Solstart

Analog Soft Starter

8-58A, 220-600V

Instruction Manual
Ver. 26/02/2009
2 • Table of Content

SOLSTART Instruction Manual

1. TABLE OF CONTENT

1. Table of Content .......................................................................................................................2

2. Safety & Warnings ....................................................................................................................3

2.1 Safety..........................................................................................................................................3
2.2 Attention......................................................................................................................................3
2.3 Warnings.....................................................................................................................................3
3. Technical Data ..........................................................................................................................4
3.1 Introduction .................................................................................................................................4
3.2 Rating and frames sizes .............................................................................................................4
3.3 Starter Selection .........................................................................................................................4
3.4 Mains and control description .....................................................................................................5
3.4.1 Mains Voltage (line to line) (Terminals/bars L1, L2, L3)..................................................5
3.4.2 Start/Stop (Terminals A1,A2) ..........................................................................................5
3.4.3 End Of Acceleration (terminals 3, 4) Solstart 31A and up...............................................5
3.5 Built-in Bypass ............................................................................................................................5
3.6 Starter selection tables for various voltage ratings. ....................................................................6
3.6.1 Ordering Information .......................................................................................................6
4. Recommended Wiring Schemes .............................................................................................7
4.1 Typical wiring diagram ................................................................................................................7
4.2 Wiring Notes ...............................................................................................................................7
4.2.1 Short Circuit Protection ...................................................................................................8
4.2.2 Transient Protection ........................................................................................................8
5. Dimensions ...............................................................................................................................9

6. Installation...............................................................................................................................10
6.1 Prior to Installation ....................................................................................................................10
6.2 Mounting ...................................................................................................................................10
6.3 Temperature range & heat dissipation......................................................................................10
6.3.1 Calculating the enclosure size, for non-ventilated metallic enclosure ...........................10
6.3.2 Additional Ventilation.....................................................................................................11
7. Front Panel ..............................................................................................................................12
7.1 Potentiometers settings ............................................................................................................12
7.2 Indication LEDs.........................................................................................................................13
8. Starting Procedure .................................................................................................................13
8.1 Standard starting procedure .....................................................................................................14
8.2 Examples of starting curves......................................................................................................15
9. Technical Specifications........................................................................................................16

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 3 • Safety & Warnings

2. SAFETY & WARNINGS

2.1 Safety
Read this manual carefully before operating the equipment and follow its
1
instructions.
Installation, operation and maintenance should be in strict accordance
2
with this manual, national codes and good practice.
Installation or operation not performed in strict accordance with these
3
instructions will void manufacturer’s warranty.
Disconnect all power inputs before servicing the soft-starter and/or the
4
motor.
After installation, check and verify that no parts (bolts, washers, etc.)
5
have fallen into the starter.
During shipping, the soft-starter might have been roughly handled,
6 therefore, it is recommended to initialize the soft-starter by connecting
supply voltage prior to operating the soft-starter with a motor

2.2 Attention
This product was designed for compliance with IEC 947-4-2 for class A
1
equipment.
Use of the product in domestic environments may cause radio
2 interference, in which case, the user may be required to employ
additional mitigation methods.
Utilization category is AC-53a or AC53b, Form 1. For further information,
3 see Technical Specification

2.3 Warnings
Internal components and PCBs are at mains potential when the
1 SOLSTART is connected to mains. This voltage is extremely dangerous
and will cause death or severe injury if contacted.
When SOLSTART is connected to mains, even if start command has not
been issued and motor is stopped, full voltage appears on starter’s output
2 and motor’s terminals.
Therefore, for isolation purposes it is required to connect an isolation
device upstream to the SOLSTART.
The starter must be grounded (models Solstart 31A and up) to ensure
3
correct operation, safety and to prevent damage.
Check that Power Factor capacitors are not connected to the output side
4
of the soft starter.
5 Do not interchange line and load connections

The company reserves the right to make any improvements or modifications to its products without
prior notice.

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4 • Technical Data
3. TECHNICAL DATA
3.1 Introduction
The SOLSTART electronic soft starter incorporates two sets of thyristors (Two phase control) to start a three-
phase squirrel cage induction motor and an internal bypass.
By supplying a slowly increasing voltage, it provides soft start and smooth stepless acceleration, while drawing
the minimum current necessary to start the motor.
A Soft Stop feature can be enabled when the Ramp-Down potentiometer is adjusted.
When used, upon stop signal, motor's voltage is slowly reduced to zero.
No control voltage is required to operate the SOLSTART.

3.2 Rating and frames sizes

SOLSTART FLC Dimensions Weight

Aluminium
EOA Relay

mounting
model [A] WxHxD [kg]

Din rail
case
[mm]

SOLSTART 8 8 45x75x110 0.42 (-) (-) 9

SOLSTART 17 17 90x75x105 0.55 (-) (-) 9
SOLSTART 22 22 90x75x105 0.55 (-) (-) 9
SOLSTART 31 31 65x190x114 1.3 9 9 O
SOLSTART 44 44 65x190x114 1.3 9 9 O
SOLSTART 58 58 65x190x114 1.3 9 9 O

Notes: • 9 – Standard
• O – Option
• C – Consult factory
• (-) – Not available
• Refer to section 5 on page 9 for detailed dimensions.

3.3 Starter Selection

Select the starter according to motor's Full Load Ampere (FLA) - as indicated on its nameplate (even if the
motor will not be fully loaded).
The SOLSTART is designed to operate under the following maximum conditions:

Ambient Starting Current Acceleration Time

Temperature [A] [sec]
[0C]
40 350%xIn 5

Max. starts per Hour: four (4) starts per hour at maximum ratings and up to 10 starts per hour at light load
applications (consult factory).

Note:
For very frequent starts (inching applications) the inching current should be considered as the Full Load
Current (FLC) (consult factory).

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 5 • Technical Data

3.4 Mains and control description

3.4.1 Mains Voltage (line to line) (Terminals/bars L1, L2, L3)
Five mains voltage levels are available: 230V, 400V, 440, 480V, 600V.
Note:
230 220 - 240 Vac +10% -15%
400 380 - 415 Vac +10% -15%
440 440 Vac +10% -15%
480 460 - 500 Vac +10% -15%
600 575 - 600 Vac +10% -15%

3.4.2 Start/Stop (Terminals A1,A2)

Start/Stop command is initiated by closing/opening a voltage free contact (Dry contact)
Close: Start command.
Open: Stop command.

WARNING! Never apply voltage to terminals A1, A2.

Start/Stop with a maintained contact!
When the line contactor is operated by a maintained contact, in case of Mains
failure, the motor will be automatically restarted upon voltage restoration!

3.4.3 End Of Acceleration (terminals 3, 4) Solstart 31A and up

Voltage free, N.O., 5A / 250VAC, Solstart 31-58A
The contact closes after the time adjusted on the "Ramp-Up" potentiometer.
The contact returns to its original position on stop signal or upon voltage outage.
This contact can be used for:
• Activating a valve after a compressor has reached full speed.
• Activating a valve after a pump has reached full speed.
• Loading a conveyor after the motor has reached full speed.

3.5 Built-in Bypass

The SOLSTART incorporates two internal bypass relays allowing current flow through the thyristors only
during starting process. At the end of the starting process, the built-in relays bypass the thyristors and carry
the current to the motor.
When Ramp-Down potentiometer is set to allow soft-Stop process, upon stop command, the bypass relays will
open immediately and the current will flow through the thyristors. The voltage will then be reduced slowly and
smoothly to zero.

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6 • Technical Data

3.6 Starter selection tables for various voltage ratings.

The starter selection table below concern standard, 1500r.p.m. 50Hz,
1
three-phase motors.
These values are given for guidance and may vary according to motor
2
manufacturer and depending on the number of poles.
It is the user’s responsibility to make sure that motor’s FLA will never
3
exceed Starter’s FLC.

Starter model Start Motor kW Motor kW Motor kW Motor kW

er @230V @400V @480V @600V
FLC [kW] [kW] [kW] [kW]
[A]

SOLSTART 8 8 1.5 3 4 5.5

SOLSTART 17 17 4 8 9 12.5
SOLSTART 22 22 5.5 11 12.5 15
SOLSTART 31 31 8 15 18.5 25
SOLSTART 44 44 12.5 22 25 30
SOLSTART 58 58 15 25 37 45

3.6.1 Ordering Information

SOLSTART 31- 400- 0- S
Full load Mains Options Front
Current Voltage Panel

Full load Current

Specify Description
Starter’s 8(1), 17(1), 22(1), 31, 44, 58
FLC [A]

Mains Voltage
Specify Description
230 220 - 240 Vac +10% -15%
400 380 - 415 Vac +10% -15%
440 440 Vac +10% -15%
480 460 - 500 Vac +10% -15%
600 575 - 600 Vac +10% -15%

Options
Specify Description
0 No options
8 Harsh environment treatment
U UL & cUL approval (Solstart 8-44A)
DRM DIN rail mounting accessory. (models 31-58A.)
Notes: • For more than one option indicate, for example: 8+DRM
(Harsh environment and DIN rail mounting accessory)
• Options must be factory installed.
Front Panel
Specify Description
S Standard lexan
Notes:
(1)
No End of Acceleration Relay in Solstart 8, 17, 22

Example:
SOLSTART rated 58A, mains voltage- 230V, harsh environment treatment and standard front panel:
SOLSTART 58 - 230 - 8 – S

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 7 • Recommended Wiring Schemes

4. RECOMMENDED WIRING SCHEMES

4.1 Typical wiring diagram

Notes:
(1) - Use fuses for class 2 coordination. Refer to section 4.2.1 on page 8
(2) – Use a maintained contact to start the motor. Open the contact to soft stop/stop the motor.
Contact must be closed one second after voltage at L1, L2, L3 is stable.
Never apply voltage to terminals A1 & A2.
(3) – End Of Acceleration contact is in SOLSTART 31A and up.
(4) – Ground connection is in SOLSTART 31A and up.
4.2 Wiring Notes

WARNINGS! When mains voltage is connected to the SOLSTART, full voltage appear on starter load
terminals.
Therefore, for isolation purposes, it is necessary to connect an isolating device before
the starter.
Power factor correction capacitors must not be installed on starters load side. When
required, install capacitors on starter’s line side.
Never connect the SOLSTART “Inside Delta”!

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8 • Recommended Wiring Schemes

4.2.1 Short Circuit Protection

For “class 2 coordination”, protect the starter against a short circuit by thyristor protection fuses for I²t as
indicated in the following table:

SOLSTART type I²t (A²S)

SOLSTART 8 400
SOLSTART 17 500
SOLSTART 22 560
SOLSTART 31 3000
SOLSTART 44 6,000
SOLSTART 58 12,000

4.2.2 Transient Protection

Line transient voltages can cause a malfunction of the starter and damage to the thyristors. All SOLSTART
starters incorporate Metal Oxide Varistors (MOV) to protect from normal line voltage spikes.

When higher transients are expected, additional external protection should be used (consult factory).

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 9 • Dimensions

5. DIMENSIONS

SOLSTART 8
Note: Mains voltage terminals: 4mm2

SOLSTART 17, 22
Note: Mains voltage terminals: 4mm2

SOLSTART 31, 44, 58

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10 • Installation
6. INSTALLATION

WARNING! Do not interchange line and load connections

Do not connect the SOLSTART “Inside Delta”

6.1 Prior to Installation

Check that Motor’s Full Load Ampere (FLA) is lower than, or equal, to the starter’s Full Load Current (FLC)
and that Mains and Control voltages are as indicated on the starter’s side label.

Make sure Starter’s FLC≥ Motor FLA!

Make sure Mains voltage is right!
Make sure control is by voltage free contact!

SOLSTART label - example

6.2 Mounting
The starter must be mounted vertically. Allow sufficient space (at least 100mm) above and below the starter
for suitable airflow.
It is recommended to mount the starter directly on the rear metal plate for better heat dissipation.
Do not mount the starter near heat sources.
Surrounding air temperature in the cabinet should not exceed 40ºC
Protect the starter from dust and corrosive atmospheres.

Note: For harsh environments (sewage treatment plants, etc.), it is recommended to order the starter with
printed circuit board coating. Refer to section 3.6.1 on page 6 for ordering information.

6.3 Temperature range & heat dissipation

The starter is rated to operate over a temperature range of -10ºC (14ºF) to + 40ºC (104ºF).
Relative non-condensed humidity inside the enclosure should not exceed 95%.

ATTENTION! Operating at surrounding air temp. (Inside the cabinet) higher than 40ºC may
cause damage to the starter.

Starter’s heat dissipation while motor is running and the internal bypass relays are closed is typically less than
0.3 x In (in watts). During soft start and soft stop, heating is approximately two times the actual starting current
(In watts).

Example: For a 17A motor, heat dissipation is less than 5.1 watts while running.

Important note: If motor is frequently started, cabinet should be designed for the higher heat dissipation.

Internal enclosure heating can be reduced through the use of additional ventilation.

6.3.1 Calculating the enclosure size, for non-ventilated metallic enclosure

Area (m2) = 0.12 x Total heat dissipation [Watts]

60 – External ambient temp. [ºC]

Where: Area [m2]] - Surface area that can dissipate heat (front, sides, top).
Total heat dissipation [Watt] – The total heat dissipation of the starter and other control devices in
the enclosure. If starter is frequently started, average power should be used.

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 11 • Installation

6.3.2 Additional Ventilation

Use the following arrangement for forced ventilation of the SOLSTART’s enclosure:

General purpose
Solstart enclosure
with filter on the air inlet
and Fan on air outlet.

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12 • Front Panel
7. FRONT PANEL
The SOLSTART front panel contains:
(1) Three potentiometers for setting: Initial Voltage, Ramp Up and Ramp Down.
(2) Three indication LEDs: On, Ramp, Run.

(1)

(2)

7.1 Potentiometers settings

Potentiometer Range Description

Initial Voltage 10-80% Determines the initial voltage to the motor (torque is directly proportional
to the square of the voltage).
This adjustment also determines the inrush current and mechanical
shock.
Too high of a setting may cause high initial mechanical shock and high
inrush current.
Too low of a setting may result in prolonged time until motor starts
revolving. The motor should start revolving immediately after Start signal
U%
100%

80%

10%

Sec.

Ramp Up 0.5-5sec. Determines motor's voltage ramp-up time from initial to full voltage.
It is recommended to set Ramp-Up Time to the minimum acceptable
value.
U%
100%

80%

10%

0.5 5 Sec.

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 13 • Starting Procedure

Potentiometer Range Description

Ramp Down 0.5-5 sec. Used to control deceleration of high friction loads. When Ramp-Down
potentiometer is set, upon stop signal the starter output voltage is
gradually ramped down.
When "Ramp-down Time" is set to minimum, the motor will stop
immediately.
U%
100%

0.5 5 sec

7.2 Indication LEDs

Green On Will lit when Mains voltage is connected to the starter.

Ramp Will lit during soft start and soft stop process, indicating that motor supply voltage
Yellow
is ramping up or down.

Will lit after completion of starting process, indicating that motor is receiving full
Green Run
voltage.

8. STARTING PROCEDURE
When mains voltage is connected to the SOLSTART, full voltage appear
1 on the starter load terminals. Therefore, for isolation purposes, it is
necessary to connect an isolating device before (upstream) the starter.
Power factor correction capacitors must not be installed on starters load
2 side. When required, install capacitors on starter’s line side.
Before starting the motor verify its rotation direction. If needed,
3 disconnect the rotor from the mechanical load and verify the right rotation
direction.
Prior to Start up procedure make sure that line voltage match the one
4 shown on the starter’s name plate.
Do not interchange line and load connections
5
Do not connect the SOLSTART “Inside delta”.
6

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14 • Starting Procedure

8.1 Standard starting procedure

1. Set initial voltage potentiometer to mid scale (approx. 40%)

2. Set Ramp-Up potentiometer to approx. 3 seconds.
3. Connect mains voltage to starter line terminals. On LED will
lit.
4. Apply Start command

No
Motor starts to turn
shortly after Start Increase “Initial Voltage” and start again
signal?

Yes

Yes
Initial inrush current or
mechanical shock is Decrease “Initial Voltage” and start again
too high?

No

Apply Stop command and wait until motor

stops.

Slightly increase Initial Voltage and Current Limit

settings to allow for load variations.

Apply Start command

No
Motor acceleration time If acceleration time is too short, increase Ramp-
to full speed is as Up time.
required?

Yes

End of process

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 15 • Starting Procedure

8.2 Examples of starting curves

Light loads - pumps, etc.
Initial Voltage - set to 40%
Ramp-up time - set to 3 sec.

U% I%
100% 600%
400%
300%
40%

100%
10%
t t
3

Upon start, the voltage quickly increases to the Initial Voltage value (40% Un) and then gradually ramps-up to
nominal.
The current will simultaneously increase to peak current value, before smoothly decreasing to the operating
current. The motor will quickly and smoothly accelerate to full speed.

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16 • Technical Specifications

9. TECHNICAL SPECIFICATIONS
Environment
Supply voltage 230 220 - 240 Vac +10% -15%
400 380 - 415 Vac +10% -15%
440 440 Vac +10% -15%
480 460 - 500 Vac +10% -15%
600 575 - 600 Vac +10% -15%
Frequency 50 / 60 Hz
Load Three-Phase, Three-Wire, Squirrel
Cage Induction Motor
Degree of protection SOLSTART 8-44A: IP 20
SOLSTART 58: IP 00
Altitude 1000 m above sea level Consult factory for derating
Adjustments
Starting Torque (Initial Voltage) 10-80 % of full voltage
Ramp Up Time (soft start) 0.5 - 5 sec.
Ramp Down Time (Soft Stop) 0.5 - 5 sec.
Indications
Indication lights (LEDs) ON - Green Lights when mains is connected to
the SOLSTART.
Ramp Up / Ramp Down – Lights during Ramp-Up and Ramp-
Yellow Down
RUN – Green Lights upon end of starting. When
the internal bypass relays close.
Temperatures
Operating -10° to 40°C
Storage -20° to 70°C
Relative humidity 93 % - non condensed
EMC
Immunity to radio electric EN 1000-4-3 level 3 Conforming to EN 60947-4-2
interference
Electrostatic discharge EN 1000-4-2 level 3 Conforming to EN 60947-4-2
Immunity to electrical EN 1000-4-4 level 4 Conforming to EN 60947-4-2
transients
Shock waves of voltage / EN 1000-4-5 level 3 Conforming to EN 60947-4-2
current
Radiated and conducted EN 1000-4-6 level 3
emissions
Radio frequency emissions According to EN 55011 class A Conforming to EN 60947-4-2
Mechanical
Shock resistance 8 gn Conforming to EN 60947-4-2
Vibration resistance 2 gn Conforming to EN 60947-4-2
Output relay (Solstart 31-58A only)
End of Acceleration Contact N.O.
Rated operating current 5 A, 250 VAC - Solstart 31-58A

Solcon Industries Ltd.

www.solcon.com; Technical support: [email protected]

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