Baldor MN894 User Manual

Multipurpose

Soft Starter

Sizes 8 to 840 AMP

Installation & Operating Manual

9/06 MN894

Section 1

General Information 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Major Components 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Protection Devices 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Configurations 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Limited Warranty 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Notice 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 2

Installation 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Receiving, Inspection and Storage 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Physical Location 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AC Main Circuit 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Protection Devices 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Disconnect 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Non-Motor and Special Motor Applications 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 3

Operation 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Types of Starting 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start Adjustments 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ramp Up 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Torque Up 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pulse Time 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Current Limit 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stop Adjustments 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ramp Down 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Torque Down 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Run Adjustments 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Current Monitor 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Factor 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Current Calibration Switch 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Parameters Switch 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Connections 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLOSE TO RUN 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

START/RUN 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SHUNT TRIP 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RAMP END 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TACH 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MTR PWR 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CUR MON 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents iMN894

Indicators 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power On 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Over Current 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Current 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Summary of Start and Stop Sequences 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 4

Start-up 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Notice 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start-up Checklist 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Equipment 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overview 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quick Set-Up 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting Instructions 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Variable Load with Voltage Ramp 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High Friction Load with Voltage Ramp 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inertial Load 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tachometer Mode 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start-up Troubleshooting 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 5

Troubleshooting 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Notice 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preliminary Checks 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Off Checks 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blocking Voltage Check 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SCR Tests 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Full Voltage Test 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Resistance Test 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SCR Replacement 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Logic Control Module Resistance Test 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting Chart 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reset the Circuit Breaker 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reset an Overload Relay 5-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuse Replacement 5-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Section 6

Specifications and Product Data 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Identification 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three Phase Starters 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three Phase Starters 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wire Size & Tightening Torque Specifications 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting Dimensions 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Open Panel 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NEMA 1, 3R and 12 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connection Diagrams 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MA Style 8, 16 and 30 AMP 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MB Style 8, 16 and 30 AMP 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MA Style 55 and 80 AMP NEMA 1 and Panels 6-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MB Style 55 and 80 AMP NEMA 1 and Panels 6-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NEMA 1 & Panel Mounted Size 160−840 AMP Control Only 6-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NEMA 1 & Panel Mounted Size 160−840 AMP Combination & Noncombination 6-12. . . . . . . . . . . . . . . . . . . .

NEMA 12 Size 160−840 AMP Combination & Noncombination Bypass 6-13. . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix A

Reference Information A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Glossary A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Current Calibration Chart A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quick Reference Chart A-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overload Relay Adjustment A-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix B

Circuit Breaker Adjustments B-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Section 1 General Information

Introduction Three phase multipurpose soft starter control provides reduced voltage, three phase

motor starting. Ramp up and extended ramp down features provide an effective means to start and stop material handling equipment and pumping equipment to minimize spillage and water hammer problems. Adjustable current limit allows constant current starting of high inertia loads such as chippers, centrifuges and compressors. It also reduces the peak demand of power required from utility companies or generating equipment.

Tachometer feedback may be used to provide consistent starting and stopping times with linear acceleration and deceleration. This is especially important under varying load conditions like: textile, material handling and pumping equipment.

Six SCR (silicon controlled rectifier) devices are connected in three sets of inverse parallel configuration to provide full wave voltage and current control of the three phase AC motor. MOV (metal oxide varistors) provide surge voltage protection at the AC input to the starter.

Several product features make this soft start control easy to use:

S Two selectable starting methods.

S Individual ramp up and ramp down adjustments.

S Flexible yet simple setup with switch selections and potentiometer adjustments.

S Simple onboard current calibration.

S Indicator lights and status contacts providing information about the starting,

running and stopping conditions.

S Bar graph display provides a visual representation of motor current to assist in

set-up and troubleshooting. (0 to 400% FLA).

S Tachometer input.

S Five output relay contacts.

S Built-in protection features to reduce down time.

General Information 1-1MN894

CPT

Figure 1-1 Layout and Identification

T1 T2 T3

GND

L1 L2 L3

F1 F2 F3

R1 R2

TB1

CT1

CT2

CT3

Shunt Trip

CT4

MOV

LCM

Legend: CB - Motor Circuit Protector or fusible disconnect CPT - Control transformer (control voltage) CT1, 2, 3, 4 - Current Transformer F1, F2, F3 - Control transformer fuses GND - Ground connection LCM - Logic control module MOV - Metal oxide varistors OL - Overload relay (electronic) PC1, 2, 3 - Power Cell

R1, R2 Control Relays TB1, 2 - Terminal block

PC1 PC2 PC3

Fan Fan

Fan

Overtemperature

Switch

Snubber Capacitor

Snubber

Resistor

1-2 General Information MN894

Ramp

Mode

Select

User

Adjustment

Current

Transformer

Tachometer

Input

Close To

Run

C U R R E N T

4 5

RDD CM OC

TACH CL BP

TU CL

MIN MAX

OFF ONS1

C A

I B R A

I O N

Figure 1-2 Logic Control Module Block Diagram

123456

1 2 3 4 5 6

OFF ONS2

S T A R T

S T O P

R U N

12345678

1 2 3 4 5 6 7 8

Reset

Logic

Gates & Sync.

Logic &

Firing

Control

Power

Supply

Control Power

Overcurrent Trip

Current Monitor

Motor Power

Ramp End

Shunt Trip

Start/Run

Close To Run

115 /230 VAC

Power Input

Power Cell

Gates and

Cathodes

PWR

400

300

O R

200

C U R

100

R E N

%FLA

3 6

7 8 9

10 11

Status Lights

Relay

Outputs &

Status

Legend:

BP - Bypass CL - Current Limit CM - Current Monitor OC - Overcurrent PF - Power Factor PT - Pulse Time RD - Ramp Down RDD - Ramp Down Disable RU - Ramp Up S1 − Calibration Switch TACH - Tachometer TD - Torque Down TU - Torque Up

General Information 1-3MN894

Major Components (Refer to Figures 1-1 and 1-2).

Logic Control Module (LCM)

The LCM (Logic Control Module) operates in the voltage ramp mode or current limit mode during ramp up and ramp down (if ramp down is selected). The LCM controls the amount of current that the power cells deliver to the motor during ramp up and ramp down. It uses gates and synchronous timing circuits to control the firing times of the SCR’s in the power cells. The current transformer provides the LCM with motor current information. The on board current calibration switches (S1-1 thru S1-8), place burden resistors in parallel with the current transformer to calibrate the LCM to the correct FLA (full load amperes) of the motor being used.

Current Transformer (CT1) provides starting, stopping and running current information to the LCM. This

information is used to control starting and stopping current, current limit, current monitor and over current shutdown, power factor effect and motor current bar graph indicator.

(CT2) is required only for sizes 160 through 840 amps. It steps down current to match primary rating of CT1 transformer.

8, 16 and 30 amp models - CT1 is mounted inside the LCM housing. 55 and 80 amp models - CT1 is mounted externally on the panel. 160 to 840 amp models - CT1 and CT2 are mounted externally on the panel.

CT1 ratio is 6000:1 CT2 ratio is 500:5 for 160, 250 and 420 Amp models. CT2 ratio is 1000:5 for 600 and 840 Amp models.

Power Cells (PC) Power cells control the voltage delivered to the motor during ramp up and ramp down (if

ramp down is enabled). The LCM controls the duty cycle of the SCR’s in the power cells (“on” time versus “off” time of each SCR). A power cell contains two silicon controlled rectifiers (SCR’s). The SCR’s are solid state switches that are able to control large amounts of current with a small amount of gate current supplied by the LCM.

8, 16 and 30 amp models - six SCR’s are mounted inside the LCM housing. 55 and 80 amp models - SCR’s are mounted in an isolated package containing two

SCR’s for each power cell. With this type of package, three power cells are mounted to a single heat sink at ground potential. A temperature switch is provided in each cell to protect the power cell from overheating.

160 to 840 amp models - Each SCR is a disk type package containing one SCR. Two SCR’s are clamped between two heat sinks. A temperature switch is provided to protect the SCR assembly from overheating. Heat sinks are mounted on an insulated base with a terminal block and snubber network. The snubber network is a capacitor resistor series circuit wired in parallel with the disk type SCR’s. The snubber network enhances the electrical characteristics of the SCR’s and provides transient voltage protection. This arrangement makes up one power cell. The power cell is at line potential for both line and load terminals when line voltage is applied.

Protection Devices

Metal Oxide Varistors (MOV)

An MOV provides voltage surge protection. Voltage surges also called high voltage spikes are caused by a number of sources. Short duration high voltage spikes caused by starting and stopping other motor loads or switching On and Off capacitor banks may appear on the incoming lines. Transients can occur from lightning storms or from other lightly loaded devices on the same line, such as motors, transformers, or solenoids. Electrical noise can be caused by lightning, arc welders and heat exchange equipment on the same transformer bus line.

An MOVs provide protection by absorbing or clamping these transient energy levels. High energy transients that exceed the MOV rating may damage the MOV and the multipurpose starter.

1-4 General Information MN894

Snubber Network 160 through 840 amp models only. A resistor and capacitor series circuit (snubber) is

wired in parallel with each disk type SCR. The RC network enhances the electrical characteristics of the SCR and provides high voltage transient protection.

Shorted SCR Detection: If a shorted SCR condition is detected while starting, running or stopping, the SHUNT

TRIP contact will close and the SHUNT TRIP light will indicate the condition.

The SHUNT TRIP contact is used to open the circuit breaker via a shunt trip device. Also, the shunt trip contact from the LCM module can be used to activate other circuit interrupting device to remove the motor and control from the AC power line.

When a bypass contactor is used, the shunt trip circuit is disabled when the bypass contactor is closed. This is accomplished by switching switch BP S2-6 On.

Over Current Shut Down: The control module has an over current detection circuit to trip and shut down the control

if motor current exceeds 450% FLA. To restart, open the Close To Run circuit, then close it.

Current Monitor: When the motor is at speed (End of Ramp light is “ON”), the current monitor can detect

over current or overload motor conditions. This warning can alert an operator or be used to stop a motor. It can also be used for indications of jams or blockages.

Motor Overload Protection: Class 30 motor overload protection is required to protect the control and the motor from

repetitive or extended starting conditions, as well as running during an overload condition. Class 10 or 20 overloads may trip when starting high inertia loads or when operating in current limit starting mode.

Over Temperature Switch: Power cells have over temperature switches to detect an overheating condition. The

switch is an isolated bimetallic, normally closed contact. If loss of cooling causes a power cell to overheat, the temperature switch contact will open and shut down the control circuit.

Note: When a temperature switch opens, the control shuts down. It must be reset

manually to restart the control.

Circuit

Breaker or

Fusible

Disconnect

Figure 1-3 Starter Diagram

Combination Starter

Non-Combination Starter

Soft

Start

Control

(Control only)

Overload

Relay

General Information 1-5MN894

Configurations

Control Only: Soft start control, without motor overload protection or branch circuit

protection circuit breaker or fusible disconnect switch. Suitable for installation with a series contactor or as a retrofit for an existing motor starter.

Non-combination Starter: Soft start control with motor overload protection, less branch circuit protection circuit breaker or fusible disconnect switch. Installation with existing branch circuit protection would use this configuration.

Combination Starter: Soft start control with motor overload protection and branch circuit protection and branch circuit protection circuit breaker or fusible disconnect switch. Only push buttons are required to complete the system. New installations with no existing control equipment would use this configuration.

Bypass System, Control Only: Soft start control without overload protection and branch protection. Includes a bypass contactor to shunt the power cells after the control is in the full run mode to eliminate heat generation across the power cells. Allows installation in a NEMA 4 or NEMA 12 enclosure.

Bypass System, Non-combination: Soft start control noncombination system with motor overload protection, less branch circuit protection. Includes a bypass contactor to shunt the power cells after the starter is in the full run mode to eliminate heat generation across the power cells. Allows installation in a NEMA 4 or NEMA 12 enclosure.

Bypass System, Combination: Soft start control combination system with motor overload protection and branch circuit protection circuit breaker or fusible disconnect switch. Includes a bypass contactor to shunt the power cells after the starter is in the full run mode to eliminate heat generation across the power cells. Allows installation in a NEMA 4 or NEMA 12 enclosure.

Enclosures and Ventilation: Soft start controls are available in panel mount or in NEMA type 1, 12, 3R enclosures. The control will generate approximately 3.3 watts of heat per running ampere during operation. All factory supplied enclosures are designed to dissipate this heat under maximum specified operating conditions. If the multipurpose control is mounted in an enclosure not supplied by the factory, this heat dissipation must be considered. Adequate ventilation or convection cooling should be provided unless a bypass contactor is used.

Panel Mount: Soft start control mounted on a panel with provisions for wall or enclosure installation.

NEMA Type 1 (IP23): Soft start control mounted in a ventilated NEMA type 1 panel enclosure. Intended for indoor use primarily to provide a degree of protection against contact with enclosed electrical components. Available for all sizes and configurations.

NEMA 12/3R (IP65/IP32): NEMA 12 enclosure provides protection from dust, dirt, oil and water. NEMA 3R outdoor installation protects from rain, sleet and snow. A NEMA 12/3R is shipped as a NEMA 12 and to convert to NEMA 3R, remove the drain screw at the bottom of the enclosure.

1-6 General Information MN894

Limited Warranty

For a period of two (2) years from the date of original purchase, BALDOR will repair or replace without charge controls and accessories which our examination proves to be defective in material or workmanship. This warranty is valid if the unit has not been tampered with by unauthorized persons, misused, abused, or improperly installed and has been used in accordance with the instructions and/or ratings supplied. This warranty is in lieu of any other warranty or guarantee expressed or implied. BALDOR shall not be held responsible for any expense (including installation and removal), inconvenience, or consequential damage, including injury to any person or property caused by items of our manufacture or sale. (Some states do not allow exclusion or limitation of incidental or consequential damages, so the above exclusion may not apply.) In any event, BALDOR’s total liability, under all circumstances, shall not exceed the full purchase price of the control. Claims for purchase price refunds, repairs, or replacements must be referred to BALDOR with all pertinent data as to the defect, the date purchased, the task performed by the control, and the problem encountered. No liability is assumed for expendable items such as fuses.

Goods may be returned only with written notification including a BALDOR Return Authorization Number and any return shipments must be prepaid.

General Information 1-7MN894

Safety Notice This equipment contains voltages that may be as high as 600 volts! Electrical shock can

cause serious or fatal injury. Only qualified personnel should attempt the start-up procedure or troubleshoot this equipment.

This equipment may be connected to other machines that have rotating parts or parts that are driven by this equipment. Improper use can cause serious or fatal injury. Only qualified personnel should attempt the start-up procedure or troubleshoot this equipment.

PRECAUTIONS

WARNING: Do not touch any circuit board, power device or electrical connection before you

first ensure that power has been disconnected and there is no high voltage present from this equipment or other equipment to which it is connected. Electrical shock can cause serious or fatal injury.

WARNING: Be sure that you are completely familiar with the safe operation of this equipment.

This equipment may be connected to other machines that have rotating parts or parts that are controlled by this equipment. Improper use can cause serious or fatal injury. Only qualified personnel should attempt the start-up procedure or troubleshoot this equipment.

WARNING: Be sure the system is properly grounded before applying power. Do not apply AC

power before you ensure that all grounding instructions have been followed. Electrical shock can cause serious or fatal injury.

Caution: To prevent equipment damage, be certain that the electrical service is not capable

of delivering more than the maximum line short circuit current amperes listed for the control rating.

Caution: Do not “Megger” test the motor while it is connected to the control. Failure to

disconnect motor will result in extensive damage to the control. The control is tested at the factory for high voltage / leakage resistance as part of Underwriter Laboratory requirements. Do not megger any part of the control.

Caution: Do not connect power factor correction capacitors to motor terminals. If power

factor correction capacitors are necessary, contact Baldor.

Caution: If a brake motor is used, the initial starting voltage may not be sufficient to release

the brake. It may be necessary to provide separate power for the brake and soft start control.

Caution: Do not connect AC incoming line power to the Motor terminals T1, T2 and T3.

Connecting AC power to these terminals may result in damage to the control.

Caution: Do not supply any power to the “Close To Run” terminals. Power on these leads

can damage the control. Use a dry contact type that requires no external power to operate.

Caution: Do not change the position of any switch while power is applied. Changing the

position of a switch during operation can damage the control and cause erratic behavior of the load.

Caution: To prevent equipment damage, be certain that the electrical service is not capable

of delivering more than the maximum line short circuit current amperes rating.

Caution: This equipment is shipped as a multipurpose apparatus. Before power is applied,

the line voltage selection and the full load current calibration must be correctly set. Failure to select the proper line voltage or to calibrate the full load current may cause damage.

1-8 General Information MN894

Section 2 Installation

Receiving, Inspection and Storage

When you receive your control, there are several things you should do immediately.

1. Observe the condition of the shipping container and report any damage immediately to the commercial carrier that delivered your control.

2. Remove the control from the carton. Inspect for shipping damage and report any damage immediately to your commercial carrier.

3. Verify that the part number of the control you received is the same as the part number listed on your purchase order.

4. If the control is to be stored for several weeks before use, be sure that it is stored in a location that is clean, dry and free from corrosives and contaminants. Storage temperatures must not exceed 140°F (60°C).

Be sure to read an become familiar with the safety notices in Section 1 of this manual. Failure to observe the product safety notices can result in injury or equipment damage. If you have questions, please contact your Baldor distributor. Do not proceed unless you understand the installation and operation requirements and safety notices.

Physical Location The location of the soft start control is important. It should be installed in an area that is

protected from direct sunlight, corrosives, harmful gases or liquids, dust, metallic particles, and vibration. Exposure to these elements can reduce the operating life and degrade performance of the control.

Several other factors should be carefully evaluated when selecting a location for installation:

1. For effective cooling and maintenance, the control should be mounted vertically on a flat, smooth, non-flammable vertical surface. Heat dissipation of 3.3 watts per running FLA of the motor must be provided. All factory supplied enclosures provided adequate heat dissipation.

2. If the control is mounted in an enclosure, sufficient air flow must be provided. The fan or blower must be rated for at least 0.8 cubic feet per minute for each ampere of motor FLA rating.

3. Keep high voltage and low voltage wiring separated. If the conduits must cross, be sure that they cross at 90° angles only.

1. Motor overload protection is required for starters that do not have an overload protection device.

2. The multipurpose soft starter is suitable for use on a circuit capable of delivering no more than the short circuit A

3. A short circuit current and overcurrent devices are required for soft start controls that do not have a circuit breaker or fusible disconnect switch.

AC Main Circuit

Protection Devices Be sure a suitable input power protection device is installed. Use the recommended circuit

breaker or fuses listed in Table 2-1. Wire sizes and protective device specifications are based on the maximum output power rating of the control.

Power Disconnect A power disconnect should be installed between the input power service and the control for

a fail safe method to disconnect power. The control will remain in a powered-up condition until all input power is removed from the control and internal voltages are depleted.

listed in Table 2-1.

RMS

Installation 2-1MN894

Table 2-1 Three Phase

Rati

SFLA

SGLA

SKLA

(AMPS)

Amps Class

Fuse MCP (GE)

Short Circuit

RMS

Amps Type

8 100 J 5,000 20 5,000 16 100 J 5,000 20 5,000 30 200 J 5,000 50 5,000

100 RK1 5,000 50

55 175 J 42,000 100

SELA

80 175 J 42,000 100

160 400 RK5 100,000 300 250 400 RK5 100,000 300 420 800 L 100,000 600 42,000 600 800 L 100,000 600 42,000 840 1200 L 100,000 600 42,000

Note: Maximum recommended fuses/breakers are based on 25°C ambient, maximum continuous current.

Figure 2-4 Multipurpose Control Terminal Locations

(A) Line Input

L1 L2 L3

(D) GND

Short Circuit

RMS

10,000 10,000 42,000 42,000

T1 T2 T3

(A) Motor Output Load

2-2 Installation MN894

(D) GND

Installation

Starter Rati

Terminal

8, 16 and 30 AMPS

h 840 AMPS

AMPS

1. Mount the panel or enclosure to the mounting surface. The panel or enclosure must be securely fastened to the mounting surface. Refer to the mounting dimensions in Section 6 of this manual.

2. Ground the panel and control per NEC article 250 as well as state and local codes.

3. Use copper wire rated for at least 75°C. Refer to Figure 2-4 and Table 2-2 for wire size recommendations.

4. Connect the incoming AC power wires from the power disconnect and/or protection devices to L1, L2 and L3 terminals. Tighten each terminal as specified in Figure 2-4 and Table 2-2.

5. * Connect earth ground to the “GND” of the control. Be sure to comply with local codes.

6. Verify the input line voltage is correct.

7. For MA#−XX models, verify the line voltage selection jumpers on the LCM module are properly set. For MB#−XX models, verify the control transformer primary taps are connected for the line voltage applied.

8. Connect the three phase power leads of the AC motor to terminals T1, T2, and T3 of the Main Circuit Terminals.

9. * Connect motor ground wire to the “GND” of the control. Be sure to comply with all applicable codes.

Caution: Do not supply any power to the “Close To Run” terminals. Power

on these leads can damage the control. Use a dry contact type that requires no external power to operate.

10. Connect the remaining control terminals as required for your installation. Refer to Figure 2-4 and Table 2-2 for wire size and terminal torque specifications.

* Grounding by using conduit or panel connection is not adequate. A separate conductor of the

proper size must be used as a ground conductor.

Table 2-2 Recommended Wire Size and Tightening Torque

Torque Wire Size

lb-in Nm AWG mm

55 throug

A 20 2.5 10-16 6-1.5 B 35 4 8 10 C 12 1.4 12-22 4-0.34 D 45 5.1 6-14 16-2.5 A Note 1 Note 1 Note 2 Note 2 B Note 1 Note 1 Note 2 Note 2 C 12 1.4 12-22 4-0.34 D 45 5.1 6-14 16-2.5

All wire sizes based on 75°C copper wire, 3% line impedance. Higher temperature smaller gauge wire may be used per NEC and local codes.

Note1: Refer to the label on the equipment panel for line and load tightening torque values. Note2: Line and Load wires sizes for 55 through 840 AMP models are as follows:

Wire Size

AWG mm

55 4 25

80 3 30 160 3/0 95 250 350 mcm 185 420 2x 300 mcm 2x 150 600 2x 500 mcm 2x 240 840 3x 500 mcm 2x 240

Installation 2-3MN894

Non-Motor and Special Motor Applications

Non-motor load: The multipurpose control is designed to provide reduced starting voltage for standard

three phase induction motors. The control may also start non-motor loads for controlled inrush current applications with resistive or inductive loads. Consult Baldor if the control is to be used with a non-motor load.

Wye-Delta or The multipurpose control can replace an existing wye-delta or part winding starter. Part Winding Starter: Begin by removing the existing contactors. Wire the motor in its “RUN” delta

configuration and connect the motor to the control. The control can be used as if it were controlling a standard design B motor.

Wound Rotor Motors: Consult Baldor if the control is to be used with a wound rotor or slip ring type motor. This

type of load produces high starting torque with reduced starting current and speed. The multipurpose control provides low starting current and low starting torque. The multipurpose control can be used for applications that do not require high starting torque and a continuous speed reduction.

High Slip Motors: The multipurpose control can be used with high slip motors, such as design D. These

motors are used with large inertial loads that require extended starting times. Reduced starting voltage will reduce the starting current and extend the starting time. Long starting times may require using slow trip overloads. However, the thermal capabilities of the motor and control must be evaluated before extending the overload trip times.

Reversing Applications: For reversing applications, two multipurpose controls can be used or a reversing

contactor can be used. Consult Baldor for more information.

Multispeed Motors: Consult Baldor if the control is to be used with a multispeed motor. The control can

be used with a multispeed motor if a multispeed starter is connected between the control and the motor. In this case, an additional MOV must be connected to the terminal side of the control. Switching is normally done be auxiliary contacts from the multispeed starter that are connected to the control circuit of the multipurpose control.

Motors on Grounded and A multipurpose starter should not be used with “Delta” or “Open” ground systems. open delta systems: Without a proper ground, the circuit to detect a shorted SCR condition may malfunction or

may not be able to detect a shorted SCR condition.

2-4 Installation MN894

Section 3 Operation

Types of Starting

Voltage Starting (S2-4 = OFF)

During start the initial voltage (TU) is set to a level where the motor will begin to turn when power is applied. The ramp time (RU) is adjustable to provide a smooth start. The pulse time (PT) is used for high friction loads to break loose “frozen” loads with up to 400% FLA.

If a ramp down function is needed, the initial voltage TD setting is used to lower voltage to a level where the motor will begin to slow down when the stop button is pushed. Ramp down (RD) can only extend motor stopping time preventing sudden stopping problems such as water hammer.

Current Limit Starting (S2-5 = ON) If current limit starting is selected the starter will operate similar

to voltage starting. On high inertia loads such as chippers and grinders the Current Limit (CL) setting is what determines the starting time. The starter will provide that current regardless of the ramp time setting. The CL setting must be high enough to provide enough starting current in all starting conditions. Ramp down (RD) can only extend motor stopping time preventing sudden stopping problems such as water hammer.

Voltage

Ramp

% Line Voltage

Current

Limit

% FLA

100

400

300

200

100

Time

Tach Feedback Starting (S2-4 = ON) Tach feedback starting/stopping uses a 0-10 VDC Tach signal.

The control will provide voltage to the motor to generate a smooth linear starting even under cycling load conditions. Ramp down (RD) can only extend motor stopping time preventing sudden stopping problems such as water hammer.

Tach

% Full Speed

100

RUN

Time

Operation 3-1MN894

Start Adjustments (Refer to Figure 3-1).

Ramp Up Ramp up time (RU) is adjustable from 3 to 50 seconds. RU adjusts the voltage ramp or

the tachometer starting ramp time. For voltage starting, RU adjusts the time it takes the motor to reach full voltage. Actual acceleration time to full speed depends upon the motor load and the setting of the additional start adjustments.

For Tach feedback starting, RU adjusts the motor starting time independent of the load when used with a 0 to 10 VDC tachometer feedback signal. Smooth linear speed ramp up with constant acceleration is achieved.

Torque Up The initial starting torque (TU) for ramp up is enabled only in the voltage ramp mode.

Usually set high enough to start the motor slowly turning the instant the start button is pressed.

Pulse Time Starting pulse time (PT) is adjustable from 0 to 1.5 seconds in the voltage ramp mode.

When the start button is pressed, the initial motor voltage depends on the setting of TU. One second after the start button is pressed, a pulse of approximately 400% FLA will occur; the duration will depend upon the setting of PT.

Current Limit Current limit (CL) is adjustable from 75 to 400% of FLA. It can be used in both the

voltage and tachometer ramp modes of operation. When CL is enabled (S2-5=ON), motor starting and stopping current will not exceed the set point of CL, except during PT.

Note: CL must be set high enough to allow the motor to start under maximum load

conditions. In the Tach feedback mode, CL will affect linearity and start and stop times. The current is held at the CL limit until the motor current decreases to less than the CL setting, regardless of the RU setting.

Figure 3-1

TU CL

S T A R T

Stop Adjustments (Refer to Figure 3-2).

Ramp Down Ramp downtime (RD) extends the stopping time from 5 to 50 seconds. RD can be used

in both the voltage and tachometer modes.

In the tachometer mode, when used with a 0 to 10 VDC tachometer feedback signal, RD will adjust the actual stopping time independent of motor load condition. Smooth linear speed ramp down with constant deceleration is achieved.

In the voltage mode, RD adjusts the time it takes to reach minimum motor voltage and turn off. The actual stopping time will depend on the motor load condition.

Note: Ramp down mode is not suitable for coasting or inertial loads that require

braking. Ramp down will only extend the stopping time.

Torque Down Torque down advance (TD) is adjustable from 0 to 100% advance. TD sets the initial

torque or voltage which ramp down starts and can be used in both voltage and tachometer modes.

In ramp down mode, when the stop button is pressed, voltage will immediately decrease to the set point of TD. Control will continue to ramp down to zero speed or voltage, depending upon RD setting, then the control will turn off.

Figure 3-2

S T O P

3-2 Operation MN894

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Baldor MN894 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

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