Mitsubishi Electric MEsoftstart/I01, MEsoftstart/I00, MEsoftstart/I02, MEsoftstart/I03, MEsoftstart/I04 User Manual
Thank
you for choosing
this Mitsubishi
Electric Europe B.V.
soft starter.
This Instruction
Manual
provides installation instructions and guidelines
soft starters. Before using the soft starter carefully read this Manual and ensure to follow all Safety Instructions.
MEsoftstart
– industry-hardened low-voltage soft starter
USERS INSTALLATION & INSTRUCTION MANUAL
Applies to models:
- MEsoftstart/I00
- MEsoftstart/I01
- MEsoftstart/I02
- MEsoftstart/I03
- MEsoftstart/I04
for advanced use of the MEsoftstart series
(100A soft starter)
(200A soft starter)
(390A soft starter)
(600A soft starter)
(900A soft starter)
INTRODUCTION ............................................................................................... 7
INSTALLATION INSTRUCTIONS ...................................................................... 17
WIRING ......................................................................................................... 32
PRECAUTIONS FOR USE OF THE SOFT STARTER ............................................. 45
BASIC OPERATION – CORE MODELS .............................................................. 49
BASIC OPERATION – PRO MODELS ................................................................ 62
MESOFTSTART COMMUNICATION INTERFACE .............................................. 82
PROTECTIVE FUNCTIONS & TROUBLESHOOTING (PRO) ............................... 100
MAINTENANCE AND INSPECTION ................................................................ 106
SPECIFICATIONS ...................................................................................... 110
APPENDICES ....................................................................................................... 117
This document is a DRAFT. Please ensure to get the latest release from your distributer
September 2018
A018_070_INT_EN_002
Updated for upgraded build of
MEsoftstart
February 2019
A018_070_INT_EN_003D
Updates for Core error pattern
Revision History
Date Document Number and Revision Change log
February 2018 A018_070_INT_EN_001 Release edition for training
August 2018 A018_070_INT_EN_002 – Draft A First update
November 2018 A018_070_INT_EN_003 Name update (MEsoftstart)
December 2018 A018_070_INT_EN_003B Updated wiring diagrams, Auto/Maintenance
feature, Bypass contactor specs updated
For Maximum Safety
Mitsubishi Electric Europe B.V. Soft starters are not designed or manufactured to be used in equipment or systems in
situations that can affect or endanger human life
When considering this product for operation in special applications such as machinery or systems in passenger
transportation, medical, aerospace, atomic power or submarine applications, please contact your nearest Mitsubishi
Electric sales representative
Although this product was manufactured under conditions of strict control, you are strongly advised to install safety
devices to prevent serious accidents when it is used in facilities where breakdowns of the product are likely to cause
serious accident.
Please check upon receiving your soft starter whether this instruction manual corresponds to the delivered Soft starter.
Compare the specifications on the label with the specifications given in this manual
2
TABLE OF CONTENTS
INTRODUCTION ........................................................................................................................................ 7
OFT STARTER SELECTION
S
HECKING THE PRODUCT WHEN UNPACKING
C
OMPONENT AND TERMINAL IDENTIFICATION
C
INSTALLATION INSTRUCTIONS ............................................................................................................... 17
REPARING FOR SOFT STARTER INSTALLATION
P
OTOR CONTROL CENTRE CABINET DESIGN
M
OFT STARTER INSTALLATION
S
WIRING .................................................................................................................................................. 32
ERMINAL IDENTIFICATION
T
IRING INSTRUCTIONS
W
PRECAUTIONS FOR USE OF THE SOFT STARTER ...................................................................................... 45
HECKLIST BEFORE APPLYING POWER
C
BASIC OPERATION – CORE MODELS ....................................................................................................... 49
OWER-UP THE SOFT STARTER
P
ONFIGURE THE SOFT STARTER FOR THE APPLICATION
C
ONTROLLING THE SOFT STARTER
C
ROUBLESHOOTING THE MESOFTSTART/I CORE VARIANT
T
BASIC OPERATION – PRO MODELS ......................................................................................................... 62
PERATIONAL MODES OF THE SOFT STARTER
O
OWER-UP THE SOFT STARTER
P
ETHOD OF VIEWING AND CHANGING CONFIGURATION PARAMETERS
M
ARAMETERS
P
ARAMETER INTER-DEPENDENCIES
P
ASIC OPERATION PROCEDURE - OPERATION FROM
B
ASIC OPERATION PROCEDURE – OPERATION FROM A REMOTE CONTROLLER
B
SING THE AUTO/MAINTENANCE-FEATURE
U
............................................................................................................................................ 65
.............................................................................................................................. 8
................................................................................................... 13
................................................................................................. 14
.................................................................................................. 18
..................................................................................................... 23
........................................................................................................................ 27
.......................................................................................................................... 33
............................................................................................................................... 35
............................................................................................................. 46
...................................................................................................................... 50
....................................................................................... 51
.................................................................................................................. 53
.................................................................................. 56
................................................................................................... 63
...................................................................................................................... 64
.................................................................. 64
................................................................................................................ 75
DISPLAY PANEL
TFT
.................................................................................................... 81
................................................................ 76
.......................................................... 79
MESOFTSTART COMMUNICATION INTERFACE ....................................................................................... 82
SOFTSTART PC APP
ME
SOFTSTART MODBUS INTERFACES
ME
PROTECTIVE FUNCTIONS & TROUBLESHOOTING (PRO) ........................................................................ 100
OFT STARTER FAULT AND ALARM INDICATIONS
S
OW TO RESET THE SOFT STARTER AFTER A FAULT HAS OCCURRED
H
ROUBLESHOOTING USING THE FAULT DISPLAY ON THE SOFT STARTER
T
ENERAL TROUBLESHOOTING
G
MAINTENANCE AND INSPECTION ......................................................................................................... 106
NSPECTION ITEM
I
SPECIFICATIONS ............................................................................................................................... 110
OFT STARTER SPECIFICATION
S
UTLINE DIMENSION DRAWINGS
O
APPENDICES................................................................................................................................................. 117
DVANCED MAINTENANCE: REPLACEMENT OF THE FAN
A
............................................................................................................................... 83
............................................................................................................ 98
.............................................................................................. 101
..................................................................... 101
................................................................ 102
.................................................................................................................... 105
..................................................................................................................................... 107
..................................................................................................................... 111
................................................................................................................. 112
.............................................................................................. 118
3
Usage
CAUTION
• The soft
starter’s built
-
in temperature trip functions can only protect the motor from overheating if the motor temperature sensor is
Safety
Instructions
Do not attempt
to
install,
operate,
maintain
or
inspect
the product
until you have read through
this Instruction
Manual
and can use the
Electric
Shock Prevention
WARNING
• Do not open the soft starter enclosure while there is power on the soft starter power terminals.
Fire Prevention
CAUTION
• The soft starter
must be installed
against
a
non-flammable
surface
-
mounting
it in
proximity
of
flammable
material
may result in
a
fire.
Injury Prevention
CAUTION
• The voltage
applied
to
each terminal
must be as specified
in
the Instruction
Manual
-
otherwise
damage
will occur.
equipment correctly. Do not use this product unless you have a full knowledge of the equipment, safety information and instructions and are
qualified to do installations of this nature.
Installation, operation, maintenance and inspection must be performed by qualified personnel. Here, an expert means a person who meets
all the conditions below:
• A person who has proper engineering training. Such training may be available at your local Mitsubishi Electric office. Contact your local
sales office for schedules and locations.
• A person who can access the operating manuals.
• A person who has read and familiarized themselves with the manuals.
In this Instruction Manual, the safety instruction levels are classified into "Warning" and "Caution":
WARNING
Incorrect handling may cause hazardous conditions, resulting in death or severe injury.
CAUTION
Incorrect handling may cause hazardous conditions, resulting in medium or slight injury, or may cause only material damage.
Note that even the CAUTION level may lead to serious consequences under certain conditions. Please follow the instructions of both
levels. They are important for personnel safety.
• Ensure that the power is OFF (MCCB open) before working on the motor or any load connected to the motor. Do not assume that the
power at the motor is OFF while the power to the soft starter is still ON.
NOTE: When wired for inside-delta connection, the six motor terminals remain live even when the motor is off.
• Do not run the soft starter with the cover removed - this increases the risk of access to the exposed terminals and electric shock.
• Even if power is OFF, do not open the soft starter enclosure.
• Before wiring or inspection, the power must be switched OFF.
• This soft starter must be earthed (grounded). Earthing (grounding) must conform to the requirements of national and local safety
regulations and electrical code (NEC section 250, IEC 536 class 1 and other applicable standards).
• Any person who is involved in wiring or inspection of this equipment shall be fully competent to do the work.
• The soft starter must be installed before wiring otherwise there is a risk of electric shock or injury.
• Ensure that cables are not damaged, under excessive stress or pinched anywhere otherwise there is a risk of causing a short circuit or
even electric shock.
• Do not change the cooling fan while power is ON - this is dangerous.
• Do not touch any part of the soft starter or handle the cables with wet hands- this increases the risk of electric shock.
• If the soft starter has become faulty, the soft starter power must be switched OFF. A continuous flow of large current may cause a fire.
• Be sure to perform daily and periodic inspections as specified in the Instruction Manual. If a product is used without regular inspection,
damage or even a fire may occur.
• The cables must be connected to the correct terminals - otherwise damage may occur.
• The connection order of the phases must be correct.
• While power is ON or for some time after it was ON, do not touch the soft starter as it may be extremely hot and could inflict a burn
injury.
wired in and connected to the motor at an appropriate temperature sensing location.
• The effect of electromagnetic interference must be reduced by using a noise filter or by other means. Otherwise nearby electronic
equipment may be affected.
• Before running a soft starter, which had been stored for a long period, inspection and test operation must be performed.
• Static electricity in your body must be discharged before you touch the product.
• Some of the diagrams, drawings and photographs in the Instruction Manual shows the product without a cover or partially open for
explanation. Never operate the product in this manner. The cover(s) must be always re-installed before operating the soft starter.
• Earthing Leakage detection is not active when Inside Delta motor wiring configuration is used.
4 Contents
Transportation
and Installation
CAUTION
• Any person
who is opening
a
package
using a sharp object,
such as a knife and cutter,
must wear gloves
to
prevent
injuries
caused
by
the
Wiring
CAUTION
• The motor
side terminals
(terminals
T1, T2 and T3)
must be connected
correctly.
The soft starter will protect against phase reversal if
Commissioning
CAUTION
• Before
starting
operation,
each configuration
parameter
must be adjusted for the installation and
motor size
. A failure
to do so
may cause
Emergency
Stop CAUTION
• A
n independent hardware
Emergency
Stop must be provided
as a safety measure
to
prevent
hazardous
conditions
to
the machine
and
Maintenance,
inspection
and parts replacement
CAUTION
• Do not carry out a megger
(insulation
resistance)
test on the soft starter
when connected.
It
may cause damage
.
edge of the sharp object.
• The product must be transported in an appropriate method for the weight of the package. Failure to do so may lead to injuries.
• Do not stand or rest heavy objects on the product.
• Do not stack the boxes containing soft starters higher than the number recommended.
• During installation, caution must be taken not to drop the soft starter as doing so may cause injuries and damage to the product.
• The product must be installed against a surface that withstands the weight of the soft starter.
• Do not install the product on a hot surface.
• The mounting orientation of the soft starter must be correct.
• The soft starter must be installed on a strong surface securely with screws so that it will not drop.
• Do not install or operate the soft starter if it is damaged or has parts missing.
• Foreign conductive objects must be prevented from entering the soft starter. That includes screws and metal fragments or flammable
substance such as oil.
• As the soft starter is a precision instrument, do not drop or subject it to impact.
• For the all ranges of the soft starter, the surrounding air temperature must be 0 to +50°C - 0therwise the soft starter may be damaged.
• The ambient humidity specification must be adhered to. Otherwise the soft starter may be damaged. (Refer to par 2.2.2.2 for details.)
• The storage temperature (applicable for a short time, e.g. during transit) specification must be adhered to. Otherwise the soft starter
may be damaged.
• The soft starter must be used indoors (without corrosive gas, flammable gas, oil mist, dust and dirt etc.) Otherwise the soft starter may
be damaged.
• The soft starter can be used as rated, at an altitude of 1400 m or less above sea level. Higher altitudes require de-rating.
• The soft starter should not be subjected to operational vibration. The soft starter is designed for transportation vibration only. (Refer to
paragraph 2.2.2.7 for details.)
• If halogen-based materials (fluorine, chlorine, bromine, iodine, etc.) infiltrate into a Mitsubishi Electric product, the product will be
damaged. Halogen-based materials are often included in fumigant, which is used to sterilize or disinfest wooden packages. When
packaging, prevent residual fumigant components from being infiltrated into Mitsubishi Electric products, or use an alternative
sterilization or disinfection method (heat disinfection, etc.) for packaging. Sterilization or disinfection of wooden package should also be
performed before packaging the product.
configured to do so. If the soft starter is configured to not check the phase rotation, the motor will rotate inversely – which may, or may
not be a problem in the installation.
• Never connect the motor side terminals (terminals T1, T2 and T3) to the grid power supply. Applying the grid power supply to motor
terminals (T1, T2, T3) will damage the soft starter. The induction motor may be connected to the grid power supply only via a bypass
contactor that is under control of the soft starter.
• Return wires from an Inside Delta motor connection should be connected to the Supply lines on L1, L2, L3 (and NOT on the Bypass
terminals BL1 BL2 BL3)
unexpected behaviour or damage to the motor.
.
equipment in case of soft starter failure (refer paragraph ).
• When the breaker on the soft starter input side trips, the wiring must be checked for fault (short circuit). The cause of the trip must be
identified and removed before turning ON the power on the breaker.
• When a fuse on the soft starter input blows, the wiring and the soft starter needs to be checked for faults. The cause of the blown fuse
must be identified and removed before replacing the fuse and turning on again.
• When a protective function activates, take appropriate corrective action, then reset the soft starter and resume the operation.
Disposal
CAUTION
• When unserviceable, the soft starter should be treated as industrial waste.
5 Contents
AC Alternating Current
BAUD
Bits per second
(relating to the Modbus link)
COM Communication
port on PCs
EMC Electromagnetic Compatibility
FC Function Codes (Modbus)
GPRS General Packet Radio Service
IEC International
Electro
-
technical
Commission
L2 Supply Line Phase 2
MCCB
Moulded Case Circuit Breaker
MFS Motor Frame Size (in kW)
MSC Maximum Starting Current
OC Open Circuit
PC
Personal Computer
PF
Power Factor
PLC Programmable Logic Controller
PTC Positive Temperature Coefficient thermistor
RJ45 Connector standard (
used for Modbus
RTU and TCP
communications on
MEsoftstart
) RMS Root Mean Square
RPM Revolutions per Minute
RS485
Electrical standard for use in serial communications
(used for Modbus
in
MEsoftstart
) RTD Resistance Temperature Detector (e.g. PTC)
RTU / TCP Protocol variants for Modbus (RTU for RS485 serial and TCP
for Ethernet communication)
SC
Short Circuit
SCADA
Supervisory Control and Data Acquisition
SCR Silicon Controlled Rectifier
SICD Software Interface Control Document
TFT Thin Film Transistor (display)
USB Universal Serial Bus
VL-L Voltage Line to
Line
List of Abbreviations
Abbreviation Definition
AC3 Device category for squirrel cage motors
AM Amplitude Modulation
CE Conformité Européenne (for conformity with protection standards of the European Economic Area)
CT Current Transformer
EMI Electromagnetic Interference
GND Ground / Earthing
HMI Human Machine Interface
I/O Input / Output
L1 Supply Line Phase 1
L3 Supply Line Phase 3
MFLC Maximum Full Load Current
MODBUS Communication Protocol originally published by Modicon (now Schneider Electric) in 1979
MOLC Motor Overload Current
MULC Motor Underload Current
6 Contents
TFT
screen
(as shown)
and/or PC Application on Modbus RTU or TCP.
INTRODUCTION
Mitsubishi Electric Europe’s MEsoftstart microprocessor-based advanced digital soft
starter range features bypass control for internal or external bypass and full 3-phase
control. It incorporates both enhanced soft-start and soft-stop characteristics providing
the best solution for a wide range of applications. Its comprehensive motor protection
package guarantees long term reliability while the external bypass connections ensure
flexibility and excellent performance – all in a compact, versatile design.
Two MEsoftstart variants are available namely “Core” and “Pro”:
- Core – Low-cost, simple-to-configure models, using 6 potentiometers each for
start and stop ramp definition and a few slider switches to fully configure the soft
starter. Monitoring and control with PC Application on Modbus RTU.
- Pro – Used for complex applications where more advanced control options are
required. Setting up, Monitoring and Control with full-function local colour touch
This manual contains the Installation and Operating instructions for the
MEsoftstart/I00 and MEsoftstart/I01 Core variants and the MEsoftstart/I01,
MEsoftstart/I02, MEsoftstart/I03 and MEsoftstart/I04 Pro variants of the MEsoftstart
range of Industrial soft starters.
Always read the instructions before connecting and using the equipment.
INTRODUCTION ................................................................................................................................................................. 7
OFT STARTER SELECTION
S
HECKING THE PRODUCT WHEN UNPACKING
C
OMPONENT AND TERMINAL IDENTIFICATION
C
......................................................................................................................................................... 8
.............................................................................................................................. 13
............................................................................................................................ 14
7 Introduction
Soft starter selection
The correct soft starter model needs to be selected according to the user’s intended application and installation environment.
The selection of the soft starter model can also be driven by a cost compromise between an expensive motor control centre
enclosure / cabinet / panel design / long cables, or a higher rated soft starter model.
The selection of the soft starter model is dependent on the following characteristics of the user’s installation:
1) Motor size and connection type – in general the soft starter current must be greater or equal to the motor full load
current.
2) Typical operating temperature – the soft starter is rated at a nominal operational temperature of 50°C but may be
operated up to 60°C. Implement de-rating of the soft starter maximum current at temperatures above 50°C. The
operating temperature is determined by the environmental factors as well as the soft starter workload.
3) Soft starter workload – The workload is defined in two categories: Normal duty and Heavy duty. This comprises the
typical starting time, the typical number of starts per hour and the running time (if no Bypass Contactor is installed)
a. Typical starting time – the shorter the starting time, the lower the thermal loading on the soft starter. A starting
time of less than 30 seconds is considered normal duty. 30 second-starts and longer, are considered heavy duty.
b. Typical number of starts per hour – frequent starting increases temperature of the heat sink in the soft starter.
Number of starts less than 10 per hour (or 6 minutes or longer between starts) are deemed normal duty. 10 or
more starts per hour (or less than 6 minutes between starts) are considered heavy duty.
c. Bypass contactor installed – if the soft starter is used with an internal or external bypass contactor, the ‘on-time’
of the soft starter is only during starting and stopping – this reduces thermal loading and a smaller soft starter
model may be appropriate. A bypass contactor is recommended for applications where the motor is started and
then runs for a long time before it is stopped. For applications where frequent start-stop cycles are required, a
bypass contactor is not recommended.
4) Altitude above sea-level – the MEsoftstart range of soft starters are designed and tested for operation up to 1400m
above sea level. De-rating of the soft starter maximum and operating currents is needed for operation at higher altitude.
Definition of motor duty applied to MEsoftstart soft starters:
1. Normal duty is defined as no more than 10 starts per hour (> 6 min between starts) and start ramp shorter than 30s.
2. Heavy duty is defined as more than 10 starts per hour (<6 min between starts) or start ramp longer than 30s.
Motor size
The tables below serve as a guideline for selecting the correct model soft starter for the application according to the motor
starting current and type of application. The tables below show the allowable starting current for the listed motor sizes as a
percentage of their maximum normal running current at power factor of 0.8.
A bypass contactor is recommended for applications where the motor runs for a long or continuous periods. A bypass contactor
reduces the current through the soft starter switching elements and can allow the use of a smaller soft starter and increases the
efficiency of the installation.
Applications with short, frequent start and stop ramps should not use a bypass contactor for mechanical life reasons of the
contactor. However, the soft starter needs to be sized correctly to handle the switching current for such heavy duty use.
8 Introduction
Model:
MEsoftstart/I00
Max starting current:
250A Heavy Duty
Model MEsoftstart/I00 soft starter is rated at 100A continuous current and can be used at 240A starting current for normal duty
and at 125A starting current for heavy duty applications and can be ordered with a built-in bypass contactor or can be installed
with an external bypass contactor, or without a bypass contactor. MEsoftstart/I00 can be ordered for voltage ranges from 400Vac
to 690Vac and can be ordered with a built-in bypass contactor or can be installed with an external bypass contactor, or without
a bypass contactor.
Continuous rated current: 100A
Max. starting current: 240A Normal duty
Max starting current: 125A Heavy Duty
Table 1: MEsoftstart/I00 guideline for motor sizes1
Model MEsoftstart/I01 is rated at 200A continuous current and can be used at 480A starting current for normal duty and at
250A starting current for heavy duty applications. MEsoftstart/I01 can be ordered for voltage ranges from 400Vac to 690Vac and
can be ordered with a built-in bypass contactor or can be installed with an external bypass contactor, or without a bypass
contactor.
Model: MEsoftstart/I01
Continuous rated current: 200A
Max. starting current: 480A Normal duty
1
The tables show the allowable starting current for the listed motor sizes as a percentage of their maximum normal running current at
power factor of 0.8 – in the case of motors with heavy duty starting requirements, use only the values from columns marked “Heavy
duty”.
9 Introduction
Model:
MEsoftstart/I03
Table 2: MEsoftstart/I01 guideline for motor sizes1
Model MEsoftstart/I02 is rated at 390A continuous current and can be used at 730A starting current for normal duty and at
390A starting current for heavy duty applications. MEsoftstart/I02 can be ordered for voltage ranges from 400Vac to 690Vac
and can be ordered with a built-in bypass contactor or can be used with an external bypass contactor, or without a bypass
contactor.
Model: MEsoftstart/I02
Continuous rated current: 390A
Max. starting current: 730A Normal duty
Max starting current: 390A Heavy Duty
Table 3: MEsoftstart/I02 guideline for motor sizes1
Model MEsoftstart/I03 is rated at 600A continuous current and can be used at 1440A starting current for normal duty and at
750A starting current for heavy duty applications. MEsoftstart/I03 can be ordered for voltage ranges from 400Vac to 690Vac and
can be ordered with a built-in bypass contactor or can be used with an external bypass contactor, or without a bypass contactor.
Continuous rated current: 600A
Max. starting current: 1440A Normal duty
Max starting current: 750A Heavy Duty
10 Introduction
Table 4: MEsoftstart/I03 guideline for motor sizes1
Model MEsoftstart/I04 is rated at 900A continuous current and can be used at 1600A starting current for normal duty and at
900A starting current for heavy duty applications. MEsoftstart/I04 can be ordered for voltage ranges from 400Vac to 690Vac
and can be used with an external bypass contactor, or without a bypass contactor.
Model: MEsoftstart/I04
Continuous rated current: 900A
Max. starting current: 1600A Normal duty
Max starting current: 900A Heavy Duty
Note: a built-in bypass contactor option is not available with model MEsoftstart/I04.
Table 5: MEsoftstart/I04 guideline for motor sizes1
11 Introduction
Typical operating temperature
The operating temperature is determined by the typical ambient temperature in the immediate vicinity of the soft starter, air
flow through the soft starter and cooling mechanisms that are used, as well as the soft starter workload. Refer par 2.2.3 for a
description of how the cabinet design can also be used to best regulate operating temperature.
De-rate the soft starter starting capacity at 1.4% per °C for higher temperatures above 50°C.
Example of temperature de-rating:
The requirement is for a 75kW 400Vac motor (normal, 3-wire connected) in a heavy duty application, to operate in an
environment where the operating temperature is likely to be 60°C. From Table 2, the motor’s FLC = 136A (at 0.8 power
factor), while the MEsoftstart/I01 model soft starter can provide a maximum starting current of 184% (or 250A) if operated
below 50°C.
These values should be de-rated for operation at 60°C i.e. (60°C - 50°C) * 1.4% = 14%, thus 184% - 14% = 170% (or 231A).
If this is insufficient for the application, then more robust selection for this application may be MEsoftstart/I02 with a derated starting current of 287% - 14% = 273% (or 371A) – see Table 3.
Soft starter workload
Soft starter workload is made up of the starting time, stopping time and number of starts per hour, as well as any run time when
a bypass contactor is not used. If the expected work load is high, a soft starter with a larger current margin should be selected.
If the expected starting time is longer than 30 seconds, a higher rated soft starter should be selected. If the application requires
frequent starts with short running time, select a soft starter from the heavy duty columns.
Figure 1 –Normal and Heavy duty applications as defined by soft starter on-time
12 Introduction
Altitude of installation.
The MEsoftstart range of soft starters are designed and tested at 1400m above sea level. When planning to use the soft starter
at altitudes higher than 1400m the soft starter the guideline is to de-rate at 0.67% per 100m for higher altitudes.
Selection example
1. The application is a fan in a 400V AC3 distribution, which does not require high starting torque. A normal 3-wire
configuration (with bypass) 90kW fan motor is specified, with normal duty starting: Ramp-start of 20s duration,
requiring no more than 200% of the motor’s running current during start-up:
a) Calculations:
- Normal full-load current = P(kW) / (√3 × PF × VL-L) × 1000
= 90 / (√3 × 0.8 × 400) × 1000
= 162.4A
- Starting current needed = 200% × 162.4
= 324.8A
b) Conclusion: our starting current < 480A allowed for normal duty with MEsoftstart/I01
Use soft starter (MEsoftstart/I01).
2. The application is a compressor or conveyor in a 400V AC3 distribution, requiring high starting torque. The same
90kW motor – this time driving a compressor motor – is specified (with bypass), with heavy duty starting: slow
ramp longer than 30s duration and approximately 400% of the motor’s running current during start-up:
a) Calculations:
Here, starting current needed = 400% × 162.4
= 649.6A
b) Conclusion: our starting current >250A allowed for heavy duty with MEsoftstart/I01. Looking at
MEsoftstart/I02, its heavy duty starting current of 390A is also too low, i.e. MEsoftstart/I03 with a heavy
duty starting current of 900A would suffice.
Use soft starter (MEsoftstart/I03).
Checking the Product when unpacking
Unpack the product and check the label on the soft starter to ensure that the model agrees with the order and that the product
is intact. Figure 2 shows product labels for the MEsoftstart/I01 and MEsoftstart/I02 models. From the label can be seen the
rated continuous current of the MEsoftstart soft starter, as well as the maximum starting current for normal duty. The rated
supply voltage is also visible on the label.
Note that the labels in Figure 2 are both labels for MEsoftstart models without built-in bypass contactors. This can be seen
from the grid side and motor side bypass terminal markings on the label.
Recommended motor sizes are shown on the label. These motor sizes are applicable for normal 3-wire installation. Also refer
to the tables in paragraph 1.1.1 for more information about the supported motor sizes.
13 Introduction
Component and Terminal identification
Component and terminals are identified in Figure 3 and Table 6 below. Comparable markings are used on all other models.
14 Introduction
Figure 2 – Product marking
Figure 3 – Soft starter terminal and component identification
15 Introduction
10 Pin
Wiring terminal
connector
3.2.4
TFT touchscreen for monitoring and controlling the soft
Table 6: List of components and terminals
Symbol Name Description Notes Ref
a) Busbar 1 / L1 Grid supply L1
b) Busbar 3 / L2 Grid supply L2
c) Busbar 5 / L3 Grid supply L3
d) Busbar 7 / BL1 Supply L1 to bypass contactor L1
e) Busbar 9 / BL2 Supply L2 to bypass contactor L2
f) Busbar 11 / BL3 Supply L3 to bypass contactor L3
g) Busbar 2 / T1 Motor phase U
h) Busbar 4 / T2 Motor phase V
i) Busbar 6 / T3 Motor phase W
j) Busbar 8 / BT1 Bypass contactor supply L1 to motor T1
k) Busbar 10 / BT2 Bypass contactor supply L2 to motor T2
l) Busbar 12 / BT3 Bypass contactor supply L3 to motor T3
m) RJ 45 (x 2)
Two RS485 to MEsoftstart PC App /
Modbus RTU interface
Only on models without
internal bypass
contactor
Only on models without
internal bypass
contactor
Two ports of the same
Modbus port for easy
daisy-chaining
3.2.1
7
n)
o)
(x2)
10 Pin Wiring terminal connector
(X2)
p) TFT touchscreen
Green Wiring terminals on top side
Green Wiring terminals on bottom side Only on Pro variants 3.2.4
starter
Only on Pro variants 6
3.2.5
q) HMI panel Potentiometer HMI panel Only on Core variants 5
r) RJ 45 TCP to MEsoftstart PC App / Modbus TCP interface Only on Pro variants 7.2
s) Earthing stud Chassis ground
t) Protective cover Finger guard for terminals
u) Warranty label
Do not remove this label. The warranty is void if the
label is removed or damaged
3.2.2
3.2.3
16 Introduction
INSTALLATION INSTRUCTIONS
This chapter explains the installation of the MEsoftstart/I00, MEsoftstart/I01, MEsoftstart/I02, MEsoftstart/I03 and
MEsoftstart/I04 model soft starters. Note that for safety reasons, it is important to install the soft starter in a cabinet or
enclosure where the terminals will not pose a hazard to personnel. This section shows how to safely install the soft starter and
provides guidelines for the selection or design of a suitable motor control centre cabinet / enclosure.
Always read the instructions before installing, connecting and using the equipment.
INSTALLATION INSTRUCTIONS ........................................................................................................................................ 17
REPARING FOR SOFT STARTER INSTALLATION
P
OTOR CONTROL CENTRE CABINET DESIGN
M
OFT STARTER INSTALLATION
S
.................................................................................................................................................. 27
............................................................................................................................ 18
............................................................................................................................... 23
17 Installation Instructions
Preparing for soft starter installation
The peripheral devices that are needed around the soft starter need to be specified before planning the installation of the soft
starter.
The soft starter can be wired to start a normal 3-wire motor or inside-delta on a six-wire motor. The installation and wiring of
the soft starter is similar for the normal and the inside-delta connections, but there may be implications for the enclosure size
and cable length, as well as the selection of external bypass contactor for the different ways of connecting the motor.
Normal Delta 3-wire connection
The diagram below shows the connection diagram for the soft starter with and without built-in bypass contactor, for normal 3wire connection. With this method of connecting the motor, the full motor starting current flows through the soft starter
switching elements during start-up. After start-up and if a built-in or external bypass contactor is used, the full running current
of the motor flows through the contactor. If no bypass contactor is used, the motor’s continuous running current flows through
the soft starter switching elements.
Figure 4 – Soft starter circuit diagram for 3-wire delta motor
With this method of installation, the bypass contactor must be scaled for the full running current of the motor. Only three
cables are needed to run the distance to the motor.
18 Installation Instructions
Inside-delta 6-wire connection
The diagram below shows the connection diagram for the soft starter with and without built-in bypass contactor, for an insidedelta 6-wire connection. With this method of connecting the motor, 58% of the motor’s starting current flows through the soft
starter switching elements during the start-up ramp. After start-up and if a built-in or external bypass contactor is used, 58% of
the running current of the motor flows through the bypass contactor. If no bypass contactor is used, 58% of the motor’s
continuous running current flows through the soft starter switching elements.
Figure 5 – Soft starter circuit diagram for 6-wire inside-delta motor
Ensure to connect the grid-side terminals of the inside-delta motor to the soft starter L1, L2, L3 terminals. Incorrectly
connecting them to the Bypass terminals may damage the soft starter. Refer Figure 19.
Note that for inside delta wiring the Earthing Leakage protection is not active.
19 Installation Instructions
Take special note of the wiring of an inside delta motor when the grid connection on the soft starter is clockwise or anticlockwise. Refer to Figure 6 to understand the difference.
Figure 6 –6-wire Inside-delta wiring for clockwise and anti-clockwise grid rotation
20 Installation Instructions
Soft starter and Peripheral devices
Always check the nameplate information on your motor before designing the peripheral devices
Figure 7 shows the MEsoftstart/I01 Core model soft starter and the associated peripheral devices. The installation for the other
MEsoftstart models will be the same.
Figure 7 – Soft starter circuit diagram with peripheral devices
21 Installation Instructions
2.
Moulded case circuit breaker
The circuit breaker must be selected according to the maximum current of the motor.
3.
The fuses are required to protect the soft starter SCRs against excessive currents. The
4.
5.
Bypass contactor relay circuit
This circuit breaker is a 2A circuit breaker protecting the Soft starter
output signal that
6.
7.
8.
The items in Figure 7 are further described in Table 7 below.
Table 7: Peripheral devices in the soft starter installation
Item Name
1.
Soft starter (MEsoftstart/I00,
MEsoftstart/I01,
MEsoftstart/I02,
MEsoftstart/I03,
MEsoftstart/I04)
(MCCB)
Fuses
Bypass contactor
(Only applicable to
MEsoftstart models without
built-in bypass contactor)
Description
The MEsoftstart soft starter connects to the supply voltage on the top side and to the
motor on the bottom side.
The circuit breaker should ideally be controllable from an Emergency Stop button and
the soft starter Shunt Trip Relay.
fuses should ideally be in line between the circuit breaker and the soft starter and
outside the delta for 6-wire installations. The fuses should be selected as follows for
the different MEsoftstart models:
Model
MEsoftstart/I00
MEsoftstart/I01
MEsoftstart/I02
MEsoftstart/I03
MEsoftstart/I04
Installed to run the motor when at full speed. The ‘BYPASS CONTACTOR’ discrete
output signal (refer Table 13) from the soft starter should be used to control the bypass
contactor. Select the bypass contactor according to the maximum running current of
the motor as indicated on the motor manufacturer’s label. If the motor is wired in an
inside-delta circuit, the bypass contactor may be selected to be 58% of the motor rated
running current.
Refer to Mitsubishi Electric’s non-reversing Magnetic Contactors.
Minimum
Fuse current
160A
315A
500A
900A
1000A
Refer
Figure 3
-
Figure 5
Max I2t
rating
6050
125000
322000
1330000 pc33ud69v900tf
1330000 pc33ud69v1000tf
Recommended
Mersen2 Fuse
pc31ud69v160tf
pc30ud69v315tf
pc31ud69v500tf
30 sec rating
@ 690V
330A
750A
1300A
2890A
3200A
Figure 25
breaker
(Only applicable to
MEsoftstart installations with
external bypass contactor)
Emergency stop
Motor Temperature Sensor The motor temperature sensor is read by the soft starter. The soft starter uses this
Induction motor
activates the external Bypass contactor via a 50/60Hz coil. The contactor coil is
powered from the supply voltage and should be selected according to the supply
voltage
A STOP button that will open the MCCB to disconnect all power to the soft starter and
motor.
reading to protect the motor from overheating.
Configured as a 3-wire motor for normal delta connection or 6-wire for inside delta
wiring.
-
-
-
Capacitors for power factor improvement
Capacitors for power factor improvement must not be connected on the output of the soft starter (between the soft starter and
the motor). If power factor correction is required, add the capacitors on the grid-side of the soft starter.
2
Mersen is a tradename of Mersen S.A. headquarted in France.
22 Installation Instructions
Environmental
Model
Specification
Notes
De-rate above 50
°C at 1.4% per °C
0.67%
per 100 m
Motor control centre cabinet design
A soft starter unit uses semiconductor devices. To ensure reliable operation and long service lifetime for the soft starter, it is
important to operate the soft starter in the ambient environment that complies with the equipment specifications.
When designing or selecting a soft starter cabinet, the structure, size and device layout inside the cabinet should be determined
by considering issues such as:
Safe and easy access for wiring;
Safe and easy access to the HMI for configuring and monitoring;
Heat generation and cooling of the soft starter;
Peripheral devices that need to be in the cabinet and
The operating environment.
Minimum cabinet size
The minimum cabinet size should be decided upon by considering the following:
a) The circuit layout with peripheral devices (refer par 2.1);
b) The installation environment (refer paragraph 2.2.2);
c) Air flow requirements of the soft starter (refer par 2.3.3);
d) Cooling requirements inside the cabinet (refer paragraph 2.2.3);
e) Minimum space required around the soft starter (refer par 2.3.3).
Soft starter installation environment
The following table lists the standard specifications of the soft starter installation environment.
Table 8: Soft starter environmental specification
parameter
Surrounding Air
temperature
Realtive humidity
Storage temperature
Atmosphere
Altitude
Vibration
Using the soft starter in an environment that does not satisfy these conditions, will deteriorate its performance, shorten its life
span and can lead to failure. The following paragraphs contain suggested measures to ensure that the environment complies
with the specification.
Measurement position 5 cm from the soft
-10°C to +60°C
MEsoftstart/I00
MEsoftstart/I01
MEsoftstart/I02
MEsoftstart/I03
MEsoftstart/I04
Indoors - free from corrosive gas, flammable
gas, oil mist, dust and dirt
1400 m above sea level.
0.02g²/Hz from 10 to 50Hz, reducing linearly
on a log-linear plot to 0.0001g²/Hz at 500Hz.
< 85%
-30°C to +70°C
(directions
of X, Y, Z axes)
starter
inside the closed cabinet
Ideally < 50% @ 50° to < 85% @20°C
For the installation at an altitude above 1400m
de-rate the rated current of the soft starter at
Road transport vibration only
23 Installation Instructions
Temperature
For the MEsoftstart range of soft starters, the permissible surrounding air temperature of the soft starter is between -10°C and
+60°C. Always operate the soft starter within this temperature range. Operation outside this range will considerably shorten
the service lives of the semiconductors, parts, capacitors and other electronics. Take the following measures to keep the
surrounding air temperature of the soft starter within the specified range.
(a) Measures against high temperature
o Use a forced ventilation system or similar cooling system. (Refer to par 2.2.3 on page 26.)
o Install the cabinet in an air-conditioned chamber.
o Block direct sunlight.
o Provide a shield or similar plate to avoid direct exposure to the radiated heat and wind of a heat source.
o Ventilate the area around the cabinet well.
(b) Measures against low temperature
o Provide a space heater in the cabinet.
o Do not power OFF the soft starter. (Keep the motor start signal of the soft starter OFF.)
(c) Sudden temperature changes
o Select an installation place where temperature does not change suddenly.
o Avoid installing the soft starter near the air outlet of an air conditioner.
o If temperature changes are caused by opening/closing of a door, install the soft starter away from the door.
Humidity
Operate the soft starter within the specified ambient air humidity. Too high humidity will pose problems of reduced insulation
and metal corrosion. On the other hand, too low humidity is conducive to the build-up of static electricity and may cause
dielectric breakdown in solid state devices.
(a) Measures against high humidity
o Seal the cabinet and provide it with a hygroscopic agent.
o Provide dry air into the cabinet from outside.
o Provide a space heater in the cabinet.
(b) Measures against low humidity
o Air with proper humidity can be blown into the cabinet from outside. Also, when installing or inspecting the unit,
discharge your body (static electricity) beforehand.
(c) Measures against condensation
Condensation may occur if the cabinet temperature changes suddenly or if the outside air temperature changes suddenly.
Condensation causes faults such as reduced insulation and corrosion.
o Take the measures against high humidity in (a) above.
o Do not power OFF the soft starter.
24 Installation Instructions
Dust, dirt, oil mist
Dust and dirt may cause such faults as poor contacts, reduced insulation and cooling effect due to the moisture-absorbed
accumulated dust and dirt and in-cabinet temperature rise due to a clogged filter. In an atmosphere where conductive powder
floats, dust and dirt may cause such faults as malfunction, deteriorated insulation and short circuit in a short time.
Since oil mist may cause similar conditions, it is necessary to take adequate measures.
Countermeasures:
o Place the soft starter in a totally enclosed cabinet.
o Take measures if the in-cabinet temperature rises. (Refer to paragraph 2.2.2.1)
o Purge air.
o Pump clean air from outside to make the in-cabinet air pressure higher than the outside air pressure.
Corrosive gas, salt damage
If the soft starter is exposed to corrosive gas or to salt (e.g. near the sea), the printed circuit board and components will corrode,
the relays and switches can deteriorate resulting in unreliable contact.
When it is required to operate the soft starter in this environment, take the measures suggested in the paragraph 2.2.2.3.
Explosive, flammable gases
It is not recommended to install and use the soft starter in an environment where flammable gasses are present. The soft starter
is not explosion proof and it will have to be contained in a certified explosion-proof cabinet If possible, avoid installation in such
environments and install the soft starter in a non-hazardous place.
High altitude
The soft starter may be used at its recommended current rating, at altitudes lower than 1400m above sea-level. For the
installation at an altitude above 1400 m, de-rate the rated current of the soft starter at 0.67% per 100 m.
If it is used at a higher altitude than 2500m above sea level, thin air will reduce the cooling effect and low air pressure will
deteriorate dielectric strength and a higher rated soft starter model should be selected.
Vibration, impact
The soft starter is not designed to withstand periods of high vibration or high impact. The vibration resistance of the soft starter
vibration spectrum is tested at 0.02g²/Hz from 10 to 50Hz, reducing linearly on a log-linear plot to 0.0001g²/Hz at 500Hz for
the directions of X, Y, Z axes. Applying vibration and impacts for a long time may loosen the structures and cause poor contacts
of connectors, even if those vibration and impacts are within the specified values. (Refer to IEC 60068-2-6).
Especially when impacts are applied repeatedly, caution must be taken because such impacts may break the installation feet.
Countermeasures:
o Provide the cabinet with rubber vibration isolators.
o Strengthen the structure to prevent the cabinet from resonance.
o Install the cabinet away from the sources of the vibration.
25 Installation Instructions
Cooling system types for soft starter cabinet
The heat that the soft starter and other equipment (transformers, lamps, resistors, etc.) generates, as well as any incoming
heat (such as direct sunlight) must be dissipated to keep the temperature inside the cabinet lower than the permissible
operating temperature of the soft starter.
When selecting or designing a cabinet for the soft starter, the following cooling considerations (for the cabinet) must be
considered:
The cooling systems are classified as follows in terms of the cooling calculation method.
(a) Cooling by natural heat dissipation from the cabinet surface (totally enclosed type).
(b) Cooling by heatsink (e.g. aluminium fin).
(c) Cooling by ventilation (forced ventilation type, pipe ventilation type).
(d) Cooling by heat exchanger or cooler (e.g. heat pipe, cooler).
Table 9: Cooling systems for soft starter cabinet
Cooling system
Cabinet layout Comment
Natural
cooling
Forced
cooling
Natural ventilation
(enclosed, open type)
Natural ventilation
(totally enclosed type)
Heatsink cooling
Forced ventilation
This system is low in cost and generally used, but the cabinet size
increases as the soft starter capacity increases.This system is for relatively
small capacities.
Being a totally enclosed type, this system is the most appropriate for
hostile environment having dust, dirt, oil mist, etc. The cabinet size
increases depending on the soft starter capacity.
This system has restrictions on the heatsink mounting position and area.
This system is for relatively small capacities.
This system is for general indoor installation. This is appropriate for
cabinet downsizing and cost reduction and often used.
Heat pipe
26 Installation Instructions
This is a totally enclosed for cabinet downsizing
Soft starter installation
Soft starter placement
Placement of the soft starter needs careful planning. The clearance below the soft starter is required for terminal access for
wiring as well as air inlet and the clearance above the soft starter is required for heat dissipation as well as terminal access for
wiring. Consider the following:
a) Install the soft starter securely on a sturdy horizontal or vertical surface with bolts (refer paragraph 2.3.6).
b) Leave enough clearances and take measures to cool the device (refer par 2.3.3).
c) Leave enough clearance to access terminals to wire the soft starter.
d) Avoid places where the soft starter is subjected to direct sunlight, high temperature and high humidity (refer
paragraph 2.2.2).
e) Install the soft starter on a non-flammable wall surface.
f) When encasing multiple soft starters, install them in parallel as a cooling measure (refer paragraph 2.3.4)
g) For heat dissipation and maintenance, keep clearance between the soft starter and the other devices or cabinet
surface.
Installation orientation of the soft starter
The MEsoftstart models without internal bypass contactor may be mounted at any orientation, but the recommended
orientation is upright against a wall or against the cabinet back or side (max. deviation from vertical is 22.5°).
This allows for easy access to the HMI, terminals and with natural air flow from bottom to top as shown in Figure 9.
If a MEsoftstart model with an internal bypass contactor is used, the orientation guidelines in Figure 8 should be adhered to.
27 Installation Instructions
Figure 8 – Mounting orientation
Air flow around the soft starter
Heat is blown up from inside the soft starter by the small built-in fan. Leave space around the soft starter for ample air flow
through the soft starter cabinet. Any equipment placed above the soft starter should be heat resistant.
Figure 9 – Air flow around the soft starter
Arrangement of multiple soft starters
When encasing multiple soft starters in the same cabinet, generally arrange them horizontally as shown in the right Figure 10
(a). When it is inevitable to arrange them vertically to minimize space, take such measures as to provide guides since heat from
the bottom soft starters can increase the temperatures in the top soft starters, causing soft starter overheating.
Figure 10 – Arrangement of multiple soft starters in a single cabinet
When mounting multiple soft starters, take caution not to make the surrounding air temperature of the soft starter higher
than the permissible value by providing ventilation and increasing the cabinet size.
28 Installation Instructions
Arrangement of the ventilation fan and soft starter
Figure 11 – Arrangement of the ventilation fan and soft starter
Heat generated in the soft starter is blown up from the bottom of the unit as warm air by the cooling fan. When installing a
ventilation fan for that heat, determine the place of ventilation fan installation after fully considering air flow. (Air passes
through areas of low resistance. Make an airway and airflow plates to expose the soft starter to cool air.)
29 Installation Instructions
Drilling plan for soft starter installation
When drilling mounting holes in a cabinet, take caution not to allow chips and other foreign matter to enter the soft starter.
Figure 12 through Figure 18 below shows the drilling plan for mounting the MEsoftstart soft starter in a cabinet or against a
wall.
MEsoftstart/I00 and MEsoftstart/I01 Drilling plan
Figure 12 – Drilling plan: MEsoftstart/I00 with and without
bypass contactor and MEsoftstart/I01 without bypass
contactor
MEsoftstart/I02 Drilling plan
Figure 13 – Drilling plan: MEsoftstart/I01 with bypass contactor
Figure 14 – Drilling plan: MEsoftstart/I02 without bypass
contactor
30 Installation Instructions
Figure 15 – Drilling plan: MEsoftstart/I02 with bypass contactor
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