On Delay -6 Seconds)
X
(Isolation Contactor)
1
AutoReset = ON
L1
480V AC
Mains
L2
L3
Figure 5-10: 24V DC Control with Edge Sensing

If it is desired to place an electromagnetic contactor on the line side of the soft starter, when
using level control, no additional control circuitry is required. A start can be completed when
the line power is supplied to the unit after the control power (24V DC), providing the autoreset feature is enabled and the unit has a green light status with +24V DC on pin 1. The Soft
Starter will not fault on either a phase loss or zero voltage-crossing faults.
If the auto-reset feature is used, CAUTION must be exercised to assure that any restart
occurs in the safe manner.
5-14
MN03901001E / Pub 50560

September 2004
Providing Control Power
Caution
Only apply 24V DC to the terminal block unless

specified otherwise in this manual. All control
wiring is 22 12 AWG (0.33 2.5 mm2). Failure to
follow this caution could result in severe damage
to the controller.
Attention
Appliquer une tension de 24 V c.c. aux bornes sauf

avis contraire dans ce manuel. Toute la filerie de
commande est de calibre 0.33 2.5mm2 (22 12
AWG). Linobservation de cette mesure pourrait
causer des dommages importants au contrleur.
1. Connect DC common (negative) to terminal -, using a minimum wire of 14 AWG

(2.5 mm2).
2. Connect +24V DC positive to terminal +, using a minimum wire of 14 AWG
(2.5 mm2).
3. Terminal P (permissive circuit) Must be energized at +24V DC to enable operation of
all SMV801 soft starters. For all units, if power is removed from the permissive circuit at
any time, the unit will initiate a stop sequence, including a soft-stop if enabled.
Note: With level sensing control, if +24V DC is removed from the permissive circuit at
any time, the unit will initiate a stop and restart when +24V DC is reapplied to
terminal P if:
a) +24V DC is still available on pin 1,
b) the device shows a green status light (not faulted), and
c) auto reset is enabled on Control Interface Module (CIM).
See the Edge and Level Sensing section on Page 5-13 of this manual for more
details. If the auto-reset feature is used, CAUTION must be exercised to assure
that any restart occurs in a safe manner.
4. Terminal 1 (Start mode) If terminal P is at +24V DC, momentary application of +24V
DC to terminal 1 will initiate a start sequence for all SMV801 soft starters.
Note: With level sensing control, if +24V DC is maintained on terminal 1 (Start) and
removed from the permissive circuit at any time, the unit will initiate a stop. The
unit will restart on application of +24V DC to terminal P if:
a) +24V DC is still available on pin 1,
b) the device shows a green status light (not faulted), and
c) auto reset is enabled on Control Interface Module (CIM).
See the Edge and Level Sensing section on Page 5-13 of this manual for more
details. If the auto-reset feature is used, CAUTION must be exercised to assure
that any restart occurs in a safe manner.
5. Terminal 2 (Jog mode) If +24V DC power is applied to this terminal while terminal P is
at +24V DC, the soft starter will operate in the jog mode as long as +24V DC is on
terminal 2 and no faults occur. In jog mode, the soft starter will operate only on the
thyristors and the bypass contactors will not close.
6. Terminal 3 (Overload disable) Application of +24V DC to terminal 3 prior to a start
disables the overload fault trip for the next start only. Once the starter commands the
bypass contacts to close, overload protection is enabled.
MN03901001E / Pub 50560
5-15

September 2004
7. Terminal 4 (Reset) Application of +24V DC power will reset the soft starter after all
fault conditions are cleared. If the auto reset feature is used with level control CAUTION
must be exercised to assure that any restart occurs in a safe manner. See Edge and
Level sensing on Page 5-13.
8. Terminals 13 and 14 (Bypass Contactor Relay Contacts, NO) Relay contacts for use up
to 120V AC or 24V DC provide bypass contactor status. The contact closes upon bypass
and will remain closed until a stop is initiated or a fault occurs. The motor and load may
continue to rotate after a stop is initiated if soft stop is being used or if the load inertia is
high. See Using an Auxiliary Relay section on Page 5-12 for additional contact interface
information. This contact closes with the command to close the bypass but doesnt
verify that the bypass is physically closed.
9. Terminals 95, 96 and 98 (Fault Relay Contacts Form C) Relay contacts for use up to
120V AC or 24V DC provide fault or ready status indication. See Page 5-4 for a
description of their operation.
Note: When 24V DC is first applied to terminals + and -, all of the LEDs on the Control
Interface Module (CIM) will be briefly illuminated. This is a normal start-up test that
verifies communication to the CIM. Pressing the Fault RESET button (located below the
CIM) or remote RESET will also momentarily light all of the LEDs. This verifies the CIM
board is functional, and tests all LEDs for functionality.
24V DC Power Requirements

When selecting a 24V DC power supply for your IT. Soft Starter, it must meet the following
steady state and inrush characteristics.
Steady State Minimum = 25 watts
Inrush minimum = 240 watts for 180 mS.
Voltage on the IT.s + and - terminals must not exceed 30V DC to prevent hardware damage.
The soft starter will shut down at approximately 19V DC.
It is recommended that Cutler-Hammer power supplies be used, as other power supplies
may not be able to meet the inrush current requirements.
The following Cutler-Hammer power supplies are available:
Table 5-3: Power Supplies
Catalog
Number
Steady State
Wattage
Inrush
Wattage
Input
Voltage
PSS300E
300W
500W
110 240V AC
Note: A minimum wire size of 14 AWG (2.5 mm2) should be used between the power supply
and the 24V DC + and - terminals.
5-16
MN03901001E / Pub 50560

September 2004
Chapter 6 Setup/Software
General
The software contained in the IT. Soft Starter is the heart of the product. This software allows
you to control nearly every aspect of the IT. Soft Starters functionality. In this section, various
features are described.
Starting Options
Note that the motor current observable with a standard RMS indicating meter may not be
correct because of its non-sinusoidal nature during starting. It is suggested that the starting
current be estimated from the T1 or T2 setting and the tabulation in Table 8-1 on Page 8-6.
The following starting choices are available in the IT. Soft Starter:
Soft Start with Selectable Kick Start

Ramp Start
Current Limit Start
Pump Start
1. Soft Start with Selectable Kick Start

This mode of operation works in both the Ramp Start and Current Limit Start modes. A kickstart (or boost) allows the motor to draw greater current to develop additional torque to
breakaway a high friction load.
The kick start torque is programmable from 5% 85% of the motors across-the-line locked
rotor torque, corresponding to 23% 92% of the motors across-the-line locked rotor current.
The factory default is 5%. The kick start time is programmable from 0.0 2.0 seconds.
If no kick-start is desired, set the kick start torque (T1) and kick start time (tk) to zero.
Kickstart
Torque
T1
tk
T2
Bypass
tr
Start
Time (Seconds)
Run
Figure 6-1: Selectable Kick-Start
MN03901001E / Pub 50560
6-1

September 2004
2. Ramp Start
This mode of operation is the most commonly used form of soft start.
Torque
The motor is accelerated using an initial torque (T2) value of 5% 85% of across-the-line
locked rotor torque, corresponding to 23% 92% of the motors across-the-line locked rotor
current. The factory default is 35%. The torque is then increased over the range of the
programmed acceleration ramp start time (tr) by increasing the motor voltage. This can be
programmed from 0.5 180 seconds. The factory default is 9 seconds. The first half of the
control adjusts from 0.5 20 seconds, the next quarter from 20 60 seconds, and the last
quarter from 60 180 seconds. The unit will limit current to the specified torque. When the
motor is up to speed, it will go into bypass.
Bypass
100%
Initial
Torque
(T2)
tr
Start
Run
Time (Seconds)
Figure 6-2: Ramp Start

3. Current Limit Start
This mode is typically used when it is necessary to limit the maximum current during
start-up. A current limit start is not recommended for variable torque applications.
Starting torque (T2) can be programmed from 5% 85% of the motors across-the-line locked
rotor torque, corresponding to 23% 92% of the motors across-the-line locked rotor current.
The T2 default is 35%. The ramp time is programmable from 0.5 180 seconds. The factory
default is 9 seconds. The control is not linear to allow finer setting of short ramp times. The
first half of the control adjusts from 0.5 20 seconds, the next quarter from 20 60 seconds,
and the last quarter from 60 180 seconds. The unit will limit current to the specified torque.
When the motor is up to speed, it will go into bypass.
Torque
Initial
Torque
(T2)
100%
Bypass
tr
Start
Run
Time (Seconds)
Figure 6-3: Current Limit Start
6-2
MN03901001E / Pub 50560

September 2004
4. Pump Start
The pump control option is addressed in Chapter 13, Special Function Options.
Soft Stop
The following soft stop choices are available in the IT. Soft Starter:
Soft Stop Standard

Soft Pump Stop
1. Soft Stop Standard

This feature is used for applications that require a controlled extended stop. It is designed for
high frictional loads that tend to stop suddenly when voltage is removed from the motor.
The ramp down time is programmable from 0 60 seconds. The factory default is 0 seconds.
The voltage is gradually reduced over the ramp down time t s, slowing the motor and its load.
100%
Coast to Stop
Percent
Voltage
Soft Stop
ts
Time (Seconds)
Run
Soft Stop
Figure 6-4: Soft Stop

Note: This is not an electronic brake function, and cannot make the load stop faster than its
normal coast-to-stop time. This feature can only extend the stop time. In some
applications the motor will come to a stop in less than the selected t s time, if t s is set
too long.
MN03901001E / Pub 50560
6-3

September 2004
2. Soft Pump Stop

The pump control option is addressed in Chapter 13, Special Function Options.
Caution
Soft Stop is not an emergency stop, and cannot

make the load stop faster than its normal coastto-stop time. If removal of control is desired,
additional control is required to open up the
24V DC to terminal +. Using terminal P to initiate
power removal is not recommended.
6-4
Attention
Larrt Soft nest pas une commande darrt

durgence et ne peut servir acclrer larrt du
chargement par rapport au temps darrt
programm. Si le retrait de la commande est
souhait, un contrle supplmentaire est requis
pour ouvrir le CC 24 V au plot +. Il nest pas
recommand de commencer couper le courant
partir de la borne P.
MN03901001E / Pub 50560

September 2004
Chapter 7 Protective Features

Thermal Overload
The IT. Soft Starter features an electronic motor overload protection feature. This is intended
to protect the motor and power wiring against overheating caused by excessive current for
extended periods of time.
Note: Short circuit protection must be applied on the line side of the soft starter.
Entering the motor full load current rating, using the FLA current adjust dial programs trip
current. It is programmable from 32% 100% of the units rated current.
Table 7-1: Short Circuit Protection Adjustment Settings
Catalog
Number
SMV801A37N3S
Current
Range
Value of Adjustment Settings (Amps)

A
11 37
11
14
16
19
22
24
27
30
34
37
20 66
20
25
30
35
40
45
50
55
61
66
32 105
32
40
48
56
64
72
80
88
97
105
42 135
42
52
63
73
83
94
104
114
125
135
56 180
56
70
83
97
111
124
138
152
166
180
75 240
75
93
112
130
148
167
185
203
222
240
95 304
95
118
141
164
187
210
233
257
280
304
112 360
112
139
167
194
221
249
276
304
332
360
131 420
131
163
195
227
259
291
323
355
388
420
SMV801B37N3S
SMV801A66N3S
SMV801B66N3S
SMV801A10N3S
SMV801B10N3S
SMV801A13N3S
SMV801B13N3S
SMV801A18N3S
SMV801B18N3S
SMV801A24N3S
SMV801B24N3S
SMV801A30N3S
SMV801B30N3S
SMV801A36N3S
SMV801B36N3S
SMV801A42N3S
SMV801B42N3S
Note: The current adjust dial is settable to any point within its range.
MN03901001E / Pub 50560
7-1

September 2004
OVLD 5 10 20 30
TRIP TRIP
CLASS
B
A FLA D
Figure 7-1: Setting Trip Class and

FLA on the CIM
Thermal memory is incorporated to accurately monitor motor operating temperature.
Ambient temperature does not affect soft starter function, within its operating limits.
The overload trip class can be set to class 5, 10, 20 or 30. The setting determines the time to
trip, based on the severity of the overload condition.
The normal overload trip setting may be disabled for the next start by placing the overload
ON/DISABLE switch in the DISABLE position. This raises the overload fault trip point to 125%
of the maximum current rating of the frame size. The overload trip resets to its normal set
value for all subsequent starts. To affect another start, the ON/DISABLE switch would need to
be moved to the ON position and then back into the DISABLE position. This same action is
possible by momentarily connecting terminal 3 to the 24V DC + terminal prior to the start.
This only affects the next start and not any subsequent starts unless terminal 3 is again
momentarily connected to the +24V DC prior to the start.
Jam Detection
This feature is selectable: ON/DISABLE.
A current value of greater than 3X FLA setting will stop the motor on a jam fault. If a jam is
detected, the soft starter shuts down and the Jam light illuminates.
Unit Will Trip
Current
Jam Protection Set

at 300% of IT. Soft
Starter Motor FLA
Setting
Normal Operating Current
Time
Figure 7-2: Jam Detection

Note: Jam detection is active only after the motor has reached full speed and is in bypass
mode. If jam is disabled and the unit is in bypass and a jam occurs, the soft starter will
trip on contactor overcurrent if the motor current exceeds 4X the starter maximum
ampere rating.
7-2
MN03901001E / Pub 50560

September 2004
Stall Detection
If the soft starter detects a stall condition greater than 2X FLA setting at end of ramp, the soft
starter shuts down and the Stall light illuminates.
Current
Stall Protectio Set

for 200% of IT. Soft
Starter Motor FLA
Setting
IT. Soft Starter

Will Trip at
End of Ramp
Actual Motor Current
Normal Operating Current
Time
Figure 7-3: Stall Detection

Note: If stall detection is off and a stall occurs during start, the soft starter will trip on SCR
overcurrent if the motor current exceeds 3X the FLA setting at the end of ramp.
Phase Loss/Current Unbalance Detection & Load Disconnect

The phase loss and unbalance current protection features monitor the line voltage and
current respectively. If a phase voltage is lost or the line current is unbalanced more than 40%
from the average of all 3 phases, the soft starter shuts down and the Phase Loss light is
illuminated. See the CIM flash code table on Page 10-9 for indication of the possible cause.
Load disconnect protection feature monitors the line current. If the phase rotation is not ABC,
the soft starter shuts down and the SS TRIP light is illuminated. See the CIM flash code table
on Page 10-9 for indication of the possible cause.
Phase Reversal Detection

The phase reversal protection feature monitors the phase rotation of the incoming power
line. If the phase rotation is not ABC, the soft starter shuts down and the Phase Reverse light
is illuminated.
MN03901001E / Pub 50560
7-3

September 2004
Protective Features Review

Thermal Motor Overload
The thermal overload is designed to protect the motor from heating caused by drawing too
much current. If the motor is overloaded, the current drawn rises and heats the motor. The
FLA sets the trip threshold and the trip class (5, 10, 20 or 30) is set on the CIM.
If the device trips on a thermal overload, an internal timer is started which inhibits a reset for
three minutes. After this timer expires, the device may be reset and the thermal fault is
cleared. At this point another internal timer is started, this timer is 26 x 3 or 48 minutes. If
another trip occurs before this timer expires, the reset inhibit time is increased to 6 minutes.
Once the trip level reaches 3, it will take 144 minutes to go back to level 2, then 96 minutes to
get back to level 1. To get from level 3 to a reset thermal overload at level 1, it takes 288
minutes without a trip. A reset thermal overload at level 1 means the next thermal overload
trip will have a 3-minute reset inhibit as in Table 7-2.
Table 7-2: Thermal Motor Overload Times
Trip
Reset
Inhibit Time
Reset Time to Previous

Trip Level
3 minutes
48 minutes
6 minutes
96 minutes
>3
9 minutes
144 minutes
Cycling power on the device will typically NOT clear the thermal trip. The thermal pile and
the reset inhibit time are saved to the non-volatile memory. These values are reloaded when
the device boots and the timer is restarted at the full reset time. This means if the 3-minute
inhibit timer has been running two minutes, cycling power will require the user to wait the
full three minutes before a reset can clear the overload fault.
If the device is shut down when the overload fault is tripped, the temperature is also saved to
the non-volatile memory. If the device is left to cool and then powered, the temperature read
from the sensor is compared to the saved temperature. If the current temperature is 87% or
less of the saved temperature, a full thermal pile rest is initiated.
The unit monitors the following condition for overload:
Thermal (current) Overload Monitors RMS current with a 5, 10, 20 or 30 second delay
time based on Trip Class setting
Table 7-3: Thermal Overload Settings
7-4
Factory
Default
Protective Features
Settings
Overload
(FLA Dial Range)
32% 100% of rated

current
32%
Trip Class
5, 10, 20, 30
Fault Reset
AUTO, Manual
Manual
Jam
ON, DISABLE
ON
Stall
ON, DISABLE
ON
Phase Loss & Load

Disconnect
ON, DISABLE
ON
Phase Reversal
ON, DISABLE
ON
Overload
ON, DISABLE
ON
MN03901001E / Pub 50560

September 2004
Chapter 8 Programming Settings

General
To program and operate the IT. Soft Starter, a Control Interface Module (CIM) is required. The
CIM (Catalog number EMA71) is for use with all models. The CIM serves as the interface
between the operator and the Soft Starter control circuitry to program the Soft Starter. The
CIM DIP switches and rotary controls are used to select the Soft Starter settings. When
making adjustments to the CIM under normal operation, the LEDs will function as follows:
A change to any DIP switch will cause all LEDs to flash momentarily.
An adjustment to any POT will cause all LEDs to light and stay lit until the adjustment of the
POT has been completed.
While selecting these parameters, 24V DC power may be applied to the Soft Starter, but it is
not required.
S.S. TRIP
EMA71
OVERLOAD - ON
JAM
ON
STALL
ON
PH. LOSS
ON
PH. REV.
ON
MANUAL RESET
DISABLE
DISABLE
DISABLE
DISABLE
DISABLE
AUTO RESET
RAMP START
T1
CURRENT LIMIT
TORQUE (T2)
tk
BYPASS
tr
ts
T1
BYPASS
tk
tr
TORQUE (%)
45
45
25
65 25
ts
START
65 OVLD
5 10 20 30
TRIP TRIP
5
T 1 85
1
0.5
tk
15
1.5 10
5
0.5
CLASS
T2 85
20
40
60
120
tr
180
A FLA D
30
5
0
45
ts
60
TIME (Sec.)
Made in U.S.A.
Figure 8-1: Soft Start Control Interface Module (CIM)

Note: The IT. Soft Starter does not have to be powered to make adjustments to the control
interface module. Once the unit is energized, it will communicate with the CIM and
load the set parameters into the Soft Starter. Allow the unit two seconds to ensure
communication checks are complete and values are set. To verify CIM is operational,
press the Fault RESET button below the CIM, or apply 24V DC to terminal 4. If the CIM
is powered and communicating, all the LEDs will momentarily flash.
MN03901001E / Pub 50560
8-1

September 2004
Trip Class
To begin programming the soft starter, choose the trip class and FLA settings desired.
The trip class setting is made by moving the DIP switches into the appropriate position to
match the class overload desired.
Find the motor FLA value in Table 7-1 on Page 7-1. Set the FLA dial to the proper position.
See Figure 8-3 for the thermal overload trip curves.
Example: For a trip Class 5, both DIP switches should be set up to the left.
OVLD 5 10 20 30
TRIP TRIP
CLASS
B
A FLA D
Figure 8-2: Setting Trip Class on the CIM
8-2
MN03901001E / Pub 50560

September 2004
Overload Trip Curves

10000.0
115%
Class 5
1000.0
Class 10
Class 20
Time (Seconds)
Class 30
100.0
Class 30
Class 20
Class 10
Class 5
10.0
1.0
0
100
200
300
400
500
Percent FLA
600
700
800
900
Figure 8-3: Overload Trip Curves
MN03901001E / Pub 50560
8-3

September 2004
Protective Features
You may choose to enable or disable each of the following motor protective features found at
the top of the CIM. These include:
Overload
Jam
Stall
Phase Loss/Load Disconnect
Phase Reversal Protection
To enable a feature, move its DIP switch to ON.

To disable a feature, move its DIP switch to DISABLE.
Note: Disabling any of the motor protective features does not disable any of the IT. Soft
Starters protective features as shown in the flash code table on Page 10-9.
Manual/Auto Fault Reset

Select auto or manual reset on the Control Interface Module.
When a fault is present, if auto-reset is on, it will attempt to reset the fault every 2.5 seconds.
If the cause of the fault has been eliminated, the fault will be reset. If the fault has not been
eliminated, the fault status will be maintained. After the fault is reset, the soft starter can be
restarted as normal.
To manually reset the fault after its cause has been cleared if auto reset is off, press the Fault
RESET button below the CIM or apply 24V DC to terminal 4 of the control terminal block.
Note: The motor does NOT automatically restart after a fault is reset UNLESS the soft starter
is equipped for Level Sensing Control. See the Edge and Level Sensing Control section
on Page 5-13 of this manual for details.
Special Function S.F.

On occasion, a special function option is purchased and installed on the IT. Soft Starter. The
special function may be enabled or disabled with this DIP switch.
The pump control option is a special function option. It is addressed in Chapter 13, Special
Functions Option.
8-4
MN03901001E / Pub 50560

September 2004
Options
Level sensing is standard and denoted with an S in the last character of Catalog Number.
Example: SMV801**N3S.
Edge sensing consult factory.
Programming the Start

This procedure covers programming the start characteristics of the soft starter. There are two
configurations to choose from.
Ramp Start sequence
Current Limit Start sequence
Set the bottom DIP switch to make your choice.

A kick-start is available for either ramp or current limit start.
The pump control option includes a variation of the ramp start suitable for centrifugal pump
applications. See Chapter 13, Pump Control Option, for specific information.
MN03901001E / Pub 50560
8-5

September 2004
Programming the Kick Start Sequence

Kick Start
The first set of parameters to be set on the CIM is for Kick Start, Figure 8-4. This feature is
designed to assist the starter in overcoming a high-friction load and break the rotor free, prior
to the normal start.
Two parameters must be set. The kick start torque value (T1) can be set from 5% 85% of the
motors across-the-line starting torque. This setting also equates to a percentage of locked
rotor current of 23% 92%.
Example: For a motor with a across-the-line locked rotor current of 6X FLA, the initial current
would be limited to 5.5 x FLA or (0.92 x 6 x FLA) for a T1 setting of 85% or 92% of locked rotor
current. The across-the-line locked rotor torque versus equivalent starting current values are
found in Table 8-1.
Table 8-1: Rotor Torque vs. Equivalent Starting Current
Torque Setting
Percent Locked Rotor Current
85%
71%
56%
45%
36%
27%
19%
14%
9%
5%
3%
1%
92%
84%
75%
67%
60%
52%
44%
37%
30%
23%
16%
10%
These are typical values for a NEMA design B type motor. The starting torque
versus locked rotor current relationship will vary for other NEMA design types as
determined by the manufacturer.
Next, adjust the time setting (tk) to apply the kick start torque from 0 2 seconds.
Note: If a kick-start is not required for your application, set T1 to 5% and tk to 0.
Kickstart
Torque
T1
tk
T2
Bypass
tr
Start
Time (Seconds)
Run
Figure 8-4: Kick Start
8-6
MN03901001E / Pub 50560

September 2004
Programming the Ramp Start Sequence

Ramp Start
The next element to be determined is the start configuration, either ramp (Figure 8-5) or
current limit (Figure 8-6). To select the ramp start, move the bottom DIP switch toward RAMP
START. In this mode, the motor torque is ramped up from an initial start level by increasing
the motor current until the motor is started or the ramp time has elapsed. The initial starting
torque point is selected by adjusting the T2 dial to the level required by the application. T2s
range is 5% to 85% of the motors across-the-line locked rotor torque. Equivalent values of
across-the-line locked rotor current versus torque are shown in Table 8-1, Page 8-6.
Once the initial torque point is determined, the ramp time must be selected by adjusting the tr
dial from 0.5 to 180 seconds.
At the end of the ramp time, the motor should be at full speed. If the motor is at 90% of rated
speed or more and its current is less than 2X FLA, the bypass contacts will close, connecting
the motor directly across the input line power. If the motor has not reached 90% speed, or its
current is greater than 2X FLA at the end of the ramp time, the soft starter will trip. A stall
fault will be indicated on the CIM. This could indicate that the load characteristics have
changed (load is jammed, full, damaged, etc.). If it occurs during the initial commissioning of
the unit, you will need to increase the initial torque setting, adjust the ramp time, or both.
Torque
Note: The tr control is not linear to allow finer setting of short ramp times. The first half of the
pot adjusts from 0.5 to 20 seconds, the next quarter from 20 to 60 seconds and the last
quarter from 60 to 180 seconds. The maximum value of tr can be modified at the
factory for special orders/applications. Contact Eaton for more information.
Bypass
100%
Initial
Torque
(T2)
tr
Start
Run
Time (Seconds)
Figure 8-5: Ramp Start
MN03901001E / Pub 50560
8-7

September 2004
Programming the Current Limit Start

Current Limit Start
The process for programming with the Current Limit Start (Figure 8-6) is similar to the
process for the Ramp Start.
To select the Current Limit Start option, move the DIP switch to the right. This will activate the
current limit start-up profile.
In the current limit start-up mode, you set a maximum current during the start. This value
(T2) can be set from 5% to 85% of the across-the-line locked rotor torque. (See Table 8-1, Page
8-6 for values). Next, set the start time (tr) for the start. This value can be set from 0.5 to 180
seconds.
Note: The ramp time is set to zero automatically.
At the end of the ramp, the motor should be at full speed. If the motor is at 90% of rated
speed or greater of this value and current is less than 2X FLA, the bypass contacts will then
close, and the unit will run at full speed. If it has not reached 90% of speed at the end of ramp,
the unit will trip off line and you will receive a stall indication on the control interface module.
This could indicate that the load characteristics have changed (load is jammed, full,
damaged, etc.). If it occurs during initial commissioning of the unit, you will need to increase
the current limit setting, increase the length of the ramp, or both to allow enough time and
energy to bring the motor up to speed.
Note: The tr pot is not linear to allow finer setting of short ramp times. The first half of the
control adjusts from 0.5 to 20 seconds, the next quarter from 20 to 60 seconds, and the
last quarter from 60 to 180 seconds. The maximum value of tr can be modified at the
factory for special orders/applications. Contact Eaton for more information.
Initial
Torque
(T2)
Torque
Ramp
Set to 0
100%
Bypass
tr
Start
Run
Time (Seconds)
Figure 8-6: Current Limit Start
8-8
MN03901001E / Pub 50560

September 2004
Programming the Soft Stop

Soft Stop
The last item to be programmed is the soft stop. This feature slowly reduces the voltage
applied to the motor to extend its stop time.
Caution
Soft Stop is not an emergency stop. If a quick stop

is desired, additional control is required to open
up the 24V DC to terminal +. Using terminal P for a
quick stop is not recommended.
Un arrt tension rduite nest pas un arrt

durgence. Pour un arrt rapide, prvoir un bouton
additionnel afin douvrir le circuit de +24 V c.c. la
borne +. Lutilisation de la borne P comme arrt
rapide nest pas recommande.
Caution
Soft Stop does not provide any braking. It cannot

cause the motor and its load to stop faster than
their normal unpowered coast down time.
Attention
Attention
Un arret a tension rduite nassure aucun freinage.

l Il ne peut assurer le freinage du moteur et de sa
charge plug rapidement quen mode dbray.
The soft stop feature has one setting, ramp time t s , programmable from 0 to 60 seconds. If ts
is set to 0 when a stop command is given, the bypass contacts will open and the de-energized
motor will coast to a stop as if connected to an electromagnetic starter. If t s is set longer than
this coast down time, the soft stop output voltage will linearly decrease upon a stop
command, extending the stop time. Note that in some applications the motor will come to a
stop in less than the selected t s time, if t s is set too long.
100%
Coast to Stop
Percent
Voltage
Soft Stop
ts
Time (Seconds)
Run
Soft Stop
Figure 8-7: Soft Stop

The pump control option includes a special soft stop feature intended to prevent water
hammer upon shutdown in centrifugal pump applications. See Chapter 13, Pump Control
Option, for specific information.
MN03901001E / Pub 50560
8-9

September 2004
8-10
MN03901001E / Pub 50560

September 2004
Chapter 9 Procedure for Starting

Line Power
Line power must be applied prior to the application of the 24V DC control power to
prevent a phase loss or zero voltage-crossing protection fault.
Terminal P must have 24V DC applied to ENABLE the soft starter.
The soft starter will start when 24V DC is applied to terminal P and either terminal 1 or
2 goes from 0V DC to 24V DC.
If either terminal 1 or 2 remains connected to 24V DC when terminal P is opened, the

soft starter will stop.
Terminals 1 through 4 are activated by momentarily applying 24V DC.
Remove 24V DC from terminal P to initiate a stop.
If either terminal 1 or 2 remains connected to 24V DC when terminal P is opened, the

soft starter will stop.
On the 37 to 420A soft starters, when the bypass contactors close, a momentary sound
similar to contactor chattering can be heard. The three/six single-phase contactors
closing in a staggered manner over a very short period of time cause this sound. This is
part of normal operation, and should not be misinterpreted as a dirty pick-up.
For two-wire control, jumper terminals P and 1 together.
Terminal P must have 24V DC applied.
Terminal 2 is edge sensitive. This means that there must be a transition for 0 to 24V DC
to jog.
In jog, the unit will follow the normal start ramp as long as terminal 2 is at 24V DC.
To stop, remove the 24V DC from terminal 2.
Jog operates the same as a normal start, except that the bypass contactors will not
close and the soft stop is not functional.
Jog
Note: Jog is only intended for short term jogging of the motor and not for long term
two-wire control. For two-wire control, tie terminals P and 1 together and connect
to 24V DC to start and disconnect from 24V DC to stop.
MN03901001E / Pub 50560
9-1

September 2004
9-2
MN03901001E / Pub 50560

September 2004
Chapter 10 Troubleshooting
General
In this section of the manual, we present a procedure you can follow to diagnose a problem
with your IT. Soft Starter.
While many potential situations are outlined in this section, it is possible you may run into a
problem that is not covered here. If you have worked through the following troubleshooting
procedure and find that you require further assistance, please contact Eaton.
Please have the following information ready when you call:
Order No. (if available):
Catalog Number:
Style Number:
Serial Number:
CIM DIP Switch Settings:
CIM Pot Settings:
Before You Begin to Troubleshoot

Warning
Make sure you read and understand all of the
safety statements in the safety section of this
manual before you begin troubleshooting.
Avertissement
Sassurer de lire et de comprendre tous les
enonces relatifs a la securite de la section securite
de ce manuel avant de proceder au depannage.
Danger High Voltage

Do not work on energized equipment unless
absolutely required. If troubleshooting procedure
requires equipment to be energized, all work must
be performed by properly qualified personnel,
following appropriate safety practices and
precautionary measures.

Ne pas travailler sur de lequipement sous tension
sauf si absolutment necessaire. Si les methodes de
depannage exigent que lequipment soit sous
tension, les travaux doivent etre executes par
personnel qualifie, et les pratiques de securite et
mesures preventives etre observees.
We highly recommend that you read this entire section of the manual before you begin to
troubleshoot the IT. Soft Starter.
You may want to obtain the following equipment to aid you in troubleshooting:
Multimeter
Clamp-on ammeter
MN03901001E / Pub 50560
10-1

September 2004
Define the Problem

There are four basic problem types you may encounter with the IT. soft starter. To begin,
select the situation below that most closely matches your problem.
1. The IT. Soft Starter fails to start. No power is applied to the motor.
Go to Figure 10-1 Troubleshooting Flowchart #1.
2. The IT. Soft Starter trips during start up, or fails to reach rated speed before going into
bypass.
3. The IT. Soft Starter trips or stops running during normal running conditions.
4. None of the above situations match the problem.
START
GREEN Consult +24V DC
Status LED
GREEN Table
Controller
What is the
status of
Power Pole
+24V DC LED
OFF
Controller LED
GREEN
Consult +24V DC
Status LED OFF
Table
OFF
Consult Status
LED OFF
Table
RED
YES
Consult Fault
Shown on CIM
Table
Are there any

Red LEDs on
the SIM?
Consult Status
LED GREEN
Table
GREEN
Consult Blower
Status LED
GREEN Table
NO
Blower LED
Consult Fault Not

Shown on CIM
Table
Consult Blower
Status LED OFF
Table
OFF
Consult Power
Pole Status SCR
Gate LED OFF
Table
SCR Gate
Trigger LED
Consult Power
Pole Status SCR
Gate AMBER
Table
Consult Bypass
AMBER Contactor Status
LED AMBER
Table
AMBER
Bypass
Contactor LED
OFF
OFF
Consult Bypass
Contactor Status
LED OFF
Table
Figure 10-1: Troubleshooting Flowchart #1
10-2
MN03901001E / Pub 50560

September 2004
Start
Yes
Does the unit

run, even
intermittently?
No
Consult
Appropriate Symptom
Table
Excess
noise/vibration
in motor
Noise from
IT.
Soft Starter
Is the
Soft Starter
Status LED lit?
Bypass fails
to close/
chatters
Unit will
not stop
running
Yes
No
Consult
Status LED OFF
Table
Consult
Figure 10-1
Other symptom
not listed
Figure 10-2: Troubleshooting Flowchart #2

Status LED OFF
Table 10-1: Troubleshooting Status LED OFF
Symptom/
Indication
Possible
Problem
Possible Solution
No indication on the
unit or on the CIM
Loss of 24V DC power
Check control wiring.

Verify 24V DC power available from power supply.
Check power supply fuse/circuit breaker.
No status light, but

CIM is powered
Failed CIM
Disconnect the CIM.

If the Status LED lights, replace the CIM.
If not, control board may be defective.
Contact Eaton.
Failed control board
Contact Eaton.
Failed LED indication
Reset the unit, verify operation.

Cycle 24V DC control power to the unit.
Status LED Green

Table 10-2: Troubleshooting Status LED Green
Symptom/
Indication
Possible
Problem
Status LED green, no Line power fault

indication on the CIM
Possible Solution
Check wiring connection on load and line side.
Check line power breakers/fuses.
Verify 24V DC power on P terminal. Then, verify power
is cycled to terminal 1.
MN03901001E / Pub 50560
10-3

September 2004
Status "Power Pole +24V DC LED OFF"

Table 10-3: Troubleshooting Power Pole +24V DC Green LED OFF
Symptom/
Indication
Possible
Problem
Power Pole +24V

DC Green LED OFF
Loss of 24V DC
power
Possible Solution
Check Control Wiring.
Verify 24V DC power available from power
supply.
Verify the +PS and -PS cable harness leads are
connected to the power supply and are connected to
the correct polarity (Red) to + and (Black) to -.
Check power supply fuse/circuit breaker.
Check Unit #1 control harness is connected to
the controller harness and Unit #2 is
connected to Unit #1 control harness. Ensure all
harnesses are latched. If harnesses do not latch
replace harnesses.
Check that P3 is totally plugged into the driver PCB
Assembly and latched.
See Troubleshooting & Repair guide Pub 51028.
Status "Power Pole +24V DC LED ON"

Table 10-4: Troubleshooting Power Pole +24V DC Green LED ON
Symptom/
Indication
Possible
Problem
Power Pole +24V

DC Green LED ON
No other functional
Power Pole LED
comes ON
Possible Solution
replace harnesses.
Check the control module to determine if it is
operational.
10-4
MN03901001E / Pub 50560

September 2004
Status "Power Pole Blower Green LED OFF"

Table 10-5: Troubleshooting Power Pole Blower Green LED OFF
Symptom/
Indication
Possible
Problem
Power Pole
Blower Green LED
OFF, Blower is not
Running
No Blower "ON"
signal from the
controller
Possible Solution
replace harnesses.
operational.
Status "Power Pole Blower Green LED ON"

Table 10-6: Troubleshooting Power Pole Blower Green LED ON
Symptom/
Indication
Possible
Problem
Power Pole
Blower Green LED
ON, Blower is not
running
The blower is not

Check the catalog number to determine if the
plugged into the blower unit comes with a blower.
cable harness
Check that the blower is fully plugged into the blower
harness and latched.
Possible Solution
Check that the blower harness is plugged into the

driver PCB Assembly.
operational.
MN03901001E / Pub 50560
10-5

September 2004
Status "Power Pole Bypass Contactor Amber LED OFF"

Table 10-7: Troubleshooting Power Pole Bypass Contactor Amber LED OFF
Symptom/
Indication
Possible
Problem
Power Pole Bypass

No Bypass
Contactor Amber
Contactor "ON" signal
LED OFF, Bypass
from the controller
contactor is not
energized when
SMV801 is in Bypass
Possible Solution
replace harnesses.
operational.
Power Pole Bypass

Contactor Amber
LED OFF, Bypass
contactor is
energized when
SMV801 is not in
Bypass
The Bypass
Contactor control
circuit on the Driver PCB
assembly is defective
Status "Power Pole Bypass Contactor Amber LED ON"

Table 10-8: Troubleshooting Power Pole Bypass Contactor Amber LED ON
Symptom/
Indication
Possible
Problem
The Bypass Contactor

Power Pole Bypass
does not close
Contactor Amber
LED ON, Bypass
contactor is not
energized when
SMV801 is in Bypass
Possible Solution
Check that the Bypass contactor harness is plugged
into the driver PCB Assembly
Check the Bypass contactor coil for continuity.
Status "Power Pole SCR Gate Trigger Amber LED OFF"

Table 10-9: Troubleshooting Power Pole SCR Gate Trigger Amber LED OFF
Symptom/
Indication
Possible
Problem
Power Pole SCR Gate No SCR Gate Trigger

signal from the
Trigger Amber LED
controller
OFF, SCR Gate
Trigger is not present
when SMV801 is a
constant current,
ramp or jogged start
Possible Solution
the controller harness and Unit #2 is connected to Unit
#1 control harness. Ensure all harnesses are latched. If
harnesses do not latch replace harnesses.
operational.
10-6
MN03901001E / Pub 50560

September 2004
Status "Power Pole CR Gate Trigger Amber LED ON"

Table 10-10: Troubleshooting Power Pole SCR Gate Trigger Amber LED ON
Symptom/
Indication
Possible
Problem
SCR Gate Trigger signal

Power SCR Gate
does not fire SCR
Trigger Amber LED
ON, Motor does not
start during a
constant current,
ramp or jogged start
mode
MN03901001E / Pub 50560
Possible Solution
Check that the Iso-Housing contactor harness
P5 is plugged into the driver PCB Assembly and
latched.
10-7

September 2004
Fault Shown on CIM

Table 10-11: Troubleshooting Fault Shown on CIM
Symptom/
Indication
Possible
Problem
S.S. LED is lit

(Overtemperature tr
setting, hardware
failure or load
disconnect)
High temperature
see flash codes
JAM LED is lit
STALL LED is lit
PH LOSS LED is lit

(Phase loss or
unbalanced line
current)
PH REV LED is lit

OVLD TRIP LED is lit
10-8
Possible Solution
Allow system to cool down with 24V DC applied to + and -.

Verify operation of unit cooling fans.
Clear any blockage or restriction of air flow.
Possible hardware
If code 32 is indicated, check actual motor start time vs. tr
failure see flash
set time. The t r should not be set more than 2 3 seconds
codes
longer than the actual motor start time. Reset tr.
Contact Eaton.
Load disconnect
Check shaft coupler between motor and load.
Fault exists in
Press the RESET button located below the CIM to clear
memory
the fault.
Current has
Clear the cause of the jam.
exceeded Jam
FLA setting too low for application. Check that it matches
program level
motor nameplate current.
Fault exists in
memory
the fault.
Unit failed to reach
Clear the cause of the stall in the application.
rated speed (90%) at Verify ramp time is sufficient for application.
end of ramp
Verify initial torque setting is sufficient for application.
FLA setting too low for application. Check that it matches
motor nameplate current.
One or more line
Verify proper line voltage present and that no other
voltages are missing equipment was affected.
or low
Confirm line power connections are correct and tight.
Check line power fuses, circuit breakers and disconnects.
the fault.
Phase voltages or
Check same solutions as for phase loss.
currents unbalanced Confirm motor current balanced when connected across
the line with balanced line voltage. If not, replace motor.
If line voltage balance but load voltage not, contact
Eaton.
Check load connections at soft starter and at motor
terminal box.
Line voltage is not in Verify proper wiring arrangement.
ABC configuration
Motor is overloaded Check motor for load problems.
FLA not set to motor Verify that the FLA setting matches the motor nameplate
ratings
current. (Consider any Service Factor being used.)
Trip class set
Adjust trip class setting on CIM.
improperly
Fault exists in
memory
the fault. If the fault remains, maintain 24V DC power
applied to the unit, and allow the system to cool down for
at least 9 minutes and try again.
Failed current sensor Contact Eaton.
MN03901001E / Pub 50560

September 2004
Soft Starter Fault Flash Codes Sent to CIM

To obtain the fault flash codes from the CIM, hold the RESET button (located below the CIM)
down or apply 24V DC to terminal 4 and count the number of times all the LEDs on the CIM
flash.
For example, if you see three flashes, and then two more flashes after a short pause, the flash
code is 32.
The CIM can provide multiple flash codes, if more than one error condition caused a stop.
Once you see the same flash code repeated, you have seen all the flash codes for the error
conditions that caused the stop.
For example, if you see three flashes, a pause, then two flashes, a pause, then four flashes, a
pause, then one flash, the flash codes are 32 and 41. If you then see three flashes, a pause,
then two flashes, you are seeing the first code again. This means you have seen all the flash
codes for this stop. You may now release the RESET button or remove 24V DC from terminal
4. (Note that if an overload trip has occurred, 24V DC power must be applied to allow the
overload thermal memory to reset. Depending on the overload history prior to the latest trip,
this may be as long as 9 minutes.)
A list of flash codes and the faults they represent is shown in Table 10-12.
Table 10-12: Flash Codes/Faults
Code
Fault
Possible Cause
11
12
13
14
15
16
Thermal overload
Motor stall
Motor jam
Phase sequence ACB
Pole over-temperature
SCR failed to fire
21
22
23
24
25
26
31
15V power supply low

Phase loss
Bypass dropout
SCR/Contactor overcurrent
Phase unbalance
Non-volatile memory error
Zero voltage cross failure
32
33
Shorted SCR, phase loss, load

disconnect
Load Disconnect
See Table 10-11

See Table 10-11
See Table 10-11
See Table 10-11
See Table 10-11
Extreme settings on lightly loaded motor, loose
connection or defective unit
Weak control power or defective unit
See Table 10-11
Weak control power or defective unit
Only if stall or jam disabled, load amps excessive
See Table 10-11
Internal control board fault
Control power applied out of sequence or power factor
correction capacitors on motor
See Table 10-11
34
SCR instantaneous overcurrent
41
42
43
44
45
24V power supply low

Timer system fault
Watchdog reset occurred
PLL (DSP)
Illegal address (DSP)
MN03901001E / Pub 50560
Load Current falls below 1/16 of FLA setting. Can be

disabled by setting phase loss to disable.
Current exceeded start ratings during the starting or
stopping mode
Improper 24V DC supply or weak control power
External electrical noise or internal control board fault
10-9

September 2004
Fault Not Shown on CIM

Table 10-13: Troubleshooting Fault Not Shown on CIM
Symptom/
Indication
Possible
Problem
Status LED is lit, no

indication on CIM
No communication
with CIM
Sensor failure
Bypass opened
during run
Possible Solution
Verify connection between Soft Starter and CIM. Press
the RESET button (located below the CIM). All LEDs
should momentarily light.
Cycle 24V DC control power to the unit. Allow unit to
reset.
Press the RESET button (located below the CIM) to reset
the fault.
Verify that the 24V DC power supply rating is large
enough to close the bypass contacts with a minimum
output rating of 250 watts for 0.15 seconds.
Excess Noise/Vibration in Motor

Table 10-14: Troubleshooting Excess Noise/Vibration in Motor
Symptom/
Indication
Possible
Problem
Motor vibration
during start-up
Load fluctuations
Misapplication
Check load conditions.

Verify that motor is a standard squirrel cage induction
motor.
Ramp time set too low for application.
Torque set too low for application.
Load voltage or
current unbalanced
but line voltage is
balanced
Hardware failure
Load fluctuations
Check line and load connections to soft starter and

connections at motor terminal box.
Motor vibration
during normal run
Possible Solution
Contact Eaton.
Check load conditions.
Check motor connections.
Audible Noise from Soft Starter, Bypass Fails to Close/Chatters

Table 10-15: Troubleshooting Audible Noise
Symptom/
Indication
Possible
Problem
Audible Noise from

Soft Starter
Bypass contact
chatter
Loose connections
Loose mountings
10-10
Possible Solution
Check 24V DC control power to Soft Starter.
Verify 24V DC power supply meets power inrush
requirements (250 watts for 0.15 seconds.)
Remove power from unit, check all connections.
Remove power from unit, check all mounting hardware.
MN03901001E / Pub 50560

September 2004
Unit Will Not Stop

Table 10-16: Troubleshooting Unit Will Not Stop
Symptom/
Indication
Possible
Problem
Motor will not shut

off
Control wiring is
incorrect
Bypass fails to open
Shorted SC
Ts Setting
Possible Solution
Verify 24V DC is removed from P terminal.
Verify no strands from +24V DC are in contact with P
terminal.
Open disconnect. Remove all power from unit and check
continuity of poles.
Open disconnect. Remove all power from unit and check
continuity of poles.
Stop Time (Ts) pot set to a value greater then 0 sec. when
not desired.
Other Symptoms Not Listed

Table 10-17: Troubleshooting Other Symptoms Not Listed
Symptom/
Indication
Possible
Problem
Motor short circuited Winding fault
Motor stops too

quickly under soft
stop
ts (soft stop) is set

too low
Misapplication
Motor stops too

slowly under soft
stop
ts (soft stop) is set

too long
Misapplication
Motor starts too

slowly
Incorrect setting
Motor starts too

quickly
Incorrect setting
MN03901001E / Pub 50560
Possible Solution
Identify and correct motor fault.
Verify all power connections are secure.
Verify no shorts exist in cabling or the motor terminal
box.
Adjust ts time longer.
If friction load is too great, motor may stall during soft
stop; reduce load if possible.
Adjust ts time as required.
Soft stop is designed to increase stopping time for loads
that would otherwise stop suddenly upon removal of
power. It cannot cause the motor to stop faster than its
normal coast-down time.
Increase initial torque (T2).
Decrease ramp time (tr).
Increase current limit setting (T2).
Increase kick start torque (T1).
Increase kick start time (tk).
Increase ramp time (tr).
Decrease initial torque (T2).
Decrease current limit setting (T2).
Decrease kick start torque (T1).
Decrease kick start time (tk).
10-11

September 2004
10-12
MN03901001E / Pub 50560

September 2004
Chapter 11 Removing Controller Interface Module (CIM)

1. To remove, release the catch lever, located in the cover just above center of the CIM.
Move it upward.
2. Disconnect the communication cable from the bottom of the CIM assembly by pressing
the lever to unlatch the communication plug.
3. Reinstall CIM in the reverse sequence.
Note: The bottom of the CIM must be inserted into the cover first, prior to snapping the CIM
into the top latch.
MN03901001E / Pub 50560
11-1

September 2004
11-2
MN03901001E / Pub 50560

September 2004
Chapter 12 Ratings
Horsepower and kW Ratings
Standard Duty Ratings
Table 12-1: 15 Second Ramp, 4 Starts per Hour, 300% Current Limit @ 40C
Three-Phase Motor
kW Rating (50 60 Hertz)
hp Rating (50 60 Hertz)
2300 3000 3300 3600 4160 4800 2300V 3000V 3300V 3600V 4160V 4800V
Max
Catalog
Frame Current Volt Volt Volt Volt Volt Volt 1.15SF 1.15SF 1.15SF 1.15SF 1.15SF 1.15SF Number
A
37
125
37
125
66
223
66
223
105
355
105
355
135
457
135
457
180
609
180
609
240
812
240
812 1059 1165 1420 1641 1893
304
1028
304
A
B
163
291
463
596
200
320
510
655
219
391
451
621
718
799
261
521
828
923 1065
125
125
250
250
400
400
500
500
200
350
500
700
200
400
600
800
200
400
600
800
250
450
700
900
300
500
800
SMV801A37N3S
SMV801B37N3S
SMV801A66N3S
SMV801B66N3S
SMV801A10N3S
SMV801B10N3S
SMV801A13N3S
1000
SMV801B13N3S
SMV801A18N3S
700
1000
1000
1100
1200
1400
SMV801B18N3S
900
SMV801A24N3S
900
1300
1400
1500
1600
1800
SMV801B24N3S
SMV801A30N3S
1028 1341 1475 1799 2078 2398 1200
1600
1800
2000
2000
2300
SMV801B30N3S
360
1218
SMV801A36N3S
360
1218 1588 1747 2130 2461 2840 1300
2000
2100
2300
2400
2800
SMV801B36N3S
420
1421
SMV801A42N3S
420
1421 1853 2038 2485 2872 3313 1600
2300
2500
2700
2800
3300
SMV801B42N3S
MN03901001E / Pub 50560
253
700
794
873 1065 1231 1420
1200
1300
1600
12-1

September 2004
Three-Phase Motor
2300 3000 3300 3600 4160 4800 2300V 3000V 3300V 3600V 4160V 4800V
Max
Catalog
A
34
115
34
115
63
213
63
213
96
325
96
325
120
406
120
406
150
507
150
507
215
727
215
727
278
940
278
940 1226 1349 1472 1701 1962 1000
320
1082
320
1082 1412 1553 1694 1958 2259 1200
380
1285
380
1285 1676 1844 2012 2325 2682 1400
12-2
150
278
424
534
662
165
306
466
582
728
180
334
385
508
587
635
734
794
208
240
445
678
847
918 1059
948 1043 1138 1315 1518
125
125
200
200
350
350
450
450
500
500
150
300
450
600
700
150
300
500
600
800
200
350
500
700
800
200
400
600
800
250
500
700
900
SMV801A37N3S
SMV801B37N3S
SMV801A66N3S
SMV801B66N3S
SMV801A10N3S
SMV801B10N3S
SMV801A13N3S
SMV801B13N3S
SMV801A18N3S
1000
1100
SMV801B18N3S
800
SMV801A24N3S
800
1000
1100
1250
1400
1600
SMV801B24N3S
1000
1200
1400
SMV801A30N3S
1300
1500
1600
1900
2100
SMV801B30N3S
SMV801A36N3S
1700
1700
1800
2200
2500
SMV801B36N3S
SMV801A42N3S
2000
2000
2200
2600
2900
SMV801B42N3S
MN03901001E / Pub 50560

September 2004
Three-Phase Motor
2300 3000 3300 3600 4160 4800 2300V 3000V 3300V 3600V 4160V 4800V
Max
Catalog
A
34
115
34
115
63
213
63
213
96
325
96
325
120
406
120
406
150
507
150
507
215
727
215
727
278
940
278
940 1226 1349 1472 1472 1962 1000
320
1082
320
A
B
150
278
424
529
662
165
306
466
582
728
180
334
334
508
508
635
635
794
180
240
445
678
847
794 1059
125
125
200
200
350
350
450
450
500
500
150
300
450
600
700
150
300
500
600
800
200
350
500
700
800
200
350
500
700
800
250
500
700
900
SMV801A37N3S
SMV801B37N3S
SMV801A66N3S
SMV801B66N3S
SMV801A10N3S
SMV801B10N3S
SMV801A13N3S
SMV801B13N3S
SMV801A18N3S
1100
SMV801B18N3S
800
SMV801A24N3S
800
1000
1100
1250
1250
1600
SMV801B24N3S
SMV801A30N3S
1300
1500
1600
1600
2100
SMV801B30N3S
SMV801A36N3S
1082 1412 1553 1694 1694 2259 1200
1500
1700
1800
1800
2500
SMV801B36N3S
380
1285
SMV801A42N3S
380
1285 1676 1844 2012 2012 2682 1400
1800
2000
2200
2200
2900
SMV801B42N3S
MN03901001E / Pub 50560
948 1043 1138 1138 1518
1000
1200
1400
12-3

September 2004
Three-Phase Motor
2300 3000 3300 3600 4160 4800 2300V 3000V 3300V 3600V 4160V 4800V
Max
Catalog
A
21
21
42
142
42
142
60
203
60
203
80
271
80
271
185
265
353
204
291
388
111
128
222
257
318
367
424
296
424
565
150
250
250
300
300
115
389
389
150
507
150
507
192
649
192
649
280
947
280
947 1235 1359 1482 1713 1976 1000
340
1150
340
1150 1500 1650 1800 2080 2400 1300
12-4
662
847
728
609
794
703
150
115
148
558
489
507
812
918 1059
935 1016 1175 1355
400
400
500
500
700
700
1000
1300
200
300
400
500
700
200
300
400
600
800
125
250
350
450
600
800
125
250
400
500
800
150
300
450
600
900
SMV801A37N3S
SMV801B37N3S
SMV801A66N3S
SMV801B66N3S
SMV801A10N3S
SMV801B10N3S
SMV801A13N3S
SMV801B13N3S
SMV801A18N3S
SMV801B18N3S
SMV801A24N3S
1000
1100
SMV801B24N3S
SMV801A30N3S
1000
1100
1300
1500
SMV801B30N3S
SMV801A36N3S
1300
1500
1600
1900
2200
SMV801B36N3S
SMV801A42N3S
1600
1800
2000
2300
2600
SMV801B42N3S
900
MN03901001E / Pub 50560

September 2004
Three-Phase Motor
2300 3000 3300 3600 4160 4800 2300V 3000V 3300V 3600V 4160V 4800V
Max
Catalog
A
29
29
49
166
49
166
73
247
73
247
94
318
94
318
155
524
155
524
219
741
219
741
280
947
280
947 1235 1359 1482 1713 1976 1000
345
1167
345
A
B
128
216
322
415
684
141
238
359
456
752
154
259
300
386
447
498
575
821
177
346
515
663
948 1094
205
150
150
247
247
350
350
500
500
150
250
350
450
700
150
250
400
500
800
150
250
400
500
900
200
300
500
600
200
350
500
700
SMV801A37N3S
SMV801B37N3S
SMV801A66N3S
SMV801B66N3S
SMV801A10N3S
SMV801B10N3S
SMV801A13N3S
SMV801B13N3S
SMV801A18N3S
1000
1200
SMV801B18N3S
800
SMV801A24N3S
800
1000
1100
1250
1500
1700
SMV801B24N3S
SMV801A30N3S
1300
1500
1600
1900
2200
SMV801B30N3S
SMV801A36N3S
1167 1522 1674 1826 2110 2435 1300
1700
1800
2000
2300
2700
SMV801B36N3S
405
1370
SMV801A42N3S
405
1370 1795 1965 2144 2477 2859 1500
2000
2100
2300
2800
3100
SMV801B42N3S
MN03901001E / Pub 50560
966 1063 1159 1340 1546
1000
1300
1500
12-5

September 2004
Three-Phase Motor
2300 3000 3300 3600 4160 4800 2300V 3000V 3300V 3600V 4160V 4800V
Max
Catalog
A
21
21
40
135
40
135
55
186
55
186
75
254
75
254
176
243
331
194
267
364
111
128
212
245
291
366
397
125
282
388
529
150
200
200
250
250
151
511
511
215
727
215
727
264
893
264
893 1165 1281 1389 1615 1863 1000
300
1015
300
1015 1323 1456 1588 1835 2118 1100
340
1150
340
1150 1500 1650 1800 2080 2400 1300
12-6
799
150
151
148
733
459
666
924 1066
948 1043 1138 1315 1518
500
500
200
250
350
700
200
300
400
800
250
300
450
800
125
250
350
500
150
300
400
600
SMV801A37N3S
SMV801B37N3S
SMV801A66N3S
SMV801B66N3S
SMV801A10N3S
SMV801B10N3S
SMV801A13N3S
SMV801B13N3S
SMV801A18N3S
1000
1100
SMV801B18N3S
800
SMV801A24N3S
800
1000
1100
1250
1400
1600
SMV801B24N3S
1000
1100
1300
SMV801A30N3S
1300
1400
1500
1800
2000
SMV801B30N3S
SMV801A36N3S
1400
1600
1700
2000
2300
SMV801B36N3S
SMV801A42N3S
1600
1800
2000
2300
2600
SMV801B42N3S
MN03901001E / Pub 50560

September 2004
Severe Duty Ratings

Table 12-7: > 30 Second Ramp, > 4 Starts per Hour or >300% Current Limit
Three-Phase Motor
2300 3000 3300 3600 4160 4800 2300V 3000V 3300V 3600V 4160V 4800V
Max
Catalog
A
22
22
42
142
42
142
65
220
65
220
80
271
80
271
115
389
115
389
150
507
150
507
192
649
192
649
240
812
240
812 1059 1165 1271 1468 1694
305
1032
305
1032 1346 1480 1615 1866 2153 1100
185
278
353
507
662
847
107
204
315
388
558
728
116
222
257
344
398
424
489
609
703
794
135
155
296
495
565
812
918 1059
932 1016 1175 1355
150
150
250
250
300
300
400
400
500
500
700
700
200
125
400
500
700
200
66
400
600
800
350
450
600
800
150
250
400
500
800
150
300
500
600
900
SMV801A37N3S
SMV801B37N3S
SMV801A66N3S
SMV801B66N3S
SMV801A10N3S
SMV801B10N3S
SMV801A13N3S
SMV801B13N3S
SMV801A18N3S
SMV801B18N3S
SMV801A24N3S
1000
1100
SMV801B24N3S
SMV801A30N3S
1000
1100
1300
1500
SMV801B30N3S
900
SMV801A36N3S
900
1200
1300
1400
1600
1800
SMV801B36N3S
SMV801A42N3S
1500
1600
1800
2100
2400
SMV801B42N3S
1100
900
125
200
300
Severe Duty Ratings are defined as any combination of parameters that exceed the Standard
Duty Ratings where the ramp time is over 30 seconds, the number of starts per hour exceeds
4, or the current limit set is over 300%. Example: 35-Second Ramp, 5 Starts per Hour, 350%
Current Limit @ 40C Ambient.
MN03901001E / Pub 50560
12-7

September 2004
Blowers
Blowers are used to cool the IT. Soft Starter. The blowers are turned on when the
temperature of any of the thermal sensors exceeds a preset value. If the temperature is
below this value, the blowers will be off.
The blowers will also be turned on whenever the IT. is started, stopped or jogged. The
blowers will remain on for 15 minutes to assure the SCRs are adequately cooled prior to the
next start or jog.
If a temperature is sensed above a second preset level, a Pole Over-Temperature Fault will
occur. This fault cannot be reset until the temperature returns to a safe level.
Note that the blowers will only operate if 24V DC is applied to the + and - terminals.
The following table lists the maximum power loss for each IT. Soft Starter when it is
operating in the across-the-line mode with its bypass contactor pulled in. These losses
should be used in conjunction with the losses of another cabinet mounted devices to
determine the enclosure size and any cooling requirements.
Table 12-8: Maximum Power Loss
Frame
Size
Catalog
Number
Max.
Current
Across-the-Line
Losses (Watts)
SMV801A37N3S
37
0.5
SMV801B37N3S
37
SMV801A66N3S
66
SMV801B66N3S
66
SMV801A10N3S
105
SMV801B10N3S
105
SMV801A13N3S
135
SMV801B13N3S
135
13
SMV801A18N3S
180
12
SMV801B18N3S
180
24
SMV801A24N3S
240
21
SMV801B24N3S
240
42
SMV801A30N3S
304
34
SMV801B30N3S
304
67
SMV801A36N3S
360
47
SMV801B36N3S
360
94
SMV801A42N3S
420
64
SMV801B42N3S
420
128
Short Circuit Ratings

All Frame Sizes: Suitable for use on a circuit capable of delivering not more than 55,000 rms
symmetrical amperes, 5,000 Volts maximum, when protected by Type 24R 450A 5 kV
Fuses.
12-8
MN03901001E / Pub 50560

September 2004
Chapter 13 Special Function Options

Pump Control Option
This option is intended to reduce the potential for water hammer in a centrifugal pump
system by utilizing a starting and stopping algorithm developed for pump control. Upon a
start command, the speed of the motor is increased, under the control of the IT. Soft Starter
microprocessor, to achieve a gentle start. After the speed has reached its nominal value, the
bypass contactors close and the pump operates as with any other starter. Upon a stop
command, the bypass contactors are opened and the motor speed is decreased in a tapered
manner, to gradually slow the flow until the motor is brought to a stop. The start and stop
ramp times are user adjustable and are to be set for the application requirements.
The pump control option is a factory installed feature. Factory installed options are
designated by the eighth character in the catalog number. Unmodified IT. Soft Starters have
an N as their eighth character. IT. Soft Starters with the pump control option have a P as their
eighth character, as in SMV801XXXP3S.
Installation
Install and wire your IT. Soft Starter per the instructions found in the beginning of this
manual.
Setup
The pump control option is enabled by the S.F. ENABLE/DISABLE DIP switch located on the
control interface module (CIM). To enable this feature, position this switch in the ENABLE
position. When the pump control is enabled, the RAMP START/CURRENT LIMIT DIP switch is
disabled. The default becomes RAMP START. See Figure 8-1 on Page 8-1.
S.S. TRIP
EMA72
OVERLOAD - ON
JAM
ON
STALL
ON
PH. LOSS
ON
PH. REV.
ON
MANUAL RESET
S.F. - ENABLE
RAMP START
T1
DISABLE
DISABLE
DISABLE
DISABLE
DISABLE
AUTO RESET
DISABLE
CURRENT LIMIT
TORQUE (T2)
tk
BYPASS
tr
ts
T1
BYPASS
tk
tr
TORQUE (%)
45
45
25
65 25
ts
START
65 OVLD
5 10 20 30
TRIP TRIP
5
T 1 85
1
0.5
tk
15
1.5 10
5
0.5
CLASS
T2 85
20
40
60
120
tr
180
A FLA D
30
5
0
45
ts
60
TIME (Sec.)
Made in U.S.A.
Figure 13-1: IT. Soft Starter CIM
MN03901001E / Pub 50560
13-1

September 2004
Adjustment
All of the adjustments to the IT. Soft Starter are made as noted in this user manual. The major
difference between the standard IT. Soft Starter and one with the pump start option is the
special algorithm for gentle start and stop with centrifugal flow loads to minimize the
potential for water hammer.
The t r, located on the CIM adjusts the start ramp. It has a range of 0.5 to 180 seconds. The
factory default is 9 seconds. The soft stop time is adjusted by t s, which has a range of 0.0
120 seconds (multiply the scale value for t s by 2 to determine the actual time setting), with
the factory default being 0.0 seconds. These adjustments are application dependent, and
should be made to minimize any surge or water hammer effects. Typically t s would not be set
short, since the stop might not differ much from a coast-to-stop. The soft stop time
adjustment may often be in the range of 30 to 40 seconds, but needs to be set appropriately
for the system requirements. If reduction or elimination of water hammer is not achieved, it
may be necessary to lengthen t s to achieve the desired result. Note that long stop times will
result in greater motor heating than shorter stop times. This can affect the number of start/
stop cycles allowed per hour due to the IT. Soft Starter or motor thermal limits.
Coast to Stop
Speed
100%
ts
tr
Start
Soft Pump Stop
Run
Time (Seconds)
Figure 13-2: Pump Start Ramp and Soft Pump Stop

The t r adjustment is tapered to provide for easier setting of both long and short times. The
first half of the control adjusts from 0.5 20 seconds, the next quarter from 20 60 seconds,
and the last quarter from 60 180 seconds. The t s adjustment is linear with a time scale twice
that shown in the CIM.
13-2
MN03901001E / Pub 50560

September 2004
Chapter 14 Accessories and Repair Parts

Accessory Kits
Table 14-1: SMV801 Accessory Kits
Catalog
No.
Common Name
Notes
Terminal Pad Kit 3/8-stud max ring tang 1.12 Inch (28.5 mm) EML50
Includes Line, Load and

Terminal Hardware.
Terminal Pad Kit 3/8-stud; 2.0 Inch (50.8 mm) Wide bus
(Hors)
EML51

Terminal Hardware.
(Vert)
EML52

Terminal Hardware.
(Hors)
EML53

Terminal Hardware.
Cooling Kit
EMA78
Lug Covers w/Blowers &

Cable Harnesses.
Surge Suppressor Kit
EMS50
Contains 3 Arrestors with

Mounting bracket and
hardware.
Lifting Kit
EMA84
Used to lift device out of

packaging box.
Comm. Kit
EMA86
Converts a MV801 to
MV811.
MN03901001E / Pub 50560
14-1

September 2004
Renewal Parts
Table 14-2: SMV801 Repair Parts
Common Name
Catalog
No.
Driver PCB (290MV POWER SUPPLY DRIVER PCB)
EMA88
SMV801...N3S, N3C Controller PCB Assembly Kit, 37A FLA
EMA90A
SMV801...N3S, N3C Controller PCB Assembly Kit, 66A FLA
EMA90B
Notes
SMV801...N3S, N3C Controller PCB Assembly Kit, 105A FLA EMA90C

SMV801...N3S, N3C Controller PCB Assembly Kit, 135A FLA EMA90D
SMV801...N3S, N3C Controller PCB Assembly Kit, 180A FLA EMA90E
SMV801...N3S, N3C Controller PCB Assembly Kit, 240A FLA EMA90F
SMV801...N3S, N3C Controller PCB Assembly Kit, 304A FLA EMA90G
SMV801...N3S, N3C Controller PCB Assembly Kit, 360A FLA EMA90H
SMV801...N3S, N3C Controller PCB Assembly Kit, 420A FLA EMA90J
SMV801...N3L Controller PCB Assembly Kit, 37A FLA
EMA91A
EMA91B
EMA91C
EMA91D
EMA91E
EMA91F
EMA91G
EMA91H
EMA91J
SMV801...P3S, P3C Controller PCB Assembly Kit, 37A FLA
EMA92A
SMV801...P3S, P3C Controller PCB Assembly Kit, 66A FLA
EMA92B
SMV801...P3S, P3C Controller PCB Assembly Kit, 105A FLA EMA92C

SMV801...P3S, P3C Controller PCB Assembly Kit, 135A FLA EMA92D
SMV801...P3S, P3C Controller PCB Assembly Kit, 180A FLA EMA92E
SMV801...P3S, P3C Controller PCB Assembly Kit, 240A FLA EMA92F
SMV801...P3S, P3C Controller PCB Assembly Kit, 304A FLA EMA92G
SMV801...P3S, P3C Controller PCB Assembly Kit, 360A FLA EMA92H
SMV801...P3S, P3C Controller PCB Assembly Kit, 420A FLA EMA92J
14-2
MN03901001E / Pub 50560

September 2004
Table 14-2: SMV801 Repair Parts (Continued)

Common Name
Catalog
No.
SMV801...P3L Controller PCB Assembly Kit, 37A FLA
EMA93A
EMA93B
EMA93C
EMA93D
EMA93E
EMA93F
EMA93G
EMA93H
EMA93J
Power pole assembly 4160V Matched pair
EMA94A
Power pole assembly 2300V
EMA94B
CIM (EMA72 CTL USER INTF W/ SS SPEC)
EMA72
CIM cable (INTERFCE WIRE HARNESS 65 & 110 mm)
EMA106
Strain Relief (power pole)
EMA104
Power pole top cover (MV COVER ASSY)
EMA100
Control module plastics kit
EMA102
Terminal block (Female 12 pin connector)
EMA72
Blower
EMA82
Harness Kits OEM Controller SMV801A
EMA96A
Harness Kits OEM Power Module SMV801A
EMA96B
Harness Kits OEM Controller SMV801B
EMA96C
Harness Kits OEM Unit #1 Power Module SMV801B
EMA96D
Harness Kits OEM Unit #2 Power Module SMV801B
EMA96E
Harness Kits OEM Controller SMV801C
EMA96F
Harness Kits OEM Unit #1 Power Module SMV801C
EMA96G
EMA96H
EMA96J
Harness Kits AG Controller SMV801A
EMA98A
Harness Kits AG Power Module SMV801A
EMA98B
Harness Kits AG Controller SMV801B
EMA98C
Harness Kits AG Unit #1 Power Module SMV801B
EMA98D
Harness Kits AG Unit #2 Power Module SMV801B
EMA98E
Harness Kits AG Controller SMV801C
EMA98F
Harness Kits AGUnit #1 Power Module SMV801C
EMA98G
Harness Kits AG Unit #2 Power Module SMV801C
EMA98H
Harness Kits AG Unit #3 Power Module SMV801C
EMA98J
Lug Cover Kit, Line or Load
EMA80
MN03901001E / Pub 50560
Notes
Gaskets & Hardware
Blower w/Hardware &

Gaskets
Plastic Only
14-3

September 2004
Table 14-2: SMV801 Repair Parts (Continued)
14-4
Common Name
Catalog
No.
OEM Controller Assembly SMV801A
EMA108A
Complete w/Cable Harness

& Controller
OEM Controller Assembly SMV801B
EMA108B

& Controller
OEM Controller Assembly SMV801C
EMA108C

& Controller
AG Controller Assembly AMV801A
EMA108D

& Controller
AG Controller Assembly AMV801B
EMA108E

& Controller
AG Controller Assembly AMV801C
EMA108F

& Controller
OEM Power Module Assembly SMV801A
EMA110A

& Mounting Panel
OEM Power Module Assembly SMV801B
EMA110B
Complete matched pair of

Power Modules w/Cable
Harness & Mounting Panel
OEM Power Module Assembly SMV801C
EMA110C
Complete matched Set of (3)

AG Power Module Assembly AMV801A
EMA110D

& Mounting Panel
AG Power Module Assembly AMV801B
EMA110E
Complete matched pair of

AG Power Module Assembly AMV801C
EMA110F
Complete matched Set of (3)

Notes
MN03901001E / Pub 50560

September 2004
MN03901001E / Pub 50560
14-5

September 2004
14-6
MN03901001E / Pub 50560
Company Information
Eatons electrical business is a global leader in electrical control, power distribution, and
industrial automation products and services. Through advanced product development,
world-class manufacturing methods, and global engineering services and support,
Eatons electrical business provides customer-driven solutions under brand names such
as Cutler-Hammer, Durant, Heinemann, Holec and MEM, which globally serve the
changing needs of the industrial, utility, light commercial, residential, and OEM markets.
For more information, visit www.EatonElectrical.com.
Eaton Corporation is a diversified industrial manufacturer with 2003 sales of $8.1 billion.
Eaton is a global leader in fluid power systems and services for industrial, mobile and
aircraft equipment; electrical systems and components for power quality, distribution and
control; automotive engine air management systems and powertrain controls for fuel
economy; and intelligent drivetrain systems for fuel economy and safety in trucks. Eaton
has 55,000 employees and sells products to customers in more than 100 countries. For
more information, visit www.eaton.com.
Eaton Electrical Inc.

1000 Cherrington Parkway
Moon Township, PA 15108-4312
USA
tel: 1-800-525-2000
www.EatonElectrical.com
2004 Eaton Corporation

All Rights Reserved
Printed in USA
Publication No. MN03901001E/Pub 50560/CPG
September 2004

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IT.

SMV801 Medium Voltage Soft Starter

MN03901001E / Pub 50560

For more information visit: www.EatonElectrical.com

IT. SMV801 Medium Voltage Soft Starter User Manual

Important Notice Please Read

MN03901001E / Pub 50560

For more information visit: www.EatonElectrical.com

IT. SMV801 Medium Voltage Soft Starter User Manual

CHAPTER 4 POWER WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 5 MOTOR/APPLICATION CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . .

For more information visit: www.EatonElectrical.com

MN03901001E / Pub 50560

IT. SMV801 Medium Voltage Soft Starter User Manual

CHAPTER 7 PROTECTIVE FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 8 PROGRAMMING SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 9 PROCEDURE FOR STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 11 REMOVING CONTROLLER INTERFACE MODULE (CIM) . . . . . . . . . . . .

CHAPTER 13 SPECIAL FUNCTION OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 14 ACCESSORIES AND REPAIR PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MN03901001E / Pub 50560

For more information visit: www.EatonElectrical.com

IT. SMV801 Medium Voltage Soft Starter User Manual

For more information visit: www.EatonElectrical.com

MN03901001E / Pub 50560

IT. SMV801 Medium Voltage Soft Starter User Manual

MN03901001E / Pub 50560

For more information visit: www.EatonElectrical.com

IT. SMV801 Medium Voltage Soft Starter User Manual

The Meaning of Safety Statements

The Safety Alert Symbol means ATTENTION! BECOME ALERT!

Caution means that failure to follow the safety

Attention signifie que linobservation de lnonc

Notice means that failure to follow these

For more information visit: www.EatonElectrical.com

MN03901001E / Pub 50560

IT. SMV801 Medium Voltage Soft Starter User Manual

IT. Soft Starter Safety Statements

Make sure you read and understand the

Danger High Voltage

Danger (Haute tension)

There can be line voltage potential at the motor

Il peut exister une tension de ligne aux bornes du

Power factor capacitors: Do not connect power

Condensateurs de compensation: ne pas raccorder

MN03901001E / Pub 50560

For more information visit: www.EatonElectrical.com

IT. SMV801 Medium Voltage Soft Starter User Manual

Dangers, Warnings and Cautions

Danger (Haute tension)

Hazard of Burn or Electrical Shock

Risque de Brulure ou Electriques de Choc

To avoid shock hazard, disconnect all power to the

Pour viter les chocs lectriques, couper

Do not apply a disconnect device on the output of

Ne pas appliquer un dispositif de sectionnement

Danger High Voltage

Danger (Haute tension)

Danger High Voltage

Danger (Haute tension)