Medium Voltage

Solid State Soft Starters

2.3 - 7.2kV
INSTALLATION & OPERATION
MANUAL

© 2007, All Rights Reserved.

Manual - REV 5
01121301MN - 10/15/07
Firmware Rev 6.86
Medium Voltage Solid
State Soft Starters
2.3 - 7.2 kV

Installation & Chapter 1: Introduction . .................................................................................................... 1

Operation Manual 1.1 Overview
1.2 Specifications
1.3 Design Features
1.4 Theory of Operation
1.5 General Protection
1.6 Thermal Overload Protection
1.7 Firing Circuit
1.8 Electronics

Chapter 2: Connections ................................................................................................... 10

2.1 Warnings
2.2 Control Connections
2.3 Reference Section with RTD, Communications and CPU Boards

Chapter 3: Start-Up ........................................................................................................ 18
3.1 Introduction
3.2 Acceleration Adjustments
3.3 Deceleration Adjustments
3.4 Sequence of Normal Operation
3.5 Emergency Bypass Operation

Chapter 4: User Interface and Menu Navigation ........................................................... 22
4.1 Keypad/Operator Interface
4.2 Menu Navigation

Chapter 5: Setpoint Programming................................................................................... 25
5 .1 Setpoints Page List
5.2 Setpoint Menu
SP.1 Basic Configuration................................................................................................35
SP.2 Starter Configuration..............................................................................................36
SP.3 Phase & Ground Settings.......................................................................................39
SP.4 Relay Assignment..................................................................................................43
SP.5 Relay Configuration................................................................................................44
SP.6 User I/O Configuration...........................................................................................45
SP.7 Custom Acceleration Curve....................................................................................48
SP.8 Overload Curve Configuration................................................................................51
SP.9 RTD Option Configuration......................................................................................52
SP.10 Set Password.........................................................................................................54
SP.11 Communications....................................................................................................55
SP.12 System Setpoints...................................................................................................56
SP.13 Calibration & Service..............................................................................................58

Chapter 6: Metering Pages............................................................................................... 59

6.1 Metering Page List
6.2 Metering Menu

Chapter 7: Maintenance and Troubleshooting .............................................................. 69

7.1 Failure Analysis
7.2 Overload Curve Definition
7.3 TCB Diagram
7.4 Typical Wiring Diagram
7.5 Spare Parts List
7.6 Instructions for Stack Replacement
7.7 Instruction for Low Voltage Test
Reference chart

Table or Page Table or Page

Section Section
Drawing Number Drawing Number
1.2 Specifications 1-3 5.2 Overcurrent Trip Delay Graph 40
Setpoint Page 4 Displays - Relay
1.3 Unit PIV Ratings 4 5.2 42
Assignment
Setpoint Page 5 Displays - Relay
1.8 Keypad Operator Interface 8 5.2 44
Configuration
Setpoint Page 6 Displays - User I/O
2.2 TCB Diagram 11 5.2 45 - 47
Configuration
Setpoint Page 7 Displays - Custom
2.2 TB1 11 5.2 48 - 50
Acceleration Curve
Setpoint Page 8 Displays - Overload
2.2 TB2 12 5.2 51
Curve Configuration
Setpoint Page 9 Displays - RTD Option
2.2 TB3 12 5.2 52
Configuration
Setpoint Page 10 Displays - Set
2.2 TB4 12 5.2 54
Password
Setpoint Page 11 Displays -
2.2 Jumper Selections 13 5.2 55
Communications
Setpoint Page 12 Displays - System
2.2 Switch Positions 13 5.2 56
Setpoints
Setpoint Page 13 Displays - Calibration
2.3 Optional RTD Board 14 5.2 58
& Service
2.3 Communications Board 15 6.1 Metering Page List 59 - 60
Communications Board Connections:
2.3 15 6.2 Metering Menu 61
RS485 and RS422
Metering Page 1 Displays - Metering
2.3 Power Board 16 6.2 62
Data

2.3 Power Board Connections 16 6.2 Metering Page 2 Displays - Metering 63

2.3 CPU Board Connections 17 6.2 Metering Page 3 Displays - RTD Values 64

3.2 Acceleration Adjustments 18 6.2 Metering Page 4 Displays - Status 65

Metering Page 5 Displays - Event

3.3 Coasting Stop 19 6.2 66
Recorder
3.3 Accel and Decel Modes 19 6.2 Metering Page 6 Displays - Last Trip 67
3.4 Sequence of Operations 20 6.2 Metering Page 7 Displays - Statistics 68
4.1 Keypad Operator Interface 22 7.1 Troubleshooting Charts 69 - 71
4.1 Programming the Operator Interface 22 7.1 SCR Testing Procedure 71
4.2 Menu Navigation 23 7.3 Overload Curve Definition 72
4.2 Changing Setpoints Example 24 7.4 TCB Diagram 73
5.1 Setpoints Page List 25 - 33 7.5 Spare Parts List Charts 76 - 77
5.2 Setpoint Menu 34 7.5 PCB Mounting Order 77
Setpoint Page 1 Displays - Basic 7.6 Stack replacement and PCB mounting 78
5.2 35
Configuration
7.6 Connections for Low Voltage Test 82
5.2 Overload Class Trip Curves 35 7.7 Waveform Diagram 84
Setpoint Page 2 Displays - Starter
5.2 36
Configuration
5.2 Jog/Voltage Ramp 37
Setpoint Page 3 Displays - Phase &
5.2 39 - 40
Ground Settings
 2.3 - 7.2kV

Chapter 1 - Introduction
This chapter is an introduction to the reduced voltage solid state starter for medium
voltage AC motors. It describes the basic configuration, operation and unit features.
It is highly recommended that new users read this section thoroughly to gain a basic
understanding of the starter system before attempting to start up a unit.

1.1 Overview
The standard soft starter panel is an SCR-based motor controller designed for
the starting, protection and control of AC medium voltage motors. It contains SCR
stack assemblies, fiber optic connections , low voltage control circuitry ready to
be interfaced with an enclosure and the necessary equipment to create a com-
plete Class E2 medium voltage motor soft starters.

1.2 Specifications

Unit Running Overload Capacity 125% - Continuous

(Percent of motor FLA) 500% - 60 seconds
1 Cycle:up to 14x FLA (internally protected by the programmable short circuit)
Frequency 50 or 60Hz, +2Hz hardware selectable
Power Circuit 6 SCRs, 12 SCRs, 18 SCRs (model dependent)
SCR Peak Inverse
6500V - 19500V (model dependent see Table 1) Note: Contact Factory
Voltage Ratings
Phase Insensitivity User selectable phase sequence detection
Transient Voltage Protection RC snubber dv/dt networks (one per SCR power module)
Enclosed units: 0° to 40°C (32° to 104°F) (optional - 20° to 50° C with heaters)
5 - 95% relative humidity
Ambient Condition Design 0 - 3300 ft. (1000m) above sea level without derating
(Ratings for ambient conditions external to unit)
Control 2 or 3 wire 120VAC (customer supplied)
Multiple: Form C (contacts), rated 5 Amps, 240VAC max.
Auxiliary Contacts 8 Relays (4 programmable): Form C contacts
Fault Indicator: Form C contact
BIL Rating 2300V - 7200V 60KV
Approvals UL recognized, Canadian UL (cUL) recognized

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 2.3 - 7.2kV
1.2 Specifications (continued)

Advanced Motor Protection

Two Stage Electronic Starting: Programmable for Class 5 through 30

Overload Curves Run: Programmable for Class 5 through 30 when "At-Speed" is detected.
Overload Reset Manual (default) or automatic
Overload circuit retains thermal condition of the motor regardless of control
Retentive Thermal Memory
power status. Unit uses real time clock to adjust for off time.

Overload will not reset until thermal capacity available in the motor is enough
Dynamic Reset Capacity for a successful restart. Starter learns and retains this information by
monitoring previous successful starts.
Phase Current Imbalance Imbalance Trip Level: 5 - 30% current between any two phases
Protection Imbalance Trip Delay: 1 -20 seconds
Over Current Protection Trip Level: 100 - 300% of motor FLA
(Electronic Shear Pin) Trip Delay: 1 - 20 seconds
Under Current Trip Level: 10 -90 % of motor FLA
Load Loss Trip Protection
Under Current Trip Delay: 1 - 60 seconds
Coast Down (Back Spin)
Coast Down Time Range: 1 - 60 minutes
Lockout Timer
Range: 1 - 6 successful starts per hour
Starts-per-hour Lockout Timer
Time between starts: 1 - 60 minutes between start attempts
Programmable Outputs
Type / Rating Form C (SPDT), Rated 5 amps 240 VAC max, (1200 VA)
Run Indication Programmable
At Speed Indication Programmable
Programmable Ramp Types: Voltage or Current Ramp (VR or CR)
Starting Torque: 0 - 100% of line voltage (VR) or 0 - 600% of motor FLA (CR)
Acceleration Adjustments
Ramp Time: 1 to 120 seconds
Current Limit: 200 - 500% (VR or CR)
4 Options: VR1+VR2; VR1+CR2; CR1+CR2; CR1+VR2
Dual Ramp Settings Dual Ramp Control: Ramp 1 = Default
Ramp 2 = selectable via dry contact input

Begin Decel Level: 0 - 100% of line voltage

Deceleration Adjustments Stop Level: 0 to 1% less than Begin Decel Level
Decel Time: 1 - 60 seconds

Jog Settings Voltage Jog: 5 - 75%

Kick Voltage: 10 - 100%
Kick Start Settings
Kick Time: 0.1 - 2 seconds
Shorted SCR, Phase Loss, Shunt Trip, Phase Imbalance Trip, Overload,
Fault Display
Overtemp, Overcurrent, Short Circuit, Load Loss, Undervoltage or Any Trip
Lockout Display Coast Down Time, Starts Per Hour, Time Between Starts, and Any Lockout
Event History

Data includes cause of event, time, date, voltage, power factor and current for
Up to 60 Events
each phase and ground fault current at time of event

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 2.3 - 7.2kV

1.2 Specifications (continued)

Metering Functions
Motor Load Percent of FLA
Current Data A, B, C Phase Current, Avg Current, Ground Fault (Option)
Thermal Data Remaining thermal register; thermal capacity to start
Avg Start Time, Avg Start Current, Measured Capacity to start, time since last
Start Data
start
RTD Data (Option) Temperature readings from up to 12 RTDs (6 stator RTDs)
Voltage Metering kW, kVAR, PF, kWH
Serial Communications
Protocol Modbus RTU
Signal RS-485, RS-422 or RS232
Network Up to 247 devices per mode
Functionality Full operation, status view, and programming via communications port
Operator Interface
LCD Readout Alpha numeric LCD display
Keypad 8 function keys with tactile feedback
Status Indicators 12 LEDs include Power, Run, Alarm, Trip, Aux Relays
Up to 1000 circuit-feet from chassis (use twisted, shielded wire & power
Remote Mount Capability
source)
Clock and Memory
Operating Memory SRAM loaded from EEPROM at initialization
Factory Default Storage Flash EPROM, field replaceable
Customer Settings and Status Non-volatile EEPROM, no battery backup necessary
Real Time Clock Lithium ion battery for clock memory only

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 2.3 - 7.2kV

1.3 Design Features

The standard soft start panel has the following features:

• SCR Power Modules: For each phase, the SCRs are matched
200 & 400 Amps Units
Total
devices arranged in inverse parallel pairs and in series strings as Voltage
Series
Number PIV Rating
indicated in the chart to facilitate sufficient Peak Inverse Voltage rat- Pairs
of SCRs
ings for the applied voltage. 2300 V 0 6 6500 V
3300 / 4160 V 2 12 13000 V
• RC Snubber Networks: provide Transient Voltage Protection for 6000 - 7200 V 3 18 19500 V
SCR Power Modules in each phase to avoid dv/dt damage.
600 Amps Units
• Firing Circuit: The SCRs are gated (turned on) using a Sustained Series
Total
Voltage Number PIV Rating
Pulse Firing Circuit. This circuitry is amplified and isolated from the Pairs
of SCRs
control voltage by means of fiber optics for current and ring trans-
2300 V 2 12 7000 V
formers. 3300 / 4160 V 4 24 14000 V
6000 - 7200 V 6 36 19500 V
1.4 Theory of Operation
The power of the soft starter is in the CPU, a microprocessor based Unit PIV Ratings
protection and control system for the motor and starter assembly. The CPU Table 1
uses Phase Angle Firing of the SCRs to apply a reduced voltage to the motor,
and then slowly and gently increases torque through control of the voltage and
current until the motor accelerates to full speed. This starting method lowers the
starting current of the motor, reducing electrical stresses on the power system
and motor. It also reduces peak starting torque stresses on both the motor and
load mechanical components, promoting longer service life and less downtime.

Acceleration: The soft starter comes standard with several methods of acceler-
ating the motor so that it can be programmed to match almost any industrial AC
motor application.

The factory default setting applies a Voltage Ramp with Current Limit as this
has been proven the most reliable starting method for the vast majority of appli-
cations. Using this starting method, the Initial Torque setting applies just enough
voltage to the motor to cause the motor shaft to begin to turn. This voltage is then
gradually increased over time (as per the Ramp Time setting) until one of three
things happen: the motor accelerates to full speed, the Ramp Time expires or a
Current Limit setting is reached.

If the motor accelerates to full speed before the ramp time setting has expired,
an automatic Anti-Oscillation feature will override the remaining ramp time and
full voltage will be applied. This will prevent any surging or pulsation in the motor
torque, which might otherwise occur due to the load not being fully coupled to the
motor when operating at reduced voltage and torque levels.

If the motor has not reached full speed at the end of the ramp time setting, the
current limit setting will proportionally control the maximum output torque. Feed-
back sensors in the provide protection from a stall condition, an overload condi-
tion or excessive acceleration time.

The Current Limit feature is provided to accommodate installations where there

is limited power available (for example, on-site generator power or utility lines
with limited capacity). The torque is increased until the motor current reaches the
pre-set Current Limit point and it is then held at that level. Current Limit overrides
the ramp time setting so if the motor has not accelerated to full speed under the
Current Limit setting, the current remains limited for as long as it takes the motor
to accelerate to full speed.

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 2.3 - 7.2kV

When the motor reaches full speed and the current drops to running levels, the
soft starter detects an At-Speed condition and closes the Bypass Contactor.
The Bypass Contactor serves to shunt power around the SCR stack assemblies
to prevent heat build-up in the starter enclosure due to the slight voltage drop
across the SCRs. At this point, the soft starter has the motor operating at full volt-
age, just as any other starter would.

Other starting methods available in the soft starter are:

· Current Ramp: uses a closed current feedback PID loop to provide a linear
torque increase up to a Maximum Current level.

· Constant Current: current is immediately increased to the Current Limit point

and held there until the motor reaches full speed.

· Custom Curve: gives the user the ability to plot torque and time points on a
graph. The soft starter will then accelerate the motor following these points.

· Tachometer Feedback Ramp: uses a closed loop speed follower method

monitoring a tachometer input signal from the motor or load shaft.

Deceleration: the soft starter provides the user with the option of having the
load coast to a stop or controlling the deceleration by slowly reducing the voltage
to the motor upon initiating a stop command. The Decel feature is the opposite
of DC injection braking in that the motor will actually take longer to come to
a stop than if allowed to coast to a stop. The most common application for the
Decel feature is pumping applications where a controlled stop prevents water
hammer and mechanical damage to the system.

1.5 General Protection

The soft starter is provided with a built-in motor protection relay that can be
programmed for primary protection of the motor/load system. Operation of the soft
starter can be divided into 4 modes; Ready, Start, Run and Stop.

Ready Mode: In this mode, control and line power are applied and the starter is
ready for a start command. Protection during this mode includes the monitoring
of current for leakage through multiple shorted SCRs or welded contacts on the
Bypass Contactor. Other protection features in effect are:

· Starter Power Pole Temperature

· Shorted SCR
· Blown Fuse Indication
· Phase Reversal (if enabled)
· Line Frequency Trip Window
· External Input Faults

Note: The “Programming Mode” can only be entered from the Ready Mode. Any
attempt to enter data while the motor is starting or running will be blocked. During
programming, all protection features and start command are disabled.

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 2.3 - 7.2kV

Start Mode: These additional protection functions are enabled when the soft
starter receives a valid Start command:

· Phase Reversal (if enabled)

· Start Curve
· Acceleration Timer
· Phase Imbalance
· Short Circuit / Load Pre-check (Toe-in-the-Water)
· Ground Fault (Optional)
· External Input Faults
· Accumulated Starting FLA Units (I2t Protection)
· Overload Protection
· Thermal Capacity

Note: Shorted SCR protection is no longer in effect once the soft starter goes into
the Start Mode.

Run Mode: The soft starter enters the Run Mode when it reaches full output
voltage and the motor current drops below the FLA setting (motor nameplate FLA
plus service factor) for a pre-determined period of time. During the Run Mode
these additional protection features are enabled:

· Running Overload Curve

· Phase Loss
· Under Current / Load Loss
· Over Current / Electronic Shear Pin (Jam Protection)
· External Input Faults

Stop Mode: Once a Stop command has been given, the protection features
change depending on which Stop Mode is selected.

· Decel Mode: retains all protection features of the Run Mode. At the end of De-
cel, the motor will be stopped and the protection features change as indicated
below.
· Coast-To-Stop Mode: power is immediately removed from the motor and the
soft starter returns to the Ready Mode.

Additional protection features activated when the stop command is given include:
· Coast-Down / Back Spin Timer
· Starts-per-Hour
· Time Between Starts
· External Input Faults

1.6 Thermal Overload Protection

The soft starter plays an important role in the protection of your motor in that it
monitors the motor for excessive thermal conditions due to starting, running or even
ambient conditions. The soft starter has a Dynamic Thermal Register system in the
CPU that provides a mathematical representation of the thermal state of the motor.
This thermal state information is kept in memory and is monitored for excesses
in both value and rate of change. Input is derived from current imbalances and
(optional) RTD measurements making it dynamic to all processes involving the motor.
The soft starter monitors these conditions separately during Start and Run modes to
provide proper thermal overload protection at all times.

Start Mode overload protection is selectable using one of three methods:

· Basic Protection: I2t data is accumulated and plotted based on an Overload
Curve selected in programming. This is programmed per NEMA Class 5-30
standard curves and is based on the Locked Rotor Current (from the motor
nameplate) as programmed into the soft starter.
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 2.3 - 7.2kV

· Measured Start Capacity: the user enters a measured amount of thermal

capacity from a pre-selected successful start as a setpoint to the Thermal Reg-
ister for the soft starter to follow.

· Learned Curve Protection: the user sets the soft starter to the “LEARN” mode
and starts the motor under normal starting conditions. The CPU then samples
and records 100 data points during the start curve, analyzes them and cre-
ates a graphical representation in memory. The soft starter is then switched to
Curve Follow protection mode and monitors motor performance against this
curve. This feature is especially useful in initial commissioning tests to record
a base line performance sample (in this case, it is not necessarily used for mo-
tor protection).

Run Mode overload protection is initiated when the soft starter determines
that the motor is At-Speed. Overload Protection is initiated when the motor RMS
current rises above a “pick-up point” (as determined by the motor nameplate FLA
and service factor). Run mode protection is provided by the CPU monitoring the
Dynamic Thermal Register. Data for the Dynamic Thermal Register is accumulat-
ed from I2t calculations and cooling rates. A trip occurs when the register reaches
100% as determined by the selected Overload Protection Curve (NEMA Class
5-30 standard curves) and is based on the programmed Locked Rotor Current
indicated on the motor nameplate. The Dynamic Thermal Register is altered, or
“biased”, by the following conditions:

· Current Imbalance: will bias the register higher to add protection from addi-
tional motor heating during a current imbalance condition.

· Normal Cooling: provided when the motor current drops below the pick-up
point or the motor is off line. The cooling rate is lower for motors that are off-
line (such as after a trip) since cooling fans are also inoperative.

· RTD Input: (requires the optional RTD monitor card): will bias the register in
either direction based on real-time input of the motor, bearing and even ambi-
ent temperature conditions.

· Dynamic Reset is another feature that adds reliability and consistency to the
performance of the soft starter. If a motor overload condition occurs and the
soft starter trips, it cannot be reset until sufficient cool down time has elapsed.
This cool down time is determined by the thermal state of the motor when it
tripped (i.e. hot motors cool more quickly due to additional convection). The
cool down time is also biased by RTD measurements when used.

· Retentive Memory provides continuous overload protection and real time
reset even if power is lost. Upon restoration of power, the soft starter will read
the Real Time Clock and restore the thermal register to what it should be given
the elapsed time.

· Learned Reset Capacity is a feature that is unique to the soft starter . By

sampling the amount of thermal capacity used in the previous three success-
ful starts, the starter will not allow a reset until a sufficient amount of thermal
capacity has been regained in the motor. This prevents nuisance tripping and
insures that unsuccessful start attempts (which would otherwise use up the
starts-per-hour capacity of the motor) are not counted.

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 2.3 - 7.2kV

1.7 Firing Circuit

The SCR gate firing circuit is critical to performance and stability of the system.
The firing circuit includes several unique features which enhance the ruggedness,
noise immunity and flexibility for maximized performance. In most applications, this
performance is attained without the need for reactors or field installed devices. These
features include:

Auto Synchronizing of the gate timing pulses match each phase firing angle
to their respective phases. The soft starter actively tracks minor shifts in the
line frequency, avoiding nuisance tripping that may happen with conventional
gate firing systems. This is especially useful on portable or backup generator
supplies, allowing the soft starter to be used confidently in applications that
have unstable power.

Sustained Pulse firing keeps the firing signal active for 270 electrical degrees,
ensuring that the DC gate pulse causes the SCR to fire even if line noise is
present at a critical moment. This provides the soft starter with superior noise
immunity and protects against misfiring, enhancing the soft starter system reli-
ability.

Closed Loop Firing Control is a method of balancing the SCR firing pattern
based on the desired output. The CPU uses feedback signals from both the
output current and voltage providing smooth output and preventing imbalances
during ramping which prevents unnecessary motor heating.

Transformer Isolation of the firing signals prevents interference from line

noise and EMI/RFI signals that may be present. Specially designed 120V
3 phase isolation transformers provide potential measurement, firing board
power and gate power systems while being isolated from the line voltage. High
isolation Ring Transformers are used to step this down to 28VAC for the Sus-
tained Pulse firing circuit, providing further isolation for the SCR gates.

Fiber Optic Isolation is provided for all signal interfaces between the Medium
Voltage and Low Voltage systems. Even the current signals from CTs are con-
verted to fiber optic signals for maximum isolation and safety.

1.8 Electronics
The soft starter electronics systems are divided into two categories, Low Voltage and
Medium Voltage, based solely on where they are located in the starter structure.

Low Voltage electronics include the Keypad Operator Interface, CPU and Main
Power PC boards are located in an isolated Low Voltage Compartment of the
enclosure.

· Keypad Operator Interface: a 2 line x 20 character LCD display with back-

lighting for low ambient conditions. The display reads out in truncated English
and can show multiple data points in each screen. Also included are 12 LED
indicators, which include Power, Run, Alarm, Trip and the status of the 8 Aux.
Relays. It communicates to the CPU via a serial link and, if necessary, can be
remotely mounted up to 1000’ from the soft starter.

· CPU Board: where the microprocessor and communications co-processor

reside. It is attached to the main power board. It communicates to the Keypad
Operator Interface via serial links. The CPU determines operating functions,
stores user programming and acts upon feedback signals for faults, metering
and historical data. This board also contains the flash EEPROM and SRAM
memory, as well as the Analog I/O and terminations. Keypad Operator Interface

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 2.3 - 7.2kV

· Main Power Board: is also referred to as the Firing Board. It contains the Digi-
tal I/O relays and interfaces to the TCB board (see below) for user interface. It
also controls the sequencing of the Isolation and Bypass contactors with the
SCR firing. This board generates all firing signals for the SCR stacks and re-
ceives feedback signals from fiber optic transmitters. It converts analog levels
to digital signals for the CPU. These firing pulses are via fiber optic signals to
isolate them from the Medium Voltage environment.

Control Electronics are located in the Medium Voltage section of the soft starter.
The main line power must be disconnected before these electronics can be
accessed. They include the TCB, Gate Drive and Temp/CT boards.

· TCB (Terminal and Control Board): is the user connection interface board.
It is located in the Medium Voltage section in order to satisfy UL termination
requirements, but does not actually connect directly to the medium voltage
components other than the contactor coils. This board contains the user termi-
nal blocks, output relays (duplicated), inputs and control power connections. It
also contains additional timed relays for interfacing with Power Factor Correc-
tion contactors (if used) and other external devices. Please note Power Factor
Capacitor warnings in Section 2.1.

· Gate Drive Boards: located directly on the SCR stacks. These boards com-
municate to the Main Power board via fiber optic cables. They amplify the gate
pulse signals with power from the Ring Transformers to create the Sustained
Pulse Firing of the SCRs. There is one Gate Drive board for each pair of SCRs
in each stack.

· Temp / CT Boards: are attached to the Gate Drive boards on the SCR stacks
and provide the heat sink temperature and current signals back to the Main
Power Board via fiber optic cables.

· MOV Boards: are attached to standoffs mounted on the SCR heat sinks and
are mounted directly below the Gate Drive boards. The MOV boards are used
to protect the gate/cathode section of the SCRs.

· DV/DT Boards: are also attached to standoffs mounted on the SCR heat
sinks and are mounted below the MOV boards. The DV/DT boards are used to
reduce voltage transients across the stack assemblies.

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 2.3 - 7.2kV

Chapter 2 - Connections
2.1 Warnings DANGER
• Do not service this equipment with voltage applied! The unit can
be the source of fatal electric shocks! To avoid shock hazard, discon- HAZARDOUS VOLTAGE
nect main power and control power before working on the unit. Warn- Disconnect all power supplying this equipment prior
ing labels must be attached to terminals, enclosure and control panel to working on it.
to meet local codes.
Failure to follow this instruction will result in death
or serious injury.
• Do not connect (PFC) capacitors or surge capacitors to the load
side (motor side) of the unit. This will cause di/dt damage to the
SCRs when they are turned on and will void the warranty on this prod-
uct. Capacitors can only be connected to the load side of the starter
! CAUTION
through the use of an isolating contactor which is closed after the soft SCR DAMAGE
starting sequence has been completed. Do not connect (PFC) capacitors to the load side of
the unit.
• Avoid connecting capacitors to the input side of the unit. If you
Doing so will cause DI/DT damage to the SCRs when
cannot avoid using capacitors across the power lines, they must be energized.
located as far upstream as possible of the input line contactor. In this
situation, an optional power factor correction (PFC) capacitor contac-
tor should be specified. For additional information and specifications,
! WARNING
please contact the factory. SAFETY HAZARD
Do not bypass electrical or mechanical interlocks.

• Never interchange the input and output power connections on Failure to follow this instruction will cause severe
equipment damage, serious injury or death.
the unit. This will cause excessive voltage to the control circuit logic.
• For bus protection, it is strongly recommended to use non-gap
lightning arrestors in areas where lightning is a significant
problem. The arrestors should be mounted on the nearest utility
pole.

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 2.3 - 7.2kV

2.2 Control Connections - TCB (Terminal and Control Board)

2.2.1 TCB Board
The TCB board provides Customer Provided
interconnections between the main power and
Momentary or Maintained
CPU boards and the customer’s control logic Start / Stop Switching
connections. It is a 120 VAC control board with Maintained
several auxiliary dry control contacts, built-in
time delay circuits and emergency bypass START STOP
Fuses Momentary
functions. It also controls the sequence of the F1: Control Fuses for TB1 1 - 9
inline isolation and bypass contactor and pro- Part #ACG1A250VAC or equivalent
F2: Contactor and relay output fuses

vides provisions for shutdown interlocks. (see Part #ACG4A250VAC or equivalent

F3: TB2 Pin #6

section 2.2.2) Part #ACG4A250VAC or equivalent

12

NC
Aux Start
2.2.2 Description of Terminal Connections 11

NO
E1 E2 E3 E4 Output
10

C
Red AC 120 VAC
TB1 LED
9
8
Neut
Neutral
Start
FUSE
7
T1 Red TB1 6
Stop

LED
5
Inter
FAULT 4
Lock
Optional
#1 #2 #3 #4 #5 #6 #7 #8 #9 #10 #11 #12
NC C NC C NC C NO AC C NO NC 3 Interlocks
Inter

AC INTER INTER MB 2
Lock

SOURCE LOCK LOCK STOP START NEUT TB2 1

AC 120 VAC

HEATSINK
Source
Source
Start/Stop Control F1 10

NC
Figure 2 - 1 9

NO
F2 8

C
HEATSINK
7
FACTORY WIRED

N
Green DO NOT USE
LED F3 6
{ Line 1

S
120VAC 5

NC
Neutral 2 -12V
TB2
Start/Stop Control - Terminal Block 1 (TB1) : 3 Green
4 Emergency Bypass

NO
Delayed Start LED Green
LED 3 AUX Contacts

C
4
5 +12V
2 Emergency Bypass
• Positions 1 and 9 are the 120 VAC control

C
Fuse Blown/ START
Disconnect Open TB6 1 Full Voltage Start

NO
6

power. Dual Ramp

7
ON OFF 12

NC
JP1
• Positions 2-3 and 4-5 have factory jumpers
8
SW1 11

NO
9 Remove JP1 for electronic 10
installed and can be removed for customer’s
Bypass Status DUAL ADJ

Fault
motor overload protection

C
10 during emergency 9

NC
bypass operation
normally closed, dry, shutdown contacts (See 8

NO
1
Fig 2-1 above).
Run 7
TCB

C
2 TB3 6

NC
• Positions 6-7-8 are for either two wire or three- 3

Lock Out
CPU (AUX1) Fault
BOARD 5

NO
4 TB7
wire start/stop logic. Two wire is connected to 4

C
5
At Speed 3
positions 6 and 8 with a N.O. dry, maintained

NC
6
2

NO
start/stop contact. Three wire control connects
7
1

C
to 6 with 7 as the stop push-button, and the
Fuse Blown/
1 12
Disconnect
NC
AUX-S
DLY-S
PFC-C
DLY-C
PFC-S

AUX-C

Green
start push-button is connected to 7 and 8. Interlock Input 2 LED 11
NO

P.F.C. CAP
3 10
TB8
• Positions 10-11-12 are a dry Form C contact.
C

External Overload PFC

4 TIMED 9
NC

The contact is an immediate start/stop contact.

7 6 5 4 3 2 1 7 6 5 4 3 2 1 7 6 5 4 3 2 1 OUT
5 8
NO

Bypass Aux Contact

6 7
C

PFC AUX START TB4

Bypass
{ A1 7 6
NC

Emergency Bypass Control - Terminal Block 2

Coil A2 8 5
NO

Time Delay

A1 4
(TB2):
Main
{ 9 Green
C

Coil LED 3
A2 10
NC

• Positions 1 and 2 are for an emergency bypass 2 DELAY

NO

1 TIMED

contact. If a dry contact closes position 1 and

C

OUT

2, this causes the CPU to be shut off so there

is no display. Then when a start is initiated, it TCB (Terminal and Control Board)
pulls in the inline isolation contactor which starts the Figure 2 - 2
motor across the line. (See Section 3.5 for more de- (For full drawing, see Section 7.4)

tails)
• Positions 3-4-5 are a Form C contact. This is a dry
contact that is initiated by the emergency contact being closed. It provides
indication of the emergency bypass mode.

- 11
 2.3 - 7.2kV

• Positions 6 and 7 is a customer connection for control power. Position 6 is TB2

the 120 VAC supply at (400 VA) and position 7 is the return.
• Positions 8-9-10 are a Form C contact. The dry contact is a delayed start/
stop contact. The amount of delay is determined by X1, X2 and SW3 (see
#1 #2 #3 #4 #5 #6 #7 #8 #9 #10
“Switch Positions” and “Jumper Selection” on the next page). Note: Addition- NO O C NO NC S N C NO NC

al Time Delay to SP2 of the CPU programming. EMER BYP

SWITCH
INTER
LOCK
CUST. POWER DELAYED
OUTPUT START
• JP1 - Motor Protection Jumper. Removing jumper JP1 on the TCB Board Emergency Bypass Control
will allow the soft starter CPU to continue providing electronic motor protec- Figure 2 - 3
tion while operating in Emergency Bypass Mode. If it is necessary to disable
the soft starter CPU system during operation in Emergency Bypass Mode,
be sure the JP1 jumper is placed over both pins and an external means of
CAUTION
OVERLOAD PROTECTION LOSS
overload protection (such as a bi-metallic style overload) is used.
When operating the unit in Emergency Bypass Mode,
there is no electronic overload protection unless
Fault - Terminal Block 3 (TB3): JP1 on TCB board is removed.
• Positions 1-2-3 and 4-5-6 are sets of Form C contacts. These are a dry con- External overload protection must then be provided
for continued safe operation.
tact that operates when a blown fuse indication is given or disconnect is
open. TB3
• Positions 7-8-9 and 10-11-12 are sets of Form C contacts. These are
fault contacts that change state if any fault condition occurs.

Optional Relay - Terminal 4 (TB4): #1 #2 #3 #4

C NO NC C
#5 #6
NO NC
#7 #8 #9 #10 #11 #12
C NO NC C NO NC
• Positions 1-2-3 and 4-5-6 are sets of Form C contacts. These are
auxiliary time delay contacts that will change state (after a delay) when Lockout/Fault Contacts
the Start contact is initiated. X3, X4 and SW4 determine the amount of Figure 2 - 4
delay. (See switch position and Jumper selection on the following page)
• 7-8-9 and 10-11-12 are sets of Form C contacts. These are power factor
correction capacitor (PFC) contacts to pull in an isolation contactor for
the power factor correction capacitors (if required by the application).
These will change state when the At Speed contact is initiated. X5, X6
and SW5 determine the amount of delay. (See “Switch Positions” and
“Jumper Selection” on the following page). Note: This delay is in addition
to SP2 of the CPU programming.
Time Delay/PFC Cap Contacts
Figure 2 - 5
Terminal Block 6 (TB6):
• Positions 1 and 2 are 120 VAC power supply to the Main and CPU circuit
boards.
• Positions 3 and 4 are the start input connections to the Main and CPU circuit
boards.
• Positions 5 and 6 are the fuse blown input connections to the Main and CPU
circuit boards.
• Positions 7 and 8 are the Dual Ramp input connections to the Main and CPU
circuit boards.
• Positions 9 and 10 are the Bypass Status input connections to the Main and
CPU circuit boards.

Terminal Block 7 (TB7):

• Positions 1 and 2 are the Run contacts (AUX 3) from the Main and CPU cir-
cuit boards to the TCB board. This signal is used to hold the Main Contactor
closed during deceleration.
• Positions 3 and 4 are the Main and CPU circuit board output connections to
the TCB that signal the AUX1 Fault Status.
• Positions 5 and 6 are the At Speed contacts (AUX 4) from the Main and CPU
circuit boards that signal the Bypass Contactor to close.
• Position 7 has no connection.

- 12
 2.3 - 7.2kV

Terminal Block 8 (TB8):

• Positions 1 and 2 accept dry, normally closed contacts from blown fuse indicators
and/or disconnect interlock contact.
• Positions 3 and 4 accept dry, normally closed contacts from an external overload
protection device (required if emergency bypass is used).
• Positions 5 and 6 accept dry, normally closed contact from the bypass contactor for
an At Speed indication. (Factory wired)
• Positions 7 and 8 are wired to the coil of the bypass contactor and energizes and de-
energizes the contactor. (Factory wired)
• Positions 9 and 10 are wired to the coil of the inline isolation contactor and energizes/
de-energizes the contactor. Note: All customer contacts are 960VA, 120VAC (Max)
rated dry contacts.

LEDs provided on the TCB board (for low voltage testing only):
• -12 VDC power supply
• +12 VDC power supply
• Start = start is initiated to TCB board
• Fault = any fault has occurred
• Fuse Blown = disconnect open or blown fuse has activated
• PFC On = Power Factor Correction Capacitor contacts have energized
• Timed Out = Auxiliary time delay contacts have energized

Jumper Selection
Start Delay (Refer to Figure 2 - 6)
This is a selectable delay period between the initiation of the start command and when the
CPU actually receives the start signal. Selecting Jumper X1 or X2 determines the method
by which this delay (in cycles or seconds) is calculated. See SW3 below for instructions on
setting the actual delay time.
• X1 = (DLY-C) Start time delay in cycles
Jumper Selections
• X2 = (DLY-S) Start time delay in seconds (Factory setting)
Figure 2- 6

Auxiliary (Start) Delay (from the time the start input is given). Selecting jumper X3 or X4
determines the method by which this delay is calculated (cycles or seconds). See SW4
below for instructions on setting delay time.
• X3 = (AUX-C) Auxiliary time delay in cycles
• X4 = (AUX-S) Auxiliary time delay in seconds (Factory setting)

Power Factor Correction (PFC) Capacitor Contactor Delay (From the time the bypass
closes to when contacts change state). Jumper selection determines the method by which
this delay is calculated. See SW5 for instructions.
• X5 = (PFC-C) Time delay in cycles
• X6 = (PFC-S) Time delay in seconds (Factory setting)

Switch Positions (Refer to Figure 2 - 7)

• SW1 = On = Dual Adjustment or OFF = Disabled
• SW2*= Not used - Switches SW3, SW4 and SW5 are 7 position dip
switches that use binary code to count up to 127 seconds/cycles (see
“Jumper Selection” above).
• SW3 = Start Delay; 7 position dip switch uses binary count up to 127 sec- Example:
onds/cycles. (See jumper selection above.) Factory setting: 1 second Switch settings are cumulative.
• SW4** = Auxiliary (Start) Delay 7 position dip switch uses binary count up Setting dip switch positions 1, 2,
to 127 seconds/cycles. (See jumper selection above.) Factory setting: 1 and 3 to “on” = 1+2+4 = 7 seconds
second total time. Note: Applies to SW3,
• SW5** = PFC time delay; 7 position dip switch uses binary count up to 127 SW4 & SW5.
seconds/cycles. (See jumper selection above) Factory setting: 1 second. Switch Positions
*Note: This switch interacts with the CPU programming when the Decel function Figure 2- 7
is enabled.
**Note: These times are in addition to SP2 in the CPU setpoints.

- 13
 2.3 - 7.2kV

2.3 Reference Section - THIS SECTION IS FOR REFERENCE ONLY.

FIELD WIRING/CONNECTIONS ARE NOT REQUIRED.

2.3a Optional RTD Board

RTD1 RTD2 RTD3 RTD4 RTD5 RTD6 RTD7 RTD8 RTD9 RTD10 RTD11 RTD12
Compensation
Shield
Power
Signal

RTD
Typical RTD
Installation

- 14
 2.3 - 7.2kV

2.3 Reference Section - THIS SECTION IS FOR REFERENCE ONLY.

FIELD WIRING/CONNECTIONS ARE NOT REQUIRED.

2.3b Communications Board

REAR
VIEW

(RS485) (RS422)

Note: Remove for last unit in modbus string

2.3c Communications Board Connections

1 2 3 4 5 6 TB2 1 2 3 4 5 6
TB1
Shield
RS422

RS422
Shield
RS485

A+

B+
NO
NC

A-
B+

B-
A-

RECEIVE TRANSMIT
RS485 Connections RS422 Connections
(Customer Connections) (Factory Only)
- 15
 2.3 - 7.2kV

2.3 Reference Section - THIS SECTION IS FOR REFERENCE ONLY.

FIELD WIRING/CONNECTIONS ARE NOT REQUIRED.
2.3d Power Board

Board
Ground Test Points
19 1 7 1 7 1 19 1

20 2 J3 20 J6 2
J5 J4

AI

AT

BI

BT

CI

CT

3
GF

1
J1

C2 C1

7
7, A - Phase
B2 B1

4, B - Phase
A2 A1

1, C - Phase

1
J2
1
3

J8
J7 J2

6
1
F1

TB1 TB2
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6
TB3

2.3e Power Board Connections

TB1 TB2
Factory use only. Do not reprogram. Refer to Setpoint Page 5 for programming information

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

C N.O. N.C. C N.O. N.C. C N.O. N.C. C N.O. N.C. C N.O. N.C. C N.O. N.C. C N.O. N.C. C N.O. N.C.
AUX1 AUX2 AUX3 AUX4 AUX5 AUX6 AUX7 AUX8
(TRIP) (ALARM) (RUN) (AT SPEED) Relay Relay Relay Relay
Relay Relay Relay Relay

(Max Relay Contact Rating is 240 VAC, 5A, 1200VA)

- 16
 2.3 - 7.2kV

2.3 Reference Section - THIS SECTION IS FOR REFERENCE ONLY.

FIELD WIRING/CONNECTIONS ARE NOT REQUIRED.
2.3f CPU Board Connections

1 2

19 20

1 2

19 20

Contact factory for remote

reset connections Factory wired. Do not change
Analog Output #1

Analog Output #2

Program Enable

External Input #2
Input

Thermostat
Tach Input

Dual Ramp
4 - 20 mA

4 - 20 mA

TCB Fault

TB1 TB2 TB3

1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

+ - + - + - + - + - + - + -
+ -
Note: Install program jumper to enable
setpoint programming. Jumper must be
removed after programming or for
prolonged storage to preserve settings.

- 17
 2.3 - 7.2kV
Chapter 3 - Start-up
3.1 Introduction
It is best to operate the motor at its full load starting condition to achieve the
proper time, torque and ramp settings. Initial settings are set to accommodate
most motor conditions. TRY INITIAL SETTINGS FIRST. See Section 5.1.2
Starter Configuration (Setpoint Page 2) to make any adjustments.

3.2 Acceleration Adjustments

The unit is set at the factory with typical starting characteristics that perform well
in most applications. When the system is ready to start, try the initial unit settings.
If the motor does not come up to speed, increase the current limit setting. If the
motor does not start to turn as soon as desired, raise the starting voltage adjust-
ment. Adjustment description and procedures are described as follows. See Sec-
tion 5.1.2 Starter Configuration (Setpoint Page 2) for additional Accel settings.

3.2.1 Starting Voltage

Factory Setting = 20% of line voltage
Range = 0% - 100% of line voltage
Starting voltage adjustment changes the initial starting voltage level to the
motor.

3.2.2 Ramp Time

Factory Setting = 10 sec.
Range = 0 - 120 sec.
Ramp time adjustment changes the amount of time it takes to reach the cur-
rent limit point or full voltage if the current limit point was not reached.
Note: Refer to your motor manual for the maximum number of starts per hour
allowed by the manufacturer and do not exceed the recommended number.

3.2.3 Current Limit

Factory Setting = 350% of motor FLA
Range = 200% - 500% of motor FLA
The current limit adjustment is factory set for 350% of the motor FLA. The
range of adjustment is 200% to 500%. The main function of current limit is
to cap the peak current. It may also be used to extend the ramping time if
required. The interaction between the voltage ramp and the current limit will
allow the soft start to ramp the motor until the maximum current is reached
and the current limit will hold the current at that level. The current limit must
be set high enough to allow the motor to reach full speed. The factory setting
of 350% is a good starting point. Do not set the current limit too low on
variable starting loads. This could cause the motor to stall and eventu-
ally cause the overload protection to trip.
Note: If the motor does stall, refer to the motor manufacturer’s motor data for the
proper cooling time.

- 18
 2.3 - 7.2kV

3.3 Deceleration Adjustments (Pump Control)

Decel extends the stopping time on loads that would otherwise stop too
quickly if allowed to coast to stop. Decel control provides smooth decel-
eration until the load comes to a stop. Three adjustments optimize the
deceleration curve to meet the most demanding requirements. The unit is
shipped from the factory with the decel feature disabled.

Deceleration Applications
The unit is shipped from the factory with the decel feature disabled.
Apply power and adjust the soft start before enabling or modifying the de-
celeration adjustments. Both acceleration and deceleration adjustments
should be made under normal load conditions.

The deceleration feature provides a slow decrease in the output voltage,

accomplishing a gentle decrease in motor torque during the stopping
mode. This is the opposite of braking in that it will take longer to
come to a stop than if the starter were just turned off. The primary use of
this function is to reduce the sudden changes in pressure that are associ-
ated with “Water Hammer” and slamming of check valves with centrifugal
pumps. Decel control in pump applications is often referred to as Pump
Control.

In a pump system, liquid is being pushed uphill. The force exerted by

gravity on the column of liquid as it goes up hill is called the “Head
Pressure” in the system. The pump is sized to provide enough Output
Pressure to overcome the Head Pressure and move the fluid up the
pipe. When the pump is turned off, the Output Pressure rapidly drops
to zero and the Head Pressure takes over to send the fluid back down
the hill. A “Check Valve” is used somewhere in the system to prevent
this (if necessary) by only allowing the liquid to flow in one direction. The
kinetic energy in that moving fluid is suddenly trapped when the valve
slams closed. Since fluids can’t compress, that energy is transformed
into a “Shock Wave” that travels through the piping system looking for
an outlet in which it dissipates. The sound of that shock wave is referred
to as “Water Hammer”. The energy in that shock wave can be extremely
damaging to pipes, fittings, flanges, seals and mounting systems.

By using the Soft Stop/Deceleration feature of the soft starter, the pump output
torque is gradually and gently reduced, which slowly reduces the pressure in
the pipe. When the Output Pressure is just slightly lower than the Head Pres-
sure, the flow slowly reverses and closes the Check Valve. By this time there is
very little energy left in the moving fluid and the Shock Wave is avoided. When
the output voltage to the motor is low enough to no longer be needed, the soft
starter will end the Decel cycle and turn itself off.

- 19
 2.3 - 7.2kV

Another common application for decel control is on material handling convey-

ors as a means to prevent sudden stops that may cause products to fall over or
to bump into one another. In overhead crane applications, soft stopping of the
Bridge or Trolley can prevent loads from beginning to over swing on sudden
stops.

3.3.1 Start Deceleration Voltage

Factory Setting = 60% of line voltage
Range = 0% - 100% of line voltage
The step down voltage adjustment eliminates the dead band in the decelera-
tion mode that is experienced while the voltage drops to a level where the
motor deceleration is responsive to decreased voltage. This feature allows
for an instantaneous drop in voltage when deceleration is initiated.

3.3.2 Stop Deceleration Voltage

Factory Setting = 20% of line voltage
Range = 0% - 100% of line voltage
The stop voltage level setpoint is where the deceleration voltage drops
to zero.

3.3.3 Deceleration Time

Factory Setting = 5 sec.
Range = 0 - 60 sec.
The deceleration ramp time adjusts the time it takes to reach the stop volt-
age level set point. The unit should be restarted and stopped to verify that
the desired deceleration time has been achieved.

Note: Do not exceed the motor manufacturer’s recommended number of
starts per hour. When calculating the number of starts per hour, a decel curve
should be counted as a start curve. For example, recommended number of
starts per hour = 6, allowable starts with decel cycle per hour = 3.

3.4 Sequence of Normal Operation

• Apply control power and check that the “Power” LED comes on.
(Display 1) Display 1 MOTOR STOPPED
READY TO START
• Apply three phase power to the unit. The motor should run only when the
start command is applied. MOTOR STARTING
• Apply the start command. (Display 2). The RUN LED will be lit. (Display Display 2 00 X FLA
3). The AUX3 LEDs will be lit. If the motor does not enter run mode in the
set time (Acceleration time limit, see SP8.2), a trip will occur. Display 3 OVERLOAD ALARM
TIME TO TRIP: XXX SECS.
• When the motor reaches full speed, the “AUX4” LED (At Speed) will be lit.
• The POWER, RUN, AUX3 LEDs will be lit, indicating that the contact has IA: _ _ _ IB: _ _ _
energized. IA, IB, IC will display the current setting for Phase A, Phase B, Display 4 IC: _ _ _ G/F: _ _ _
and Phase C and the G/F indicates ground fault. (Display 4)
• If the motor decelerates, or stops, during the acceleration period, hit the
stop button immediately and open the disconnect line. If the unit does not
follow this operational sequence, please refer to the Troubleshooting
Chapter.

- 20
 2.3 - 7.2kV

It is best to operate the motor at its full load starting condition to achieve the
proper time, torque and ramp settings. Initial settings are set to accommodate
most motor conditions. TRY INITIAL SETTINGS FIRST. See (Section 5.1.1 Set-
point Page 2 to make any adjustments.
• Initial Voltage
• Soft Start Curve
• Current Limit
• Acceleration Time

If decel is enabled, the following parameters for Deceleration Time, Start Decel
Voltage (see Setpoint Page 2 and Stop Decel Voltage must also be programmed.

3.5 Emergency Bypass Operation
• Remove input power (using line start section and lock
! DANGER
out disconnect). HAZARDOUS OPERATION
• Close the emergency bypass contact. Do not operate the Bypass Contactor with medium
• Re-close disconnect on line start panel. voltage power applied to the unit.
• If integral overload protection is not to be used (see Failure to follow this instruction will cause the motor
JP-1 Motor Protection Jumper, Page 12), then to start unexpectedly.
bi-metallic overload protection is required (customer
supplied if factory emergency overload protection
option has not been included.)

Note: In the emergency bypass mode, there is no overload protection unless a sepa-
rate (optional or customer supplier) thermal overload relay is installed, or JP-1 (Motor
Protection Jumper, Page 12) is removed from the TCB Board.

The line start panel is operable as a normal across-the-line starter. When
power is applied, the bypass contactor is energized, tying the input terminals
directly to its output terminals. When the “ON/OFF” contact is closed, the
main contactor is energized and the motor line starts. When the “ON/OFF”
contact is opened, the motor is disconnected from the line via the main in-
line vacuum contactor.

- 21
 2.3 - 7.2kV

Chapter 4 - User Interface & Menu Navigation

This chapter explains the keypad operator interface, the LCD descriptions and the
programming features

4.1 Keypad/Operator Interface

The user keypad/ keypad operator interface consists of:
• 2 row by 20 characters Liquid Crystal Display (LCD)
• 12 LEDs
• 8 pushbuttons

Note: The soft starter is menu driven and there are three levels of programming. The
programming for two of these levels is password protected. Level two requires a
three digit password and level three requires a four digit password.

Toggle between the menu selection for metering and

MENU
setpoint pages.

RESET Will clear the trip indicator and release the trip relay.
Keypad Operator Interface
In the edit mode, press the ENTER pushbutton so the
unit will accept the new programming information.
ENTER When not in the edit mode, the ENTER pushbutton
will toggle through the event indicator list (such as
alarms or trips)

Provides general help information about a specific

HELP
setpoint or action.
Will scroll up through the setpoint and metering menu
page. It will scroll to the top of the setpoint page or a
Button UP ARROW section. In edit mode it will increase a setpoint in an
incremental step or toggle through the available
options in the setpoint.

In the main menu the RIGHT ARROW button provides

access to the setpoint page. For setpoint pages with
RIGHT ARROW multiple columns, the RIGHT ARROW will scroll the
setpoint page to the right. When in edit mode it will
shift one character to the right.

Will scroll down through the setpoint pages and down

through the setpoints. In edit mode, it will decrement
DOWN ARROW
through values and toggle available options in the
setpoint.
Will move to the left through setpoint pages with
multiple columns. When in edit mode it will become
LEFT ARROW
the backspace key and will shift one character to the
left.
Power Indicates control power is present
Run Indicates unit/motor is running
Lights in conjunction with AUX 2 to indicate event or
Alarm
LED warn of possible critical condition.
Lights in conjunction with AUX 1 to indicate a critical
Trip
condition has occurred.
AUX 1-8 Auxilary relays

Note: The directional arrow buttons require careful operation. In edit mode, if
the buttons are held for a long period, the scrolling speed will increase.

- 22
 2.3 - 7.2kV

4.2 Menu Navigation

Notes:
1. The MENU keys allow you to toggle the screens between the Setpoint Menu and
MENU the Metering Menu. Simply use the arrow keys to get to the different screens
(1) within each menu.
Example: To access Setpoint Page 3: PHASE & GROUND SETTINGS, press the
MENU key once and the DOWN ARROW two times.
PAGE 1 BASIC 2. Levels 1, 2 and 3 indicate password protection levels for these setpoint pages.
CONFIGURATION

LEVEL 1
PAGE 2 STARTER
CONFIGURATION

PAGE 3 PHASE &

GROUND SETTINGS

PAGE 4 RELAY
ASSIGNMENT

LEVEL 2

PAGE 5 RELAY
CONFIGURATION

PAGE 6 USER I/O

CONFIGURATION

PAGE 7 CUSTOM
ACCELERATION CURVE

PAGE 8 OVERLOAD
CURVE CONFIGURATION

PAGE 9 RTD
CONFIGURATION

LEVEL 3
PAGE 10 SECURITY
SET PASSWORD

PAGE 11
COMMUNICATIONS

PAGE 12 SYSTEM
SETPOINTS

FACTORY PAGE 13 CALIBRATION

LEVEL & SERVICE

- 23
 2.3 - 7.2kV

4.2.1 Password Access

Screens in Level 1 of the setpoint menu can be changed without password
access because they list basic motor information. Screens in Levels 2 and
3 require passwords because they provide more in-depth protection and
control of the unit. The password in Levels 2 and 3 can be changed by the
user.

NOTE: Setpoints can only be changed when the motor is in Stop/

Ready Mode! The soft starter will not allow a start if it is
still in the Edit Mode. When the unit is in the Edit Mode, an
asterisk is displayed in the top right corner screen.

4.2.2 Changing Setpoints

Example 1: Changing Motor FLA
A. Press MENU button to display Setpoint Page 1, Basic Configuration
B. Press the RIGHT ARROW you will view the screen Motor Full Load
Amps.
C. Press the ENTER button for edit mode. Note the asterisk (*) in the top
right corner of the LCD screen that indicates Edit Mode.
D. To change the value, select the UP ARROW or DOWN ARROW.
E. To accept the new value, press the ENTER button. The unit will accept
the changes and will leave the edit mode. Note the * is no longer in the
top right corner of the LCD Display.

MENU

PAGE 1 BASIC MOTOR FULL LOAD AMPS

CONFIGURATION : 140 AMPS

ENTER

MOTOR FULL LOAD AMP*

2x : 142 AMPS

ENTER

MOTOR FULL LOAD AMP

: 142 AMPS

- 24
 2.3 - 7.2kV
Chapter 5 - Setpoint Programming
The soft starter has thirteen programmable setpoint pages which define the motor
data, ramp curves, protection, I/O configuration and communications. In Section 5.1,
the setpoint pages are outlined in chart form. In Section 5.2 the setpoint pages are
illustrated and defined for easy navigation and programming. Note: Setpoints can only
be changed when the starter is in the Ready Mode. Also the soft start will not start
when it is in programming mode.

5.1 Setpoints Page List

These charts list the Setpoint Page, the programmable functions and the section.
5.1.1 Basic Configuration (Setpoint Page1)
Setpoint Security Factory Setting
Description Range Section
Page Level Default
50 - 100% of Unit Max Current Rating
Motor Full Load Amps (FLA) Model dependent SP1.1
No Passowrd Required

(Model and Service Factor dependent)

Basic Configuration

Service Factor 1.15 1.00 – 1.3 SP1.2

Level 1
Page 1

Overload Class 10 O/L Class 5-30 SP1.3

NEMA Design B A-F SP1.4
Insulation Class B A, B, C, E, F, H, K, N, S SP1.5
Line Voltage Model dependent 1000 to 7200V SP1.6
Line Frequency 60 50 or 60 HZ SP1.7

5.1.2 Starter Configuration (Setpoint Page 2)

Setpoint Security Factory Setting
Description Range Section
Page Level Default

Jog, Start Ramp 1, Start Ramp 2, Custom

SP2.1
Start Control Mode Start Ramp 1 Accel Curve, Start Disabled, Dual Ramp,
Tach Ramp
Jog Voltage 50% 5-75%, Off SP2.2
Start Ramp #1 Type Voltage Current, Voltage
Initial Voltage #1 20% 0-100%
Ramp Time #1 10 sec 0-120 sec
Current Limit #1 350% FLA 200-500 % SP2.3
Initial Current #1 200% FLA 0-300%
Ramp Time #1 10 sec 0-120 sec
Maximum Current #1 350% FLA 200-500 %
Start Ramp #2 Type Disabled Current, Voltage, Disabled
No Passowrd Required
Starter Configuration

Initial Voltage #2 60% 0-100 %

Ramp Time #2 10 sec 0-120 sec
Level 1
Page 2

Current Limit #2 350 % FLA 200-500 % SP2.4

Initial Current #2 200% FLA 0-300 %
Ramp Time #2 10 sec 0-120 sec
Maximum Current #2 350% FLA 200-500 %
Kick Start Type Disabled Voltage or Disabled
Kick Start Voltage 65% 10-100 % SP2.5
Kick Start Time 0.50 sec 0.10-2.00
Deceleration Disabled Enabled or Disabled
Start Deceleration Voltage 60% 0-100 %
SP2.6
Stop Deceleration Voltage 30% 0-59 %
Deceleration Time 5 sec 1-60 sec
Timed Output Time Off 1-1000 sec, Off SP2.7
Run Delay Time 1 Sec 1-30 sec, Off SP2.8
At Speed Delay Time 1 Sec 1-30 sec, Off SP2.9
- 25
 2.3 - 7.2kV

5.1.3 Phase and Ground Settings (Setpoint Page 3)

Setpoint Security Factory Setting

Description Range Section
Page Level Default
Imbalance Alarm Level 15% FLA 5-30 %, Off
SP3.1
Imbalance Alarm Delay 1.5 sec 1.0-20.0 sec
Imbalance Trip Level 20% 5-30 %, Off
SP3.2
Imbalance Trip Delay 2.0 sec 1.0-20.0 sec
Undercurrent Alarm Level Off 10-90 %, Off
SP3.3
Undercurrent Alarm Delay 2.0 sec 1.0-60.0 sec
Overcurrent Alarm Level Off 100-300 %, Off
SP3.4
Overcurrent Alarm Delay 2.0 sec 1.0-20.0 sec
Overcurrent Trip Level Off 100-300 %, Off
SP3.5
Overcurrent Trip Delay 2.0 sec 1.0-20.0 sec
Phase Loss Trip Enabled Enabled or Disabled
SP3.6
Phase Loss Trip Delay 0.1 sec 0-20.0 sec
Phase Rotation Detection ABC ABC, ACB or Disabled
SP3.7
Phase Rotation Trip Delay 1.0 sec 1.0 - 20.0 sec
*Ground Fault Alarm Level Off 5-90 %, Off
SP3.8
*Ground Fault Alarm Delay 0.1 sec 0.1-20.0 sec
*Ground Fault Loset Trip Level Off 5-90 %, Off
SP3.9
*Ground Fault Loset Trip Delay 0.5 sec 0.1-20 sec
Phase and Ground Settings

*Ground Fault Hiset Trip Level Off 5-90 %, Off

SP3.10
Password Protection

*Ground Fault Hiset Trip Delay 0.008 sec 0.008-0.250 sec

Overvoltage Alarm Level Off 5 -30%, Off
Level 2
Page 3

SP3.11
Overvoltage Alarm Delay 1.0 sec 1.0-30.0 sec
Overvoltage Trip Level 10% 5-30%, Off
SP3.12
Overvoltage Trip Delay 2.0 sec 1.0-30.0 sec
Undervoltage Alarm Level Off 5-30%, Off
SP3.13
Undervoltage Alarm Delay 1.0 sec 1.0-30.0 sec
Undervoltage Trip Level 15% 5-30%, Off
SP3.14
Undervoltage Trip Delay 2.0 sec 1.0-30.0 sec
Line Frequency Trip Window Disabled 0-6 Hz, Disabled
SP3.15
Line Frequency Trip Delay 1.0 sec 1.0-20.0 sec
P/F Lead P/F Alarm Off 0.1-1.00, Off
SP3.16
P/F Lead Alarm Delay 1.0 sec 1-120 sec
P/F Lead P/F Trip Off .01-1.00, Off
SP3.17
P/F Lead Trip Delay 1.0 sec 1-120 sec
P/F Lag P/F Alarm Off .01-1.00, Off
SP3.18
P/F Lag Alarm Delay 1.0 sec 1-120 sec
P/F Lag P/F Trip Off .01-1.00, Off
SP3.19
P/F Lag Trip Delay 1.0 sec 1-120 sec
Power Demand Period 10 min 1 - 60 min
KW Demand Alarm Pickup Off KW Off, 1-100000
KVA Demand Alarm Pickup Off KVA Off, 1-100000 SP3.20
KVAR Demand Alarm Pickup Off KVAR Off, 1-100000
Amps Demand Alarm Pickup Off Amps Off, 1-100000

* Ground fault option must be installed

- 26
 2.3 - 7.2kV

5.1.4 Relay Assignments (Setpoint Page 4)

Setpoint Security Factory Setting

Description Range Section
Page Level 1st 2nd 3rd
O/L Trip Trip Only None None
I/B Trip Trip None None
S/C Trip Trip Only None None
Overcurrent Trip Trip None None
Stator RTD Trip None None None
Non Stator RTD Trip None None None
*G/F Hi Set Trip Trip None None
*G/F Lo Set Trip Trip None None
Phase Loss Trip Trip None None
Accel. Time Trip Trip Only None None
Start Curve Trip Trip Only None None
Over Frequency Trip None None None
Under Frequency Trip Trip None None
I*I*T Start Curve Trip None None
Learned Start Curve Trip None None
Phase Reversal Trip None None
Overvoltage Trip Trip None None
Undervoltage Trip Trip None None None
Power Factor Trip None None None Trip(AUX1)
Tach Accel Trip None None None Alarm(AUX2)
Inhibits Trip Trip None None AUX3
Shunt Trip None None None AUX4
AUX5-8
Bypass Discrepancy None None None
Password Protection
Relay Assignments

Only Available in 8 Relay

TCB Fault Trip None None System
External Input #2 None None None
Level 2
Page 4

Notes:
Dual Ramp None None None AUX1 to AUX4 are for Factory SP4.1
Thermostat Trip None None Use only. Do not change!
O/L Warning Alarm None None Only AUX 5 - 8 are used in the
Overcurrent Alarm Alarm None None 2nd & 3rd relay assignments.
SCR Fail Shunt Alarm None None None
*Ground Fault Alarm Alarm None None
Under Current Alarm None None None
Motor Running AUX3 None None
I/B Alarm Alarm None None
Stator RTD Alarm None None None
Non-Stator RTD Alarm None None None
RTD Failure Alarm None None None
Self Test Fail Trip None None
Thermal Register Alarm None None
U/V Alarm Alarm None None
O/V Alarm Alarm None None
Power Factor Alarm None None None
KW Demand Alarm None None None
KVA Demand Alarm None None None
KVAR Demand Alarm None None None
Amps Demand Alarm None None None
Timed Output None None None
Run Delay Time None None None
At Speed AUX4 None None

* Ground fault option must be installed

- 27
 2.3 - 7.2kV

5.1.5 Relay Configuration (Setpoint Page 5)

Setpoint Security Factory Setting

Description Range Section
Page Level Default
Trip (AUX1) Fail-Safe No Yes or No SP5.1
Trip (AUX1) Relay Latched Yes Yes or No SP5.2
Alarm (AUX2) Fail-Safe No Yes or No SP5.1
Alarm (AUX2) Relay Latched No Yes or No SP5.2
AUX3 Relay Fail-Safe No Yes or No SP5.1
AUX3 Relay Latched No Yes or No SP5.2
Password Protection
Relay Configuration

AUX4 Relay Fail-Safe No Yes or No SP5.1

Level 2
Page 5

AUX4 Relay Latched No Yes or No SP5.2

AUX5 Relay Fail-Safe No Yes or No SP5.1
AUX5 Relay Latched No Yes or No SP5.2
AUX6 Relay Fail-Safe No Yes or No SP5.1
AUX6 Relay Latched No Yes or No SP5.2
AUX7 Relay Fail-Safe No Yes or No SP5.1
AUX7 Relay Latched No Yes or No SP5.2
AUX8 Relay Fail-Safe No Yes or No SP5.1
AUX8 Relay Latched No Yes or No SP5.2

- 28
 2.3 - 7.2kV

5.1.6 User I/O Configuration (Setpoint Page 6)

Setpoint Security Factory Setting

Description Range Section
Page Level Default
Tachometer Scale Selection Disabled Enabled or Disabled
Manual Tach Scale 4.0 mA: 0 RPM 0 - 3600 SP6.1
Manual Tach Scale 20.0 mA: 2000 RPM 0 - 3600
Tach Accel Trip Mode Select Disabled Underspeed, Overspeed or Disabled
Tach Ramp Time 20 sec 1 - 120
Tach Underspeed Trip PT 1650 RPM 0-3600 SP6.2
Tach Overspeed Trip PT 1850 RPM 0 - 3600
Tach Accel Trip Delay 1 sec 1 - 60
Off, RPM 0-3600, Hottest Non-Stator RTD
0-200°C, Hottest Stator RTD
Analog Output #1 RMS Current
0 - 200°C, RMS Current 0 - 7500 A, %
Motor Load 0 - 600% Kw SP6.3

Analog Output #1 4mA: 0 0-65535

Analog Output #1 20mA: 250 0-65535
Analog Output #2 % Motor Load Same As Analog Input #1
User I/O Configuration

Passowrd Protection

Analog Output #2 4mA: 0 0-65535 SP6.4

Analog Output #2 20mA: 1000 0-65535
Lavel 2
Page 6

User Programmable External

Inputs
TCB Fault Enabled Enabled or Disabled
Name Ext. Input #1 TCB Fault User Defined, up to 15 Characters
TCB Fault Type NO Normally Open or Closed
TCB Fault Time Delay 1 sec 0-60 sec
External Input #2 Disabled Enabled or Disabled
Name Ext. Input #2 User Defined, up to 15 Characters
External Input #2 Type NO Normally Open or Closed
SP6.5
External Input #2 Time Delay 0 sec 0-60 sec
Dual Ramp Dual Ramp Enabled or Disabled or Dual Ramp
Name Ext. Input #3 Dual Ramp User Defined, up to 15 Characters
Dual Ramp Type NO Normally Open or Closed
Dual Ramp Time Delay 0 sec 0-60 sec
Thermostat Enabled Enabled or Disabled
Name Ext. Input #4 Thermostat User Defined, up to 15 Characters
Thermostat Type NC Normally Open or Closed
Thermostat Time Delay 1 sec 0-60 sec

- 29
 2.3 - 7.2kV

5.1.7 Custom Acceleration Curve (Setpoint Page 7)

Setpoint Security Factory Setting
Description Range Section
Page Level Default
Custom Accel Curve Disabled Disabled, Curve A, B, or C
Custom Curve A
Curve A Voltage Level 1 25% 0-100%
Curve A Ramp Time 1 2 sec 1-60 sec
Curve A Voltage Level 2 30% 0-100%
Curve A Ramp Time 2 2 sec 1-60 sec
Curve A Voltage Level 3 37% 0-100%
Curve A Ramp Time 3 2 sec 1-60 sec
Custom Acceleration Curve

Curve A Voltage Level 4 45% 0-100%

Password Protection

Curve A Ramp Time 4 2 sec 1-60 sec

Curve A Voltage Level 5 55% 0-100%
Level 3
Page 7

Curve A Ramp Time 5 2 sec 1-60 sec SP7.1

Curve A Voltage Level 6 67% 0-100%
Curve A Ramp Time 6 2 sec 1-60 sec
Curve A Voltage Level 7 82% 0-100%
Curve A Ramp Time 7 2 sec 1-60 sec
Curve A Voltage Level 8 100% 0-100%
Curve A Ramp Time 8 2 sec 1-60 sec
Curve A Current Limit 350% FLA 200-500%
Same Programmable Data Points and Ranges
Custom Curve B
as Custom Curve A

Same Programmable Data Points and Ranges

Custom Curve C
as Custom Curve A

5.1.8 Overload Curve Configuration (Setpoint Page 8)

Setpoint Security Factory Setting

Description Range Section
Page Level Default
Basic Run Overload Curve
Run Curve Locked Rotor Time O/L Class 1-30 sec, O/L Class
SP8.1
Run Locked Rotor Current 600% FLA 400-800%
Coast Down Timer Disabled 1-60 Min, Disabled
Overload Curve Configuration

Basic Start Overload Curve

Password Protection

Start Curve Locked Rotor Time O/L Class 1-30 sec, O/L Class
Start Locked Rotor Current 600% FLA 400-800%
Level 3
Page 8

SP8.2
Acceleration Time Limit 30 sec 1-300 sec, Disabled
Number of Starts Per Hour Disabled 1-6, Disabled
Time Between Starts Time 5 min 1-60 Min, Disabled
Area Under Curve Protection Disabled Enabled or Disabled
SP8.3
Max I*I*T Start 368 FLA 1-2500 FLA*FLA*sec
Current Over Curve Disabled Disabled, Learn, Enabled
Learned Start Curve Bias 10% 5-40% SP8.4
Time for Sampling 30 sec 1-300 sec

- 30
 2.3 - 7.2kV

5.1.9 RTD Option Configuration (Setpoint Page 9)

Setpoint Security Factory Setting
Description Range Section
Page Level Default

Use NEMA Temp for RTD Values Disabled Enabled or Disabled SP9.1

# of RTD Used for Stator 4 0-6 SP9.2

RTD Voting Disabled Enabled or Disabled SP9.3
120 OHM NI, 100 OHM NI, 100 OHM PT, 10
Stator Phase A1 Type Off
OHM CU
RTD #1 Description Stator A1 User defined, Up to 15 Characters
Stator Phase A1 Alarm Level Off 0-240C (32-464F), Off
Stator Phase A1 Trip Level Off 0-240C (32-464F), Off
Stator Phase A2 Type Off Same as Stator Phase A1
RTD #2 Description Stator A2 User defined, Up to 15 Characters
Stator Phase A2 Alarm Off 0-240C (32-464F), Off
Stator Phase A2 Trip Level Off 0-240C (32-464F), Off
Stator Phase B1 Type Off Same as Stator Phase A1
RTD #3 Description Stator B1 User defined, Up to 15 Characters
Stator Phase B1 Alarm Level Off 0-240C (32-464F), Off
Stator Phase B1 Trip Level Off 0-240C (32-464F), Off
Stator Phase B2 Type Off Same as Stator Phase A1
Password Protection
RTD Configuration

RTD #4 Description Stator B2 User defined, Up to 15 Characters

Stator Phase B2 Alarm Level Off 0-240C (32-464F), Off
Level 3
Page 9

Stator Phase B2 Trip Level Off 0-240C (32-464F), Off

Stator Phase C1 Type Off Same as Stator Phase A1
RTD #5 Description Stator C1 User defined, Up to 15 Characters SP9.4
Stator Phase C1 Alarm Level Off 0-240C (32-464F), Off
Stator Phase C1 Trip Level Off 0-240C (32-464F), Off
Stator Phase C2 Type Off Same as Stator Phase A1
RTD #6 Description Stator C2 User defined, Up to 15 Characters
Stator Phase C2 Alarm Level Off 0-240C (32-464F), Off
Stator Phase C2 Trip Level Off 0-240C (32-464F), Off
End Bearing Type Off Same as Stator A1
RTD #7 Description End Bearing User defined, Up to 15 Characters
End Bearing Alarm Level Off 0-240C (32-464F), Off
End Bearing Trip Level Off 0-240C (32-464F), Off
Shaft Bearing Type Off Same as Stator Phase A1
RTD #8 Description Shaft Bearing User defined, Up to 15 Characters
Shaft Bearing Alarm Level Off 0-240C (32-464F), Off
Shaft Bearing Trip Level Off 0-240C (32-464F), Off
RTD #9 Type Off Same as Stator Phase A1
RTD #9 Description User defined User defined, Up to 15 Characters
RTD #9 Alarm Level Off 0-240C (32-464F), Off
RTD #9 Trip Level Off 0-240C (32-464F), Off

- 31
 2.3 - 7.2kV

5.1.9 RTD Option Configuration Page 9 Cont’d

Setpoint Security Factory Setting

Description Range Section
Page Level Default
RTD #10 Type Off Same as Stator Phase A1
RTD #10 Description User defined User defined, Up to 15 Characters
RTD #10 Alarm Level Off 0-240C (32-464F), Off
RTD #10 Trip Level Off 0-240C (32-464F), Off
Password Protection
RTD Configuration

RTD #11 Type Off Same as Stator Phase A1

Level 3
Page 9

RTD #11 Description User defined User defined, Up to 15 Characters

SP9.4
RTD #11 Alarm Level Off 0-240C (32-464F), Off
RTD #11 Trip Level Off 0-240C (32-464F), Off
RTD #12 Type Off Same as Stator Phase A1
RTD #12 Description User defined User defined, Up to 15 Characters
RTD #12 Alarm Level Off 0-240C (32-464F), Off
RTD #12 Trip Level Off 0-240C (32-464F), Off

Setpoint Security Factory Setting

Description Range Section
Page Level Default
Level
Page

Set Level 2 Password 100 000 – 999 Three Digits SP10.1

10

Set Level 3 Password 1000 0000 – 9999 Four Digits SP10.2

Setpoint Security Factory Setting

Description Range Section
Page Level Default
Set Front Baud Rate 9.6 KB/sec 2.4, 4.8, 9.6, 19.2, 38.4 KB/sec SP11.1
Password Protection
Communiications

Set Modbus Baud Rate 9.6 KB/sec 2.4, 4.8, 9.6, 19.2, 38.4 KB/sec SP11.2
Page 11

Level 3

Modbus Address Number 247 1 – 247 SP11.3

Set Access Code 1 1 – 999 SP11.4
Set Link Baud Rate 38.4 KB/sec 2.4, 4.8, 9.6, 19.2, 38.4 KB/sec SP11.5
Remote Start/Stop Disabled Enabled or Disabled SP11.6

- 32
 2.3 - 7.2kV

5.1.12 System (Setpoint Page 12)

Setpoint Security Factory Setting
Description Range Section
Page Level Default
Default Display Screen
Metering Data Page # 1 Enter Metering Page (1-4)
Enter Metering Screen
SP12.1
Page 1(1-10)
Metering Data Screen # 1 Page 2 (1-11)
Page 3 (1 - 29)
Page 4 (1 - 6)
Alarms
RTD Failure Alarm Disabled Enabled or Disabled
SP12.2
Thermal Register Alarm 90% Off, 40-95%
Thermal Alarm Delay 10 sec 1-20 sec
Password Protection

Thermal Register Setup Info

System Setpoints

Cold Stall Time O/L Class O/L Class (5-30) or 4-40 second time delay
Page 12

Level 3

Hot Stall Time ½ O/L Class ½ O/L Class, 4-40 sec

Stopped Cool Down Time 30 Min 10-300 Min
Runing Cool Down Time 15 Min 10-300 Min
Relay Measured Cool Rates Disabled Enabled or Disabled
Thermal Register Minimum 15% 10-50% SP12.3
Motor Design Ambient Temp 40C 10-90C

Motor Design Run Temperature 80% Max 50-100% of Motor Stator Max Temp

Motor Stator Max Temp INS CLS INS CLS, 10-240 C

I/B Input to Thermal Register Enabled Enabled or Disabled
Use Calculated K or Assign 7 1-50, On

Press Enter to Clr Thermal Register SP12.4

5.1.13 Calibration and Service (Setpoint Page 13)

Setpoint Security Factory Setting

Description Range Section
Page Level Default
Set Date and Time FACTORY SET;
(DDMMYY:HHMM) ##/##/## ##:##
FACTORY USE ONLY
Calibration & Service

FACTORY SET;
Enter Date (DDMMYYYY) D=1-31, M=1-12, Y=1970-2069 SP13.1
##/##/####
Page 13

FACTORY SET;
Enter Time (HH:MM) H=00-23, M=0-59
##:##
Model # FACTORY SET;
Display Only, Cannot be changed SP13.2
Firmware REV. # ###### ######
Press Enter to Access Factory
Available to Qualified Factory Personnel SP13.3
Settings

- 33
 2.3 - 7.2kV

5.2 Setpoint Menu

Note:
1. Push MENU key to toggle the screens between Setpoint Menu and Metering
MENU Menu.
(1) 2. Follow the arrow keys to get to different screens.
Example: For Page 3 PHASE & GROUND SETTINGS, press the MENU key and
the DOWN ARROW two times.
PAGE 1 BASIC
CONFIGURATION

LEVEL 1
PAGE 2 STARTER
CONFIGURATION

PAGE 3 PHASE &

GROUND SETTINGS

PAGE 4 RELAY
ASSIGNMENT

LEVEL 2

PAGE 5 RELAY
CONFIGURATION

PAGE 6 USER I/O

CONFIGURATION

PAGE 7 CUSTOM
ACCELERATION CURVE

PAGE 8 OVERLOAD
CURVE CONFIGURATION

PAGE 9 RTD
CONFIGURATION

LEVEL 3
PAGE 10 SECURITY
SET PASSWORD

PAGE 11
COMMUNICATIONS

PAGE 12 SYSTEM
SETPOINTS

FACTORY PAGE 13 CALIBRATION

LEVEL & SERVICE

- 34
 2.3 - 7.2kV

SP.1 Basic Configuration (Setpoint Page 1)

In Setpoint Page 1, the is looking for the following basic MENU
nameplate data of the motor.

SP1.1 Motor Full Load Amps (FLA): Allows the user to enter the PAGE 1 BASIC MOTOR FULL LOAD AMPS
CONFIGURATION : 200 AMPS
motor’s FLA rating. Range of adjustment is 50 - 100%
Range: 50 - 100% of Unit
(less programmed service factor). MAX CURRENT AMPS
Increments of 1
SP1.2 Service Factor: Sets the pickup point on the overload SERVICE FACTOR
curve as defined by the programmed motor full load : 1.15 X FLA
current. Ex: If the motor FLA is 100 and the service factor Range: 1.00 - 1.3
Increments of 0.01
is 1.15, the overload pickup point will be 115 Amps.
OVERLOAD
SP1.3 Overload Class: Choose the motor protection overload CLASS: 10
class, range from 5-30. Range: 5 - 30
Increments of 5
Ex: Overload Class 10 will trip in 10 seconds at six times
FLA. NEMA
DESIGN: B
Range: A - F

INSULATION
CLASS: B
Range: A - S

LINE VOLTAGE
INPUT: 4160 VOLTS
Range: 1000 - 7200

LINE FREQUENCY
HZ: 60
Range: 50 or 60

SP1.4 NEMA design: The motor design maximum allowed slip (Select from
Class A through F).

SP1.5 Insulation Class: The motor insulation temperature class (Select A,

B, C, E, F, G, H, K, N or S).

SP1.6 Line Voltage Input: Applied Voltage

SP1.7 Line Frequency: The user may choose either 50 Hz or 60 Hz.

- 35
 2.3 - 7.2kV

SP.2 Starter Configuration (Setpoint Page 2)

MENU
(Hit DOWN ARROW one time)

PAGE 2 STARTER START CONTROL MODE

CONFIGURATION : START RAMP 1
JOG, START RAMP 1,
START RAMP 2, DUAL
RAMP, CUSTOM ACCEL
CURVE,START DISABLED
If If
VOLTAGE CURRENT
JOG VOLTAGE selected selected
: 50% these these
screens screens
Range: 5 - 75% or Off will appear. will appear.
Increments 5

START RAMP #1 TYPE INITIAL VOLTAGE INITIAL CURRENT

: VOLTAGE #1: 20% #1: 200% FLA
Options:Voltage, Current Range: 0 - 100% Range: 0 - 300%
or Off Increments of 1 Increments of 1

RAMP TIME RAMP TIME

#1: 10 SEC. #1: 10 SEC.
Range: 0 - 120 SEC. Range: 0 - 120 SEC
Increments of 1 Increments of 1

CURRENT LIMIT MAXIMUM CURRENT

#1: 350% FLA #1: 350% FLA
Range: 200 - 500% Range: 200-500%
Increments of 10 Increments of 10

If If
START RAMP #2 TYPE VOLTAGE CURRENT
: DISABLED selected INITIAL VOLTAGE selected INITIAL CURRENT
these these
#2: 60% #2: 200% FLA
Options: Voltage, Current screens screens
or Off will appear. Range: 0 - 100% will appear. Range: 0 - 300%
Increments of 1 Increments of 1

RAMP TIME RAMP TIME

#2: 10 SEC. #2: 10 SEC.
Range: 0 - 120 SEC. Range: 0 - 120 SEC
Increments of 1 Increments of 1

CURRENT LIMIT MAXIMUM CURRENT

#2: 350% FLA #2: 350% FLA
Range: 200 - 500% Range: 200-500%
Increments of 10 Increments of 10

KICK START KICK START VOLTAGE

TYPE: DISABLED : 65%
Range: Voltage or Disabled Range: 10 - 100%
Increments of 5

DECELERATION KICK START TIME

: DISABLED : 0.50 SEC.
Range: Enabled or Disabled Range: 0.10 - 2.00
Increments of 0.10

START DECELERATION
TIMED OUTPUT VOLTAGE: 60%
TIME: OFF
Range: 0 - 100%
Range: 1 - 1000 sec, OFF Increments of 1
Increments of 1

RUN DELAY STOP DECELERATION

TIME: 1 SEC. VOLTAGE: 30%
Range: 0 - 30 sec, OFF Range: 0 - 59%
Increments of 1 Increments of 1

AT SPEED DELAY DECELERATION

TIME: 1 SEC. TIME: 5 SEC.
Range: 0 - 30 sec, OFF Range: 1 - 60
Increments of 1 Increments of 1
- 36
 2.3 - 7.2kV

SP.2 Starter Configuration (Setpoint Page 2) • Voltage Ramping with Current Limit is the most
Provides multiple choices for starting ramps that can be used curve and is similar to voltage ramping.
selected for particular loads and applications. However, it adds an adjustable maximum current
output. Voltage is increased gradually until the
SP2.1 Start Control Mode: Dual Ramp, Custom Accel setting of the Maximum Current Limit setpoint
Curve, Jog Voltage, Start Ramp 1, Start Ramp 2. is reached. The voltage is held at this level until
• Dual Ramp: The dual ramp mode works in the motor accelerates to full speed. This may be
conjunction with External Input #3. This allows necessary in applications where the electrical
the user to switch between the two start ramps power is limited. Typical applications include
without having to reconfigure the start mode. (For portable or emergency generator supplies, utility
details on configuring External Input #3 for DUAL power near the end of a transmission line and
RAMP see Setpoint Page 6.) utility starting power demand restrictions. Note:
• Custom Accel Curve: Allows the user to Using Current Limit will override the Ramp Time
custom design the acceleration start curve to the setting if necessary, so use this feature when
application. (See setpoint page 7 for configuration acceleration time is not critical. To achieve Voltage
setup.) Note: If Custom Accel Curve has not Ramping with Current Limit, select VOLTAGE for
been enabled in setpoint page 7, the soft starter the START RAMP #1 setpoint and set CURRENT
will ignore the start control mode and read this LIMIT#1 setpoint to a desired lower setting, as
setpoint as disabled. determined by your application requirements.

SP2.2 Jog Voltage: The voltage level necessary to Start Ramp 1 Type: Current
cause the motor to slowly rotate. • Current Ramping (Closed Loop Torque Ramping)
is used for smooth linear acceleration of output
SP2.3 Start Ramp 1 Type: The ramp type can be setup torque. This ramp is only used on some conveyor
for either Voltage or Current. If Voltage is selected, systems (long haul or down hill). For other
initial voltage, ramp time and current limit are applications, use Voltage Ramp or a custom accel
adjustable. If Current is selected, initial current, curve. Output voltage is constantly updated to
ramp time and maximum current are adjustable. provide the linear current ramp, and therefore the
Start Ramp 1 Type: Voltage available torque is maximized at any given speed.
• Voltage Ramping is the most reliable starting This is for applications where rapid changes in
method, because the starter will eventually reach torque may result in load damage or equipment
an output voltage high enough to draw full current changes. Typical applications include overland
and develop full torque. This method is useful for conveyors if belt stretching occurs; fans and
applications where the load conditions change mixers if blade warping is a problem; and material
frequently and where different levels of torque handling systems if stacked products fall over or
are required. Typical applications include material break. This feature can be used with or without
handling conveyors, positive displacement pumps the Maximum Current Limit setting. To achieve
and drum mixers. Current Ramping select CURRENT for START
Voltage is increased RAMP #1 TYPE setpoint and the MAXIMUM
from a starting point CURRENT #1 setpoint to the desired level.
(Initial Torque) to
full voltage over an • Current Limit Only: (Current Step) start uses the
adjustable period of Current Limit feature exclusively. This method of
time (Ramp Time). starting eliminates the soft start voltage/current
To achieve Voltage ramp and instead, maximizes the effective
Ramping, select application of motor torque within the limits of
VOLTAGE for the the motor. In this mode, setpoint RAMP TIME
START RAMP #1 #1 is set to zero (0), so the output current jumps
TYPE setpoint and set to the current limit setting immediately. Typically
CURRENT LIMIT#1 used with a limited power supply, when starting
setpoint to 500% (the a difficult load such as a centrifuge or deep well
maximum setting). Since this is essentially Locked pump, when the motor capacity is barely adequate
Rotor Current on most motors, there is little or no (stall condition or overloading occurs) or if other
Current Limit effect on the Ramp profile. starting modes fail. Since ramp times are set to
zero (0), START RAMP #1 TYPE is set to either
VOLTAGE or CURRENT.

- 37
 2.3 - 7.2kV

• Initial Torque (Initial Voltage #1 or Initial SP2.4 Start Ramp 2: The same options and screen
Current #1): Sets the initial start point of either setups as Start Ramp 1. Note: CUSTOM ACCEL
the Voltage Ramp or the Current Ramp. Every CURVE overrides the voltage or current start in
load requires some amount of torque to start from Ramps 1 and 2 when selected to be the start
a standstill. It is inefficient to begin ramping the control mode.
motor from zero every time, since between zero
and the WK2 break-away torque level, no work is SP2.5 Kick Start: Used as an initial energy burst in
being performed. The initial torque level should be applications with high friction loads.
set to provide enough torque to start rotating the
motor shaft, enabling a soft start and preventing • Kick Start Voltage: The initial voltage (as a
torque shock damage. Setting this start point too percent of full voltage value) that is needed to
high will not damage the starter, but may reduce start the motor. (i.e., Breakaway or Initial Torque.)
or eliminate the soft start effect.
• Kick Start Time: The time the initial torque boost
• Ramp Time #1: Sets the maximum allowable time is applied.
for ramping the initial voltage or current (torque)
setting to either of the following: SP2.6 Deceleration: Allows the motor to gradually come
1) the Current Limit setting when the motor is still to a soft stop.
accelerating, or
2) full output voltage if the Current Limit is set to • Start Deceleration Voltage: The first part of
maximum. the deceleration ramp. The initially drops to this
Increasing the ramp time softens the start process voltage level upon receiving a STOP command.
by gradually increasing the voltage or current. (Represented as a percent of voltage value.)
Ideally, the ramp time should be set for the longest
amount of time the application will allow (without • Stop Deceleration Voltage: The drop-off point of
stalling the motor). Some applications require the deceleration ramp. (Percent of voltage value.)
a short ramp time due to the mechanics of the
system. (i.e, centrifugal pumps, because pump • Deceleration Time: Decel ramp time.
problems can occur due to insufficient torque).
SP2.7 Timed Output: Used with an AUX 5-8 relay.
• Current Limit: Sets the maximum motor current When enabled, and upon a start command, it
the starter will allow during Ramping. As the motor waits until the programmed time plus the run
begins to ramp, the Current Limit feature sets a delayed time has expired. The relay energizes
ceiling at which the current draw is held. Current and remains so until a stop command is received.
Limit remains in effect until the following occurs: It de-energizes upon receiving a stop command.
1) the motor reaches full speed (detected by the
At-Speed detection circuit) or SP2.8 Run Delay Time: Can be used with an AUX 5-8
2) the Overload Protection trips on Motor Thermal relay. The delay timer begins upon receipt of the
Overload. start command. The relay will then drop out when
Once the motor reaches full speed, the Current the time has expired.
Limit feature becomes inactive.
SP2.9 At Speed Delay Time: Used with an AUX 4
In the Voltage Ramp Profile, the voltage output is relay, it waits until after the motor reaches the
increased until it reaches the Current Limit. Ramp end of ramp and the programmed delay time has
time is the maximum amount of time it takes for expired. The relay energizes until a stop command
the voltage to increase until the Current Limit has been received.
setting takes over. With some load conditions, the
Current Limit is reached before the Ramp Time
expires.

The Current Ramp profile varies the output
voltage to provide a linear increase in current up
to the Maximum Current setpoint value. A closed
loop feedback of motor current maintains the
Current Ramp profile.

- 38
 2.3 - 7.2kV

SP.3 Phase & Ground Settings

(Setpoint Page 3) MENU
(Security Level: 2) (Hit DOWN ARROW two times)

PAGE 3 PHASE & IMBALANCE ALARM IMBALANCE ALARM

GROUND SETTINGS LEVEL: 15% FLA DELAY: 1.5 SEC.
Range: 5 - 30%, OFF Range: 1.0 - 20.0 SEC.
Increments of 1 Increments of 0.1

IMBALANCE TRIP IMBALANCE TRIP

LEVEL: 20%FLA DELAY: 2.0 SEC.

Note: Proper phase sequence must be observed when

Range: 5 - 30%, OFF Range: 1.0 - 20.0 SEC.
Increments of 1 Increments of 0.1
connecting the input power. For example, phase A
must lead phase B, which in turn must lead phase UNDERCURRENT ALARM
LEVEL: OFF
UNDERCURRENT ALARM
DELAY: 2.0 SEC.
C by 120° respectively. If the phase rotation is Range: 10 - 90%, OFF Range: 1.0 - 60.0 SEC.
not correct, a fault light and the LCD display will Increments of 1 Increments of 0.1
indicate the problem. OVERCURRENT ALARM OVERCURRENT ALARM
LEVEL: OFF DELAY: 2.0 SEC.
SP3.1 Imbalance Alarm Level: This is an advance Range: 100 - 300%, OFF Range: 1.0 - 20.0 SEC., OFF
Increments of 1 Increments of 0.1
warning of a phase imbalance problem. The
problem may not be a fault in the motor, but merely OVERCURRENT TRIP OVERCURRENT TRIP
caused by imbalanced voltages. LEVEL: OFF DELAY: 2.0 SEC.
Range: 100 - 300%, OFF Range: 1.0 - 20.0 SEC.
Increments of 1 Increments of 0.1
• Imbalance Alarm Delay: The amount of time the
imbalance condition must exist before an alarm PHASE LOSS TRIP
: ENABLED
PHASE LOSS TRIP
DELAY: 0.1 SEC.
occurs. Options: Enabled or Disabled Range: 0 - 20.0 SEC.
Increments of 0.1
SP3.2 Imbalance Trip Level: This will trip the motor on
excessive phase imbalance. The trip level should PHASE ROTATION PHASE ROTATION TRIP
be programmed to a higher value than the alarm DETECTION: ABC DELAY: 1.0 SEC
Options: ABC, ACB or Range: 1.0 - 20.0 SEC.
level. Disabled

• Imbalance Trip Delay: The amount of time the * GROUND FAULT ALARM GROUND FAULT ALARM
imbalance condition must exist before a trip will LEVEL: OFF DELAY: 0.1 SEC.
occur. Range: 5 - 90%, OFF
Increments of 1
Range: 0.1 - 20.0 SEC.
Increments of 0.1

SP3.3 Undercurrent Alarm Level: Typically used to warn * GROUND FAULT LOSET GROUND FAULT LOSET
of possible load loss, a coupling breaking or other TRIP LEVEL: OFF TRIP DELAY: 0.5 SEC
Range: 5 - 90%, OFF Range: 0.1 - 20.0 SEC.
mechanical problems. Increments of 1 Increments of 0.1

• Undercurrent Alarm Delay: The amount of time * GROUND FAULT HISET GROUND FAULT HISET
TRIP LEVEL: OFF
the undercurrent condition must exist before an TRIP DELAY: 0.008 SEC.
Range: 5 - 90%, OFF Range: 0.008 - 0.250 SEC.
alarm will occur. Increments of 1 Increments of 0.002

OVERVOLTAGE ALARM OVERVOLTAGE ALARM

SP3.4 Overcurrent Alarm Level: Typically used to LEVEL: OFF DELAY: 1.0 SEC.
indicate when the motor is overloaded. This Range: 5 - 30%, OFF Range: 1.0 - 30.0 SEC.
feature can be used to either stop the feed to Increments of 1 Increments of 0.1

the equipment or warn operators of an overload OVERVOLTAGE TRIP OVERVOLTAGE TRIP

condition. LEVEL: 10% DELAY: 2.0 SEC.
Range: 5 - 30%, OFF Range: 1.0 - 30.0 SEC.
Increments of 1 Increments of 0.1
• Overcurrent Alarm Delay: The amount of time the
UNDERVOLTAGE ALARM UNDERVOLTAGE ALARM
overcurrent condition must exist before an alarm LEVEL: OFF DELAY: 1.0 SEC.
will occur. Range: 5 - 30%, OFF Range: 1.0 - 30.0 SEC.
Increments of 1 Increments of 0.1

UNDERVOLTAGE TRIP UNDERVOLTAGE TRIP

LEVEL: 15% DELAY: 2.0 SEC.
Range: 5 - 30%, OFF Range: 1.0 - 30.0 SEC.
Increments of 1 Increments of 0.1

LINE FREQUENCY TRIP LINE FREQUENCY TRIP

WINDOW: DISABLED DELAY: 1.0 SEC.
Range: 0 - 6, Disabled Range: 1.0 - 20.0 SEC.
Increments of 1 Increments of 0.1
- 39
 2.3 - 7.2kV
SP.3 Phase & Ground Settings (Setpoint Page 3)
(Security Level: 2)

(Continued from previous page)

POWER FACTOR LEAD P/F LEAD ALARM

P/F ALARM: OFF DELAY: 1 SEC.
Range: .01 - 1.00, OFF Range: 1 - 120 SEC
Increments of .01 Increments of 1

SP3.5 Overcurrent Trip Level: Typically used to indicate POWER FACTOR LEAD P/F LEAD TRIP
the motor is severely overloaded and at which P/F TRIP: OFF DELAY: 1.0 SEC.
point a trip occurs. Range: .01 - 1.00, OFF Range: 1 - 120 SEC.
Increments of .01 Increments of 1

• Overcurrent Trip Delay: The amount of time the POWER FACTOR LAG P/F LAG ALARM
overcurrent P/F ALARM: OFF DELAY: 1.0 SEC.
Range: .01 - 1.00, OFF Range: 1 - 120 SEC.
condition must Increments of .01 Increments of 1
exist before a trip
POWER FACTOR LAG P/F LAG TRIP
will occur. P/F TRIP: OFF DELAY: 1.0 SEC.
Range: .01 - 1.00, OFF Range: 1 - 120 SEC.
SP3.6 Phase Loss Increments of .01 Increments of 1

Trip: When POWER DEMAND

enabled, the soft PERIOD: 10 MINUTES

starter will trip the Range: 1 - 60 Minutes

Increments of 1
motor off-line upon a loss of phase power.
KW DEMAND ALARM
• Phase Loss Trip Delay: The amount of time the PICKUP: OFF KW
Range: OFF, 1 - 100000
phase loss condition must exist before a trip will Increments of 1
occur.
KVA DEMAND ALARM
PICKUP: OFF KVA
SP3.7 Phase Rotation Detection: The soft starter is Range: OFF, 1 - 100000
continuously monitoring the phase rotation. Upon Increments of 1

a start command, a trip will occur if it detects a

change in the phase rotation. KVAR DEMAND ALARM
PICKUP: OFF KVAR
Range: OFF, 1 - 100000
• Phase Rotation: There are two possible phase Increments of 1
rotation options: ABC or ACB. This setpoint
monitors the wiring to ensure that the phase AMPS DEMAND ALARM
rotation is correct. To view the present phase PICKUP: OFF AMPS
Range: OFF, 1 - 100000
rotation, go to Metering Page1, screen number 4. Increments of 1

SP3.10 *Ground Fault Hiset Trip Level: Used to trip the

SP3.8 *Ground Fault Alarm: Typically used to warn of motor (within milliseconds) upon detecting a high
low level ground current leakage level of ground current leakage. This setpoint is
intended to detect low impedance faults.
• *Ground Fault Alarm Delay: The amount of time
that the ground fault condition must exist before an • *Ground Fault Hiset Trip Delay: The amount
alarm will occur. of time that the ground fault condition must exist
before a trip will occur.
SP3.9 *Ground Fault Loset Trip Level: Typically used
to trip the motor on a low level of ground current SP3.11 Overvoltage Alarm Level: Typically used to
leakage. This setpoint is intended to detect high indicate when the line voltage is too high. This is
impedance faults. an alarm level.

• *Ground Fault Loset Trip Delay: The amount • Overvoltage Alarm Delay: The amount of time
of time that the ground fault condition must exist that the overvoltage condition must exist before a
before a trip will occur. trip will occur.

* Ground Fault Option must be installed

- 40
 2.3 - 7.2kV

SP3.12 Overvoltage Trip Level: Typically used to indicate SP3.17 Power Factor Lead Trip: The acceptable amount
that the line voltage is too high and at which point a of power factor lead before a trip is generated.
trip occurs
• Power Factor Lead Delay: The amount of time
• Overvoltage Trip Delay: The amount of time that that the power factor lead condition must exist
the overvoltage condition must exist before a trip beyond the window before a trip will occur.
will occur.
SP3.18 Power Factor Lag Alarm: Typically used to
SP3.13 Undervoltage Alarm Level: Typically used to indicate a lagging power factor.
indicate when the line voltage is too low. This is an
alarm level. • Power Factor Lag Alarm Delay: The amount of
time that the power factor lagging condition must
• Undervoltage Alarm Delay: The amount of time exist beyond the window before a trip will occur.
that the overvoltage condition must exist before a
trip will occur. SP3.19 Power Factor Lag Trip: The acceptable amount
of power factor lag before a trip is generated.
SP3.14 Undervoltage Trip Level: Typically used to
indicate that the line voltage is too low and at which • Power Factor Lag Delay: The amount of time
point a trip occurs that the power factor lag condition must exist
beyond the window before a trip will occur.
• Undervoltage Trip Delay: The amount of time that
the undervoltage condition must exist before a trip SP3.20 Power Demand Period: The soft starter
will occur. measures the demand of the motor for several
parameters (current, kW, kVAR, kVA). The
SP3.15 Line Frequency Trip Window: The acceptable demand values of motors assists in energy
amount of drift above or below the line frequency management programs where processes may be
(Hz) before a trip is generated. altered or scheduled to reduce overall demand.
Demand is calculated by a programmed amount
• Line Frequency Trip Delay: The amount of time of time where current, kW, kVAR and kVA samples
that the frequency drift condition must exist beyond are taken and then averaged and stored to assess
the window before a trip will occur. demand.

SP3.16 Power Factor Lead Alarm: Typically used to

indicate a leading power factor.

• Power Factor Lead Alarm Delay: The amount of

time that the power factor lead condition must exist
beyond the window before a trip will occur.

- 41
 2.3 - 7.2kV
SP.4 Relay Assignment (Setpoint Page 4)
PHASE REVERSAL I/B ALARM
MENU 1ST: TRIP 1ST: ALARM

(Hit DOWN ARROW three times)

OVERVOLTAGE TRIP STATOR RTD ALARM

PAGE 4 RELAY O/L TRIP 1ST: TRIP 1ST: NONE
ASSIGNMENT 1ST: TRIP ONLY
Range: TRIP (AUX1),
ALARM (AUX2), AUX3,
AUX4 UNDERVOLTAGE TRIP
1ST: TRIP NON-STATOR RTD ALARM
1ST: NONE
I/B TRIP
1ST: TRIP
POWER FACTOR TRIP
1ST: NONE RTD FAILURE ALARM
1ST: NONE
S/C TRIP
1ST: TRIP ONLY
TACH ACCEL TRIP
1ST: NONE SELF-TEST FAIL
1ST: TRIP
OVERCURRENT TRIP
1ST: TRIP
INHIBITS TRIP
1ST: TRIP
THERMAL REGISTER
STATOR RTD TRIP 1ST: ALARM
1ST: NONE
SHUNT TRIP
1ST: NONE
U/V ALARM
NON-STATOR RTD TRIP 1ST: ALARM
1ST: NONE
BYPASS DISCREPANCY
1ST: NONE

O/V ALARM
G/F HI SET TRIP 1ST: ALARM
1ST: TRIP TCB FAULT
1ST: TRIP

EXTERNAL INPUT #2 POWER FACTOR ALARM

G/F LO SET TRIP 1ST: NONE
1ST: NONE
1ST: TRIP

DUAL RAMP
1ST: NONE KW DEMAND ALARM
PHASE LOSS TRIP 1ST: NONE
1ST: TRIP

THERMOSTAT
1ST: TRIP
KVA DEMAND ALARM
ACCEL. TIME TRIP 1ST: NONE
1ST: TRIP ONLY
O/L WARNING
1ST: ALARM

KVAR DEMAND ALARM

START CURVE TRIP
1ST: NONE
1ST: TRIP ONLY
OVERCURRENT ALARM
1ST: ALARM

AMPS DEMAND ALARM

OVER FREQUENCY TRIP 1ST: NONE
1ST: NONE SCR FAIL SHUNT ALARM
1ST: NONE

TIMED OUTPUT
UNDER FREQUENCY TRIP GROUND FAULT ALARM 1ST: NONE
1ST: TRIP 1ST: ALARM

UNDERCURRENT ALARM RUN DELAY TIME

I*I*T START CURVE 1ST: NONE 1ST: NONE
1ST: TRIP

LEARNED START CURVE MOTOR RUNNING AT SPEED

1ST: TRIP 1ST: AUX3 1ST: AUX4

- 42
 2.3 - 7.2kV

SP.4 Relay Assignment (Setpoint Page 4)

(Security Level: 2)

All of the protection functions of the soft starter are user programmable to an
output relay. The factory will ship with all tripping functions assigned to TRIP
(AUX1) relay, and all alarm functions to ALARM (AUX2) relay. Note: AUX1
- 4 are Factory Set and should not be changed.

SP4.1
The following is a list of all the user programmable functions.
Note: The 1st Relay Assignments are factory defaults and should
not be changed.
FUNCTIONS RELAY ASSIGNMENTS
1st 2nd 3rd
OVERLOAD TRIP TRIP ONLY NONE NONE
IMBALANCE TRIP TRIP (AUX1) NONE NONE
SHORT CIRCUIT TRIP TRIP ONLY NONE NONE
OVERCURRENT TRIP TRIP (AUX1) NONE NONE
STATOR RTD TRIP NONE   NONE NONE
NON-STATOR RTD TRIP NONE NONE NONE
GROUND FAULT HI SET TRIP* TRIP (AUX1) NONE NONE
GROUND FAULT LO SET TRIP* TRIP (AUX1) NONE NONE
PHASE LOSS TRIP TRIP (AUX1) NONE NONE
ACCEL TIME TRIP TRIP ONLY NONE NONE
START CURVE TRIP TRIP ONLY NONE NONE
OVER FREQUENCY TRIP NONE NONE NONE
UNDER FREQUENCY TRIP TRIP (AUX1) NONE NONE
I*I*T START CURVE TRIP (AUX1) NONE NONE
LEARNED START CURVE TRIP (AUX1) NONE NONE
PHASE REVERSAL TRIP (AUX1) NONE NONE
OVERVOLTAGE TRIP TRIP (AUX1) NONE NONE
UNDERVOLTAGE TRIP TRIP (AUX1) NONE NONE
POWER FACTOR TRIP NONE NONE NONE
TACH ACCEL TRIP NONE NONE NONE
INHIBITS TRIP ALARM (AUX1) NONE NONE
SHUNT TRIP NONE NONE NONE
BYPASS DISCREPANCY NONE NONE NONE
TCB FAULT TRIP (AUX1) NONE NONE
EXTERNAL INPUT 2 NONE NONE NONE
DUAL RAMP NONE NONE NONE
THERMOSTAT TRIP (AUX1) NONE NONE
OVERLOAD WARNING ALARM (AUX2) NONE NONE
OVERCURRENT ALARM ALARM (AUX2) NONE NONE
SCR FAIL SHUNT ALARM ALARM (AUX2) NONE NONE
GROUND FAULT ALARM* ALARM (AUX2) NONE NONE
UNDERCURRENT ALARM NONE NONE NONE
MOTOR RUNNING AUX3 NONE NONE
IMBALANCE ALARM ALARM (AUX2) NONE NONE
STATOR RTD ALARM NONE NONE NONE
NON-STATOR RTD ALARM NONE NONE NONE
RTD FAILURE ALARM NONE NONE NONE
SELF TEST FAIL TRIP (AUX1) NONE NONE
THERMAL REGISTER ALARM (AUX2) NONE NONE
U/V ALARM ALARM (AUX2) NONE NONE
O/V ALARM ALARM (AUX2) NONE NONE
POWER FACTOR ALARM NONE NONE NONE
KW DEMAND ALARM NONE NONE NONE
KVA DEMAND ALARM NONE NONE NONE
KVAR DEMAND ALARM NONE NONE NONE
AMPS DEMAND ALARM NONE NONE NONE
TIMED OUTPUT NONE NONE NONE
RUN DELAY TIME NONE NONE NONE
AT SPEED AUX4 NONE NONE
*Ground fault option must be installed

- 43
 2.3 - 7.2kV

SP.5 Relay Configuration (Setpoint Page 5)

(Security Level: 2)
MENU
In Setpoint Page 5 the user
(Hit DOWN ARROW four times)
can configure the four output
relays as either fail-safe or
non fail-safe and latching or PAGE 5 RELAY TRIP (AUX1) RELAY TRIP (AUX1) RELAY
CONFIGURATION FAIL-SAFE: NO LATCHED: YES
non-latching.
Options: Yes or No

SP5.1 When a relay has been configured

as fail-safe and power is applied, ALARM (AUX2) RELAY
FAIL-SAFE: NO
ALARM (AUX2) RELAY
LATCHED: NO
the relay will be energized. The
relay will then de-energize when
an event occurs or if the power AUX 3 RELAY AUX3 RELAY
fails. NOTE: The relays in the FAIL-SAFE: NO LATCHED: NO
soft starter will not prevent a start
sequence unless they are wired in
as interlocks. If power is lost, the AUX4 RELAY AUX4 RELAY
motor power is also lost. Do not FAIL-SAFE: NO LATCHED: NO
change the programming for AUX
1-4. These are for factory use only.
AUX 5-8 are user defined outputs. AUX5 RELAY AUX5 RELAY
FAIL-SAFE: NO LATCHED: NO
SP5.2 A relay configured as non-latching
will reset itself when the cause of
the trip event is not continuous. AUX6 RELAY AUX6 RELAY
The TRIP (AUX1) relay should FAIL-SAFE: NO LATCHED: NO
always be programmed for latching,
because this trip should require a
visual inspection of the motor and
starter before issuing a manual AUX7 RELAY
FAIL-SAFE: NO
AUX7 RELAY
LATCHED: NO
reset to release the relay after a trip
has been stored.

AUX8 RELAY AUX8 RELAY

FAIL-SAFE: NO LATCHED: NO

- 44
 2.3 - 7.2kV

SP.6 User I/O Configuration (Setpoint Page 6)

(Security Level: 2)

MENU
(Hit DOWN ARROW five times)

ENABLED
PAGE 6 USER I/O TACHOMETER SCALE MANUAL TACH SCALE
CONFIGURATION SELECTION: DISABLED 4.0 mA: 0 RPM
Options: ENABLED or Range: 0-3600
DISABLED Increments of 5

MANUAL TACH SCALE

20.0 mA: 2000 RPM
Range: 0-3600
Increments of 5
TACH ACCEL TRIP MODE
SELECT: DISABLED
TACH RAMP TIME
: 20 SEC
Range: 1 - 120 SEC.,
Disabled
Increments of 1

TACH UNDERSPEED TRIP

PT: 1650 RPM
Range: 0 - 3600
Increments of 5

TACH OVERSPEED TRIP

PT: 1850 RPM
Range: 0 - 3600
Increments of 5

TACH ACCEL TRIP

DELAY: 1 SEC
Options: UNDERSPEED,
OVERSPEED or DISABLED Range: 1 - 60
Increments of 1

ANALOG OUTPUT #1 ANALOG OUTPUT #1 ANALOG OUTPUT #1

:RMS CURRENT 4ma: 0 20mA: 250
Range: Range: 0-65535 Range: 0-65535
Analog Output Range Increments of 1 Increments of 1
RPM 0 - 3600
Hottest Bearing 0 - 200°C
Hottest Stator RTD 0 - 200°C
RMS Current 0 - 6500A
% Motor Load 0 - 1000%
KW 0-30000 KW
OFF
Increments of 1

ANALOG OUTPUT #2 ANALOG OUTPUT #2 ANALOG OUTPUT #2

:% MOTOR LOAD 4mA: 0 20mA: 1000
Range: See Analog Output #1 Range: 0-65535 Range: 0-65535
Increments of 1 Increments of 1 Increments of 1

USER PROGRAMMABLE
EXTERNAL INPUTS

Continued...

- 45
 2.3 - 7.2kV

SP.6 User I/O Configuration (Setpoint Page 6)

(Security Level: 2)
The soft starter can be configured to accept a tachometer
feedback signal through the 4-20mA input.

SP6.1 The first screen of setpoint page 6 is

TACHOMETER SCALE SELECTION. When this SP6.3 The controller provides two 4-20mA analog
is set to ENABLED, the user will need to input the outputs. Each analog output is independent of the
tachometer scale of the 4-20mA input range. other and can be assigned to monitor different
functions. The available output ranges are RPM,
• Manual Tach Scale 4.0 mA: The unit is looking Hottest Non-Stator (Bearing) RTD, Hottest Stator
for an RPM value to assign to the lowest point on RTD, RMS current, or % Motor Load.
the scale. This value should represent the motor
at zero speed. • Analog Output #1 – Select a function from the
available five options to be transmitted from
• Manual Tach Scale 20.0 mA: The unit is looking the 4-20mA output. Note: If selecting RPM,
for an RPM value to assign to the highest point on the Tachometer feedback input signal must be
the scale. This value should represent the motor present in order for the controller to give proper
at full speed. output. If selecting RTD, the RTD option must
be installed and an RTD input signal must be
SP6.2 Tach Accel Trip Mode Select: When enabled, present for a proper output to be given from the
the underspeed or overspeed must be selected analog output.
for the Tach Accel Trip. If underspeed is selected,
only the Tach Underspeed Trip Point will be used. • Analog Output #1 (4 mA): Enter a value that the
If overspeed is selected only the Tach Overspeed 4mA level will represent for the selected function;
Trip Point will be used. typically this value should be 0.

• Tach Ramp Time: This is the duration of time • Analog Output #1 (20 mA): Enter a value that
before the tachometer begins to sample. the 20mA level will represent for the selected
function.
• Tach Underspeed Trip: The minimum value of
motor RPM which must be achieved before the SP6.4 Analog Output #2 – All of the setpoints and
Tach Ramp Time sample is taken. setup screens for Analog Output #2 are the same
as those for Analog Output #1.
• Tach Overspeed Trip: The maximum motor RPM
allowed when the Tach Ramp Time sample is
taken.

• Tach Accel Trip Delay: The duration of time that

the Tach Accel trip condition must persist before a
trip is generated.

- 46
 2.3 - 7.2kV
SP.6 User I/O Configuration (Setpoint Page 6)
(Security Level: 2)
USER TCB FAULT NAME EXT. INPUT #1 TCB FAULT TCB FAULT
PROGRAMMABLE SELECT: ENABLED TCB FAULT TYPE: NORMALLY OPEN TIME DELAY: 1 SEC.
EXTERNAL Options: Enabled or Disabled See text for directions Options: Normally Open or Range: 0 - 60 SEC
INPUTS Normally Closed Increments of 1
(Continued)

EXTERNAL INPUT #2 NAME EXT INPUT #2 EXTERNAL INPUT #2 EXTERNAL INPUT #2

SELECT: DISABLED TYPE: NORMALLY OPEN TIME DELAY: 0 SEC.
Options: Enabled or Disabled See text for directions Options: Normally Open or Range: 0 - 60 SEC.
Normally Closed Increments of 1

DUAL RAMP NAME EXT INPUT #3 DUAL RAMP DUAL RAMP

SELECT: DUAL RAMP SECOND RAMP TYPE: NORMALLY OPEN TIME DELAY: 0 SEC.
Options: Enabled, Disabled or See text for directions Options: Normally Open or Range: 0 - 60 SEC
Dual Ramp Normally Closed Increments of 1

THERMOSTAT NAME EXT INPUT #4 THERMOSTAT THERMOSTAT

SELECT: ENABLED THERMOSTAT TYPE: NORMALLY CLOSED TIME DELAY: 1 SEC.
Options: Enabled or Disabled See text for directions Options: Normally Open or Range: 0 - 60 SEC.
Normally Closed Increments of 1

SP6.5 User Programmable External Inputs: The • External Input #3: The setup screens and
controller provides up to 4 digital external setpoints for External Input #3 includes the option
inputs which are individually programmable. of being configured for Dual Ramp. In Dual Ramp
A description name can be assigned to each mode, the initial contact setting is the same as the
individual input for easy identification. START RAMP #1. Upon a change in input contact
state, the controller will switch over to START
• External Input #1: Factory programmed for TCB RAMP #2 and use that setting for start control
Fault. mode. Note: The start RAMP types should
only be switched while the motor is stopped. In
• External Input #2: If used, this setpoint must be Setpoint Page 4 Relay Assignments, do not assign
enabled. any output relay to this function. The controller will
ship with External input #3 programmed for dual
• Name Ext. Input #2: The user can assign a ramp. If it is not needed, disable the dual ramp.
description name to the input to easily identify
the cause of external trip or alarm. Up to 15 • External Input #4 – These input screens are
characters including spaces can be used to assign for the thermostat input and can be enabled
the name. or disabled. Note: It is recommended that
this function remain enabled. If the thermostat
• External Input #2 Type: The external input can indicates an over temperature condition, the
be set as either a normally open or normally controller will trip the motor.
closed contact.

• External Input #2 Time Delay: Upon a change in

contact setting, the unit will wait the programmed
amount of time before generating an output. If
no delay is needed, then input 0 seconds. The
controller will post an event upon seeing a change
in state.

- 47
 2.3 - 7.2kV
SP.7 Custom Acceleration Curve (Setpoint Page 7)
(Security Level: 3)
MENU
(Hit DOWN ARROW six times)

PAGE 7 CUSTOM CUSTOM ACCEL CURVE

ACCELERATION CURVE : DISABLED
Range: DISABLED,
CURVE A, B or C
SP7.1 Setpoint Page 7 allows the user to custom design CURVE A VOLTAGE
CUSTOM CURVE A LEVEL 1: 25%
the acceleration curve (start curve) to the specific
Range: 0 - 100%
application. The user can custom design up to Increments of 1
three different curves in the soft starter. Only one
CURVE A RAMP
curve can be active (enabled) at a time. Each of TIME 1: 2 SEC
the three curves allow for eight voltage plotting Range: 1 - 60 SEC
points, with corresponding ramp times and a Increments of 1

current limit setting. CURVE A VOLTAGE

Note: Each successive voltage level must be LEVEL 2: 30%
Range: 0 - 100%
programmed to a voltage level equal to or greater Increments of 1
than the previous level. All eight levels of voltages
CURVE A RAMP
must be programmed and the eighth level has TIME 2: 2 SEC.
been preset at 100%. Range: 1 - 60 SEC
Increments of 1

• If Custom Accel Curve has been set to curve A, B CURVE A VOLTAGE

or C on this page, the soft starter will override the LEVEL 3: 37%
Range: 0 - 100%
Start Control Mode selected in Setpoint Page 2, Increments of 1
(even if Start Control Mode in Setpoint Page 2 has
not been set to Custom Accel Curve). CURVE A RAMP
TIME 3: 2 SEC.
Note: Setpoint Page 7 has a security level 3
Range: 1 - 60 SEC
requirement. Increments of 1

CURVE A VOLTAGE
LEVEL 4: 45%
Range: 0 - 100%
Increments of 1

CURVE A RAMP
TIME 4: 2 SEC.
Range: 1 - 60 SEC
Increments of 1

CURVE A VOLTAGE
LEVEL 5: 55%
Range: 0 - 100%
Increments of 1

CURVE A RAMP
TIME 5: 2 SEC.
Range: 1 - 60 SEC
Increments of 1

CURVE A VOLTAGE
LEVEL 6: 67%
Range: 0 - 100%
Increments of 1

CURVE A RAMP
TIME 6: 2 SEC.
Range: 1 - 60 SEC
Increments of 1

CURVE A VOLTAGE
LEVEL 7: 82%
Range: 0 - 100%
Increments of 1

CURVE A RAMP
TIME 7: 2 SEC.
Range: 1 - 60 SEC
Increments of 1

- 48
 2.3 - 7.2kV
SP.7 Custom Acceleration Curve (Setpoint Page 7)
(Security Level: 3)

CURVE A VOLTAGE CURVE B VOLTAGE

CUSTOM CURVE A LEVEL 8: 100% CUSTOM CURVE B LEVEL 7: 82%
Range: 0 - 100% Range: 0 - 100%
Increments of 1 Increments of 1

CURVE A RAMP CURVE B RAMP

TIME 8: 2 SEC TIME 7: 2 SEC.
Range: 1 - 60 SEC Range: 1 - 60 SEC
Increments of 1 Increments of 1

CURVE A CURRENT
LIMIT: 350% FLA CURVE B VOLTAGE
LEVEL 8: 100%
Range: 200 - 500%
Increments of 10 Range: 0 - 100%
Increments of 1

CURVE B RAMP
CURVE B VOLTAGE TIME 8: 2 SEC
CUSTOM CURVE B LEVEL 1: 25%
Range: 1 - 60 SEC
Range: 0 - 100% Increments of 1
Increments of 1
CURVE B CURRENT
CURVE B RAMP LIMIT: 350% FLA
TIME 1: 2 SEC.
Range: 200 - 500%
Range: 1 - 60 SEC Increments of 10
Increments of 1

CURVE B VOLTAGE
LEVEL 2: 30% CUSTOM CURVE C CURVE C VOLTAGE
Range: 0 - 100% LEVEL 1: 25%
Increments of 1 Range: 0 - 100%
Increments of 1
CURVE B RAMP
TIME 2: 2 SEC. CURVE C RAMP
Range: 1 - 60 SEC TIME 1: 2 SEC.
Increments of 1 Range: 1 - 60 SEC
Increments of 1
CURVE B VOLTAGE
LEVEL 3: 37% CURVE C VOLTAGE
Range: 0 - 100% LEVEL 2: 30%
Increments of 1
Range: 0 - 100%
Increments of 1
CURVE B RAMP
TIME 3: 2 SEC. CURVE C RAMP
Range: 1 - 60 SEC TIME 2: 2 SEC.
Increments of 1
Range: 1 - 60 SEC
Increments of 1
CURVE B VOLTAGE
LEVEL 4: 45% CURVE C VOLTAGE
Range: 0 - 100% LEVEL 3: 37%
Increments of 1
Range: 0 - 100%
Increments of 1
CURVE B RAMP
TIME 4: 2 SEC.
CURVE C RAMP
Range: 1 - 60 SEC TIME 3: 2 SEC.
Increments of 1
Range: 1 - 60 SEC
Increments of 1
CURVE B VOLTAGE
LEVEL 5: 55%
CURVE C VOLTAGE
Range: 0 - 100% LEVEL 4: 45%
Increments of 1
Range: 0 - 100%
Increments of 1
CURVE B RAMP
TIME 5: 2 SEC.
CURVE C RAMP
Range: 1 - 60 SEC
Increments of 1 TIME 4: 2 SEC.
Range:1 - 60 SEC
Increments of 1
CURVE B VOLTAGE
LEVEL 6: 67%
CURVE C VOLTAGE
Range: 0 - 100%
Increments of 1 LEVEL 5: 55%
Range: 0 - 100%
Increments of 1
CURVE B RAMP
TIME 6: 2 SEC.
Range: 1 - 60 SEC CURVE C RAMP
Increments of 1 TIME 5: 2 SEC.
Range: 1 - 60 SEC
Increments of 1

- 49
 2.3 - 7.2kV
SP.7 Custom Acceleration Curve (Setpoint Page 7)
(Security Level: 3)

SP7.1 Setpoint Page 7 allows the user to custom design

the acceleration curve (start curve) to the specific CUSTOM CURVE C CURVE C VOLTAGE
LEVEL 6: 67%
application. The user can custom design up to Range: 0 - 100%
three different curves in the soft starter. Only one Increments of 1
curve can be active (enabled) at a time. Each of
the three curves has eight voltage levels, with CURVE C RAMP
corresponding ramp times and a current limit TIME 6: 2 SEC.
Range: 1 - 60 SEC
setting. Increments of 1
Note: Each successive voltage level must be
programmed to a voltage level equal to or greater CURVE C VOLTAGE
than the previous level. All eight levels of voltages LEVEL 7: 82%
must be programmed and the eighth level has Range: 0 - 100%
Increments of 1
been preset at 100%.

• If Custom Accel Curve has been set to curve A, B CURVE C RAMP

TIME 7: 2 SEC.
or C on this page, the soft starter will override the Range: 1 - 60 SEC
Start Control Mode selected in Setpoint Page 2, Increments of 1

(even if Start Control Mode in Setpoint Page 2 has

not been set to Custom Accel Curve). CURVE C VOLTAGE
LEVEL 8: 100%
Note: Setpoint Page 7 has a security level 3 Range: 0 - 100%
requirement. Increments of 1

CURVE C RAMP
TIME 8: 2 SEC.
Range: 1 - 60 SEC
Increments of 1

CURVE C CURRENT
LIMIT: 350% FLA
Range: 200 - 500%
Increments of 10

- 50
 2.3 - 7.2kV
SP.8 Overload Curve Configuration (Setpoint Page 8)
(Security Level: 3)

MENU
(Hit DOWN ARROW seven times)

PAGE 8 OVERLOAD BASIC RUN RUN CURVE LOCKED RUN LOCKED ROTOR
CURVE CONFIGURATION OVERLOAD CURVE ROTOR TIME: O/L CLASS CURRENT: 600% FLA
Range: 1 - 30 SEC, O/L CLASS Range: 400 - 800%
Configures the unit’s start and Increments of 1
run protection mode. The unit has
independent start and run curve COAST DOWN TIMER
TIME: DISABLED
protection and the settings can be
Range:1 - 60 MIN, DISABLED
based on the OL Class or set by the Increments of 1
motor’s locked rotor current and time. BASIC START START CURVE LOCKED START LOCKED ROTOR
OVERLOAD CURVE ROTOR TIME: O/L CLASS CURRENT: 600% FLA

SP8.1 Basic Run Overload Curve Range:1 - 30 SEC, O/L CLASS Range: 400 - 800%
Increments of 10
Increments of 1

• Run Curve Locked Rotor ACCELERATION TIME

Time: Set the locked rotor time LIMIT: 30 SEC
to the OL Class default chosen Range:1 - 300 SEC, DISABLED
Increments of 1
in Setpoint Page 1 or set the
time in seconds. This is the NUMBER OF STARTS PER
time the locked rotor condition HOUR: DISABLED
exists before a trip occurs. Range: 1 - 6, DISABLED
Increments of 1
• Run Locked Rotor Current:
The current the motor draws TIME BETWEEN STARTS
with full voltage on the windings TIME: 5 MIN
and no rotor movement (as a Range:1 - 60 MIN, DISABLED
Increments of 1
percent of motor FLA). Refer to
the nameplate data or contact AREA UNDER CURVE MAX I*I*T START
PROTECTION: DISABLED : 368 FLA*FLA*SEC
the motor manufacturer. Range: ENABLED or DISABLED Range:1 - 2500, FLA*Time (Sec)
• Coast Down Timer: If enabled, Increments of 1
this prevents the motor from
restarting for the programmed CURRENT OVER LEARNED START CURVE TIME FOR SAMPLING
amount of time, after a stop CURVE: DISABLED BIAS: 10% : 30 SEC
Options: DISABLED, LEARN Range: 5 - 40% Range: 1 - 300 SEC
command is given. or ENABLED Increments of 1 Increments of 1

SP8.2 Basic Start Overload Curve

SP8.3 Area Under Curve Protection: If enabled, this
• Start Curve Locked Rotor Time: The locked
secondary start protection uses both the basic start
rotor time can be set to the OL Class default
protection and the area under the curve protection.
chosen in Setpoint Page 1 or to a specific
• Max I*I*T Start: The maximimum I2T allowed
time. The overload condition must exist for the
during start. If the I2T to start exceeds this number
programmed amount of time before a trip occurs.
then the soft starter will generate a trip.
• Start Locked Rotor Current: The current the
motor draws with full voltage on the windings and
SP8.4 Current Over Curve: Learns the motor’s starting
no motor movement (as a percent of motor FLA).
characteristics and protects the motor based upon
Refer to the motor nameplate data or contact the
the learned curve. It is useful when commissioning
motor manufacturer.
a new motor.
• Acceleration Time Limit: If the motor does not
• Learn: The unit reads the motor’s starting
enter run mode (reach at speed) within the preset
characteristics. Start the motor and allow it to come
time, the unit trips on acceleration time limit.
to full speed. The start feedback enables the motor
• Number of Starts per hour: If enabled, this
protection based on the learned start curve.
limits the maximum number of starts permitted per
• Learned Start Curve Basis: The maximum
hour. This setpoint allows a maximum of 6 starts
allowed deviation above or below the start curve
per hour. Contact motor manufacturer.
before a trip is generated.
• Time Between Starts: If enabled, the soft
• Time for sampling: The time the soft starter
starter prevents another start attempt until the
continues to sample the start curve characteristic
programmed time has expired.
during learn mode.

- 51
 2.3 - 7.2kV

SP.9 RTD Option Configuration (Setpoint Page 9)

(Security Level: 3)
Please note, this is supplied as an option.
Contact factory for more information.
MENU
Optional
(Hit DOWN ARROW eight times)
Ranges:
* 120 OHM NICKEL (NI)
PAGE 9 RTD USE NEMA TEMP FOR 100 OHM NICKEL (NI)
CONFIGURATION RTD VALUES: DISABLED 10 OHM COPPER (CU)
100 OHM PLATINUM (PT)
Options: ENABLED OR OFF
DISABLED
** OFF or 0 - 240C (32-464F) Example: ### C = ### F
# OF RTD’S USED FOR Increments of 1
STATOR: 4
*** STATOR A1, STATOR A2, STATOR B1, STATOR B2, STATOR C1, STATOR C2,
Range: 0 - 6 FRONT BEARING, BACK BEARING, BEARING BOX, AMBIENT, NONE
Increments of 1

RTD VOTING
: DISABLED
Options: ENABLED or
DISABLED

STATOR PHASE A1 TYPE RTD # 1 DESCRIPTION STATOR PHASE A1 ALARM STATOR PHASE A1 TRIP
: OFF STATOR PHASE A1 LEVEL: OFF LEVEL: OFF
Range: * Range: *** Range: ** Range: **

STATOR PHASE A2 TYPE RTD # 2 DESCRIPTION STATOR PHASE A2 ALARM STATOR PHASE A2 TRIP
: OFF STATOR PHASE A2 LEVEL: OFF LEVEL: OFF
Range: * Range: *** Range: ** Range: **

STATOR PHASE B1 TYPE RTD # 3 DESCRIPTION STATOR PHASE B1 ALARM STATOR PHASE B1 TRIP
: OFF STATOR PHASE B1 LEVEL: OFF LEVEL: OFF
Range: * Range: *** Range: ** Range: **

STATOR PHASE B2 TYPE RTD # 4 DESCRIPTION STATOR PHASE B2 ALARM STATOR PHASE B2 TRIP
: OFF STATOR PHASE B2 LEVEL: OFF LEVEL: OFF
Range: * Range: *** Range: ** Range: **

STATOR PHASE C1 TYPE RTD # 5 DESCRIPTION STATOR PHASE C1 ALARM STATOR PHASE C1 TRIP
: OFF STATOR PHASE C1 LEVEL: OFF LEVEL: OFF
Range: * Range: *** Range: *** Range: ***

STATOR PHASE C2 TYPE RTD # 6 DESCRIPTION STATOR PHASE C2 ALARM STATOR PHASE C2 TRIP
: OFF STATOR PHASE C2 LEVEL: OFF LEVEL: OFF
Range: * Range: *** Range: ** Range: **

END BEARING TYPE RTD #7 DESCRIPTION END BEARING ALARM END BEARING TRIP
: OFF END BEARING LEVEL: OFF LEVEL: OFF
Range: * Range: *** Range: ** Range: **

SHAFT BEARING TYPE RTD # 8 DESCRIPTION SHAFT BEARING ALARM SHAFT BEARING TRIP
: OFF SHAFT BEARING LEVEL: OFF LEVEL: OFF
Range: * Range: *** Range: ** Range: **

RTD # 9 TYPE RTD # 9 DESCRIPTION RTD # 9 ALARM RTD # 9 TRIP

: OFF RTD # 9 LEVEL: OFF LEVEL: OFF
Range:* Range: *** Range: ** Range: **

RTD # 10 TYPE RTD # 10 DESCRIPTION RTD # 10 ALARM RTD # 10 TRIP

: OFF RTD # 10 LEVEL: OFF LEVEL: OFF
Range: * Range: *** Range: ** Range: **

RTD # 11 TYPE RTD # 11 DESCRIPTION RTD # 11 ALARM RTD # 11 TRIP

: OFF RTD #11 LEVEL: OFF LEVEL: OFF
Range: * Range: *** Range: ** Range: **

RTD # 12 TYPE RTD # 12 DESCRIPTION RTD # 12 ALARM RTD # 12 TRIP

: OFF RTD # 12 LEVEL: OFF LEVEL: OFF
Range: * Range: *** Range: ** Range: **
- 52
 2.3 - 7.2kV

SP.9 RTD Option Configuration (Setpoint Page 9)

(Security Level: 3)
The soft starter is available with an optional RTD card that
provides 12 programmable RTDs which are individually
programmable for type. The available types are 100 ohm
platinum, 100 ohm nickel, 120 ohm nickel and 10 ohm copper.
Each RTD can be identified with a description name of up to
15 characters (including spacing). Also, each individual RTD
has it own alarm and trip level.

SP9.1 Use NEMA Temp for RTD Value: When this setpoint
is enabled, the soft starter will use the NEMA design
insulation class to limit the maximum allowed range
of the alarm and trip level. The maximum allowed
temperature range is 240° C or (464°F).

SP9.2 # Of RTD’S Used for Stator: Up to six RTDs can be

assigned to monitor the stator of the motor.

SP9.3 RTD Voting: When this is enabled, the soft starter

will not post a trip until 2 RTD’s have exceeded the
trip level. This prevents nuisance RTD tripping.

SP9.4 Each of the 12 RTDs is configured in the following

manner. The first column is the RTD type, the second
column is the RTD description, the third column is the
alarm level, and the fourth column is the trip level.
The first six RTDs have been pre-programmed with
a description name for the STATOR, with two RTDs
per phase. RTDs #1 & #2 have been named STATOR
PHASE A1 and A2 respectively. RTDs #3&4 are
named STATOR PHASE B1 and B2, RTDs #5&6
are named STATOR PHASE C1 and C2. If other
description names are required, press the right arrow
button from the RTD Type screen to go the RTD
description screen. If no alarm or trip level is required
these setpoints can be turned off.

- 53
 2.3 - 7.2kV

SP.10 Set Password (Setpoint Page 10)

(Security Level: 3) MENU
The soft starter has three levels of user programmable (Hit DOWN ARROW nine times)
setpoint screens. Level one setpoints do not require a
password because the data contained in level one is basic PAGE 10 SECURITY SET LEVEL 2
nameplate data and starter control. Level two setpoint SET PASSWORD PASSWORD: 100
screens require a three-digit password to configure the Range: 000 - 999
protection schemes. Level three setpoint screens require
a four-digit password to access the full range of protection SET LEVEL 3
and starter schemes. PASSWORD: 1000
Range: 0000 - 9999

SP10.1 Set Level 2 Password: This level uses a 3-digit

password. The default level 2 password is 100.

SP10.2 Set Level 3 Password: Level three uses a 4-digit

password. The default level 3 password is 1000.

- 54
 2.3 - 7.2kV

SP.11 Communications (Setpoint Page 11)

(Security Level: 3) MENU
SP11.1 Set Front Baud Rate: Configures the RS232
communications baud rate. (Hit DOWN ARROW ten times)

SP11.2 Set Modbus Baud Rate: Configures the modbus PAGE 11 SET FRONT BAUD
communications baud rate. COMMUNICATIONS RATE: 9.6 KB/SEC
Range: 2.4, 4.8, 9.6, 19.2
38.4 KB/SEC
SP11.3 Modbus Address Number: Assigns a Modbus
address to the relay. SET MODBUS BAUD
RATE: 9.6 KB/SEC

SP11.4 Set Access Code: Assigns an access code to the Range: 2.4, 4.8, 9.6, 19.2
38.4 KB/SEC
Modbus addressing. This is typically not used.
MODBUS ADDRESS
NUMBER: 247
SP11.5 Set Link Baud Rate: Configures the RS422
Range: 1 - 247
communications baud rate between the keypad Increments of 1
operator and the CPU board. (For applications SET ACCESS CODE
with remote keypad only.) CODE: 1
Range: 1 - 999
SP11.6 Remote Start/Stop: Allows the RS485 Modbus
Increments of 1

communications to start and stop the motor. SET LINK BAUD

Contact factory for details. RATE: 38.4 KB/SEC
Range: 2.4, 4.8, 9.6, 19.2
38.4 KB/SEC

REMOTE START/STOP:
DISABLED
Option: Enabled or Disabled

- 55
 2.3 - 7.2kV
SP.12 System Setpoints (Setpoint Page 12)
(Security Level: 3)
MENU
(Hit DOWN ARROW eleven times)

PAGE 12 SYSTEM DEFAULT DISPLAY METERING DATA METERING DATA

SETPOINTS SCREEN PAGE #: 1 SCREEN #: 1
Enter Metering Page (1 - 4) Enter Metering
Number for display Screen Number for display

ALARMS RTD FAILURE ALARM

ALARM: DISABLED
Enabled or Disabled

THERMAL REGISTER THERMAL ALARM

ALARM: 90% DELAY: 10 SEC.
Range: Off, 40 - 95% Range: 1 - 20 SEC.
Increments of 1 Increments of 1

COLD STALL TIME

THERMAL REGISTER : O/L CLASS
SETUP INFORMATION
Range: O/L CLASS,
4 - 40 SEC
Increments of 1
HOT STALL TIME
: 1/2 O/L CLASS
Range: 1/2 O/L CLASS,
4 - 40 SEC
Increments of 1
STOPPED COOL DOWN
TIME: 30 MIN
Range: 10 - 300 MIN
Increments of 1

RUNNING COOL DOWN

TIME: 15 MIN
Range: 10 - 300 MIN
Increments of 1

RELAY MEASURED COOL

RATES: DISABLED
Range: ENABLED or
DISABLED

THERMAL REGISTER
MINIMUM: 15%
Range: 10 - 50%, OFF
Increments of 1

MOTOR DESIGN AMBIENT

TEMPERATURE: 40 C
Range: 10 - 90 C
Increments of 1

MOTOR DESIGN RUN

TEMPERATURE: 80% MAX
Range: 50 - 100% of Motor
Stator Max Temp.
Increments of 1%

MOTOR STATOR MAX

TEMPERATURE: INS CLS
Range: Insulation Class
10 - 240 C
Increments of 1

I/B INPUT TO THERMAL

REGISTER: ENABLED
Options: ENABLED or
DISABLED

USE CALCULATED K OR
ASSIGN: 7
Range: 1 - 50, ON

PRESS ENTER TO CLR

THERMAL REGISTER
- 56
 2.3 - 7.2kV

SP.12 System Setpoints (Setpoint Page 12)

(Security Level: 3)
SP12.1 Default Display Screen: This setpoint group • Thermal Register Minimum: Sets the value
allows the user to choose the default screen the in the thermal register which represents a
soft starter displays while the motor is running. motor running at the nameplate current (with
Select the metering page number (1-3), then no overheating or negative sequence currents
select the metering screen number. The range present).
varies depending on the selected page. To display • Motor Design Ambient Temperature: Use the
a default screen, program the following two data from the motor manufacturer’s specifications.
setpoints: When RTD option is supplied, this setpoint will be
• Metering Data Page#: Range is Page 1 - 3. the base point for the RTD biasing of the Thermal
• Metering Data Screen#: If Page 1 is selected Register.
as the default page, then Screens 1- 10 are • Motor Design Run Temperature: Use the data
available. If Page 2 Screens 1-29 are available. If from the motor manufacturer’s specifications. This
Page 3 is selected then Screens 1-6 are available. setpoint defines the operating temperature rise of
(See Metering Menu, MP.1, for screen number the motor at full load amps or 100% load.
assignment.) • Motor Stator Max Temperature: This represents
the maximum temperature the stator insulation
SP12.2 Alarms: Configures the RTD failure alarm (when will withstand. The user may choose to use
RTD option is included) and the thermal register the temperature setting of the insulation class
alarm. (selected in Setpoint Page 1) or enter a specific
• RTD Failure Alarm: If enabled, and an RTD maximum temperature. This value should not
shorts or open, an alarm occurs. (Only if RTD exceed the stator’s insulation temperature. This
option is installed). maximum temperature represents 100% thermal
• Thermal Register Alarm: Sets a level in the capacity.
thermal register to generate an alarm when the • U/B Input to Thermal Register: Always enabled.
Thermal Register Capacity Used has exceeded It allows the soft starter to use the line current
this level. imbalance information to bias the Thermal
• Thermal Alarm Delay: The amount of time that Register.
the Thermal Register Used must exceed the • User Calculated K or Assign: When the setpoint
setpoint before an alarm condition will occur. is set to ON the soft starter will calculate the k
constant factor for biasing the thermal register, or
SP12.3 Thermal Register Setup Information: This the user may choose to assign the k value.
setpoint group will configure the thermal register
and indicate to the soft starter which inputs to use SP12.4 Press Enter to CLR Thermal Register: Allows
when thermal modeling. the level three password user to clear the thermal
• Cold Stall Time: Enter the time from the motor register for emergency restarts.
manufacturer’s specification sheet or use the time
defined by the OL Class. This setpoint is used to
define the thermal capacity of the motor.
• Hot Stall Time: Enter the amount of time
specified by the motor manufacturer or use half of
the time defined by the OL Class.
• Stopped Cool Down Time: The time the motor
requires to cool down after it has stopped. Use
only the data provided by the motor manufacturer.
This setpoint is used to configure the cooling rate
of the thermal register.
• Running Cool Down Time: The amount of
time the motor requires for cooling down while
running. Use only the data provided by the motor
manufacturer.
• Relay Measured Cool Rates: When the
RTD option is supplied, the soft starter can be
configured to use the measured cool rates from
the RTDs instead of the programmed settings.
This setpoint should only be enabled when the
RTD option is present.

- 57
 2.3 - 7.2kV

SP.13 Calibration & Service (Setpoint Page 13)

(Security Level: Factory Use Only)

MENU
(Hit DOWN ARROW twelve times)

PAGE 13 CALIBRATION SET DATE AND TIME ENTER DATE (DDMMYYYY) ENTER TIME (hh:mm)
& SERVICE ##/##/## ##:## :##/##/#### :##:##
Range: D = 1 - 31, M = 1-12, Range: H = 00 - 23, M = 0 - 59
Y = 1970 - 2069 Increments of 1
Increments of 1
MODEL #: ######
FIRMWARE REV. #: ######

PRESS ENTER TO ACCESS

FACTORY SETTINGS

SP.13 Calibration & Service (Setpoint Page 13)

Certain screens are displayed for user information only, such
as: Current date and time, Model number and Firmware
revision number. Setpoint changes in this page will only be
accessible to factory personnel.
SP13.1 Set Date and Time: Displays the date and time.
• Enter Date (DDMMYYYY): Allows the factory
personnel to program the date for the soft starter in
the format shown.
• Enter Time (HH:MM): Allows the factory personnel to
program the time for the soft starter.

SP13.2 Model & Firmware #: Displays the model number

and firmware revision in the soft starter.

SP13.3 Press Enter to Access Factory Settings: Available

to qualified personnel.

- 58
 2.3 - 7.2kV
Chapter 6 - Metering Pages
The soft starter offers performance metering which gives the user the ability to view
information about the motor and the unit.

6.1 Metering Page List

The following charts list each Metering Page and the functions within that page. The
applicable section of the manual is also referenced.

6.1.1 Metering Menu & Data (Metering Page 1)

Metering
Description of Display Screen
Page
Phase A, B, C and Ground Fault (Option) 1
Average current of the % of imbalance and the motor's RPM 2
Metering Menu & Data

Motor load as a percentage of motor FLA 3

Line frequency and present phase sequence 4
Page 1

Percentage of remaining Thermal Register 5

Thermal capacity required to start the motor 6
Average time required to start 7
Average current during start 8
2
Measured I T required to start the motor 9
Amount of time required to start the motor during the last successful start 10

6.1.2 Metering (Metering Page 2)

Metering
Description of Display Screen
Page
Phase A, B, C currents and Power Factor 1
Phase A, B, C currents and Ground Fault (Option) 2
Displays kW and kVA 3
Displays kVAR and Power Factor 4
Displays Peak ON and kW Demand 5
Metering
Page 2

Displays Peak ON and kVA Demand 6

Displays Peak ON and kVAR Demand 7
Displays Peak ON and Amps Demand 8
Clears Demand values 9
Displays Megawatt hours used 10
Press enter to clear statistics on MWH values 11

6.1.3 RTD Option Values (Metering Page 3)

Metering
Description of Display Screen
Page
Hottest stator RTD (#1 - 6) 1
Hottest non-stator RTD (#7 - 12) 2
Temperature of start phase A1 in °C and °F 3
RTD Values
Page 3

Maximum temperature for RTD #1 4

Same as Screens 3 - 4 for RTDs #2 - 12 5 - 26
Clear the maximum temperature register (Level 3 password required) 27
Measured running thermal stabilization time of motor (in minutes) 28
Measured stopped cooling time (to ambient) of motor (in minutes) 29

- 59
 2.3 - 7.2kV
6.1.4 Status (Metering Page 4)

Metering
Description of Display Screen
Page
Current status 1
Amount of time remaining before an overload trip occurs 2
Page 4
Status
Amount of time remaining from a thermal inhibit signal 3
Coast down time remaining 4
Amount of time remaining before a start command can be given 5
Excessive number of starts per hour 6

6.1.5 Event Recorder (Metering Page 5)

Metering
Description of Display Screen
Page
Recorder

Displays the event with date and time (Up to 60 events) 1

Page 5
Event

Displays Phase A, B, C current values, Ground Fault (Option) at time of trip 1A

Displays Vab, Vbc, Vca and Power Factor at time of trip 1B

6.1.6 Last Trip (Metering Page 6)

Metering
Description of Display Screen
Page
Cause of last trip 1
Measured phase current 2
Last Trip
Page 6

Measured voltage and power factor 3

Imbalance percentage, the frequency and the kW 4
Hottest stator RTD temperature 5
Hottest non-stator RTD temperature 6

6.1.7 Statistics (Metering Page 7)

Metering
Description of Display Screen
Page
Total megawatt hours 1
Accumulated total running hours 2
Clear the total running hour count 3
Total number of trips 4
Number of start and run overload trips since the last statistical data
5
clearing
Number of frequency trips and imbalance trips 6
Overcurrent trips 7
Stator and non-stator RTD trips 8
Ground fault hiset and loset trips 9
Acceleration time trips 10
Start under curve trips 11
Start over curve trips 12
Statistics
Page 7

2
I T start curve trips 13
Learned start curve trips 14
Fail shunt trip trips 15
Phase loss trip trips 16
Tach accel trip trips 17
Undervoltage and Overvoltage trips 18
Power Factor trips 19
Phase reversal trips 20
Ext Inp #1 21
Ext Inp #2 22
Ext Inp #3 23
Ext Inp #4 24
Press enter to clear statistics 25

- 60
 2.3 - 7.2kV

6.2 Metering Menu

(1) Push MENU key to toggle the screens between Setpoint Menu and Metering
Menu and follow the arrow keys to get to different screens.

MENU

METERING PAGE 1
CURRENT METERED DATA

METERING PAGE 2
VOLTAGE & POWER DATA

METERING PAGE 3
RTD VALUES

METERING PAGE 4
STATUS

METERING PAGE 5
EVENT RECORDER

METERING PAGE 6
LAST TRIP

METERING PAGE 7
STATISTICS

- 61
 2.3 - 7.2kV

MP.1 Metering Data (Metering Page 1)

Displays the basic current metering data:
Screen 1: Phase A, B, C and ground fault (option) MENU
current.

Screen 2: Displays the average current, the percent of IA: ###### IB: ######
METERING PAGE 1
imbalance and the motor’s RPM (available CURRENT METERED DATA IC: ###### G/F: #####
Screen 1
with tachometer input)

Screen 3: Displays the motor load in percent of motor

I (AVG): ####
FLA. I/B: ## % RPM: ####
Screen 2

Screen 4: Displays the line frequency and the present

Phase Order.
MOTOR LOAD % OF FLA
Screen 3
Screen 5: Displays the percent of the remaining thermal FLA: ### %

register. In order for the motor to successfully

start, the percentage must be greater than
the thermal capacity required for a successful LINE FREQUENCY:: ##.##
Screen 4
start. PHASE ORDER: ###

Screen 6: Displays the thermal capacity required to

successfully start the motor. THERMAL REGISTER
Screen 5
REMAINING: ### %
Screen 7: Displays the average time required to start.

Screen 8: Displays the average current during start. THERMAL CAPACITY

TO START: ### %
Screen 6
Screen 9: Displays the measured I2T required to start
the motor.

Screen 10: Displays the amount of time required to start AVERAGE START TIME
Screen 7
TIME: ##.# SECS
the motor during the last successful start.

AVG START CURENT

Screen 8
: ###### AMPS

I*I*T TO START
Screen 9
I*I*T: #######

LAST START
Screen 10
TIME: ##.# SEC

- 62
 2.3 - 7.2kV

MP.2 Metering (Metering Page 2) MENU (Hit DOWN ARROW one time)
Displays the soft starter statistical voltage metering
information. Screen 1
METERING PAGE 2 Vab: ### Vbc: ###
VOLTAGE & POWER DATA
Screen 1: Displays Phase A, B, C and Power Factor. Vca: ### P/F: ## #.##

Note: P/F: N/A Motor stopped

Screen 2
P/F: LG #.## (Lagging) IA: ##### IB: #####
P/F: LD #.## (Leading) IC: ##### G/F:###.#

Screen 2: Displays Phase A, B, C and Ground Fault Screen 3

Current. kW: #####
kVA: #####

Screen 3: Displays kW and kVA. Screen 4

kVAR: #####
Screen 4: Displays kVAR and Power Factor. P/F: ## #.##

Screen 5
Screen 5: Displays Peak On and kW demand.
PEAK ON: ##/## ##:##
kW: #####
Screen 6: Displays Peak On and kVA demand.
Screen 6
Screen 7: Displays Peak On and kVAR demand. PEAK ON: ##/## ##:##
Note: P/F: N/A Motor stopped kVA: #####
P/F: LG #.## (Lagging)
Screen 7
P/F: LD #.## (Leading)
PEAK ON: ##/## ##:##
kVAR: #####
Screen 8: Displays Peak On and Amps demand.
Screen 8
Screen 9: Clears Demand Values. PEAK ON: ##/## ##:##
AMPS: #####

Screen 10: Displays the Megawatthours used. Screen 9

PRESS ENTER TO CLEAR
Screen 11: Press Enter to clear statistics on MWH values. DEMAND VALUES

Screen 10
MWH USED
: #####

Screen 11
PRESS ENTER TO CLEAR
MWH VALUES

- 63
 2.3 - 7.2kV
MENU (Hit DOWN ARROW two times)

Screen 1
METERING PAGE 3 HOTTEST STATOR
RTD VALUES RTD#: # @ ### C

MP.3 RTD Values (Metering Page 3) Screen 2

HOTTEST NON-STATOR
Displays the RTD information (when RTD option is supplied) RTD#: # @ ### C

Screen 1: Displays the hottest stator RTD (#1 - 6 Screen 3 Screen 4

depending upon number of RTDs used for STATOR PHASE A1 MAX TEMP SINCE
stator). RTD #1: ### C = ### F CLEAR RTD #1: ### C

Screen 5 Screen 6
Screen 2: Displays the hottest non-stator RTD (#7-12 if STATOR PHASE A2 MAX TEMP SINCE
#1-6 is used for stator). RTD #2: ### C = ### F CLEAR RTD #2: ### C

Screen 3: Displays the temperature of stator phase A1 in Screen 7 Screen 8

°C and °F. STATOR PHASE B1
RTD #3: ### C = ### F
MAX TEMP SINCE
CLEAR RTD #3: ### C

Screen 4: Displays the maximum temperature for RTD Screen 9 Screen 10

#1 since the last command to clear the thermal STATOR PHASE B2 MAX TEMP SINCE
register. RTD #4: ### C = ### F CLEAR RTD #4: ### C

Screen 11 Screen 12
Screen 5 - 26: Same as Screens 3 - 4 for RTDs # 2 - 12.
STATOR PHASE C1 MAX TEMP SINCE
RTD #5: ### C = ### F CLEAR RTD #5: ### C
Screen 27: Allows the user to clear the maximum
temperature register upon entering the setpoint Screen 13 Screen 14
level 3 password. STATOR PHASE C2 MAX TEMP SINCE
RTD #6: ### C = ### F CLEAR RTD #6: ### C

Screen 28: Displays the measured run cool time in minutes. Screen 15 Screen 16
END BEARING MAX TEMP SINCE
Screen 29: Displays the measured stopped cool time in RTD #7: ### C = ### F CLEAR RTD #7: ### C
minutes.
Screen 17 Screen 18
SHAFT BEARING MAX TEMP SINCE
RTD #8: ### C = ### F CLEAR RTD #8: ### C

Screen 19 Screen 20
RTD #9 MAX TEMP SINCE
RTD #9: ### C = ### F CLEAR RTD #9: ### C

Screen 21 Screen 22
RTD #10 MAX TEMP SINCE
RTD #10: ### C = ### F CLEAR RTD #10: ### C

Screen 23 Screen 24
RTD #11 MAX TEMP SINCE
RTD #11: ### C = ### F CLEAR RTD #11: ### C

Screen 25 Screen 26
RTD #12 MAX TEMP SINCE
RTD #12: ### C = ### F CLEAR RTD #12: ### C

Screen 27
PRESS ENTER TO
CLEAR MAX TEMP REGS

Screen 28
MEASURED RUN COOL
TIME: ### MIN

Screen 29
MEASURED STOPPED
COOL TIME: ### MIN

- 64
 2.3 - 7.2kV

MP.4 Status (Metering Page 4)

Displays the present status of the soft start. MENU (Hit DOWN ARROW three times)

Screen 1: Displays the present state of the unit as Screen 1 (See note at left)
follows: METERING PAGE 4
STATUS
(CURRENT STATUS)

Screen 2: Displays the amount of time remaining before Screen 2

an overload trip will occur. O/L TRIP LEFT TO
TRIP: ###### SEC

Screen 3
Screen 1 Note:
THERM INH TIME LEFT
CURRENT STATUS Screens include: : #### MIN
1. MOTOR STOPPED
READY TO START Screen 4
2. MOTOR STARTING COAST DOWN TIMER
TIME LEFT: #:## MIN
MULT. OF FLA
3. MOTOR RUNNING Screen 5
AT ###.## X FLA TIME BETWEEN STARTS
TIME: #:## MIN
4. LAST TRIP CAUSE
NONE (or trip cause)
Screen 6
5. PROGRAMMING STARTS PER HOUR TIME
SETPOINTS ## ## ## ## ## ## ##

6. MOTOR STATUS
UNKNOWN STATE ### (displays relay state upon error)

Screen 3: Displays the amount of time remaining from

a thermal inhibit. The inhibit time comes from
the amount of thermal register remaining
versus the amount of thermal capacity
required to start.

Screen 4: Displays the coast down time remaining

(Backspin time). The time remaining depends
upon the user setting in Setpoint Page 8,
Coast Down Time.

Screen 5: Displays the amount of time remaining before

a start command can be given.

Screen 6: If the number of starts per hour has exceeded

the setting.

- 65
 2.3 - 7.2kV

MP.5 Event Recorder - 60 Events (Metering Page 5)

MENU (Hit DOWN ARROW four times)

Screen 1 Screen 1a Screen 1b

METERING PAGE 5 :<cause of event> IA: ###### IB: ###### Vab: ###### Vbc: ######
Event Recorder (60 event) 1st :##/##/## ##:## IC: ###### G/F: #### Vca: ###### P/F: ####
Event

:<cause of event> IA: ###### IB: ###### Vab: ###### Vbc: ######
2nd :##/##/## ##:## IC: ###### G/F: #### Vca: ###### P/F: ####
Event

:<cause of event> IA: ###### IB: ###### Vab: ###### Vbc: ######
59th :##/##/## ##:##
Event
IC: ###### G/F: #### Vca: ###### P/F: ####

:<cause of event> IA: ###### IB: ###### Vab: ###### Vbc: ######
60th :##/##/## ##:## IC: ###### G/F: #### Vca: ###### P/F: ####
Event

All events will be viewed from oldest event in buffer to most recent event.

The events are listed from oldest to most recent.

Screen 1: Displays the event (i.e., Imbalance Trip) with the
date and time it occurred.

Screen 1a: Displays the current at Phase A, B, C and the

ground fault at the time of the trip.

Screen 1b: Displays the Vab, Vbc, Vca and power factor at the
time of trip.

- 66
 2.3 - 7.2kV

MP.6 Last Trip (Metering Page 6) MENU (Hit DOWN ARROW five times)
Displays the information regarding the last trip.
Screen 1
Screen 1: Displays the cause of the last trip. METERING PAGE 6 (cause of trip)
LAST TRIP (value at time of trip)

Screen 2: Displays the measured phase current at the

time of the trip. Screen 2
Ia: #### Ib: ####
Ic: #### G/F: ####.#
Screen 3: Displays the Vab, Vbc, Vca and power factor
at the time of trip. Screen 3
Vab: ###### Vbc: ######
Screen 4: Displays the imbalance percentage, the Vca: ###### P/F: ######

frequency and the kW at the time of the trip.

Screen 4
Screen 5: Displays the hottest stator RTD temperature I/B: ## % Hz: ##.#
KW: ########
(when RTD option present) at time of the trip.
Screen 5
Screen 6: Displays the hottest non-stator RTD HOTTEST STATOR
temperature (when RTD option present) at the RTD# # @ ### C

time of the trip.

Screen 6
HOTTEST NON-STATOR
RTD# # @ ### C

- 67
 2.3 - 7.2kV

MENU (Hit DOWN ARROW six times)

Screen 1
METERING PAGE 7 MWH TOTAL
STATISTICS : ###

Screen 2 Screen 3
MP.7 Statistics (Metering Page 7) RUNNING HOURS TOTAL PRESS ENTER TO
TIME: ## ## HOURS CLEAR RUN HOURS
Displays the statistical trip information.
Screen 1: Displays the total of megawatt hours. Screen 4
Screen 2: Displays the accumulated total running hours. TOTAL TRIPS: ###
Screen 3: Clears the total running hour count. S/C TRIPS: ###

Screen 4: Displays the total number of trips since the Screen 5 Screen 18
last clearing of the statistical data and the total START O/L TRIPS: ### U/V TRIPS: ###
number of short circuit trips. RUN O/L TRIPS: ### O/V TRIPS: ###
Screen 5: Displays the number of start overload and run
Screen 6
overload trips since the last clearing of the Screen 19
FREQUENCY TRIPS: ###
statistical data. I/B TRIPS: ###
POWER FACTOR
TRIPS: ###
Screen 6: Displays the number of frequency trips and
Imbalance trips. Screen 7
OVERCURRENT Screen 20
Screen 7: Displays the number of overcurrent trips TRIPS: ### PHASE REVERSAL
Screen 8: Displays the number of Stator and non-Stator TRIPS: ###
RTD Trips Screen 8
Screen 9: Displays the number of Ground Fault Hi and STATOR TRIPS: ### Screen 21
NON-STATOR TRIPS: ###
Lo Set trips EXT INP #1: ###

Screen 10: Displays the number of acceleration time trips. Screen 9

Screen 11: Displays the number of start under curve trips G/F HISET TRIPS: ###
Screen 22
G/F LOSET TRIPS: ###
Screen 12: Displays the number start over curve trips EXT INP #2: ###
Screen 13: Displays the number of I2T start curve trips Screen 10
Screen 14: Displays the number of learned start curve ACCELERATION TIME
Screen 23
trips. TRIPS: ###
EXT INP #3: ###
Screen 15: Displays the number of fail shunt trips. Screen 11
Screen 16: Displays the number of phase loss trips. START UNDER CURVE
Screen 24
Screen 17: Displays the number of tachometer TRIPS: ###
EXT INP #4: ###
acceleration trips.
Screen 12
Screen 18: Displays the number of undervoltage and START OVER CURVE
Screen 25
overvoltage trips. TRIPS: ###
PRESS ENTER TO
Screen 19: Displays the number of power factor trips. CLEAR STATISTICS
Screen 20: Displays the number of phase reversal trips. Screen 13 LEVEL 2 Password required
I*I*T START CURVE
Screen 21: Displays the number of external input #1 trips. TRIPS: ###
Screen 22: Displays the number of external input #2 trips.
Screen 23: Displays the number of external input #3 trips. Screen 14
LEARNED START CURVE
Screen 24: Displays the number of external input #4 trips. TRIPS: ###
Screen 25: Requires a Security Level 2 password to clear
the statistics. Screen 15
FAIL SHUNT TRIP
TRIPS: ###

Screen 16
PHASE LOSS TRIP
TRIPS: ###

Screen 17
TACH ACCEL TRIP
TRIPS: ###

- 68
 2.3 - 7.2kV
Chapter 7 - Maintenance and Troubleshooting
The soft starter is designed to be a maintenance-free product. However, as with all electronic equipment, the unit
should be checked periodically for dirt, moisture or industrial contaminants. These can cause high voltage arc-over,
carbon tracking or prevent proper cooling of the SCR heat sinks. All bolts should be checked annually for proper
tightness using an accurate torque wrench. According to the manufacturer’s manual, check the contactor for air gap
spacing of the vacuum bottles.

Note: If the unit is installed in a contaminated environment and forced air cooling is used, blower filters must be
checked and cleaned regularly to insure proper air flow and cooling of the enclosure.

7.1 - Failure Analysis

When a fault occurs, the LCD will display the fault error while the listed LED and AUX Relay will be lit. Please clear
all faults before attempting to restart the unit. Note: If the problem persists after the required programming changes
have been made, and all corrective action has been taken, please contact the factory for assistance.

Aux
Problem CPU LCD Display LED Possible Cause Solutions
Relay
One of the main Short circuit between the
fuses blows or inputs
Locate and remove short
circuit breaker
opens when the TCB FAULT TRIP Trip AUX1
Remove power and test SCR(s). Refer to
power is applied
Faulty SCRs Section 7.1.1 for the SCR testing
or disconnect is procedure
open
Short circuit or ground fault
Locate and remove short or ground
in motor/cabling
Phase Loss Repair cause of phase loss
Branch circuit protection Verify correct sizing of branch circuit
Short Circuit Trip SHORT CIRCUIT TRIP Trip AUX1 not correctly sized protection

Remove power and replace main circuit

Faulty main circuit board
board.
Remove power and test SCR(s). Refer to
Faulty SCRs Section 7.1.1 for the SCR testing
procedure
Single phase incoming
Correct problem with incoming power
SINGLE PHASE TRIP power
Single Phase Trip (Check LCD display for Trip AUX1
Remove power and test SCR(s). Refer to
possible fault indicators)
Faulty SCRs Section 7.1.1 for the SCR testing
procedure

If fans have power, remove power and

Fan(s) not functioning
replace fan(s). If fans do not have power,
(If supplied)
find cause of power loss and repair.

Remove power and clean heatsink with

Heatsink coated with dirt high pressure air (80 - 100 psi max clean
and dry air)

Thermostat trips EXTERNAL TRIP ON Verify that running current does not
Trip AUX1 Overcurrent on unit
during run THERMOSTAT exceed unit rating

Environment temperature
over 122° F (ambient
Place unit in environment temperature
temperature for chassis
less than 122°F for panel version or less
units) or over 104°F
than 104°F for enclosed version.
(ambient temperature for
enclosed version

Bypass failed to close Check bypass contactor and wiring

- 69
 2.3 - 7.2kV

Aux
Problem CPU LCD Display LED Possible Cause Solutions
Relay
Loss of 1 or more phases
of power from utility or Check power source
Phase Loss PHASE LOSS Trip AUX1
generated power

Blown power fuses Check for short circuits

Check motor nameplate versus
Improper programming
programmed parameters
Overload OVERLOAD TRIP Trip AUX1
Possible load damage or
Check motor currents
jammed load

Improper setting for motor

Verify current limit setting
load condition
Stall prevention ACCEL TIME TRIP Trip AUX1
Damaged load Check for load failure

Improper programming Check setpoint settings

Wrong position of
Check disconnect or open breaker
disconnected breaker
Under Voltage
UNDER VOLTAGE TRIP Trip AUX1
Trip Main contactor failed to
Check internal connections
close

Reduce current limit setting, saturation or

Transformer too small
sagging power supply transformer

Under Current Improper programming Check setpoint settings

UNDER CURRENT TRIP Trip AUX1
Trip
Unloaded motor Check load

Failed CPU or Main Firing

Contact factory
Self-test Failure SELF-TEST FAILURE Trip AUX1 Board
Vibration Check internal wiring connections
Troubleshoot and repair generator
Contact utilities company
Line Frequency OVER OR UNDER Generator Power Problem
Trip AUX1 Main board failure
Trip FREQUENCY TRIP or grid change
Three phase power removed from Main
Board
Improper programming Check program setpoints

Any wire going to ground

GROUND FAULT Check with meggar or Hi-pot motor leads
Any Ground Fault (I.e. stator ground, motor
HI-SET OR LO-SET Trip AUX1 and motor
Trip ground, soft start ground)

High vibration or loose

Check internal connections
connections

Warning: This is a serious fault condition. Ensure that the fault

condition is cleared on the load before attempting to restart the
motor.
Motor stopped
Check for fault indication Trip AUX1
during run
Load shorted/ grounded/
Remove power and repair.
faulted
Faulty main circuit board Replace the main circuit board

Control circuit Remove power, locate and remove this

Short in control circuit
fuses blow after short
None None None
control power is
Apply the correct voltage to the control
applied. Wrong control voltage
circuit

- 70
 2.3 - 7.2kV

Aux
Problem CPU LCD Display LED Possible Cause Solutions
Relay
No control voltage applied Apply control voltage to TB1 pins 1 and 6
to control board on the power board

Control power transformer Remove power and replace the power

failure or CPT fuse failure transformer or the CPT fuse

Start circuit wired Remove power and correct the start

incorrectly circuit wiring

Any fault indication No start command Apply the start command

Motor will not start Trip AUX1
message No 3 phase line voltage Apply 3 phase line voltage to the unit

Remove power and test SCR(s). Refer to

Shorted SCR in starter Section 7.1.1 for the SCR testing
procedure

Remove power and repair the control

Faulty control logic
logic.

Failure of main circuit

Replace the main circuit board
board

Check the motor and the motor

Faulty motor
connections

Remove power and perform the SCR

Motor vibrates/ Faulty SCRs
Trip AUX1 device checks
Motor growls
while starting or IMBALANCE TRIP Remove power and test SCR(s). Refer to
extremely IMBALANCE ALARM Faulty gate/cathode on
Section 7.1.1 for the SCR testing
unbalanced motor SCRs
procedure
currents run mode
Faulty main circuit board Replace the main circuit board
Faulty motor/wiring Troubleshoot and repair/replace wiring
Alarm AUX2
Faulty main circuit board Replace the main circuit board

7.1.1 - SCR Testing Procedure

Perform the SCR Heat Sink Ohm test on each Stack Assembly.

Test To Perform Ohm Meter Reading Test Result

From Position A to Greater than 10K Ohm Pass
Position B Less than 10K Ohm Fail
C
From Position B to Greater than 10K Ohm Pass
Position C Less than 10K Ohm Fail
Pass (Typical 8 to 20
Gate (G) to Cathode 8 to 100 Ohms
Ohms)
(K) for each SCR
B Less than 10 or greater than 100 Ohms Fail

A
Gate Drive Note: Allow 15 minutes after shutdown for DV/DT network to dis-
Board
charge DC voltage.

K = Cathode = Red Wire

G = Gate = White Wire
- 71
 2.3 - 7.2kV

7.2 - Overload Curve Definition

- 72
 2.3 - 7.2kV
Customer Provided

7.3 - TCB Diagram Momentary or Maintained

Start / Stop Switching
Maintained

START STOP
Fuses Momentary
F1: Control Fuses for TB1 1 - 9
Part #ACG1A250VAC or equivalent
F2: Contactor and relay output fuses
Part #ACG4A250VAC or equivalent
F3: TB2 Pin #6
Part #ACG4A250VAC or equivalent

12

NC
Aux Start
11

NO
E1 E2 E3 E4 Output
10

C
Red AC 120 VAC
9
LED Neut
Neutral
8
Start
FUSE
7
T1 Red TB1 6
Stop

LED
5
Inter
FAULT 4
Lock
Optional
3 Interlocks
Inter
Lock
2
1
AC 120 VAC
HEATSINK

Source
Source
F1 10

NC
9

NO
F2 8

C
HEATSINK
7
FACTORY WIRED

N
Green DO NOT USE
LED F3 6
{ Line 1

S
120VAC 5

NC
Neutral 2 -12V
TB2 4 Emergency Bypass
3 Green

NO
Delayed Start Green
LED LED 3 AUX Contacts

C
4
5 +12V
2 Emergency Bypass
C
Fuse Blown/ START
Disconnect Open 6
TB6 1 NO
Full Voltage Start
7
Dual Ramp ON OFF 12
NC

8 JP1
SW1 11
NO

9 Remove JP1 for electronic 10

Bypass Status DUAL ADJ
Fault

motor overload protection

C

10 during emergency 9
NC

bypass operation
8
NO

1
Run 7
TCB
C

2 TB3 6
NC

3
Lock Out

CPU (AUX1) Fault

BOARD 5
NO

4 TB7 4
C

5
At Speed 3
NC

6
2
NO

7
1
C

Fuse Blown/
1 12
Disconnect
NC
AUX-S
DLY-S
PFC-C
DLY-C
PFC-S

AUX-C

Green
Interlock Input 2 LED 11
P.F.C. CAP
NO

3 10
TB8
C

External Overload PFC

4 TIMED 9
NC

7 6 5 4 3 2 1 7 6 5 4 3 2 1 7 6 5 4 3 2 1 OUT
5 8
NO

Bypass Aux Contact

6 7
C

PFC AUX START TB4

Bypass
{ A1 7 6
NC

Coil A2 8 5
NO

Time Delay

A1 4
Main
{ 9 Green
C

Coil LED 3
A2 10
NC

DELAY
2
NO

TIMED 1
C

OUT

- 73
 2.3 - 7.2kV

7.4 - Typical Wiring Diagram

- 74
 2.3 - 7.2kV

- 75
 2.3 - 7.2kV
7.5- Spare Parts List
Spare Parts

Unit Voltage Quantity

Description Part Number
and Amp Rating Req./Unit
Current
Contact Factory Specify model number 3
Transformer
MVC3-STK23200 2300V, 200A 3
MVC3-STK23400 2300V, 400A 3
MVC3-STK23600 2300V, 600A 3
Heatsink
MVC3-STK41200 3300/4160V, 200A 3
Assembly with
MVC3-STK41400 3300/4160V, 400A 3
Boards
MVC3-STK41600 3300/4160V, 600A 3
(1 Phase)*
MVC3-STK72200 6000 - 7200V, 200A 3
MVC3-STK72400 6000 - 7200V, 400A 3
MVC3-STK72600 6000 - 7200V, 600A 3
25-0200-6500-23 2300V, 200A 3
25-0400-6500-23 2300V, 400A 3
25-0600-3500-23 2300V, 600A 3
SCR(s) Clamped 25-0200-6500-41 3300/4160V, 200A 3
in Heat Sink 25-0400-6500-41 3300/4160V, 400A 3
Alone 25-0600-3500-41 3300/4160V, 600A 3
25-0200-6500-72 6000 - 7200V, 200A 3
25-0400-6500-72 6000 - 7200V, 400A 3
25-0600-3500-72 6000 - 7200V, 600A 3
10-0090 2300V, 200A & 400A 3
10-0090 2300V, 600A 6
Gate Drive 10-0090 3300/4160V, 200A & 400A 6
Transfomer 10-0090 3300/4160V, 600A 12
10-0090 6000 - 7200V, 200A & 400A 9
10-0090 6000 - 7200V, 600A 9
Temperature &
MVC3-Temp/CT-PS All models 3
Current Board

*Recommended spare parts

- 76
 2.3 - 7.2kV
Spare Parts

Unit Voltage Quantity

Description Part Number
and Amp Rating Req./Unit
MVC3-GDF 2300V, 200A & 400A 3
MVC3-GDFP 2300V, 600A 6
Gate Drive MVC3-GDF 3300/4160 V, 200A & 400A 6
Boards MVC3-GDFP 3300/4160 V, 600A 12
MVC3-GDF 6000 - 7200V, 200A & 400A 15
MVC3-GDFP 6000 - 7200V, 600A 18
MVC3-MOV 2300V, 200A & 400A 3
MVC3-MOV 2300V, 600A 6
MVC3-MOV 3300/4160 V, 200A & 400A 6
MOV Board
MVC3-MOV 3300/4160 V, 600A 12
MVC3-MOV 6000 - 7200V, 200A & 400A 15
MVC3-MOV 6000 - 7200V, 600A 18
MVC3-Dv/Dt 2300V, 200A & 400A 3
MVC3-Dv/Dt 2300V, 600A 6
MVC3-Dv/Dt 3300/4160 V, 200A & 400A 6
dv/dt Board MVC3-Dv/Dt 3300/4160 V, 600A 12
MVC3-Dv/Dt 6000 - 7200V, 200A & 400A 15

MVC3-Dv/Dt 6000 - 7200V, 600A 18

Main board, CPU

board & digital
controller assembly MVC3-MB/CPU-KIT* All models 1
with lexan cover and
harness

Control Board MVC3-TCB All models 1

RTD (Option) Board DSS1000-RTD Option 1

Ground fault (Option)

MVC3-GFCT Option 1
Board
Contact
Medium Voltage Fuses Contact Factory Specify FLA
Factory

*Recommended spare parts

PCB Mounting Order

DVDT MOV Gate Drive

Board Board Board

Temp CT
Board

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 2.3 - 7.2kV

7.6 - Instructions for Stack Replacement

(For Reference Only)

TEMP / CT Board

Gate Drive Board

MOV Board

DV/DT Board

PCB Mounting Order

DVDT MOV Gate Drive

Board Board Board

Temp CT
Board

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 2.3 - 7.2kV

7.6 - Instructions for Stack Replacement

DANGER
HAZARDOUS VOLTAGE
Disconnect all power supplying this equipment prior
to working on it.

Failure to follow this instruction will result in death

or serious injury.

Note: All power sources must be removed and a waiting period of at least 15
minutes must be observed before initiating any repairs to the unit(s) be-
cause DC voltage may still be present immediately after turning off power
to the unit.
Note: It is good practice to disassemble and reassemble one stack at a time so
you can have an assembled and wired stack in the unit as a reference.
Note: It is recommended that the order include the SCR with the heatsink as-
sembly at a minimum. Only an experienced technician should attempt to
replace the SCRs.

Tools:
• Phillips screwdriver
• 3/8” 12 point socket set
• 2 9/16” wrenches
• ½” wrench
• AC/DC Multimeter
• Manual (refer to drawings in this section)

Procedure:
1. Verify that no DC or AC voltage is present on any of the power components.
2. Disconnect all four wires connected to TB1 positions 1-3 on the temperature
CT board.
3. Disconnect the 4 red transformer wires on each of the gate drive boards.
These would be TB1, positions 3 and 5 for each gate drive board. Typically,
the 2300V unit will have only 4 wires per phase to disconnect, a 4160V unit
will have 8 wires per phase and a 6000 - 7200V unit will have 12 wires per
phase (Note: the 6000 - 7200V/600 amp unit will also have 24 wires.)
4. Use the 9/16 wrench and carefully unbolt all of the line and load power con-
nections attached to the heat sinks. Note: If the unit is a 6000 - 7200V, remove
the power strap connecting one side of the stack to the stack directly below it.
5. Before removing the fiber optic wiring, make a note of the label on the fiber
cable to ensure they are placed exactly in the same socket they were re-
moved from. Now remove all fiber optic connectors on the stack. Gently push
on the connector tab and pull with a gentle left-to-right motion on the con-
nector in the direction away from the fiber optic device. Two connectors will
be found per gate drive board and one duplex connector will be found on the
small Temp/CT board on top. Caution: Do not touch the tip of the connectors
or contaminate the connection sockets with any dust or foreign material.
6. Remove the wires from the Temp/CT board terminal block (3 screws)
7. Use a 9/16” socket with a 6” extension to remove the lower bolt that routes
through the front face of the heat sink and into the isolation standoff mounted
to the white panel. Then carefully hold the heat sink in place with one hand
and remove the top bolt from the heat sink.
8. Ensure the fiber optic connectors and all wires are positioned out of the way,
and then the heat sink can be gently removed from the unit.

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 2.3 - 7.2kV

SCR Replacement:
1. Remove white jumper wires on the gate drive board and make a note of
their placement.
2. Remove both 7/16 bolts and single 10 - 32 screw at the top of gate drive
board and lift off the board.
3. To remove the MOV board, remove the SCR gate/cathode leads (thin
red and white wires) and the white jumper wires attached to them. Make
a note as to how they were connected. Unbolt the ½” fasteners as well.
4. At this point, all boards should now be removed from the aluminum heat
sink assembly.
5. Make a note (or drawing) of how each of the SCRs are oriented within
the heat sink. If factory supplied replacement SCRs and heatsinks are
used, the following steps are not required.
6. Loosen and carefully remove the ½” feed-through bolt and two black
springs that hold the assembly together and turn it on its side.
7. Remove the two (2) SCRS in the top layer, making certain to note that
the SCRs are not facing the same direction.
8. Remove the two (2) SCRs in the bottom layer, also making certain to
note that the SCRs are not facing the same direction.
9. Clean the heat sink surface area thoroughly and reapply some thermal
heat sink grease sparingly to the SCRs mating surfaces.
10. Please note that replacement SCRs are in matched sets of four and as
such, please try to keep the matched sets within the same phase.
11. Now, take any two SCRs from a set and place them on the heat sink in
the same direction as the old SCRs were, ensuring that the dimple in the
center of the SCR is properly placed onto the center pin of the heat sink
assembly. Place the next level of heat sink bar on the mounted SCRs.
Note: There is a difference in the heat sink bars. The center bar has
more holes drilled in it for mounting the circuit boards on it.
12. Now replace the other two (2) SCRs by repeating steps 10 and 11.
13. Next, carefully sandwich the SCRs and turn the stack over so the heat
sink bars are vertical and run the center bolt through the springs and
hand tighten the nut on the center bolt assembly.
14. Then make approximately 3 and ½ full revolutions on the nut to create
the appropriate amount of compression force. You can tell if there is
enough compression force applied to the heat sink by the fact that the
force needed to turn the nut will suddenly increase.
15. Finally, reinstall all boards in the same manner in which they were re-
moved.
16 Refer to drawing PCB mounting order drawings for disassembling and
reassembling the stack assembly.

Reinstallation:
1. Hold the rebuilt or new stack assembly in the vertical position with the
Temp/CT board on top (only the top stack assembly will have this board
in a multi-stack phase) and place the stack on the positioning studs that
protrude from the isolation standoffs.
2. While pressing on the stack to hold it on the positioning studs, place the
feed-through bolt through the heat sink and finger-tighten the top bolt.
Then repeat the process with the bottom feed-through bolt to ensure the
stack is held against the isolation standoffs.
3. After verifying no wires or fibers have been pinched between the stack
assembly and isolation standoffs, tighten the top bolt completely, then
repeat the process for the bottom bolt. Now the stack assembly should be
held firmly in place.
4. Using the 9/16” wrench reinstall the line and load power cables and
tighten.
5. If needed, refer to the appropriate drawing to reconnect red transformer
wires on each gate drive board. As an example, for the 4160V stack,
reattach TB4-1 to X3, TB4-3 to X4, TB1-3 to X2 and TB1-1 to X1. Verify
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 2.3 - 7.2kV

all X(#) wires are reconnected to their original position on the gate drive
boards. Otherwise the SCRs will misfire.
6. Reconnect thermostat wires on TB1 positions 2 and 3 of the Temp/CT
board.
7. Reconnect the main CT black wire to TB1-1. Then feed the white wire
through the board mounted CT and connect to TB1-1 on the Temp/CT
board. Please note that one each of the thick white wires from the encap-
sulated CT must be connected with the Main CTs wiring.
8. Ensure the same fiber optic routing is used as before. If the fiber optic
wiring is positioned close to a heat source, (such as the 25-watt resistors
on the gate drive board) melting or distortion of the plastic fiber may occur.
Minimum distance is a ½ inch with a minimum bend radius of 2 inches. All
gate drive boards require 2 single connectors per board and the Temp/CT
connector is a duplex piece with a mating tab that faces away from the
stack. If the tab is broken off, refer to an adjacent stack’s labels to see
how the labels should be positioned when installing a duplex connector
with a broken tab. Again, caution should be taken not to touch the fiber
connector end or force it in with the tab facing down.

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 2.3 - 7.2kV

7.7 - Instructions for Low Voltage Test

Tools:

DANGER
HAZARDOUS VOLTAGE
Disconnect all power supplying this equipment prior
to working on it.

Failure to follow this instruction will result in death

or serious injury.

• Phillips screwdriver
• Medium voltage fuse pullers if available
• Two control power transformer (Test PT) 500 VA minimum
• 120 VAC control power (Test plug)
• Low voltage motor strapped for the proper voltage (typically 5 HP or
less)
• Oscilloscope if available
• Wire jumper
• Test switch (single pole i.e. - light switch)
• Manual (reference drawing
above) 480 or 240 VAC 3 Phase Supply
Construct an open delta low A B C

DANGER voltage source for powering

the MVC for low voltage testing
Ensure proper
phase sequence
HAZARDOUS VOLTAGE (Minimum of 500VA each) H2 H1 H1 H2
Remove all medium voltage fuses to prevent back-
feeding transformers. PTs

Failure to follow this instruction will result in death

X1
X1
or serious injury. X2 X2
A B C
Low Voltage Panel
TB1 Terminal 1 TB1 Terminal 3 TB1 Terminal 5
Procedure: 120 VAC 3 Phase Output
1. Verify that no DC or AC voltage is present Connect to MVC3-MB (Main Firing Board)
on any of the power components. Caution: Remove the three phase transformer PT fuses and CPT fuses
2. Verify setup of control power transformers on panel to prevent backfeed to the Medium Voltage
for the proper voltage. If using 480 VAC or
240 VAC 3 phase verify transformers are
strapped for that voltage. See above drawing. Configure as an open
delta for 3 phase as shown in drawing.
3. Verify medium voltage disconnect is open and pull medium voltage
fuses including VT and CPT fuses.
4. Connect 3 phase power 480 or 240 VAC to the down stream side of
the fuses. Do not connect to disconnect side of fuses. The size of the
small test motor will dictate the current drawn and minimum cable
size for connection. Also, connect the Primaries of the TEST PT in
the proper phase sequence of A-B-C.
5. Disconnect medium voltage motor.
6. Connect low voltage motor. (Typically 5 HP or less)
7. Connect a wire jumper between TB8 pins 1 and 2 on the TCB (con-
trol board) to bypass fuse blown and open disconnect fault. The TCB
is located in the medium voltage compartment.
8. Install a switch on TB1 pins 1 and 8 on the TCB (control board) to
bypass all interlocks (Interlock Switch).

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 2.3 - 7.2kV

9. Verify or wire a 120 VAC plug to the TEST plug supplied by the fac-
tory. (Line start packages only)
10. Remove both control power fuses on the medium voltage CPT
(single phase control power transformer)
11. Remove 3 fuses from the medium voltage potential transformer (PT)
12. Verify the 120-volt test switch is in the “NORMAL” position. (Line
start package only)
13. Connect test power to test plug connector and place the 120-volt test
switch to the “TEST” position.
14. The keypad should be energized with the “Power LED,” Stop LED
15. Close the temporary Start switch, which is connected to the control
board.
16. The Main Vacuum contactor should close and the keypad should trip
on “Under Voltage” Open temporary Interlock switch and reset CPU
fault.
17. Connect the Secondary of the TEST PT to Panel TB1 positions 1 -
phase A, position 3- phase B, and position 5 - phase C. It is physical-
ly located behind the low voltage compartment door. (Screw terminal
block)
18. Verify all connections are good and then energize the low voltage of
either 480 or 240 volt, three phases.
19. Use the multimeter on the AC scale and verify 3 phase 120 VAC
(phase to phase) at TB1 pins 1, 3 and 5 of the main firing board.
20. If all 120 VAC 3 phase is present then de-energize low voltage of 480
or 240 VAC.
21. Re-energize the low voltage of 480 or 240 VAC.
22. Now all test voltages should be present 480 or 240 VAC and three
phase 120 VAC (TEST PT) and 120 VAC single phase for control
power.
23. Close the temporary Start switch and the test motor should spin up
smoothly.
24. Use the Multimeter on the AC scale and check (phase to phase)
voltages on T1, T2 and T3 motor leads. The voltages should be bal-
anced.
25. If the motor doesn’t spin up smoothly the soft starter is malfunction-
ing. Proceed to step 27 for troubleshooting.
26. If the motor starts and runs smoothly then repeat this procedure in
reverse to remove all test connections and reinstall all fuses.

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 2.3 - 7.2kV

Low Voltage Troubleshooting:

Tools: Ungrounded Oscilloscope
27. Open test switch and stop motor.
28. Change Setpoint Page 5 AUX4 is set at non-fail safe. Change it to fail
safe.
29. Observe bypass contactor closes immediately.
30. Place the Oscilloscope on the 2msec time scale and 1 v per
division.
31. Connect the Oscilloscope probe to the Gate and Cathode of the
SCRs.
32. The gate and cathode leads are the white wires on the gate drive
board in the medium voltage cabinet. See drawing below.
33. If waveform is inverted, swap Oscilloscope connections for proper
polarity. Close the temporary Start switch and allow the test motor to
reach full speed.
34. Then verify all gating signals to each SCR (two gating signals on
every gate drive board). See drawing below for correct waveform.
35. Once the bad signal(s) are found; write down the location and call

Waveform is
the gating signal as
measured with an
ungrounded oscilloscope
at the gate to cathode
of the SCR. The
waveform should be 1.7
to 2msec off time and
approximately 1.5 to
3 Vdc. This signal is only
present at full conduction
or the motor is at speed.
Each SCR gating signal
should be checked
in accordance with the
low voltage test procedure.

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 2.3 - 7.2kV

Notes:

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 2.3 - 7.2kV

- 86