Date subject to change without notice.
We reserve all rights to this document, even in the event that a patent is
issued and a different commercial proprietary right is registered. Improper
use, in particular reproduction and dissemination to third parties, is not
permitted.
This document has been carefully checked. If the user nevertheless
detects any errors, please notify us as soon as possible.
The data contained in this manual is intended solely for the product description and is not to be deemed to be a statement of guaranteed properties. In the interests of our customers, we constantly seek to ensure that
our products are developed to the latest technological standards.
As a result, it is possible that there may be some differences between the
softstarter and the information in this manual.
Author’s address:
Low Voltage Products and Systems
ABB Inc.
1206 Hatton Road
Wichita Falls, TX 76302
Tel: 888.385.1221
Caution icon indicates the presence of a hazard which could result
in personal injury.
!
Warning icon indicates the presence of a hazard which could result
in corruption of software or damage to equipment/property.
Alerts the reader to pertinent facts and conditions.
Caution!
Warning!
Information!
2 Safety
This section describes warning and information signs used in this manual.
The user should pay close attention to these signs.
The softstarter should be installed by authorized personnel only.
This manual is a part of the softstarter and should always be accessible to
personnel working with this product.
The manual should always be read before performing any installation or
commissioning tasks.
II Low Voltage Products & Systems
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Installation and maintenance manualPST30...PSTB1050
About the documentation for the softstarter .........................................................1.2
About the installation and commissioning manual ...............................................1.2
For other documents related to the PST Softstarters, see www.abb-control.com/products/softstarters.htm#type_pst
1:2 About the installation and commissioning manual
This manual contains instructions on how to install and commission the softstarter. The manual covers procedures for mechanical and electrical installation and installation of communication devices. It also covers how to energize, set, confi gure and verify settings.
For the quickest possible start, read Chapter 2 “ Quickstart” .
1:2.1 Intended audience
1:2.1.1 General
The installation and commissioning manual is intended for personnel responsible for installing, commissioning and maintaining the softstarter.
1:2.1.2 Requirements
All personnel who interact with the softstarter must have a basic knowledge in handling electric equipment. The commissioning and maintenance personnel must be well experienced in using this kind of equipment.
1:2.2 Chapters included
• Introduction introduces the reader to this manual.
• Quickstart contains information on how to install the softstarter and put it into oper ation in the quickest and safest way. This chapter is intended for
the experienced user.
• Description describes the softstarter in general, its functions and specifi cations.
• Mounting contains information on receiving, unpack ing and mounting the softstarter.
• Connection contains instructions on how to make the electrical connections as well as connections for com munication devices.
• Human-Machine Interface describes the local Human-Machine Interface, how it works and what it contains.
• Settings and confi guration describes all possible set tings and how to navigate in the menu system.
• Fieldbus communication describes how to install and set up the fi eldbus communication.
• Maintenance describes what maintenance is required.
• Functions describes all functions included in the soft starter. This chapter also describes parameter ranges and default values.
• Trouble shooting contains instructions on how to quickly fi nd and correct the most common faults.
• Diagrams contains a number of electrical diagrams for the softstarter itself. It also contains some typical application diagrams.
1.2 Low Voltage Products & Systems
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Chapter 1
Introduction
1:2.3 Revision notes
Please check www.abb-control.com/products/softstarters.htm#type_pstfor latest information on revisions.
1.2.4 Acronyms and abbreviations
The following acronyms and abbreviations are used in this manual.
Acronym/abbreviationDescription
LEDLight Emitting Diode
LCDLiquid Crystal Display
SCRSilicon Controlled Rectifi er
ITInformation T echnology
HMIHuman-Machine Interface
FBPFieldbusplug
PLCProgrammable Logic Controller
PCBPrinted Circuit Board
TORTop of Ramp (full voltage)
1
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Notes
1
1.4 Low Voltage Products & Systems
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Installation and maintenance manualPST30...PSTB1050
Start of the motor ....................................................................................................2.3
Chapter 2
Quickstart
2
Low Voltage Products & Systems 2.1
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Chapter 2
Quickstart
1
Power onProtectionFault
2
4
Figure 1:
1 Status indication LEDs
2 LCD display
3 Selection keys for selecting, changing and storing parameters
4 Navigation keys for navigating in the menus
* Arrows shown in the display indicate that the value/menu is
possible to change or scroll
This chapter is a short guide on how to connect, confi gure and start the softstarter in the quickest
and safest way.
2
!
Warning!
Mounting and installing the softstarter shall be done in accordance with local laws and
regulations and must be performed by authorized personnel only.
Do not change any parameters in the Service Settings menu.
3
2:1 Connection
1. Mount the softstarter according to Chapter 4 “ Mounting” .
2. Be aware of the ambient temperature. Derating is required above 40 °C (104 °F). See Chapter
3 for more information.
3. Connect the main circuit: terminals 1L1 - 3L2 - 5L3 to the line side and terminals
2T1 - 4T2 - 6T3 to the motor side.
4. Connect the control voltage: terminals 1 and 2 (100-250V 50/60Hz).
5. Connect the functional ground: terminal 3.
Figure 2: Standard connection PST
Power onProtectionFault
Figure 3: Top level
Information!
The wire shall be as short as possible, and be connected to the mounting plate.The
mounting plate should also be grounded.
6. Connect the start/stop circuits: terminal 4, 5, 8, 9 and 10 according to Figure 2. 24 VDC only!
7. Verify that the main and control voltage corresponds to the softstarter ratings.
8. Switch on the control voltage.
9. The green “Power on” LED should be lit and the LCD should appear as shown in Figure 3.
2.2 Low Voltage Products & Systems
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Chapter 2
Quickstart
Application Setting
Select Back
Figure 4: Application setting menu
Centrifugal Pump
Store Set Back
Figure 5: Centrifugal pump
Centrifugal Pump
Next Back
Figure 6: Centrifugal pump stored
Setting Ie 99.0A
Store
Figure 7: Setting Ie
Setting Ie 99.0A
Next Back
Figure 8: Setting Ie stored
OL Class 10
Store
Figure 9: OL Class
2:2 Confi guration
1. Enter the Application Setting by pressing the left selection key twice. Press Select using the
left selection key. See Figure 4.
2. Select the appropriate type of load by using the navigation keys. See Figure 5.
3. Press Store Set and Next to continue or Back to previ ous parameter using the selection
keys. See Figure 6.
4. Set Ie (motor FLA) using the navigation keys.
In Line connected = rated motor current
Inside Delta connected = 58% (1/( 3)) of the rated motor current. For example, if the soft
starter is connected in line with a 100A motor, Ie = 100A. If the softstarter is connected inside
the delta of a 100A motor, Ie = 58A. See Figure 7.
5. Press Store and Next to continue or press Back to access the previous parameter. See Fig-
ure 8.
6. Set the required overload class using the navigation keys. See Figure 9.
7. Press Store and Next to continue or press Back to access the previous parameter. See Fig-
ure 10.
8. If an external by-pass contactor is used set Ext ByPass to Yes using the navigation keys.
(PST30...300 only). See Figure 11.
9. Press Store and Next to continue or Back to previous parameter using the selection keys.
See Figure 12.
10. Select Yes if ready or Tune Set if ramp times, initial voltage, current limit etc. need to be
adjusted. See Figure 13.
11. To change language, see Section 7:2.5.
2:3 Start of the motor
1. Switch on the main voltage.
2. Give a start command to the softstarter.
(To start the softstarter from the keypad, enter the LOCAL CONTROL menu, select Start/Stop and press Start. The motor must be stopped before leaving this menu.)
2
OL Class 10
Next Back
Figure 10: OL Class stored
Ext ByPass No
Store
Figure 11: External Bypass
Ext ByPass No
Next Back
Figure 12: External Bypass stored
Ready?
Yes Tune Set
Figure 13: Ready / Tune Set
Low Voltage Products & Systems 2.3
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Notes
2
2.4 Low Voltage Products & Systems
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Installation and maintenance manualPST30...PSTB1050
ABB Inc. • 888-385-1221 • www.abb-control.com 1SXU 132 021 M0201
Chapter 3 - Description
This chapter describes the softstarter in general, specifi cations and available accessories and
spare parts.
3:1 Overview
The PST softstarter is a microprocessor-based softstarter designed with the latest technology for
the soft start and soft stop of squirrel cage motors. The softstarter has several advanced motor
protection features as standard.
The softstarter is designed to be used with or without a by-pass contactor except for the larger
sizes, PSTB370...1050 where the bypass contactor is integrated. In an emergency, it is possible
to start the motor across the line with the integrated bypass contactor. See Section 3:8.4 for AC3
ratings.
The keypad on the front is designed to be as user-friendly as possible, with a clear text display. It
is possible to choose between twelve different languages (default is English).
The softstarter can be controlled in four ways:
3
• Hardware inputs
• Keypad control (local)
• Fieldbus communication interface
• Remote keypad (option)
The integrated fans for cooling are operated only during ramping (start/stop) and when the tem-
perature of the heat sink is too high. The temperature is monitored by a thermistor.
Only one type of control method can be enabled simultaneously.
Default selection is hardware inputs.
Information!
Keypad control has the highest priority and overrides all other control methods.
3:2 Functions
The PST softstarter has several integrated protection and warning functions. Almost any type of
fault can be detected and displayed.
All available protections, warnings and fault indications are listed below.
Start/Stop functions
• Start ramp
• Stop ramp (also called soft stop or decel)
• Initial voltage
• Step down voltage
• Current limit
• Kick Start
• Extended start range
• Extended stop range
• Sequence start
Protection functions
• Motor overload protection
• Locked rotor protection
• Motor underload protection
• High current protection
• Phase imbalance protection
• Phase reversal protection
• SCR overload protection
• PTC input for motor protection
• Shorted SCR
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Chapter 3 - Description
Warning functions
• Warning high current
• Warning low current
• Warning motor overload
• Warning SCR overload
Fault Supervision functions
• Internal softstarter faults
• Shorted SCR
• Non conducting SCR
• Open circuit motor side
• Over-temperature heat sink
• Phase loss
• Frequency out of range
• Fieldbus communication
• Non-closing by-pass contactor
• Non-opening by-pass contactor
Other functions
• Jog
• Real time clock
• Event log
• Keypad password
3
3:3 Markings and connections
Line side
connection
e
1234567891011121314151617181920
L
N
100-250V
Stop
50/60 Hz
1L1
B1 B2 B3
3L2 5L3
2T1 4T2 6T3
1SFA 894 007 R1002
IEC 947-4-2
Us: 100-250V AC/DC
Ie: 37-72A
Overload Capacity 115% of Continuous
UL 508
Uc: 100-250V AC/DC
FLA: 37-68A
Fuse 250A TYPOWER ZILOX
CAUTION
Max short circuit current 65kA at 480V
Terminal marking
of main circuit
Order code
Technical data
according to
IEC 947-4-2
Technical data
according to
UL 508
Control voltage U
Start
In1 Vc Vn Vp Vp
In0
Made in Sweden
72: AC-53a: 8-1.6: 80-6
Ue: 220-230 380-400 500 V
In line 18,5 37 45 kW
Ue 208 220-240 440-480 V
In line 20 20 50 Hp
PTCKeypad Fieldbus
IND. CONT. EQ
LISTED
7F39
K4
Wire 1-8 Al Cu 75C only, 35lb-in
Bypass connection
(PST30...300 only)
Terminal marking
of control circuits
K5 K6
Green
Red
Yellow
Display
Keypad
Fieldbus connection
Us: 100
-250V AC/DC
Ie: 37-7
2A
UL
Ue:
Uc: 100
In line
220-23
-250V AC/DC
Overload Capacity
FLA: 37-6
0
18,5
380-400
8A
CAUTI
Ue
37
1
15% of Contin
500
ON
Fuse 250
In lin
V
45
Max short circui
208
e
uous
A
T
kW
YPOW
22
20
0-240
ER ZILOX
t current 65kA
44
20
0-480
L
IS
50
V
at
T
ED
Keypad
IND. C
7
F3
Hp
ON
9
T
.
EQ
.
PTC connection
External keypad
connection
PTC
Wire 1-8
Al Cu 75C
only, 35lb-in
Fieldb
us
213
11
456789101
123
103020123
1S160100
Serial number
Motor side connection
Figure 1: Markings and connections
Low Voltage Products & Systems 3.3
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Thanks to ABB’s broad program of product standardisation, today’s Industrial IT components are - whether they are products or systems, hardware or
software - the building blocks of larger solutions, incorporating functionalities that will allow seamless interactions in real-time automation and information systems.
At the product level, ABB’s Industrial IT enabled symbol ensures that all the products can fully interact. All product information pertaining to these
products is available in electronic format, based on Aspect Object
equipped with the tools necessary to install, operate and maintain it effi ciently throughout the product’s life cycle.
The PST softstarters is an Industrial IT enabled product. Documentation such as brochures, catalogues, certifi cates and drawings can be found at :
www.abb-control.com/products/softstarters.htm#type_pst.
TM
technology. The Industrial IT commitment from ABB ensures that every product is
3:6 Environmental infl uence
The product is designed to minimize the environmental affects during manufacturing and use of the product. Most of the materials used are recyclable.
3:7 Specifi cations
ItemSpecifi cation
Degree of protection (main circuit)IP 10 for PST30...72; IP 00 for PST85...1050
Operating positionVertical at ± 10°
Ambient temperatureStorage: -25°C to +70°C (-13°C to 158°F)
Operation
Without derating
With derating
Altitude1000 m (3281 ft.) above sea level without derating
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Chapter 3 - Description
3:8.3 Softstarter types
TypePST30PST37PST44PST50
Connection methodInlineDeltaInlineDeltaInlineDeltaInlineDelta
Rated Current Ie (A)3052376444765085
Motor rating at 480V (HP)2030254030504060
Motor rating 380-415V (KW)152518.53022372545
AC-3 Rating with integrated Bypass (A)––––
Power loss at rated current (W)100120140160
Control power requirements (VA)5555
TypePST60PST72PST85PST105
Connection methodInlineDeltaInlineDeltaInlineDeltaInlineDelta
Rated Current Ie (A)601057212485147105181
3
Motor rating at 480V (HP)407550756010075150
Motor rating 380-415V (KW)3055375945755590
AC-3 Rating with integrated Bypass (A)––––
Power loss at rated current (W)190230270325
Control power requirements (VA)551010
TypePST142PST175PST210PST250
Connection methodInlineDeltaInlineDeltaInlineDeltaInlineDelta
Rated Current Ie (A)142245175300210360250430
Motor rating at 480V (HP)100150125200150250200350
Motor rating 380-415V (KW)7513290160110184132220
AC-3 Rating with integrated Bypass (A)––––
Power loss at rated current (W)435540645765
Control power requirements (VA)10151515
TypePST300PSTB370PSTB470PSTB570
Connection methodInlineDeltaInlineDeltaInlineDeltaInlineDelta
Rated Current Ie (A)300515370640470814570987
Motor rating at 480V (HP)250400300500400600500700
Motor rating 380-415V (KW)160257200355250450315475
Contactor type–AF302AF302AF480
AC-3 Rating with integrated Bypass (A)–302302480
Power loss at rated current (W)92090110110
Control power requirements (VA)1520/48020/48025/900
TypePSTB720PSTB840PSTB1050
Connection methodInlineDeltaInlineDeltaInlineDelta
Rated Current Ie (A)7201247840145510501810
Motor rating at 480V (HP)600100070012009001500
Motor rating 380-415V (KW)400670450780560875
Contactor typeAF580AF750AF750
AC-3 Rating with integrated Bypass (A)590720720
Power loss at rated current (W)110170170
Control power requirements (VA)25/86025/86025/860
3.6 Low Voltage Products & Systems
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Equipment suitable for use in a circuit with maximum available fault current as shown when protected by devices indicated.
ModelRating (kA)Max VFuse (A)MCCB (A)
PST30...14210600Any UL ListedAny UL Listed
PST175...30018600Any UL ListedAny UL Listed
PSTB370...47030600Any UL ListedAny UL Listed
PSTB57030600Any UL ListedAny UL Listed
PSTB720426001200/L1200
PSTB840426001200/L1200
PSTB105085480-800
PSTB1050856001200/LPSTB105042600-1200
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Chapter 3 - Description
3:8.7 Dimensions
PST30...72
3
Figure 1: Dimensions PST30...72
[
Inches
[
Millimeters
PST85...142
Figure 2: Dimensions PST85...142
3.8 Low Voltage Products & Systems
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Chapter 3 - Description
[
Inches
[
Millimeters
PSTB175...300
3
Figure 3: Dimensions PST175...300
PSTB370...470
Figure 4: Dimensions PSTB370...470
Low Voltage Products & Systems 3.9
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Chapter 3 - Description
PSTB570...1050
3
[
Inches
[
Millimeters
Figure 5: Dimensions PSTB570...1050
3.10 Low Voltage Products & Systems
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Installation and maintenance manualPST30...PSTB1050
Receiving, unpacking and checking .......................................................................4.2
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Chapter 4
Mounting
This chapter describes instructions on how to receive the softstarter and how to mount it in the proper
way.
4:1 Receiving, unpacking and checking
• Check that the package is turned with the correct side up, Figure 1.
• Check for transport damages
• Remove transport casing.
• Visually inspect the softstarter
• Check that the serial number corresponds with the delivery documents
Figure 1: Package
4
• Check the softstarter as well as the package. If you fi nd any damages, please contact the transport
company or supplier immediately.
4:1.1 Intermediate storage
Until the softstarter is mounted, it should be stored in its package.
4:2 Mounting
4:2.1 Handling when mounting
The softstarter is available in fi ve physical sizes. Models PST30 to PST300 can be taken out of the
packages and mounted without lifting equipment.
For all other models, lifting equipment is recommended due to the weight.
See Chapter 3 “Description”, for weights.
Figure 2: Airways
BB
Do not lift the softstarter by the connection bars. Lifting by the connection bars may cause
4:2.2 Requirements
See Chapter 3 “Description” for environmental requirements.
A
4:2.3 Minimum distance to wall/front
To ensure a suitable cooling, the softstarter must be mounted vertically and in such a way that the
Use the table below and Figure 3 for minimum distances between wall/front of the PST softstarter.
Technical data ..........................................................................................5.9
Chapter 5
Connection
5
Low Voltage Products & Systems 5.1
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Chapter 5
Connection
This chapter describes the electrical connections as well as connections for communication
devices (optional) that must be made before the softstarter can be operated.
5:1 General
PST30...
PSTB1050
Caution!
All wiring and connection must be carried out by a qualifi ed electrician, and in
accordance with installation standards and safety regulations.
Figure 1: In Line Connection
PST30...
PSTB1050
5
Figure 2: Inside Delta connection
See Chapter 2 “ Quickstart”.
5:2 Electrical connection
5:2.1 Main circuit
Softstarters PST30...PSTB1050 can be connected both “ In Line”, see Figure 1, and “ In-
side Delta”, see Figure 2.
Connect the line side to terminals 1L1, 3L2, 5L3.
Connect the motor to terminals 2T1, 4T2, 6T3 on the motor side.
The terminal marking is printed on the front label.
For torque requirements and cable sizes, see Figure 5.
1L1
3L2
5L3
Line side
20
19
18
K6
17
16
15
K5
14
13
12
11
K4
10
Vp
9
Vp
8
Vn
7
Vc
6
In1
5
In0
4
3
Start
p
2
Sto
1
0V
0-25
10
Hz
/60
50
en
Swed
Made in
.
n
7F39
i
V
-
6:
lb
.
ED
kW
35
500
ly,
8-1
n
CONT. EQ
LIST
.
USS
45
C o
a:
B
D
75
IND
0-400
FEL
Cu
0 38
Al
AC-53
37
V
us
re 1-8
220-23
o
72:
u
Wi
5
,
n
80
i
4 007
18
Cont
f
89
440-4
Ue:
o
%
40
ne
5
li
11
In
20-2
y
1SFA
t
7-4-2
2
paci
94
208
Ca
d
oa
l
IEC
er
Ov
Us: 100-250V AC/DC
Ue
PTC
OX
t
37-72A
L
ZI
Ie:
A a
R
DC
65k
WE
rrent
u
TYPO
t c
UL
ui
rc
i
100-250V AC/
Pad
-
ort c
Uc:
use 250A
h
-68A
F
Key
s
ax
: 37
M
FLA
ON
I
T
CAU
Figure 3: Connection of line side and motor side
2T1
4T2
1SF
A 8
IEC
Us: 100
947-4-2
-250V AC/DC
Ie: 37-72A
UL
Uc: 100
-250V AC/DC
FLA: 37
-68A
CAU
TI
ON
94 007
Ue:
In
Ov
er
l
oa
d
Capac
Ue
F
u
In
se 250A
li
M
ne
a
x
s
h
TYPO
ort ci
rc
ui
6T3
72:
Made in Sweden
AC-53a:
22
li
ne
0-230
18
380-400
8-1
,5
.
6:
i
t
y
37
11
5
500
%
of
Cont
45
V
208
i
n
u
ou
kW
220-24
s
20
W
E
0 440-480
t c
R
u
Z
rrent
ILOX
20
65k
A at
50
Ke
y
-
P
a
d
PT
C
Motor side
LISTED
V
IND. CONT
7F39
Hp
. EQ
.
Wi
re 1-8 Al C
u 75C on
ly,
35
lb-in
FIELD
B
US
5.2 Low Voltage Products & Systems
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Chapter 5
Connection
B3
B2
B1
17
16
15
K5
14
13
12
11
K4
10
Vp
9
Vp
8
Vn
7
Vc
6
In1
5
In0
4
3
Start
2
Stop
1
100-250V
50/60 Hz
Figure 4: External bypass contactor
connection
5:2.1.1 External Bypass contactor
An external by-pass contactor can be used for softstarter sizes PST30...300 (built in for
PSTB370...1050).
Connect the contactor to terminals B1, B2 and B3 on the line side and terminals 2T1, 4T2
and 6T3 on the motor side.
The terminal markings are printed on the front label.
20
19
18
K6
Information!
Do not use terminals B1, B2 or B3 for the “Inside Delta” connection. The current
measurement will be wrong.
5:2.1.2 Protective earthing
Softstarters type PST85...PSTB1050 should be earthed using the terminals as shown in
Figure 5 (one connection is suffi cient).
Warning!
Do not operate machine with the grounding wire disconnected
PST 30...72
B1B2 B3
3L2 5L3
1L1
2T1 4T2 6T3
4 mm
M8
6 Nm - 53 lb.in
1 x 6 ...... 70 mm
2 x 6 ...... 35 mm
!WG 1...8
1 x 6 ...... 70 mm
2 x 6 ...... 35 mm
2
2
2
2
14
5
14
Figure 5: Protective earthing.
PST 85...142
B1B2 B3
3L2 5L3
1L1
2T1 4T2 6T3
PST 175...300
1L1
B1B2 B3
3L2 5L3
2T1 4T2 6T3
PSTB 370...470
3L2
1L1
2T1 4T2 6T3
5L3
PSTB 570...1050
3L2
1L1
2T1 4T2 6T3
5L3
M8
9 Nm - 80 lb.in
M8
18 Nm - 160 lb.in
M10
40 Nm - 354 lb.in
M12
45 Nm - 443 lb.in
Figure 6: Tightening torques and cable sizes
Low Voltage Products & Systems 5.3
ABB Inc. • 888-385-1221 • www.abb-control.com 1SXU 132 021 M0201
V
Chapter 5
Connection
5:2.2 Control voltage and control circuit
N
5:2.2.1 Control voltage, terminals 1 and 2
L
Connect the hot and neutral and phase to terminals 1 and 2.
Information!
Check that you have the correct control voltage Us.
7
6
In1
5
In0
4
rt
3
Sta
2
Stop
1
100-250V
Hz
0
/6
50
Figure 7: Control voltage
5:2.2.2 Grounding, terminal 3
Connect the cable to a grounding point close to the softstarter. The cable should be as short as possible. A
suitable grounding point would be next to the softstarter on the mounting plate, see Figure 8. The mounting
plate should also be grounded.
Information!This is not a protective ground, it is a functional ground. The grounding cable should be