Motortronics MVC Plus User Guide

MVC Plus User Manual: 2.3 – 7.2kV Class

Table of Contents

PAGE

Chapter 1: Introduction .................................................................................................................. 1

1.1 Overview ..................................................................................................................................... 1

1.2 Specifications ...........................................................................................................................1-2

1.3 Reference Chart ......................................................................................................................... 3

1.4 Design Features ......................................................................................................................... 4

1.5 Theory of Operation .................................................................................................................4-5

1.6 General Protection ...................................................................................................................5-6

1.7 Thermal Overload Protection ...................................................................................................... 6

1.8 Firing Circuit ................................................................................................................................ 7

1.9 Electronics .................................................................................................................................. 8

Fig. 1.9 Keypad Interface ............................................................................................................ 8

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

2.1 Warnings .................................................................................................................................. 10

2.2 Control Connections ................................................................................................................. 11

2.2.1 TCB Board ............................................................................................................................. 10

Fig. 2.2.1 TCB Terminal and Control Board .............................................................................. 10

2.2.2 Description of Terminal Connections ................................................................................. 12-14

2.2.3 Description of Jumper Selections and Functions .................................................................... 15

2.2.4 Description of Switch Settings and Functions ......................................................................... 15

2.2.5 Description of LED Indicator Functions .................................................................................. 16

2.3 Circuit Board Layout Reference Section .............................................................................. 17-19

Fig. 2.3.1 Optional RTD Board .................................................................................................. 17

Fig. 2.3.2 RS485 / RS422 Communications Board .................................................................... 17

Fig. 2.3.3 Main Board ................................................................................................................ 18

Fig. 2.3.4 CPU Board ................................................................................................................ 19

2.4 Typical Wiring Diagram ............................................................................................................. 20

Fig. 2.4 Typical Wiring Diagram ................................................................................................ 20

Chapter 3: Start-Up ....................................................................................................................... 21

3.1 Introduction ............................................................................................................................... 21

3.2 Acceleration Adjustments .......................................................................................................... 21

3.3 Deceleration Adjustments ......................................................................................................... 22

3.4 Sequence of Normal Operation ................................................................................................. 23

3.5 Emergency Bypass Operation .................................................................................................. 25

Chapter 4: User Interface and Menu Navigation ......................................................................... 26

4.1 Keypad/Operator Interface ........................................................................................................ 26

4.1.1 Keypad Operator designations and functions ......................................................................... 26

4.2 Menu Navigation ....................................................................................................................... 27

4.2.1 Password Access ................................................................................................................... 28

4.2.2 Changing Setpoints ................................................................................................................ 28

Chapter 5: Setpoint Programming ............................................................................................... 29

5 .1 Setpoints Page List ............................................................................................................. 29-35

5.1.1 Basic Configuration (Setpoint Page 1) .................................................................................. 29

5.1.2 Starter Configuration (Setpoint Page 2) ................................................................................ 29

5.1.3 Phase and Ground Settings (Setpoint Page 3) ...................................................................... 30

5.1.4 Relay Assignments (Setpoint Page 4) ................................................................................... 31

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5.1.5 Relay Configuration (Setpoint Page 5) .................................................................................. 32

5.1.6 User I/O Configuration (Setpoint Page 6) .............................................................................. 32

5.1.7 Custom Acceleration Curve (Setpoint Page 7) ...................................................................... 33

5.1.8 Overload Curve Configuration (Setpoint Page 8) .................................................................. 33

5.1.9 RTD Option Configuration (Setpoint Page 9) ........................................................................ 34

5.1.10 RTD Password Level Configuration (Setpoint Page 10) ...................................................... 35

5.1.11 Communication (Setpoint Page 11) ..................................................................................... 35

5.1.12 System (Setpoint Page 12) ................................................................................................. 35

5.1.13 Calibration and Service (Setpoint Page 13) ......................................................................... 35

5.2 Setpoints Menu and Parameter Explanation ........................................................................ 36-65

SP.1 Basic Configuration ................................................................................................................ 36

SP.2 Starter Configuration ......................................................................................................... 37-42

Fig. SP2.3 Example of Switching from Jog to Start Ramp #1 Type: Voltage ............................. 39

Fig. SP2.4 Power Ramp ............................................................................................................ 41

SP.3 Phase & Ground Settings .................................................................................................. 43-46

Fig. SP3.5 Overcurrent Trip Delay Graph .................................................................................. 43

SP.4 Relay Assignment ............................................................................................................. 47-42

SP.5 Relay Configuration ................................................................................................................ 48

SP.6 User I/O Configuration....................................................................................................... 49-51

SP.7 Custom Acceleration Curve ............................................................................................... 52-54

SP.8 Overload Curve Configuration ........................................................................................... 55-57

SP.9 RTD Option Configuration ................................................................................................. 58-59

SP.10 Set Password ....................................................................................................................... 60

SP.11 Communications .................................................................................................................. 60

SP.12 System Setpoints ............................................................................................................ 61-62

SP.13 Calibration & Service ............................................................................................................ 63

Chapter 6: Metering Pages ........................................................................................................... 64

6.1 Metering Page List .................................................................................................................... 64

6.1.1 Metering Menu & Data (Metering Page 1) ............................................................................. 64

6.1.2 Metering (Metering Page 2) .................................................................................................. 64

6.1.3 RTD Option Values (Metering Page 3) .................................................................................. 64

6.1.4 Status (Metering Page 4) ...................................................................................................... 64

6.1.5 Event Recorder (Metering Page 5) ........................................................................................ 65

6.1.6 Last Trip (Metering Page 6) .................................................................................................. 65

6.1.7 Statistics (Metering Page 7) ................................................................................................. 65

6.2 Metering Menu and Explanation ................................................................................................ 66

MP.1 Metering Data ........................................................................................................................ 67

MP.2 Metering ................................................................................................................................ 68

MP.3 RTD Values ........................................................................................................................... 69

MP.4 Status .................................................................................................................................... 70

MP.5 Event Recorder – 60 Events .................................................................................................. 71

MP.6 Last Trip ................................................................................................................................ 72

MP.7 Statistics ................................................................................................................................ 73

Chapter 7: Maintenance and Troubleshooting ........................................................................... 74

7.1 Failure Analysis ................................................................................................................... 74-76

7.1.1 SCR Testing Procedure ......................................................................................................... 76

GENERAL

Unit Running Overload Capacity
(Percent of motor FLA)

125% - Continuous
500% - 30 seconds
1 Cycle: Up to 14x FLA (Internally protected by the programmable short circuit)

Frequency

50 or 60Hz, +2Hz hardware selectable

Power Circuit

6 SCRs, 12 SCRs, 18 SCRs (Model dependent)

SCR Peak Inverse Voltage
Ratings

6500V - 19500V (Model dependent see Table 1) Note: Contact Factory

Phase Insensitivity

User selectable phase sequence detection

Transient Voltage Protection

RC snubber dv/dt networks (One per inverse pair of SCRs)

Ambient Condition Design

Enclosed units: 0° to 40°C (32° to 104°F) (optional - 20° to 50° C with heaters)
5 - 95% relative humidity
0 - 3300 ft. (1000m) above sea level without de-rating
(Ratings for ambient conditions external to unit)

Control

2 or 3 wire 120VAC (Customer supplied)

Auxiliary Contacts

Multiple: Form C (Contacts), rated 5 Amps, 240VAC max.

8 Relays (4 programmable): Form C contacts

Fault Indicator: Form C contacts

BIL Rating

2300V - 7200V 60KV

Approvals

UL recognized, Canadian UL (cUL) recognized

ADVANCED MOTOR PROTECTION

Two Stage Electronic
Overload Curves

Starting: Programmable for Class 5 through 30
Run: Programmable for Class 5 through 30 when "At-Speed" is detected.

Overload Reset

Manual

Retentive Thermal Memory

Overload circuit retains thermal condition of the motor regardless of control
power status. Unit uses real time clock to adjust for off time.

Dynamic Reset Capacity

Overload will not reset until thermal capacity available in the motor is sufficient for
a successful restart. Starter learns and retains this information by monitoring
previous successful starts.

Phase Current Imbalance
Protection

Imbalance Trip Level: 5 - 30% current between any two phases
Imbalance Trip Delay: 1 -20 seconds

Over Current Protection
(Electronic Shear Pin)

Trip Level: 100 - 300% of motor FLA
Trip Delay: 1 - 20 seconds

Load Loss Trip Protection

Under Current Trip Level: 10 -90 % of motor FLA
Under Current Trip Delay: 1 - 60 seconds

Coast Down (Back Spin)
Lockout Timer

Coast Down Time Range: 1 - 60 minutes

Starts-per-hour Lockout Timer

Range: 1 - 6 successful starts per hour
Time between starts: 1 - 60 minutes between start attempts

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Chapter 1 - Introduction

This chapter is an introduction to the Reduced Voltage Solid State Soft Starter for medium voltage AC motors. It is highly
recommended that users read this section thoroughly to become familiar with the basic configuration, operation and
features before applying the Soft Starter.

1.1 Overview

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

1.2 Specifications

Motortronics Inc. Page 1

PROGAMMABLE OUTPUTS

Type / Rating

Form C (SPDT), Rated 5 amps 240 VAC max, (1200 VA)

Run Indication

Programmable

At Speed Indication

Programmable

Acceleration Adjustments

Programmable Ramp Types: Voltage or Current Ramp (VR or CR)
Starting Torque: 0 - 100% of line voltage (VR) or 0 - 600% of motor FLA (CR)
Ramp Time: 1 to 120 seconds
Current Limit: 200 - 500% (VR or CR)
Power Ramp: 0 – 300%

Dual Ramp Settings

4 Options: VR1+VR2; VR1+CR2; CR1+CR2; CR1+VR2
Dual Ramp Control: Ramp 1 = Default
Ramp 2 = selectable via dry contact input

Deceleration Adjustments

Begin Decel Level: 80 - 100% of line voltage
Stop Level: 0 to 1% less than Begin Decel Level
Decel Time: 1 - 60 seconds

Jog Settings

Voltage Jog: 5 - 75%

Kick Start Settings

Kick Voltage: 10 - 100%
Kick Time: 0.1 - 2 seconds

Fault Display

Shorted SCR, Phase Loss, Shunt Trip, Phase Imbalance Trip, Overload,
Overtemp, Overcurrent, Short Circuit, Load Loss, Undervoltage or Any Trip

Lockout Display

Coast Down Time, Starts Per Hour, Time Between Starts, and Any Lockout

EVENT HISTORY

Up to 60 Events

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

METERING FUNCTIONS

Motor Load

Percent of FLA

Current Data

A, B, C Phase Current, Avg Current, Ground Fault (Option)

Thermal Data

Remaining thermal register; thermal capacity to start

Start Data

Avg Start Time, Avg Start Current, Measured Capacity to start, time since last
start.

RTD Data (Option)

Temperature readings from up to 12 RTDs (6 stator RTDs)

Voltage Metering

kW, kVAR, PF, kWH

SERIAL COMMUNICATIONS

Protocol

Modbus RTU

Signal

RS-485, RS-422 or RS232

Network

Up to 247 devices per mode

Functionality

Full operation, status view, and programming via communications port

OPERATOR INTERFACE

LCD Readout

Alpha numeric LCD display

Keypad

8 function keys with tactile feedback

Status Indicators

12 LEDs include Power, Run, Alarm, Trip, Aux Relays

Remote Mount Capability

Up to 1000 circuit-feet from chassis (Use twisted, shielded wire & power source)

CLOCK and MEMORY

Operating Memory

SRAM loaded from F-RAM at initialization

Factory Default Storage

Flash Memory

Customer Settings and Status

Non-volatile F-RAM, no battery backup necessary

Real Time Clock

Lithium ion battery for clock memory only

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SEC.

Table or Drawing

Page

Number

SEC.

Table or Drawing

Page

Number

1.2

Specifications

1 - 2

5.2

Setpoint Page 7 Displays –
Custom Acceleration Curve

52-54

1.4

Design Features
(Unit PIV Ratings)

4

Setpoint Page 8 Displays –
Overload Curve Configuration

55-57

1.9
&

4.1

Electronics
(Keypad Operator Interface)

8 & 26

Setpoint Page 9 Displays –
RTD Option Configuration

58-59

2.2

TCB Board Layout and
Connections

10

Setpoint Page 10 Displays –
Set Password

60

TB1, TB2 & TB3 Description

12

Setpoint Page 11 Displays -
Communications

60

TB4, TB5 & TB6 Description

13

Setpoint Page 12 Displays –
System Setpoints

61-62

TB7 & TB8 Description

14

Setpoint Page 13 Displays –
Calibration & Service

63

Jumper Selections

15

6.1

Metering Page List

54-65

Switch Settings

15

6.2

Metering Menu

66

LED Indicators

16

Metering Page 1 Displays - Metering Data

67

2.3

Optional RTD Board

17

Metering Page 2 Displays - Metering

68

Communications Board
Layout & Connections: RS485
and RS422

17

Metering Page 3 Displays - RTD Values

69

Power Board & Connections

18

Metering Page 4 Displays - Status

70

CPU Board Layout &
Connections

19

Metering Page 5 Displays - Event Recorder

71

2.4

Typical Wiring Diagram

20

3.2

Acceleration Adjustments

21

Metering Page 6 Displays - Last Trip

72

3.3

Deceleration Adjustments

22

Metering Page 7 Displays - Statistics

73

3.4

Sequence of Operation

23

7.1

Failure Analysis & Troubleshooting

74-76

4.2

Menu Navigation

27

7.1

SCR Testing Procedure

76

Changing Setpoints Example

25

NOTES-

5.1

Setpoints Page List

29 – 35

5.2

Setpoint Menu & Parameter
Explanation

36-65

Setpoint Page 1 Displays ­Basic Configuration

36

Overload Class Trip Curves

37

Setpoint Page 2 Displays ­Starter Configuration

37-42

Jog/Voltage Ramp

39

Setpoint Page 3 Displays ­Phase & Ground Settings

41

Overcurrent Trip Delay Graph

43

Setpoint Page 4 Displays ­Relay Assignment

47-42

Setpoint Page 5 Displays ­Relay Configuration

48

Setpoint Page 6 Displays ­User I/O Configuration

49-51

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1.3 Reference chart

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200 & 400 Amps Units

600 Amps Units

Voltage

Series

Devices

Total

Number

of

SCRs

PIV Rating

Voltage

Series

Devices

Total

Number
of SCRs

PIV Rating

2300 V

0 6 6500 V

2300 V

2

12

9000 V

3300 / 4160 V

2

12

9000/13000 V

3300 / 4160 V

4

24

9000/18000 V

6000 - 7200 V

3

18

19500 V

6000 - 7200 V

4

36

18000 V

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1.4 Design Features

The standard Soft Start panel has the following features:

 SCR Power Modules: For each phase, the SCRs are arranged in inverse parallel pairs and series strings as

indicated in Table1 below to facilitate sufficient Peak Inverse Voltage ratings for the application

 RC Snubber Networks: Provide Transient Voltage Protection for SCR Power Modules in each phase to avoid dv/dt

damage.

 Firing Circuit: The SCRs are gated (turned on) using a Sustained Pulse Firing Circuit. This circuitry is isolated from

the control voltage by means of fiber optics.

Table 1 Unit PIV Ratings

1.5 Theory of Operation

The Soft Starter is CPU controlled, using a microprocessor based protection and control system for the motor and starter
assembly. The CPU uses Phase Angle Firing control of the SCRs to apply a reduced voltage to the motor, and then
slowly and gently increases torque using voltage and current control until the motor accelerates to full speed. This starting
method lowers the starting current of the motor, reducing electrical stresses on the power system and motor. It also
reduces peak starting torque stresses on both the motor and mechanical load, promoting longer service life and less
downtime.

1.5.1 Acceleration:

The soft starter comes standard with several methods of accelerating the motor so that it can be programmed to match
almost any industrial AC motor application. The factory default setting applies a Voltage Ramp with Current Limit as this
has been proven to be the most reliable starting method for the vast majority of applications. Using this starting method,
the Initial Voltage setting applies just enough voltage to cause the motor shaft to begin to turn. This voltage is then
gradually increased over the "Ramp Time" setting, until one of two things happen: the motor accelerates to full speed, or
the Ramp Time expires and the Current Limit setting is reached.

If the motor accelerates to full speed before the ramp time has expired, an automatic Anti- Oscillation feature will override
the remaining ramp time and full voltage will be applied. This will prevent any surging or pulsation in the motor torque,
which might otherwise occur If the motor has not reached full speed at the end of the ramp time setting, the current limit
setting will proportionally regulate the maximum output torque. CPU algorithms provide protection against a stall condition,
an overload condition or excessive acceleration time.

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

When the motor reaches full speed and the current drops to running levels, the soft starter detects an At-Speed condition
and automatically closes the Bypass Contactor. The Bypass Contactor serves to shunt power around the SCR stack
assemblies to prevent heat build-up in the starter enclosure. At this point, the motor is operating at full voltage, speed and
power.

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Other starting methods available in the soft starter are:

• Current Ramp: Uses a closed loop current feedback algorithm to provide a linear current increase up to a Maximum

Current level.

• Constant Current: current is immediately increased to the Current Limit point and held there until the motor reaches

full speed.

• Power (KW) Ramp: Uses a True RMS KW feedback PID loop to provide a linear increase in True RMS motor power

to a maximum set KW value.

• Custom Curve: Gives the user the ability to plot torque and time points on a graph. The soft starter will then

accelerate the motor following these points.

• Tachometer Feedback Ramp: uses a closed loop speed follower method monitoring a tachometer input signal from
the motor or load shaft to provide a linear RPM acceleration.

1.5.2 Deceleration: The soft starter provides the user with the option of having the load coast to a stop or controlling the

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

1.6 General Protection

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

1.6.1. Ready Mode: In this mode, control and line power are applied and the Starter is ready for a start command.

Protection during this mode includes the monitoring of current for leakage through multiple shorted SCRs or
welded contacts on the Bypass Contactor. Other protection features in effect are:

• Starter Power Pole Temperature

• Shorted SCR

• Blown Fuse Indication

• Phase Reversal (if enabled)

• Line Frequency Trip Window

• External Input Faults (Digital Input Faults are active in all modes)

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

1.6.2 Start Mode: These additional protection functions are enabled when the Soft Starter receives a valid Start

command:

• Phase Reversal (if enabled) Phase Reversal will still be on and is not a newly activated feature when starting.

• Start Curve

• Acceleration Timer

• Phase Imbalance

• Short Circuit / Load Pre-check (Toe-in-the-Water)

• Ground Fault (Optional)

• External Input Faults

• Accumulated Starting FLA Units (I2t Protection)

• Starting Overload Protection Curve Selection

• Thermal Capacity

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

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1.6.3 Run Mode: The soft starter enters the Run Mode when it reaches full output voltage and the motor current drops

below the FLA setting (motor nameplate FLA plus service factor) for a pre-determined period of time. During the Run
Mode these additional protection features are enabled:

• Running Overload Protection Curve Selection

• Phase Loss

• Under Current / Load Loss

• Over Current / Electronic Shear Pin (Jam Protection)

• External Input Faults

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

is selected.

• Decel Mode: Retains all protection features of the Run Mode. At the end of Decel, the motor will be stopped and the
protection features change as indicated below.

• Coast-To-Stop Mode: Power is immediately removed from the motor and the Soft Starter returns to the Ready Mode.

• Additional protection features activated when the stop command is given include:

o Coast-Down / Back Spin Timer
o Starts-per-Hour
o Time between Starts
o External Input Faults

1.7 Thermal Overload Protection

The Soft Starter plays an important role in the protection of your motor in that it monitors the motor for excessive thermal

conditions due to starting, running and ambient conditions. The soft starter has a Dynamic Thermal Register system in the
CPU that provides a mathematical representation of the thermal condition of the motor.

This thermal information is retained in memory and is monitored for excesses in both value and rate of change. Inputs are
derived from current values, imbalances and (optional) RTD measurements making it dynamic to all processes involving
the motor. The Soft Starter monitors these conditions separately during the Start and Run modes to provide proper
thermal protection at all times.

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

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

• Measured Start Capacity: The user enters a measured amount of thermal capacity from a pre-selected successful
start as a set point to the Thermal Register for the soft starter to follow.

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

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1.7.2 Run Mode overload protection is initiated when the soft starter determines that the motor is At-Speed. Overload

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

• Current Imbalance will bias the register higher due to additional motor heating as a result of a line current imbalance
condition.

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

• RTD Input (Requires the optional RTD monitor card) provides a separate means of motor protection based on actual
temperatures measurements inside the motor. It runs independently of the Thermal Register Model and does not
provide input to, or bias that model.

• Dynamic Reset is another feature that adds reliability and consistency to the performance of the soft starter. If a
motor overload condition occurs and the Overload protection trips, it cannot be reset until sufficient cool down time
has elapsed. This cool down time is determined by the "Learned Thermal Capacity" required to start the motor which
must be regained before the overload can be reset. This ensures sufficient thermal capacity for a successful restart of
the motor.

• Retentive Memory provides continuous overload protection and true thermal modeling by means of a running back
up of the thermal register even if power is lost. Upon restoration of power, the soft starter will read the Real Time
Clock, then recalculate and restore the thermal register to what it should be, given the elapsed time and the cool down
rate of the motor.

• Learned Reset Capacity is a feature that is unique to the Soft Starter. By sampling the amount of thermal capacity
used in the previous three successful starts, the starter will not allow a reset until a sufficient amount of thermal
capacity has been regained in the motor. This prevents nuisance tripping and insures that unsuccessful start attempts
(which would otherwise use up the starts-per-hour capacity of the motor) are not counted.

1.8 Firing Circuit

The SCR gate firing circuit is critical to the performance and stability of the system. The firing circuit includes several
unique features which enhance the ruggedness, noise immunity and flexibility for maximized performance. These features
include:

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

• Sustained Pulse firing keeps the firing signal active for 270 electrical degrees ensuring that the DC gate pulse forces
the SCR to fire even if line noise is present. This provides the Soft Starter with superior noise immunity and protects
against misfiring, enhancing the soft starter system stability.

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

• Transformer Isolation of SCR firing information and signals prevents interference from line noise and EMI/RFI that
may be present. Three phase isolation transformers provide potential measurement, firing board timing while
providing isolation from the line voltage. High isolation Ring Transformers are used to step the 120v control voltage
down to 28VAC for the Sustained Pulse firing circuit, providing further isolation for the SCR gates.

• Fiber Optic Isolation is provided for all gate drive and current feedback signal interfaces between the Medium and
Low Voltage systems.

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ENTERRESETMENU

POWER
RUN

ALARM

TRIP

1

2

3

4

5

6

7

8

AUX. RELAYS

HELP

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1.9 Electronics

The Soft Starter electronic systems are divided into two categories; Low Voltage and Medium Voltage and are based on
where they are located in the Starter structure.

1.9.1 Low Voltage electronics include the Keypad Operator Interface, the CPU and Main Power PC boards which are

located in an isolated Low Voltage compartment of the enclosure.

• Keypad Operator Interface is a 2 line x 20 character LCD display with back-lighting for low ambient light conditions.
The display reads out in truncated English and can show multiple data points in each screen. Twelve LED indicators
are included which show the status of, Power, RUN, ALARM, TRIP and the 8 AUX RELAYS. The Operator
communicates with the CPU board via a serial cable link and can be remotely located up to 1000ft. from the starter.

FIG. 1.9 shows the Keypad Operator Interface.

FIG. 1.9 Keypad Operator Interface.

• CPU Board is where the microprocessor and communications co-processor are located. It is attached to the main

Power board. The CPU determines operating functions, stores user programming, acts upon feedback signals for
faults, and calculates metering and historical data. The board communicates with the Keypad Operator Interface
via a serial link cable. Analog and Digital I/O are also located on the CPU board. (See FIG. 2.3.4)

• Main Board also referred to as the Firing Board, contains the Auxiliary I/O relays and interfaces to the TCB board

(see below) for user interface. This board generates all firing signals for the SCR stacks and receives feedback
signals which are isolated via fiber optics. The board also provides signal conditioning in preparation for analog to
digital conversion. (See FIG. 2.3.3)

Motortronics Inc. Page 8

HAZARDOUS VOLTAGE

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

Failure to follow this instruction will result in
death or serious injury.

DANGER

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1.9.2 Control Electronics are located in the Medium Voltage section of the soft starter. They include the TCB, Gate Drive

and Temp / CT boards.

• TCB (Terminal and Control Board) is the user connection interface board. This board contains the user terminal
blocks, output relays (duplicated), inputs and control power connections. It also contains additional timed relays for
interfacing with Power Factor Correction contactors (if used) and other external devices. Please note Power Factor
Capacitor warnings in Section 2.1.; also see FIG. 2.2.1.

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

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

• MOV Boards are attached to standoffs mounted on the SCR heat sinks and are mounted directly below the Gate
Drive boards. The MOV boards are used to protect the SCRs from over voltage.

• DV/DT Boards are also attached to standoffs mounted on the SCR heat sinks and are mounted below the MOV

boards. The DV/DT boards are used to mitigate voltage transients across the stack assemblies.

Motortronics Inc. Page 9

HAZARDOUS VOLTAGE

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

Failure to follow this instruction will result in
death or serious injury.

SCR DAMAGE

Do not connect (PFC) capacitors to the load
side of the unit.

Doing so will cause DI/DT damage to the
SCRs when energized.

!

CAUTION

DANGER

!

WARNING

SAFETY HAZARD

Do not bypass electrical or mechanical interlocks.

Failure to follow this instruction will cause severe
equipment damage, serious injury or death.

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Chapter 2 – Connection

2.1 Warnings

• Do not service this equipment with voltage applied! The unit can
be the source of fatal electric shock! To avoid shock hazard,
disconnect main power and control power before working on the unit.
Warning labels must be attached to terminals, enclosure and control
panel to meet local codes observing Lock Out, Tag Out procedures.

• Do not connect (PFC) capacitors or surge capacitors to the load
side (motor side) of the unit. This will cause di/dt damage to the

SCRs when they are turned on and will void the warranty on this
product. Capacitors can only be connected to the load side of the
starter through the use of an isolating contactor which is closed after
the soft starting sequence has been completed or when di/dt limiting
inductors are factory installed.

• Avoid connecting capacitors to the input side of the unit. If you
cannot avoid using capacitors across the power lines, they must be
located as far upstream as possible of the input line contactor. In this
situation, an optional power factor correction (PFC) capacitor contactor
should be specified. For additional information and specifications or
when di/dt limiting inductors are factory installed, please contact the
factory.

• Never interchange the input and output power connections on the
unit. This will cause excessive voltage to the control circuit logic.

• For bus protection, it is strongly recommended to use non-gap
MOV Type lightning arrestors in areas where lightning is a significant problem. The arrestors should be

mounted on the nearest utility pole at the Station or optionally included with the unit at the time of order.

• Medium Voltage cables can have significant capacitance values by design which can elevate Di/Dt thru the
SCRs to unsafe levels. Compensating inductors can limit these values to safe levels. Contact the factory if you need
more information on this subject.

Motortronics Inc. Page 10

2

3

4

5

6

7

8

9

10

1

2

3

4

5

6

7

8

9

10

1

2

3

4

5

6

7

1

2

3

4

5

6

7

1

8

9

10

11

12

TB4

Time Delay

NCC NO NCC NO

P.F.C. CAP

NCC NO NCC NO

2

3

4

5

6

7

1

8

9

10

11

12

TB3

Lock Out

NCC NO NCC NO

Fault

NCC NO NCC NO

2

3

4

5

6

7

8

9

10

TB2

2

3

4

5

6

7

1

8

9

10

11

TB1

CNO C ACNO NC

NOAC NC

1

Emergency Bypass
Switch Input

Relay changes state
when the Emergency
Bypass Switch is closed.

Control Power Output
(120 VAC @ 200VA)

Normally closed dry contact input, that
when opened will initiate an Emergency
stop to the system

Relays Operate to indicate
a Blown Fuse or that the
Disconnect is open

Relays Operates (with a
time delay) when the
Start Contact is initiated.

Relays Operate to pull in an
Isolated Contactor to
activate Power Factor
Correction Capacitors

Relays Operate when any
Fault condition occurs

NCNC C CC NC

NONO AC NC

AC

C

12

Optional Interlock (Factory installed Jumpers)

Relay Operates on

immediate Start / Stop

Stop

Maintain

Contact

Start

120 VAC

Control Input Power

N

N

N

N

120 VAC Input Power

Start Input

Fuse Blown Input

Dual Ramp Input

Main and CPU Circuit Board

Bypass Status Input

TB6

TB7

TB8

NC

Run Contacts

(AUX 3) Status.

Fault (AUX 1)

Status.

At Speed (AUX 4)

Status.

To TCB Board

Blown Fuse and / or Disconnect
Interlock N.O. dry contact Input.

At Speed N.C. dry contact Input

(Factory wired)

External Overload Protection
Device N.C dry contact Input.

Energizes / De-energizes

the Bypass Contactor Coil

Energizes / De-energizes

the Inline Isolation

Contactor Coil

Red LED

Red LED

FAULT

FUSE

Green LED

DELAYED

START

Green LED

PFC

TIMED OUT

Green LED

DELAYED

TIMED OUT

7 6 5

4 3

2 1

PFC

7 6 5

4 3

2 1

AUX

7 6 5

4 3

2 1

START

DLY-C

AUX-C

PFC-C

Jumpers

F1

F2

F3

JP1

Remove JP1 for
electronic Motor
overload protection
During emergency
bypass operation.

SW1

ON OFF

DUAL ADJ

F1 – Control fuse for TB1 1-9
Part No. ACG1A250AC or equiv.
F2 – Contactor and relay output fuse.
Part No. ACG4A250AC or equiv.
F3 – TB2 terminal 6 (120VAC Input)

Part No. ACG4A250AC or equiv.

2 or 3 Wire Control

Momentary or

Maintained Start /

Stop Switching

supplied by customer

FIG. 2.2.1 TCB Terminal and Control Board

SW3

SW4

SW5

7 6 5

4 3

2 1

ON

64

32

16 8 4

2

1

Switch position value;

Ex. Position 1+2+3: 1+2+4 = 7

Postion

Value

X1

X3

X5

Power

Supply

POWER

Green LED

EMERGENCY

BYPASS

Green LED

Green LED

Green LED

AUX BYPASS

AT SPEED

2

1

NEUT.

LINE

PERM

PFC

3

TB5

N

120 VAC Power

L

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2.2 Control Connections - TCB (Terminal and Control Board)

2.2.1 TCB Board

The TCB board, FIG. 2.2.1 shown below, provides interconnections between the main power and CPU boards and the
customer’s control logic connections. It is a 120 VAC control board with several auxiliary dry contacts, built-in time delay
circuits and an emergency bypass function. It also controls the inline isolation and bypass contactor and provides
provisions for shutdown interlocks. (See Section 2.2.2 for terminal designations and descriptions)

Motortronics Inc. Page 11

TB1 Start / Stop Control

T

Description

1

AC

120 VAC Control Power (Line)

2 3 NC

C

Shutdown Input – Accepts customer N.C dry contact (Factory jumper installed)

4
5

NC
C

Shutdown Input – Accepts customer N.C dry contact (Factory jumper installed)

6
7
8

NC
C
NO

Terminal 6, 7 & 8;"2-wire control is connected to pins 6 & 8". Also; "For 3 wire control, connect the N.C. STOP
button to pins 6&7 and the N.O. START button to pins 7 & 8

9

AC

120 VAC Control Power (Neutral)

10
11
12

C
NO
NC

Common
Normally Open
Normally Closed, Form C Relay that changes state on Start and Stop commands

TB2 Emergency Bypass Control

T

Description

1 2 NO

C

When the N.O. contact closes the unit reverts to an electromechanical starter. When a start command is
given the unit will start the motor across the line.

3
4
5

C
NO
NC

Terminals 3, 4 and 5 is a form C output relay that changes state when the contact at TB2 pins 1 & 2 is closed

6 7 NO

NC

120 VAC @ 200VA Aux Control Power output.

8

-

Not Used

9

10

NO
NC

Normally Open
Normally Closed, "Normally closed dry contact, opens when Emergency stop is initiated.

TB3 Fault Relay Outputs

T

Description

1
2
3

C
NO
NC

(2) Form C relay output that transfer on blown fuse or disconnect open indication.

3
4
5

C
NO
NC

(2) Form C relay output that transfer on blown fuse or disconnect open indication.

7
8
9

C
NO
NC

(2) Form C relay output that transfer on any fault indication.

10
11
12

C
NO
NC

(2) Form C relay output that transfer on any fault indication.

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2.2.2 Description of Terminal Connections

Motortronics Inc. Page 12

TB4 Optional Relay Outputs

T

Description

1
2
3

C
NO
NC

2 Form C time delay Aux relay output contacts. Time delay starts when the Start commend is given.

3
4
5

C
NO
NC

7
8
9

C
NO
NC

2 Form C time delay Aux relay output contacts. Time delay starts when the "At Speed" condition is reached
ideal for controlling a PFC contactor.

10
11
12

C
NO
NC

TB5 TCB Power

T

Description

1

L

By connecting TB5 of multiple units in parallel, PFC contactors will be inhibited from closing while a unit is
soft starting. PFCs that are already on line will remain on line. The lead unit in the parallel string requires
TB5 pins 1 & 3 to be connected to the 120Vac source and neutral respectively.

2

PFC

3

N

TB6 Main and CPU Circuit Board Control Inputs

T

Description

1 2 L

N

120 Vac Control Power Input (Main & CPU Circuit)

3 4 -

-

Start Input

5 6 -

-

Fuse Blown Input

7 8 -

-

Dual Ramp Input

9

10 - -

Bypass Status Input

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2.2.2. Description of Terminal Connections - Continued

Motortronics Inc. Page 13

TB7 Main and CPU Circuit Board Control Outputs

T

Description

1
2

Run contacts (AUX3) to the TCB board. (Signal is used to hold the Main Contactor closed during deceleration)

3
4

To the TCB board indicating the status of AUX 1.

5
6

At Speed Contacts (AUX 4) used to signal the Bypass Contactor to close.

7

Not Connected / Not Used

TB8 Control Inputs and Outputs

T

Description

1
2

N.C. dry contact input from blown fuse and/or disconnect interlock.

3
4

N.C. dry contact input from an external Overload Protection device. (Required if emergency bypass is used)

5
6

N.C. dry contact input from the Bypass Contactor for at speed indication.

7
8

Output connected to the Bypass Contactor and energizes / de-energizes the Contactor. (Factory wired)

9

10

Output connected to the Inline Isolation Contactor and energizes / de-energizes the Contactor. (Factory wired)

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2.2.2 Description of Terminal Connections - Continued

Motortronics Inc. Page 14

Jumper Selection

Jumper

Time Delay

Function

DLY-C

X1

Cycles

Start Delay

This is a selectable delay period between the initiations of a Start command and when
the CPU actually receives the signal.

AUX-C

X3

Cycles

Auxiliary Start Delay
This is a selectable delay period from the initiation of a Start command.

PFC-C

X5

Cycles

PFC Contactor Delay
This is a selectable delay period between when the Bypass Contactor closes to when
the Power Factor Capacitors Contactor is activated.

JP1

N/A

Motor Protection Jumper

When this jumper is in place, the CPU will be disabled during operation in the
Emergency Bypass Mode. In this case, insure that there is an external means of
overload protection. When the jumper is removed, the CPU will be enabled to provide
electronic motor protection when operating in the Emergency Bypass Mode.

DIP Switches

Switch

Function

SW1

ON: Sets Dual Adjustment
OFF: Disabled

SW2

Not Used

SW3

Sets the
Start Delay
Value

SW3, SW4 and SW5 are 7 position DIP Switches that use binary coding to set the value
of the time delay in Cycles or Seconds as selected via jumpers X1 to X6. (See Jumper
Table.) The setting range is 0 to 127 (1+2+4+8+16+32+64). The example shown
results in a value of 7 (1+2+4)

7 6 5

4 3

2 1

ON

64

32

16 8 4

2

1

Switch position value;

Ex. Position 1+2+3: 1+2+4 = 7

Postion

Value

SW4

Sets the
AUX Start
Delay Value

SW5

Sets the
PFC
Contactor
Delay Value

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2.2.3 Description of Jumper Selections and Functions

Motortronics Inc. Page 15

LED Indicators

Function

Location

Color

Function

Fuse Blown/
Disconnect

D4

Red

ON: When a Fuse is blown and / or a Disconnect is open.

Fault

D16

Red

ON: When any Fault has occurred.

Start

D7

Yellow

ON: When a Start signal has been initiated.

PFC Timed Out

D17

Yellow

ON: When the Power Factor Correction Capacitors Contactor is energized.

Delay Timed Out

D15

Yellow

ON: When the Auxiliary Start Contacts have been energized.

+24V

D28

Green

ON: +24V supply is good.

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2.2.5 Description of LED Indicators Functions

Motortronics Inc. Page 16

12 13

24

25

36 37

48

TB1 TB2 TB3

TB4

RTD1

RTD2 RTD3 RTD4

RTD5 RTD6 RTD7

RTD8 RTD9 RTD10

RTD11 RTD12

1

Signal

Power

Compensation

Shield

Typical RTD Installation

U5

U10

U11

R49

R35

U1

U12

U7

U8

U13

U4

U9

R9

C4 C6+

C9

C7

U2

R15

C17

P1

R6

R10

C10

C11

C31

R2

Q1

Q3

R16

C18

C33

C32

C1

R7

R11

R17

C12

C19

U3

R3

C2

C13

R2

Q3

Q4

X1

C8+

C3

U6

C39

L1

C45

C38

C44

L2

C43

C37

C36

C42

1

6

TB1

TB2

J1

(RS485)

X1

(RS422)

X2

X3

1

6

X4

1

7

RS485

Customer Connections

A+ A- NC NC Shield

RS422

Factory Only

A+ A- B+ B- Shield

RCV XMIT

Install jumper X1 to insert termination resistor
for last unit in Modbus string. All other units in
the string should have the X1 jumper off

J4

Connects to the

Keypad Interface

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2.3 PCB Layout Section - THIS SECTION IS FOR REFERENCE ONLY. NO FIELD WIRING OR

CONNECTIONS ARE REQUIRED.

2.3.1 Optional RTD Board

FIG. 2.3.1 Optional RTD Board

2.3.2 RS485 / RS422 Communications Board

Note: This Board is mounted on the back of the Keypad Interface

2.3.3 Main Board

Motortronics Inc. Page 17

FIG. 2.3.2 RS485 / RS422 Communications Board

TB1

654

3

2

112

11

1098

7654

3

2

1

12

11

1098

7654

3

2

1

TB2

TB3

F1

J7

J2

1- C Phase

4- B Phase

7- A Phase

J1

J3

J4

1

1

7

7

J6

19

20

1

2

J5

19

20

1

2

X1

Test Points

Circuit Board

Ground

AI

AT

BI

BT

CI

CT

GF

C1

C2

A1

A2

B1B2

J8

1 3

1

3

1 6

C NCNO C NCNO

C

NCNO

C NCNO

C NCNO C NCNO

C NCNO C NCNO

AUX 1
(TRIP)

AUX 2

(ALARM)

AUX 3

(RUN)

AUX 4

(AT SPEED)

AUX 5 AUX 6

AUX 7

AUX 8

Factory Only

Do Not Program

Refer to Set Point Page 5 information

Relay Output Contact Rating : 240VAC @ 5A (1200VA)

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FIG. 2.3.3 Power Board

Motortronics Inc. Page 18

TB1

98

7654

3

2

1 8

7654

3

2

1

TB2

TB3

J1

1 8

1

8

7654

3

2

1

CGND1

CGND3

J3

39

40

12

J2

CGND4

CGND2

TB4

7 6 5 4 3 2 1

X3

1

3

Bat

2

J5

1

7

J4

J7

19

20

1

2

BT1

+

J6

19

20

1

2

Tach.
Input

+

_

Analog
Output #1
4 – 20 mA

+

_

+

_

Analog
Output #2
4 – 20 mA

+

_

+

_

+

_

+

_

+

_

Program

Enable

Input

NOTE: Install program jumper to enable set
point programming. Jumper must be removed
after programming or for prolonged storage to
preserve settings.

External
Input #2

Opto – isolated Inputs

TB3: Only use terminal 3 and 4, all
other terminals are for factory use.

DO NOT

CONNECT

DO NOT

CONNECT

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2.3.4 CPU Board

Motortronics Inc. Page 19

FIG. 2.3.4 CPU Board

ENTERRESETMEN U

POWER

RUN

ALARM

TRIP

1

2

3

4

5

6

7

8

AUX. RELAYS

HELP

2

3

4

5

6

7

8

9

10

1

2

3

4

5

6

7

8

9

10

1

2

3

4

5

6

7

1

2

3

4

5

6

7

1

8

9

10

11

12

TB4

Time Delay

NCC NO NCC NO

P.F.C. CAP

NCC NO NCC NO

2

3

4

5

6

7

1

8

9

10

11

12

TB3

Lock Out

NCC NO NCC NO

Fault

NCC NO NCC NO

2

3

4

5

6

7

8

9

10

TB2

2

3

4

5

6

7

1

8

9

10

11

TB1

CNO C SNO NC NON NC

1

NCNC C CC NC NONO AC NCAC C

12

Stop

Maintain
Contact

Start

N

TB6

TB7

TB8

NC

Red LED

Red LED

FAULT

FUSE

Green LED

DELAYED

START

Green LED

PFC

TIMED OUT

Green LED

DELAYED

TIMED OUT

7 65 4 3 2 1

PFC

7 65 4 3 2 1

AUX

7 65 4 3 2 1

START

DLY-C

AUX-C

PFC-C

Jumpers

F1

F2

F3

JP1

Remove JP1 for
electronic Motor
overload protection
During emergency
bypass operation.

SW1

ON OFF

DUAL ADJ

SW3

SW4

SW5

X1X3X5

Power

Supply

POWER

Green LED

EMERGENCY

BYPASS

Green LED

Green LED

Green LED

AUX BYPASS

AT SPEED

2

1

NEUT.

LINE

PERM

PFC

TB5

3

TB1

6543

2

112

111098

7654

321

12

111098

7654

321

TB2

TB3

F1

J7

J2

J1

J3

J4

1

1

7

7

J6

19

20

1

2

J5

19

20

1

2

X1

C1C2

A1A2

B1B2

J8

1 3

1

31 6

C NCNO C NCNO C NCNO C NCNO C NCNO C NCNO C NCNO C NCNO

AUX 1

(TRIP)

AUX 2

(ALARM)

AUX 3

(RUN)

AUX 4

(AT SPEED)

AUX 5 AUX 6 AUX 7

AUX 8

TB1

987654321 87654321

TB2 TB3

J1

1 8

1

8

7654

321

CGND1

CGND2

J3

39

40

12

J2

CGND4

CGND2

TB4

7 6 5 4 3 2 1

X3

1 3

Bat

2

J5

1

7

J4

J7

19 20

1 2

BT1

+

J6

19 20

1 2

12 13

24

25 36 37 48

TB1 TB2 TB3 TB4

RTD1 RTD2 RTD3 RTD4

RTD5 RTD6 RT D7 RTD8 R TD9 RTD10 R TD11 RTD12

1

U5

U10

U11

R49

R35

U1

U12

U7

U8

U13

U4

U9

R9

C4 C6+

C9

C7

U2

R15

C17

P1

R6

R10

C10

C11

C31

R2

Q1

Q3

R16

C18

C33

C32

C1

R7

R11

R17

C12

C19

U3

R3

C2

C13

R2

Q3

Q4

X1

C8+

C3

U6

C39

L1

C45

C38

C44

L2

C43

C37

C36C42

1

6

TB1 TB2

J1

(RS485)

X1

(RS422)

X2

X3

1 6

X4

1

7

(RS485)

B+ A- NC NO Shield

(RS422) Factory Only

A+ A- B+ B- Shield

RCV XMIT

Remove Jumper for last unit in Modbus string

3Ø Medium

Voltage Supply

Medium Voltage

CPT

(Optional)

Ø BØ A

Ø C

Ø A

Ø B

H1

H2

X1 X2

H1

H1H2 H2

X1 X1X2 X2

H

N

Ø A

Ø B

Ø C

120VAC

120VAC 120VAC

Located in Medium Voltage Section

199
201
180
179

Program Jumper

199

201

180
179

191

192

195

197

189

190

194

193

202
204

189

190

191

192

197

195

202

194

193

204

NOTE 1 - See FIG. 2.2.1 for TCB Board
detailed connections

NOTE 1

GROUND FAULT

BOARD

(Optional)

MVC3-GF / CT

ZERO
SEQUENCE
CT @ 0.05A

CPU BOARD

(See FIG. 2.3.4)

TCB BOARD

(See FIG. 2.2.1)

RTD BOARD

(See FIG. 2.3.1)

(Optional)

FIBER OPTIC

HARNESS

POWER BOARD

(See FIG. 2.2.3)

A+A-B+ B-

COMM BOARD
(See FIG. 2.3.2)

(Rear View of Board)

J4

RS485

Customer

Connection

6543

2

1

Ø A Ø B

Ø C

Ø A

Ø B

Ø C

START

STOP

Maintain
Contact

2-Wire or 3-Wire
Start Control Wiring

3Ø to

Power

Poles

NOTE 1

N

H

To SCR Power Section

KEYPAD INTERFACE

(See FIG. 1.9)

A+

A-

NC

NC

S

Twisted Pair

S

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2.4 Typical Wiring Diagram

FIG. 2.4 Typical Wiring Diagram

Motortronics Inc. Page 20

ACCELERATION

Starting Torque Level

Current Limit

TORQUE VOLTAGE

100 %

Acceleration Mode

Ramp Time

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Chapter 3 - Start-up

3.1 Introduction

It is best to operate the motor at its full load starting condition to achieve the proper settings. Initial settings are set to
accommodate most motor conditions. TRY INITIAL SETTINGS FIRST. See Section 5.1.2 Starter Configuration (Set Point
Page 2) to make any adjustments.

3.2 Acceleration Adjustments

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

3.2.1 Initial Voltage

Factory Setting = 20% of line voltage
Range = 0% - 100% of line voltage

Initial voltage adjustment changes the initial starting voltage level to the motor.

3.2.2 Ramp Time

Factory Setting = 10 sec.
Range = 0 - 120 sec.

Ramp time adjustment changes the amount of time it takes to reach the current limit point or full voltage if the Current limit
point was not reached.

Note: Refer to your motor manual for the maximum number of starts per hour allowed by the manufacturer and do not
exceed the recommended number.

3.2.3 Current Limit (see FIG. 3.2.3)

Factory Setting = 350% of motor FLA
Range = 200% - 500% of motor FLA

The main function of current limit is to limit the maximum current. It may also be used to extend the ramp time if required.
The interaction between the voltage ramp and the current limit will allow the soft start to ramp the motor until the
maximum current is reached and the current limit will hold the current at that level. The current limit must be se high
enough to allow the motor to reach full speed. The factory setting of 350% is a good starting point.

Do not set the current limit too low on variable starting loads. This could cause the motor to stall and eventually
cause the overload protection to trip.

Note: If the motor does stall, refer to the motor manufacturer’s motor data for the proper cooling time.

Motortronics Inc. Page 21

FIG. 3.2.3 Current Limit

ACCELERATION

Starting Torque

Level

Current Limit

TORQUE VOLTAGE

100 %

Acceleration Mode

R

am

p

T

i

m

e

DECELERATION

Ramp Time

Step Down

Voltage Level

Start Deceleration

Mode

Stop

Deceleration

ModeStop Voltage

Level

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3.3 Deceleration Adjustments (Pump Control)

Decel control extends the stopping time on loads that would otherwise stop too quickly when power is removed. Decel
control provides smooth deceleration until the load comes to a stop. Three adjustments optimize the deceleration curve to
meet the most demanding requirements. The unit is shipped from the factory with the Decel control feature

disabled.

3.3.1 Deceleration Applications

Apply power and adjust the soft start before enabling or modifying the deceleration adjustments. Both, acceleration and
deceleration adjustments should be made under normal load conditions. The deceleration feature provides a slow
decrease in the output voltage, accomplishing a gentle decrease in motor torque during the stopping mode. This is the
OPPOSITE OF BRAKING in that, it will take longer to come to a stop than if the starter were just turned off. The primary
use of this function is to reduce the sudden changes in pressure that are associated with “Water Hammer” and slamming
of check valves with centrifugal pumps. Decel control in pump applications is often referred to as Pump Control. In a
pump system, liquid is being pushed uphill. The force exerted by gravity on the column of liquid as it goes up hill is called
the “Head Pressure” in the system. The pump is sized to provide enough Output Pressure to overcome the Head
Pressure and move the fluid up the pipe. When the pump is turned off, the Output Pressure rapidly drops to zero and the
Head Pressure takes over to send the fluid back down the hill. A “Check Valve” is normally used somewhere in the
system to prevent this (if necessary) by only allowing the liquid to flow in one direction. The kinetic energy in that moving
fluid is suddenly trapped when the check valve slams closed. Since fluids can’t compress, that energy is transformed into
a “Shock Wave” that travels through the piping system looking for an outlet in which to dissipate. The sound of that shock
wave is referred to as “Water Hammer” and the energy in that shock wave can be extremely damaging to pipes, fittings,
flanges, seals and mounting systems.

By using the Soft Stop/Deceleration feature of the soft starter, the pump output torque is gradually and gently reduced,
which slowly reduces the pressure in the pipe. When the Output Pressure is just slightly lower than the Head Pressure,
the flow slowly reverses and closes the Check Valve. By this time there is very little energy left in the moving fluid and the
Shock Wave is avoided. When the output voltage to the motor is low enough to no longer be needed, the soft starter will
end the Decel cycle and turn itself off. (See FIG. 3.3)

FIG. 3.3 Deceleration Control

Another common application for decel control is on material handling conveyors as a means to prevent sudden stops that

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

Motortronics Inc. Page 22

MOTOR STOPPED
READY TO START

MOTOR STARTING
00 x FLA

OVERLOAD ALARM
TIME TO TRIP .XXX SECS

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3.3.2 Start Deceleration Voltage

Factory Setting = 100% of line voltage
Range = 80% - 100% of line voltage

The step down voltage adjustment eliminates the dead band in the deceleration mode that is experienced while the
Voltage drops to a level where the motor deceleration is responsive to decreased voltage. This feature allows for an
instantaneous drop in voltage when deceleration is initiated.

3.3.3 Stop Deceleration Voltage

Factory Setting = 20% of line voltage
Range = 0% - 100% of line voltage

The stop voltage level set point is where the deceleration voltage drops to zero.

3.3.4 Deceleration Time

Factory Setting = 5 sec.
Range = 0 - 60 sec.

The deceleration ramp time adjusts the time it takes to reach the stop voltage level set point. The unit should be restarted
and stopped to verify that the desired deceleration time has been achieved. When calculating the number of starts per
hour, a decel curve should be counted as a start curve. For example, recommended number of starts per hour = 6,
allowable starts with decel cycle per hour = 3.

Note: Do not exceed the motor manufacturer’s recommended number of starts per hour.

3.4 Sequence of Normal Operation

It is best to operate the motor at its full load starting condition to achieve the proper time, torque and ramp settings. Initial
settings are set to accommodate most motor conditions.

TRY INITIAL SETTINGS FIRST FOR: - Initial Voltage

- Current Limit

- Ramp Time

See (Section 5.1.2 Set- point Page 2) to make any adjustments. If the Decel function is enabled, related parameters may
also need adjusting to achieve optimal Decel performance

Sequence:

 Close the disconnect switch to apply 3 phase power" Verify the power LED on the keypad comes on.

 Activate the start command, the motor should start accelerating and the RUN LED will come ON.

Motortronics Inc. Page 23

IA:_ _ _ IB:_ _ _
IC:_ _ _ GF:_ _ _

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Check: If the motor decelerates, or stops, during the acceleration period, activate the Stop button immediately.
Adjustments to the ramp time and or current limit setting are necessary to provide the motor sufficient energy to reach full
speed. If the unit does not follow this operational sequence, please refer to the Troubleshooting Chapter.

If the motor does not enter the run mode in the set time (Acceleration time limit, see SP8.2), a trip will occur. When the
motor reaches full speed, the “AUX 4” LED (At Speed) will be ON. The POWER, RUN, AUX3 LEDs will be ON, indicating
that the contact has energized. Phase A, B, C and Ground Fault current is shown on the keypad during operation.

Motortronics Inc. Page 24

HAZARDOUS OPERATION

DANGER

Do not operate the Bypass Contactor
with medium voltage power applied
to the unit.
Failure to follow this instruction will
cause the motor to start
unexpectedly.

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3.5 Emergency Bypass Operation

Emergency Bypass (2.3 to 7.2kV Class)

 Remove input power by opening the disconnect switch and lock out.
 Close the emergency Bypass contact located on the TCB board at TB2

(See section 2.2.1 for location).

 Unlock and reclose the disconnect switch.

Note: In the emergency bypass mode, there is no overload protection
unless a separate (optional or customer supplier) thermal overload relay is
installed, or JP-1 (Motor Protection Jumper, Sec.2.2.3) is removed from the
TCB Board.

The unit is operable as a normal across-the-line starter. When power is applied, the bypass contactor is energized, tying
the input terminals directly to the output terminals. When the "START" command is given, the main (in line) contactor is
energized and the motor line starts. When the "STOP" command is given, the motor is disconnected from the line power
via the main (in-line) vacuum contactor.

Motortronics Inc. Page 25

ITEM

DESIGNATION

DESCRIPTION

KEY

MENU

Toggle between the menu selection for metering and set point pages.

RESET

Will clear the trip indicator and release the trip relay.

ENTER

Pressing the ENTER button once enters the EDIT mode where set point values can
be changed. An "Asterisk" will appear on the display to indicate it is in the edit mode.
After a set point value is changed, pressing the ENTER button again will save the
revised value to memory and the asterisk will go off indicating the change has been
saved. When not in the edit mode, the ENTER pushbutton will toggle through the
event indicator list (such as alarms or trips)

HELP

Provides general help information about a specific set point or action.

UP ARROW

Will scroll up through the set point and metering menu page. It will scroll to the top of
the set point page or a section. In edit mode it will increase a set point in an
incremental step or toggle through the available options in the set point.

RIGHT ARROW

In the main menu the RIGHT ARROW button provides access to the set point page.
For set point pages with multiple columns, the RIGHT ARROW will scroll the set
point page to the right. When in edit mode it will shift one character to the right.

DOWN ARROW

Will scroll down through the set point pages and down through the set points. In edit
mode, it will decrement through values and toggle available options in the set point.

LEFT ARROW

Will move to the left through set point pages with multiple columns. When in edit
mode it will become the backspace key and will shift one character to the left.

LED

POWER

Indicates control power is present

RUN

Indicates unit/motor is running

ALARM

Lights in conjunction with Relay AUX 2 to indicate an Alarm event or warn of
possible critical condition.

TRIP

Lights in conjunction with Relay AUX 1 to indicate a Trip condition has occurred.

AUX 1- 8

Auxiliary relays (Note: Relays 5-8 are available for customer use)

ENTERRESETMENU

POWER
RUN
ALARM

TRIP

1

2

3

4

5

6

7

8

AUX. RELAYS

HELP

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Chapter 4 - User Interface & Menu Navigation

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

4.1 Keypad/Operator Interface

The user keypad/ operator interface consists of:

• 2 row by 20 characters Liquid Crystal Display (LCD)

• 12 LEDs

• 8 pushbuttons

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

4.1.1. Keypad Operator designations and functions

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

Motortronics Inc. Page 26

Page 1

Basic Configuration

Page 2

Starter Configuration

Page 3

Phase & Ground Settings

Page 4

Relay Assignment

Page 5

Relay Configuration

Page 6

User I/O Configuration

Page 7

Custom Acceleration Curve

Page 8

Overload Curve Config.

Page 9

RTD Configuration

Page 10

Security Set Password

Page 11

Communications

Page 12

System Setpoints

Page 13

Calibration & Service

MENU

LEVEL 1

LEVEL2

LEVEL3

FACTORY LEVEL

Notes:

1. The MENU key allows you to toggle the screens between
the Setpoint Menu and the Metering Menu. Simply use
the arrow keys to get to the different screens within each
menu.
Example: To access Setpoint Page 3 PHASE &
GROUND SETTINGS, press the MENU key once and
the DOWN ARROW twice.

2. Levels 1, 2 and 3 indicate password protection levels for
these setpoint pages.

Page 1

Current Metered Data

Page 2

Voltage & Power Data

Page 3

RTD Values

Page 4

Status

Page 5

Event Recorder

Page 6

Last Trip

Page 7

Statistics

METERING MENU

CONFIGURATION MENU

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4.2 Menu Navigation

Motortronics Inc. Page 27

PAGE 1 BASIC
CONFIGURATION

MENU

ENTER

MOTOR FULL LOAD AMPS
: 140 AMPS

MOTOR FULL LOAD AMPS*
: 140 AMPS

ENTER

MOTOR FULL LOAD AMPS
: 142 AMPS

(Push Twice)

(Save Entry)

MOTOR FULL LOAD AMPS
: 142 AMPS

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4.2.1 Password Access

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

Note: Set Points can only be changed when the motor is in Stop/ Ready Mode! The soft starter will not allow a
start if it is still in the Edit Mode. When the unit is in the Edit Mode, an asterisk is displayed in the top right corner
screen.

4.2.2 Changing Set Points

Example 1: Changing Motor FLA from 140 AMPS to 142 AMPS

1. Press MENU button to display Set point Page 1, Basic Configuration

2. 2Press the RIGHT ARROW you will view the screen Motor Full Load Amps.

3. Press the ENTER button for edit mode. Note: The asterisk (*) in the top right corner of the LCD screen that indicates

Edit Mode.

4. To change the value, select the UP ARROW or DOWN ARROW. In this case push the UP ARROW twice (2x).

5. To accept the new value, press the ENTER button. The unit will accept the changes and will leave the edit mode.
Note the * is no longer in the top right corner of the LCD Display.

Motortronics Inc. Page 28

Setpoint

Page

Security

Level

Description

Factory Setting

Default

Range

Section

Page 1

Basic Configuration

Level 1

No Password

Required

Motor Full Load Amps (FLA)

Model dependent

50 - 100% of Unit Max Current Rating
(Model and Service Factor dependent)

SP1.1

Service Factor

1.15

1.00 – 1.3

SP1.2

Overload Class

10

O/L Class 5-30

SP1.3

NEMA Design

B

A-F

SP1.4

Insulation Class

B

A, B, C, E, F, H, K, N, S

SP1.5

Line Voltage

Model dependent

100 to 20000V

SP1.6

Line Frequency

60

50 or 60 HZ

SP1.7

Setpoint

Page

Security

Level

Description

Factory Setting

Default

Range

Section

Page 2

Starter Configuration

Level 1

No Password Required

Start Control Mode

Start Ramp 1

Jog, Start Ramp 1, Start Ramp 2, Custom
Accel Curve, Start Disabled, Dual Ramp,
Tach Ramp

SP2.1

Jog Voltage

50%

5-75%, Off

SP2.2

Start Ramp #1 Type

Voltage

Voltage, Current

SP2.3

Initial Voltage #1

20%

0-100%

Ramp Time #1

10 sec

1-120 sec

Current Limit #1

350% FLA

200-500 %

Initial Current #1

200% FLA

0-300 %

Ramp Time #1

10 sec

1-120 sec

Maximum Current #1

350% FLA

200-500 %

Start Ramp #2 Type

Disabled

Disabled, Voltage, Power

Initial Voltage #2

60%

0-100 %

SP2.4

SP2.5

Ramp Time #2

10 sec

1-120 sec

Current Limit #2

350% FLA

200-500 %

Initial Power #2

20%

0-100 %

Ramp Time #2

10 sec

1-120 sec

Maximum Power #2

80%

0 – 300 %

Kick Start Type

Disabled

Voltage or Disabled

Kick Start Voltage

65%

10-100 %

Kick Start Time

0.50 sec

0.10-2.00

Deceleration

Disabled

Enabled or Disabled

SP2.6

Start Deceleration Voltage

100%

80-100 %

Stop Deceleration Voltage

30%

0-79 %

Deceleration Time

5 sec

1-60 sec

Timed Output Time

Off

1-1000 sec, Off

SP2.7

Run Delay Time

1 Sec

1-30 sec, Off

SP2.8

At Speed Delay Time

1 Sec

1-30 sec, Off

SP2.9

Bypass Pull-in Current

100% FLA

90 – 300%

SP2.10

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Chapter 5 - Setpoint Programming

The soft starter has thirteen programmable Setpoint pages which define the motor data, ramp curves, protection, I/O
configuration and communications. In Section 5.1, the Setpoint pages are outlined in chart form. In Section 5.2 the
Setpoint pages are illustrated and defined for easy navigation and programming. Note: Setpoints can only be changed

then the starter is in the Ready Mode. Also the soft start will not start when it is in programming mode.

5.1 Setpoints Page List

These charts list the Setpoint Page, the programmable functions and the section.

5.1.1 Basic Configuration (Setpoint Page1)

5.1.2 Starter Configuration (Setpoint Page 2)

Motortronics Inc. Page 29

Setpoint

Page

Security

Level

Description

Factory Setting

Default

Range

Section

Page 3

Phase and Ground Settings

Level 2

Password Protected

Imbalance Alarm Level

15% FLA

5-30 %, Off

SP3.1

Imbalance Alarm Delay

1.5 sec

1.0-20.0 sec

Imbalance Trip Level

20%

5-30 %, Off

SP3.2

Imbalance Trip Delay

2.0 sec

1.0-20.0 sec

Undercurrent Alarm Level

Off

10-90 %, Off

SP3.3

Undercurrent Alarm Delay

2.0 sec

1.0-60.0 sec

Overcurrent Alarm Level

Off

100-300 %, Off

SP3.4

Overcurrent Alarm Delay

2.0 sec

1.0-20.0 sec

Overcurrent Trip Level

Off

100-300 %, Off

SP3.5

Overcurrent Trip Delay

2.0 sec

1.0-20.0 sec

Phase Loss Trip

Enabled

Enabled or Disabled

SP3.6

Phase Loss Trip Delay

0.1 sec

0-20.0 sec

Phase Rotation Detection

ABC

ABC, ACB or Disabled

SP3.7

Phase Rotation Trip Delay

1.0 sec

1.0 - 20.0 sec

*Ground Fault Alarm Level

Off

5-90 %, Off

SP3.8

*Ground Fault Alarm Delay

0.1 sec

0.1-20.0 sec

*Ground Fault Loset Trip Level

Off

5-90 %, Off

SP3.9

*Ground Fault Loset Trip Delay

0.5 sec

0.1-20 sec

*Ground Fault Hiset Trip Level

Off

5-90 %, Off

SP3.10

*Ground Fault Hiset Trip Delay

0.008 sec

0.008-0.250 sec

Overvoltage Alarm Level

Off

5 -30%, Off

SP3.11

Overvoltage Alarm Delay

1.0 sec

1.0-30.0 sec

Overvoltage Trip Level

10%

5-30%, Off

SP3.12

Overvoltage Trip Delay

2.0 sec

1.0-30.0 sec

Undervoltage Alarm Level

Off

5-30%, Off

SP3.13

Undervoltage Alarm Delay

1.0 sec

1.0-30.0 sec

Undervoltage Trip Level

15%

5-30%, Off

SP3.14

Undervoltage Trip Delay

2.0 sec

1.0-30.0 sec

Line Frequency Trip Window

Disabled

0-6 Hz, Disabled

SP3.15

Line Frequency Trip Delay

1.0 sec

1.0-20.0 sec

P/F Lead P/F Alarm

Off

0.1-1.00, Off

SP3.16

P/F Lead Alarm Delay

1.0 sec

1-120 sec

P/F Lead P/F Trip

Off

.01-1.00, Off

SP3.17

P/F Lead Trip Delay

1.0 sec

1-120 sec

P/F Lag P/F Alarm

Off

.01-1.00, Off

SP3.18

P/F Lag Alarm Delay

1.0 sec

1-120 sec

P/F Lag P/F Trip

Off

.01-1.00, Off

SP3.19

P/F Lag Trip Delay

1.0 sec

1-120 sec

Power Demand Period

10 min

1 - 60 min

SP3.20

KW Demand Alarm Pickup

Off KW

Off, 1-100000

KVA Demand Alarm Pickup

Off KVA

Off, 1-100000

KVAR Demand Alarm Pickup

Off KVAR

Off, 1-100000

Amps Demand Alarm Pickup

Off Amps

Off, 1-100000

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5.1.3 Phase and Ground Settings (Setpoint Page 3)

* Ground fault option must be installed

Motortronics Inc. Page 30

Setpoint

Page

Security

Level

Description

Factory Setting

Range

Section

1st

2nd

3rd

Page 4

Relay Assignments

Level 2

Password Protected

O/L Trip

Trip Only

None

None

None
Trip(AUX1) / Trip Only
Alarm(AUX2)
AUX3
AUX4
AUX5 - 8
Only Available in 8 Relay
System

Notes:
AUX1 to AUX4 are for
Factory
Use only. Do not change!
Only AUX 5 - 8 are used in
the 2nd & 3rd relay
assignments.

SP4.1

I/B Trip

Trip

None

None

S/C Trip

Trip Only

None

None

Overcurrent Trip

Trip

None

None

Stator RTD Trip

None

None

None

Non Stator RTD Trip

None

None

None

*G/F Hi Set Trip

Trip

None

None

*G/F Lo Set Trip

Trip

None

None

Phase Loss Trip

Trip

None

None

Accel. Time Trip

Trip Only

None

None

Start Curve Trip

Trip Only

None

None

Over Frequency Trip

None

None

None

Under Frequency Trip

Trip

None

None

I*I*T Start Curve

Trip

None

None

Learned Start Curve

Trip

None

None

Phase Reversal

Trip

None

None

Overvoltage Trip

Trip

None

None

Undervoltage Trip

Trip

None

None

Power Factor Trip

None

None

None

Tach Accel Trip

None

None

None

Inhibits Trip

Trip

None

None

Shunt Trip

None

None

None

Bypass Discrepancy

Trip Only

None

None

Low Control Voltage

Trip Only

None

None

TCB Fault

Trip

None

None

External Input #2

None

None

None

Dual Ramp

None

None

None

Thermostat

Trip

None

None

O/L Warning

Alarm

None

None

Overcurrent Alarm

Alarm

None

None

SCR Fail Shunt Alarm

None

None

None

*Ground Fault Alarm

Alarm

None

None

Under Current Alarm

None

None

None

Motor Running

AUX3

None

None

I/B Alarm

Alarm

None

None

Stator RTD Alarm

None

None

None

Non-Stator RTD Alarm

None

None

None

RTD Failure Alarm

None

None

None

Self Test Fail

Trip

None

None

Thermal Register

Alarm

None

None

U/V Alarm

Alarm

None

None

O/V Alarm

Alarm

None

None

Power Factor Alarm

None

None

None

KW Demand Alarm

None

None

None

KVA Demand Alarm

None

None

None

KVAR Demand Alarm

None

None

None

Amps Demand Alarm

None

None

None

Timed Output

None

None

None

Run Delay Time

None

None

None

At Speed

AUX4

None

None

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5.1.4 Relay Assignments (Setpoint Page 4)

* Ground fault option must be installed

Motortronics Inc. Page 31

Setpoint

Page

Security

Level

Description

Factory Setting

Default

Range

Section

Page 5

Relay Configuration

Level 2

Password Protected

Trip (AUX1) Fail-Safe

No

Yes or No

SP5.1

Trip (AUX1) Relay Latched

Yes

SP5.2

Alarm (AUX2) Fail-Safe

No

SP5.1

Alarm (AUX2) Relay Latched

No

SP5.2

AUX3 Relay Fail-Safe

No

SP5.1

AUX3 Relay Latched

No

SP5.2

AUX4 Relay Fail-Safe

No

SP5.1

AUX4 Relay Latched

No

SP5.2

AUX5 Relay Fail-Safe

No

SP5.1

AUX5 Relay Latched

No

SP5.2

AUX6 Relay Fail-Safe

No

SP5.1

AUX6 Relay Latched

No

SP5.2

AUX7 Relay Fail-Safe

No

SP5.1

AUX7 Relay Latched

No

SP5.2

AUX8 Relay Fail-Safe

No

SP5.1

AUX8 Relay Latched

No

SP5.2

Setpoint

Page

Security

Level

Description

Factory Setting

Default

Range

Section

Page 6

User I/O Configuration

Level 2

Password Protected

Tachometer Scale Selection

Disabled

Enabled or Disabled

SP6.1

Manual Tach Scale 4.0 mA:

0 RPM

0 - 3600

Manual Tach Scale 20.0 mA:

2000 RPM

0 - 3600

Tach Accel Trip Mode Select

Disabled

Underspeed, Overspeed or Disabled

SP6.2

Tach Ramp Time

20 sec

1 - 120

Tach Underspeed Trip PT

1650 RPM

0 - 3600

Tach Overspeed Trip PT

1850 RPM

0 - 3600

Tach Accel Trip Delay

1 sec

1 - 60

Analog Output #1

RMS Current

Off, RPM 0-3600, Hottest Non-Stator RTD
0-200°C, Hottest Stator RTD
0 - 200°C, RMS Current 0 - 7500 A, %
Motor Load 0 - 600% Kw

SP6.3

Analog Output #1 4mA:

0

0-65535

Analog Output #1 20mA:

250

0-65535

Analog Output #2

% Motor Load

Same As Analog Input #1

SP6.4

Analog Output #2 4mA:

0

0-65535

Analog Output #2 20mA:

1000

0-65535

User Programmable External
Inputs

SP6.5

TCB Fault

Enabled

User Defined, up to 15 Characters

Name Ext. Input #1

TCB Fault

Normally Open or Closed

TCB Fault Type

NO

0-60 sec

TCB Fault Time Delay

1 sec

Enabled or Disabled

External Input #2

Disabled

User Defined, up to 15 Characters

Name Ext. Input #2

NO

Normally Open or Closed

External Input #2 Type

0 sec

0-60 sec

External Input #2 Time Delay

Dual Ramp

Enabled or Disabled or Dual Ramp

Dual Ramp

Dual Ramp

User Defined, up to 15 Characters

Name Ext. Input #3

NO

Normally Open or Closed

Dual Ramp Type

0 sec

0-60 sec

Dual Ramp Time Delay

Enabled

Enabled or Disabled

Thermostat

Thermostat

User Defined, up to 15 Characters

Name Ext. Input #4

NC

Normally Open or Closed

Thermostat Type

1 sec

0-60 sec

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5.1.5 Relay Configuration (Setpoint Page 5)

5.1.6 User I/O Configuration (Setpoint Page 6)

Motortronics Inc. Page 32

Setpoint

Page

Security

Level

Description

Factory Setting

Default

Range

Section

Page 7

Custom Acceleration Curve

Level 3

Password Protected

Custom Accel Curve

Disabled

Disabled, Curve A, B, or C

SP7.1

Custom Curve A

Curve A Voltage Level 1

25%

0-100%

Curve A Ramp Time 1

2 sec

1-60 sec

Curve A Voltage Level 2

30%

0-100%

Curve A Ramp Time 2

2 sec

1-60 sec

Curve A Voltage Level 3

37%

0-100%

Curve A Ramp Time 3

2 sec

1-60 sec

Curve A Voltage Level 4

45%

0-100%

Curve A Ramp Time 4

2 sec

1-60 sec

Curve A Voltage Level 5

55%

0-100%

Curve A Ramp Time 5

2 sec

1-60 sec

Curve A Voltage Level 6

67%

0-100%

Curve A Ramp Time 6

2 sec

1-60 sec

Curve A Voltage Level 7

82%

0-100%

Curve A Ramp Time 7

2 sec

1-60 sec

Curve A Voltage Level 8

100%

0-100%

Curve A Ramp Time 8

2 sec

1-60 sec

Curve A Current Limit

350% FLA

200-500%

Custom Curve B

Same Programmable Data Points and
Ranges as Custom Curve A

Custom Curve C

Same Programmable Data Points and
Ranges as Custom Curve A

Setpoint

Page

Security

Level

Description

Factory Setting

Default

Range

Section

Page 8

Overload Curve Configuration

Level 3

Password Protected

Basic Run Overload Curve

SP8.1

Run Curve Locked Rotor Time

O/L Class

1-30 sec, O/L Class

Run Locked Rotor Current

600% FLA

400-800%

Coast Down Timer

Disabled

1-60 Min, Disabled

Basic Start Overload Curve

SP8.2

Start Curve Locked Rotor Time

O/L Class

1-30 sec, O/L Class

Start Locked Rotor Current

600% FLA

400-800%

Acceleration Time Limit

30 sec

1-300 sec, Disabled

Number of Starts Per Hour

Disabled

1-6, Disabled

Time Between Starts Time

5 min

1-60 Min, Disabled

Area Under Curve Protection

Disabled

Enabled or Disabled

SP8.3

Max I*I*T Start

368 FLA

1-2500 FLA*FLA*sec

Current Over Curve

Disabled

Disabled, Learn, Enabled

SP8.4

Learned Start Curve Bias

10%

5-40%

Time for Sampling

30 sec

1-300 sec

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5.1.7 Custom Acceleration Curve (Setpoint Page 7)

5.1.8 Overload Curve Configuration (Setpoint Page 8)

Motortronics Inc. Page 33

Setpoint

Page

Security

Level

Description

Factory Setting

Default

Range

Section

Page 9

RTD Configuration

Level 3

Password Protected

Use NEMA Temp for RTD Values

Disabled

Enabled or Disabled

SP9.1

# of RTD Used for Stator

4

0-6

SP9.2

RTD Voting

Disabled

Enabled or Disabled

SP9.3

Stator Phase A1 Type

Off

120 OHM NI, 100 OHM NI, 100 OHM PT,
10 OHM CU

SP9.4

RTD #1 Description

Stator A1

User defined, Up to 15 Characters

Stator Phase A1 Alarm Level

Off

0-240C (32-464F), Off

Stator Phase A1 Trip Level

Off

0-240C (32-464F), Off

Stator Phase A2 Type

Off

Same as Stator Phase A1

RTD #2 Description

Stator A2

User defined, Up to 15 Characters

Stator Phase A2 Alarm

Off

0-240C (32-464F), Off

Stator Phase A2 Trip Level

Off

0-240C (32-464F), Off

Stator Phase B1 Type

Off

Same as Stator Phase A1

RTD #3 Description

Stator B1

User defined, Up to 15 Characters

Stator Phase B1 Alarm Level

Off

0-240C (32-464F), Off

Stator Phase B1 Trip Level

Off

0-240C (32-464F), Off

Stator Phase B2 Type

Off

Same as Stator Phase A1

RTD #4 Description

Stator B2

User defined, Up to 15 Characters

Stator Phase B2 Alarm Level

Off

0-240C (32-464F), Off

Stator Phase B2 Trip Level

Off

0-240C (32-464F), Off

Stator Phase C1 Type

Off

Same as Stator Phase A1

RTD #5 Description

Stator C1

User defined, Up to 15 Characters

Stator Phase C1 Alarm Level

Off

0-240C (32-464F), Off

Stator Phase C1 Trip Level

Off

0-240C (32-464F), Off

Stator Phase C2 Type

Off

Same as Stator Phase A1

RTD #6 Description

Stator C2

User defined, Up to 15 Characters

Stator Phase C2 Alarm Level

Off

0-240C (32-464F), Off

Stator Phase C2 Trip Level

Off

0-240C (32-464F), Off

End Bearing Type

Off

Same as Stator A1

RTD #7 Description

End Bearing

User defined, Up to 15 Characters

End Bearing Alarm Level

Off

0-240C (32-464F), Off

End Bearing Trip Level

Off

0-240C (32-464F), Off

Shaft Bearing Type

Off

Same as Stator Phase A1

RTD #8 Description

Shaft Bearing

User defined, Up to 15 Characters

Shaft Bearing Alarm Level

Off

0-240C (32-464F), Off

Shaft Bearing Trip Level

Off

0-240C (32-464F), Off

RTD #9 Type

Off

Same as Stator Phase A1

RTD #9 Description

User defined

User defined, Up to 15 Characters

RTD #9 Alarm Level

Off

0-240C (32-464F), Off

RTD #9 Trip Level

Off

0-240C (32-464F), Off

RTD #10 Type

Off

Same as Stator Phase A1

RTD #10 Description

User defined

User defined, Up to 15 Characters

RTD #10 Alarm Level

Off

0-240C (32-464F), Off

RTD #10 Trip Level

Off

0-240C (32-464F), Off

RTD #11 Type

Off

Same as Stator Phase A1

RTD #11 Description

User defined

User defined, Up to 15 Characters

RTD #11 Alarm Level

Off

0-240C (32-464F), Off

RTD #11 Trip Level

Off

0-240C (32-464F), Off

RTD #12 Type

Off

Same as Stator Phase A1

RTD #12 Description

User defined

User defined, Up to 15 Characters

RTD #12 Alarm Level

Off

0-240C (32-464F), Off

RTD #12 Trip Level

Off

0-240C (32-464F), Off

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5.1.9 RTD Option Configuration (Setpoint Page 9)

Motortronics Inc. Page 34

Setpoint
Page

Security
Level

Description

Factory Setting
Default

Range

Section

Page 10
Password

Level 3
Password

Set Level 2 Password

100

000 – 999 Three Digits

SP10.1

Set Level 3 Password

1000

0000 – 9999 Four Digits

SP10.2

Setpoint
Page

Security
Level

Description

Factory Setting
Default

Range

Section

Page 11
Communi­cations

Level 3
Password

Set Front Baud Rate

9.6 KB/sec

2.4, 4.8, 9.6, 19.2, 38.4 KB/sec

SP11.1

Set Modbus Baud Rate

9.6 KB/sec

2.4, 4.8, 9.6, 19.2, 38.4 KB/sec

SP11.2

Modbus Address Number

247

1 – 247

SP11.3

Set Access Code

1

1 – 999

SP11.4

Set Link Baud Rate

38.4 KB/sec

2.4, 4.8, 9.6, 19.2, 38.4 KB/sec

SP11.5

Remote Start/Stop

Disabled

Enabled or Disabled

SP11.6

Setpoint
Page

Security
Level

Description

Factory Setting
Default

Range

Section

Page 12

System Setpoints

Level 3

Password Protected

Default Display Screen

SP12.1

Metering Data Page #

1

Enter Metering Page (1-4)

Metering Data Screen #
1

Enter Metering Screen
Page 1(1-10)
Page 2 (1-11)
Page 3 (1 - 29)
Page 4 (1 - 6)

Alarms

SP12.2

RTD Failure Alarm

Disabled

Enabled or Disabled

Thermal Register Alarm

90%

Off, 40-95%

Thermal Alarm Delay

10 sec

1-20 sec

Thermal Register Setup Info

SP12.3

Cold Stall Time

O/L Class

O/L Class (5-30) or 4-40 second time
delay

Hot Stall Time

½ O/L Class

½ O/L Class, 4-40 sec

Stopped Cool Down Time

30 Min

10-300 Min

Runing Cool Down Time

15 Min

10-300 Min

Relay Measured Cool Rates

Disabled

Enabled or Disabled

Thermal Register Minimum

15%

10-50%

Motor Design Ambient Temp

40C

10-90C

Motor Design Run Temperature

80% Max

50-100% of Motor Stator Max Temp

Motor Stator Max Temp

INS CLS

INS CLS, 10-240 C

I/B Input to Thermal Register

Enabled

Enabled or Disabled

Use Calculated K or Assign

7

1-50, On

Press Enter to Clr Thermal
Register

SP12.4

Setpoint

Page

Security

Level

Description

Factory Setting

Default

Range

Section

Page 13

Calibration & Service

Factory Use Only

Set Date and Time
(DDMMYY:HHMM)

FACTORY SET;
## / ## / ## ## : ##

SP13.1

Enter Date (DDMMYYYY)

FACTORY SET;
## / ## / ####

D=1-31, M=1-12, Y=1970-2069

Enter Time (HH:MM)

FACTORY SET;
## :##

H=00-23, M=0-59

Model #
Firmware REV. #

FACTORY SET;
###### ######

Display Only, Cannot be changed

SP13.2

Press Enter to Access Factory
Settings

Available to Qualified Factory Personnel

SP13.3

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5.1.10 Password Level Configuration (Setpoint Page10)

5.1.11 Communications Configuration (Setpoint Page11)

5.1.12 System (Setpoint Page 12)

5.1.13 Calibration and Service (Setpoint Page 13)

Motortronics Inc. Page 35

Page 1

Basic Configuration

MOTOR FULL LOAD AMPS
: 200AMPS

SERVICE FACTOR
: 1.15 X FLA

OVERLOAD
CLASS: 10

NEMA
DESIGN: B

INSULATION
BLASS: B

LINE VOLTAGE
INPUT: 4160 VOLTS*

LINE FREQUENCY
HZ: 60

MENU

Range: 1.00 - 1.3

Increments of 0.01

Range: 5 - 30

Increments of 5

Range: A - F

Range: A - S

Range: 100 – 20,000

* Model dependent

Range: 50 or 60

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5.2 Setpoints Menu and Parameter Explanation (SP1 – SP13)

SP.1 Basic Configuration (Setpoint Page 1)

In Setpoint Page 1, is used to setup basic nameplate data of the motor.

SP1.1 Motor Full Load Amps (FLA): Allows the user to enter the motor’s FLA rating. Range of adjustment is 50 - 100%
(less programmed service factor).

SP1.2 Service Factor: Sets the pickup point on the overload curve as defined by the programmed motor full load current.
Ex: If the motor FLA is 100 and the service factor is 1.15, the overload pickup point will be 115 Amps.

Motortronics Inc. Page 36

0 1 2 3 4 5 6 7 8 9
M FLA

1x10

1000

100

10

1

4

Overload Class 30
Overload Class 25
Overload Class 20

Overload Class 15

Overload Class 10

Overload Class 5

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SP1.3 Overload Class: Choose the motor protection overload class, range from 5-30. Ex: Overload Class 10 will trip in
10 seconds at six times.

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

SP1.5 Insulation Class: The motor insulation temperature class (Select A, B, C, E, F, G, H, K, N or S).

SP1.6 Line Voltage Input: Applied Voltage.

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

Motortronics Inc. Page 37

Page 2

Starter Configuration

START CONTROL MODE
: START RAMP 1

JOG VOLTAGE
: 50%

START RAMP #1 TYPE
: VOLTAGE

START RAMP #2
: DISABLED

MENU

Range: 5-75% or

Off Increments of 5

Options: Voltage,
Current, or Off

Options: Voltage,
Power, or Off

INITIAL VOLTAGE
#1: 20%

RAMP TIME
#1: 10 SEC.

CURRENT LIMIT
#1: 350% FLA

Range: 0-100%

Increments of 1

Range: 1-120 SEC.
Increments of 1

Range: 200-500%.
Increments of 10

INITIAL VOLTAGE
#2: 60%

RAMP TIME
#2: 10 SEC.

CURRENT LIMIT
#2: 350% FLA

Range: 0-100%

Increments of 1

Range: 1-120 SEC.
Increments of 1

Range: 200-500%.
Increments of 10

INITIAL CURRENT
#1: 200% FLA

RAMP TIME
#1: 10 SEC.

MAXIMUM CURRENT
#1: 350% FLA

Range: 0-300%

Increments of 1

Range: 1-120 SEC.
Increments of 1

Range: 200-500%.
Increments of 10

INITIAL POWER
#2: 20%

RAMP TIME
#2: 10 SEC.

MAXIMUM POWER
#2: 80% FLA

Range: 0-100%

Increments of 1

Range: 1-120 SEC.
Increments of 1

Range: 0-300%.
Increments of 10

KICK START
TYPE: DISABLED

DECELERATION
: DISABLED

TIMED OUTPUT
TIME: OFF

Range: Voltage or

Disabled

Range: Enabled or
Disabled

Range: 1-1000 SEC..
Increments of 10

RUN DELAY
TIME: 1 SEC.

AT SPEED DELAY
TIME: 1 SEC.

BYPASS PULL-IN
CURRENT: 100% FLA

Range: 0-30 SEC., Off

Increments of 1

Range: 0-30 SEC. ,Off
Increments of 1

Range: 90-300%.
Increments of 1

KICK START VOLTAGE
: 55%

KICK START TIME
: 0.50 SEC.

START DECEL VOLTAGE
: 60%

Range: 10-100%

Increments of 5

Range: 0.10-2.00 SEC.
Increments of 0.10

Range: 0-100%
Increments of 1

DECELERATION
TIME: 5 SEC.

Range: 0-59%

Increments of 1

Range: 1-60 SEC.
Increments of 1

STOP DECELERATION
VOLTAGE: 30%

If Power is selected these
screens will appear

If Current is selected these
screens will appear

If Voltage is selected these
screens will appear

or

or

OPTIONS: Jog, Start Ramp 1,
Start Ramp 2, Dual Ramp, Custom
Accel Curve, Start Disabled

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SP.2 Starter Configuration (Setpoint Page 2)

Provides multiple choices for starting ramps that can be selected for particular loads and applications.

Motortronics Inc. Page 38

Ramp 1 = Voltage

New Start

Command

Voltage

Jog Button

Held

Jog Voltage

Setting

Start Control Mode

Setpoint changed from Jog to

Start Ramp #1 Type: Voltage

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SP2 Starter Configuration (Setpoint Page 2) Menu Navigation

SP2.1 Start Control Mode: Dual Ramp, Custom Accel Curve, Jog Voltage, Start Ramp 1, Start Ramp 2.

• Dual Ramp: The dual ramp mode works in conjunction with External Input #3. This allows the user to switch between

the two start ramps without having to reconfigure the start mode. (For details on configuring External Input #3 for DUAL
RAMP see Setpoint Page 6.)

• Custom Accel Curve: Allows the user to custom design the acceleration start curve to the application. (See Setpoint

page 7 for configuration setup.)

Note: If Custom Accel Curve has not been enabled in Setpoint page 7, the soft starter will ignore the start control mode
and read this Setpoint as disabled.

SP2.2 Jog Voltage: The voltage level necessary to cause the motor to slowly rotate.

SP2.3 Start Ramp 1 Type: The ramp type can be setup for either Voltage or Current. If Voltage is selected, initial voltage,

ramp time and current limit are adjustable. If Current is selected, initial current, ramp time and maximum current are
adjustable.

Start Ramp 1 Type: Voltage

• Voltage Ramping is the most reliable starting method, because the starter will eventually reach an output voltage high

enough to draw full current and develop full torque. This method is useful for applications where the load conditions
change frequently and where different levels of torque are required. Typical applications include material handling
conveyors, positive displacement pumps and drum mixers. Voltage is increased from a starting point, (Initial Torque) to
full voltage over an adjustable period of time (Ramp Time). To achieve Voltage Ramping, select VOLTAGE for the START
RAMP #1 TYPE Setpoint and set CURRENT LIMIT #1 Setpoint to 500% (The maximum setting). Since this is essentially
Locked Rotor Current on most motors, there is little or no Current Limit effect on the Ramp profile.

FIG. SP2.3 Example of Switching from Jog to Start Ramp #1 Type: Voltage

• Voltage Ramping with Current Limit is the most used curve and is similar to voltage ramping however, it adds an

adjustable maximum current output. Voltage is increased gradually until the setting of the Maximum Current Limit Setpoint
is reached. The output is held at this level until the motor accelerates to full speed. This may be necessary in applications
where the electrical power is limited. Typical applications include portable or emergency generator supplies, utility power
near the end of a transmission line and utility starting power demand restrictions.

Note: Using Current Limit will override the Ramp Time setting if necessary, so use this feature when acceleration time is
not critical.

To set Voltage Ramping with Current Limit, select VOLTAGE for the START RAMP #1 Setpoint and set CURRENT LIMIT

#1 Setpoint to a desired lower setting, as determined by your application requirements.

Motortronics Inc. Page 39

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Start Ramp 1 Type: Current

• Current Ramping (Closed Loop Torque Ramping)

This method is used for smooth linear increase of output torque. This ramp is only used on some conveyor systems (long
haul or down hill). For other applications, use Voltage Ramp or a custom Accel curve. Output voltage is constantly
updated to provide the linear current ramp, and therefore the available torque is maximized at any given speed. This is for
applications where rapid changes in torque may result in load damage or equipment changes. Typical applications include
overland conveyors if belt stretching occurs; fans and mixers if blade warping is a problem; and material handling systems
if stacked products fall over or break.

This feature can be used with or without the Maximum Current Limit setting. To achieve Current Ramping select
CURRENT for START RAMP #1 TYPE Setpoint and set the MAXIMUM CURRENT #1 Setpoint to the desired level.

• Current Limit Only (Current Step) uses the Current Limit feature exclusively.

This method of starting eliminates the Soft Start voltage/current ramp and instead, maximizes the effective application of
motor torque within the limits of the motor. In this mode, Setpoint RAMP TIME #1 is set to minimum so that the output
current jumps to the current limit setting immediately. Typically used with a limited power supply when starting a difficult
load such as a centrifuge or a deep well pump, when the motor capacity is barely adequate (stall condition or overloading
occurs) or if other starting modes fail. Since ramp times are set to minimum, START RAMP #1 TYPE is set to either
VOLTAGE or CURRENT.

• Initial Torque (Initial Voltage #1 or Initial Current #1)

Sets the initial start point of either Voltage Ramp or the Current Ramp. Every load requires some amount of torque to start
from a standstill. It is inefficient to begin ramping the motor from zero every time, since between zero and the WK2 break­away torque level, no work is being performed. The initial torque level should be set to provide enough torque to start
rotating the motor shaft, enabling a Soft Start and preventing torque shock damage. Setting this start point too high will
not damage the starter, but may reduce or eliminate the soft start effect.

• Ramp Time #1

Sets the maximum allowable time for ramping the initial voltage, current (torque) or power setting to either of the following:

 The Current Limit setting when the motor is still accelerating.
 Full output voltage if the Current Limit is set to maximum.
 kW if Power Ramp is selected.

Increasing the ramp time softens the start process by gradually increasing the voltage, current or power. Ideally, the ramp
time should be set for the longest amount of time the application will allow (without stalling the motor). Some applications
require a short ramp time due to the mechanics of the system. (i.e. centrifugal pumps, because pump problems can occur
due to insufficient torque).

• Current Limit

Sets the maximum motor current the starter will allow during the acceleration. As the motor begins to ramp, the Current
Limit feature sets a maximum at which the current draw is held. Current Limit remains in effect until the following occurs:

1) The motor reaches full speed (Detected by the At-Speed detection circuit) or;

2) The Overload Protection trips on Motor Thermal Overload. Once the motor reaches full speed, the Current Limit feature

becomes inactive. In the Voltage Ramp Profile, the voltage output is increased until it reaches the Current Limit. Ramp
time is the maximum amount of time it takes for the voltage to increase until the Current Limit setting takes over. The
Current Ramp profile varies the output voltage to provide a linear increase in current up to the Maximum Current Setpoint
value. A closed loop feedback of motor current maintains the Current Ramp profile

Motortronics Inc. Page 40

t

Initial Power

Maximum Power

Power Ramp

It is recommended to use the power ramp on a
loaded motor! Using the power ramp on an
unloaded motor may result is shorter than
anticipated acceleration times.

!

CAUTION

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SP2.4 Start Ramp 2 Type: Please refer to Ramp 1 settings for Ramp 2 Type: Voltage selection.

Start Ramp 2: Power

The Power Ramp feature has three programmable set points, Initial Power, Ramp Time and Maximum Power.

 The Initial Power set point allows the user to define an initial KW

(motor power) value that will be applied to the motor when the start
sequence is begun. It has a range of 0-100% and a default value of
20%.

 The Ramp Time set point functions as all other ramp time set points

and allows the user to define a time period during which the applied KW (motor power) will be increased linearly to the
Maximum Power value set point. The adjustment range is 1 to 120 seconds. Once the Power Limit value is reached,
the system enters a constant power mode that regulates the applied motor power until the motor reaches full speed.

 The Maximum Power set point has an adjustment range of 0-300% and a default value of 80%.

Power Ramp Calculations: The basic motor power value is derived from the line voltage and motor FLA, using a

unity power factor as a default. This allows for approximation of the motor power rating without any other input data.
During the Power Ramp process, the RMS line voltage, RMS motor current and power factor are measured on a cycle by
cycle basis and applied to the Power Ramp algorithm. The CPU then calculates the True RMS motor power and will
control the SCR firing to deliver the programmed power ramp values to the motor.

FIG. SP2.4

 Initial Power: The Initial power set point allows the user to define an initial KW (motor power) value that will be

applied to the motor at the beginning of the start sequence.

 Ramp Time #2: See Ramp Time #1 for description

 Maximum Power: Sets the maximum motor power the starter will allow during the acceleration. As the motor begins

to ramp, the “Maximum Power” sets a limit.

SP2.5 Kick Start: Used as an initial energy burst in applications with high friction loads.

 Kick Start Voltage: The initial voltage (as a percent of full voltage value) that is needed to start the motor. (i.e.

Breakaway or Initial Torque.)

 Kick Start Time: The time the initial torque boost is applied.

Motortronics Inc. Page 41

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SP2.6 Deceleration: Allows the motor to gradually come to a soft stop.

 Start Deceleration Voltage: Upon receiving a STOP command the output voltage initially drops to this voltage.

(Represented as a percent of voltage value.)

 Stop Deceleration Voltage: The drop-off point of the deceleration ramp. (Percent of voltage value.) The point at

which the unit output drops to zero to end the deceleration.

 Deceleration Time: The time to get to the stop Deceleration Voltage Set point value.

SP2.7 Timed Output: Used with an AUX (5-8) relay. When enabled, and upon a start command, it waits until the

programmed time plus the run delayed time has expired. The relay energizes and remains so until a stop command is
received. It de-energizes upon receiving a stop command.

SP2.8 Run Delay Time: Can be used with an AUX (5-8) relay. The delay timer begins upon receipt of the start command.
The relay will then drop out when the time has expired.

SP2.9 At Speed Delay Time: Used with the AUX 4 relay, it energizes when the motor reaches At Speed and the
programmed delay time has expired. The relay remains energized until a stop command has been received.

Motortronics Inc. Page 42

Overcurrent Trip

Setting 250% FLA

Current

Time

Current Level

Running

Under a

Normal Load

Load
Jamb

Trip Delay Time

Trip

Page 2

Phase & Ground Settings

IMBALANCE ALARM
LEVEL: 15% FLA

IMBALANCE TRIP
LEVEL: 20%FLA

UNDERCURRENT
ALARM LEVEL: OFF

Range: 5-30%, Off

Increments of 1

Range: 10-90%, Off.
Increments of 1

OVERCURRENT ALARM
LEVEL: OFF

OVERCURRENT TRIP
LEVEL: OFF

PHASE LOSS TRIP :
ENABLED

Range: 100-300%, Off

Increments of 1

Options: Enabled or
Disabled

IMBALANCE ALARM
DELAY: 1.5 SEC.

IMBALANCE TRIP
DELAY: 2.0 SEC.

UNDERCURRENT
ALARM DELAY: 2.0 SEC.

OVERCURRENT ALARM
DELAY: 2.0 SEC.

OVERCURRENT TRIP
DELAY: 2.0 SEC.

PHASE LOSS TRIP
DELAY: 0.1 SEC.

PHASE ROTATION
DETECTION: ABC

GROUND FAULT ALARM
LEVEL: OFF

GROUND FAULT LOSET
TRIP LEVEL: OFF

Range: ABC, ACB

or Disabled

Range: 5-90%,Off
Increments of 1

GROUND FAULT HISET
TRIP LEVEL: OFF

OVERVOLTAGE ALARM
LEVEL: OFF

Range: 5-30%, Off

Increments of 1

Range: 100-300%, Off
Increments of 1

Range: 5-90%,Off
Increments of 1

Range: 5-90%,Off
Increments of 1

Range: 5-30%,Off
Increments of 1

OVERVOLTAGE TRIP
LEVEL: 10%

Range: 5-30%,Off

Increments of 1

Range: 1.0-20.0 SEC.
Increments of 0.1

Range: 1.0-20.0 SEC.
Increments of 0.1

Range: 1.0-60.0 SEC.
Increments of 0.1

Range: 1.0-20.0 SEC, Off.
Increments of 0.1

Range: 1.0-20.0 SEC.
Increments of 0.1

Range: 1.0-20.0 SEC.
Increments of 0.1

PHASE ROTATION TRIP
DELAY: 1.0 SEC

GROUND FAULT ALARM
DELAY: 0.1 SEC.

GROUND FAULT LOSET
TRIP DELAY: 0.5 SEC

GROUND FAULT HISET
TRIP DELAY: 0.008 SEC.

OVERVOLTAGE ALARM
DELAY: 1.0 SEC

OVERVOLTAGE TRIP
DELAY: 2.0 SEC.

Range: 1.0-20.0 SEC.

Increments of 0.1

Range: 1.0-20.0 SEC.
Increments of 0.1

Range: 1.0-20.0 SEC.
Increments of 0.1

Range: 0.008-0.250 SEC.
Increments of 0.002

Range: 1.0-30.0 SEC.
Increments of 0.1

Range: 1.0-20.0 SEC.
Increments of 0.1

Continued (Next Page)

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SP.3 Phase & Ground Settings (Setpoint Page

3)

(Security Level 2)

SP3.1 Imbalance Alarm Level: This is an advance warning
of a phase imbalance problem. The problem may not be a
fault in the motor, but merely caused by imbalanced
voltages.

• Imbalance Alarm Delay: The amount of time the

imbalance condition must exist before an alarm occurs.

SP3.2 Imbalance Trip Level: This will trip the motor on
excessive phase imbalance. The trip level should be
programmed to a higher value than the alarm level.

• Imbalance Trip Delay: The amount of time the imbalance

condition must exist before a trip will occur.

SP3.3 Undercurrent Alarm Level: Typically used to warn of
possible load loss, a coupling break or other mechanical
problems.

• Undercurrent Alarm Delay: The amount of time the

undercurrent condition must exist before an alarm will occur.

SP3.4 Overcurrent Alarm Level: Typically used to indicate
when the motor is overloaded. This feature can be used to
either stop the feed to the equipment or warn operators of an
overload condition.

• Overcurrent Alarm Delay: The amount of time the

overcurrent condition must exist before an alarm will occur.

SP3.5 Overcurrent Trip Level: Typically used to indicate the
motor is severely overloaded and at which point a trip occurs.

• Overcurrent Trip Delay: The amount of time the

overcurrent condition must exist before a trip will occur.

Motortronics Inc. Page 43

FIG. SP3.5

UNDERVOLTAGE TRIP
LEVEL: 15%

LINE FREQUENCY TRIP
WINDOW: DISABLED

Range: 5-30%, Off

Increments of 1

Range: 0-6, Disabled
Increments of 1

POWER FACTOR LEAD
P/F ALARM: OFF

POWER FACTOR LEAD
P/F TRIP: OFF

POWER FACTOR LAG
P/F ALARM: OFF

Range: -.01-1.00, Off

Increments of .01

UNDERVOLTAGE ALARM
DELAY: 1.0 SEC.

UNDERVOLTAGE TRIP
DELAY: 2.0 SEC.

LINE FREQUENCY TRIP
DELAY: 1.0 SEC.

P/F LEAD ALARM
DELAY: 1 SEC.

P/F LEAD TRIP
DELAY: 1.0 SEC.

P/F LAG ALARM
DELAY: 1.0 SEC.

POWER FACTOR LAG
P/F TRIP: OFF

POWER DEMAND
PERIOD: 10 MINUTES

KW DEMAND ALARM
PICKUP: OFF KW

Range: ABC, ACB or

Disabled

Range: 1-60 Min.
Increments of 1

KVA DEMAND ALARM
PICKUP: OFF KVA

KVAR DEMAND ALARM
PICKUP: OFF KVAR

Range: 5-30%, Off

Increments of 1

Range: Off , 1-100000
Increments of 1

AMPS DEMAND ALARM
PICKUP: OFF AMPS

Range: 1.0-30.0 SEC.

Increments of 0.1

Range: 1.0-30.0 SEC.
Increments of 0.1

Range: 1.0-20.0 SEC.
Increments of 0.1

Range: 1-120 SEC.
Increments of 1

Continued (From Previous Page)

UNDERVOLTAGE ALARM
LEVEL: OFF

Range: -.01-1.00, Off

Increments of .01

Range: -.01-1.00, Off
Increments of .01

Range: 1-120 SEC.
Increments of 1

Range: 1-120 SEC.
Increments of 1

P/F LAG TRIP
DELAY: 1.0 SEC.

Range: 1-120 SEC.

Increments of 1

Range: Off , 1-100000
Increments of 1

Range: Off , 1-100000
Increments of 1

Range: Off , 1-100000
Increments of 1

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SP3.6 Phase Loss Trip: When enabled, the Soft
Starter will trip the motor off-line upon a loss of phase
power.

• Phase Loss Trip Delay: The amount of time the

phase loss condition must exist before a trip will occur.

SP3.7 Phase Rotation Detection: The soft starter is
continuously monitoring the phase rotation. Upon a
start command, a trip will occur if it detects a change
in the phase rotation.

• Phase Rotation: There are two possible phase

rotation options: ABC or ACB. This Setpoint monitors
the wiring to ensure that the phase rotation is correct.
To view the present phase rotation, go to Metering
Page1, screen number 4.

SP3.8 *Ground Fault Alarm: Typically used to warn
of low level ground current leakage

• Ground Fault Alarm Delay: The amount of time that

the ground fault condition must exist before an alarm
will occur.

SP3.9 *Ground Fault Loset Trip Level: Typically
used to trip the motor on a low level of ground current
leakage. This Setpoint is intended to detect high
impedance faults.

• Ground Fault Loset Trip Delay: The amount of time

that the ground fault condition must exist before a trip
will occur.

* Ground Fault Option must be installed

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

the motor (within milliseconds) upon detecting a high
level of ground current leakage. This Setpoint is
intended to detect low impedance faults.

• *Ground Fault Hiset Trip Delay: The amount of

time that the ground fault condition must exist before a
trip will occur.

SP3.11 Overvoltage Alarm Level: Typically used to
indicate when the line voltage is too high. This is an
alarm level.

• Overvoltage Alarm Delay: The amount of time that

the overvoltage condition must exist before an alarm
occurs.

Motortronics Inc. Page 44

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SP3.12 Overvoltage Trip Level: Typically used to indicate that the line voltage is too high and at which point a trip occurs

• Overvoltage Trip Delay: The amount of time that the overvoltage condition must exist before a trip will occur.

SP3.13 Undervoltage Alarm Level: Typically used to indicate when the line voltage is too low. This is an alarm level.

• Undervoltage Alarm Delay: The amount of time that the undervoltage condition must exist before an alarm occurs.

SP3.14 Undervoltage Trip Level: Typically used to indicate that the line voltage is too low at which point a trip occurs.

• Undervoltage Trip Delay: The amount of time that the undervoltage condition must exist before a trip occurs.

SP3.15 Line Frequency Trip Window: The acceptable amount of drift above or below the line frequency (Hz) before a

trip is generated.

• Line Frequency Trip Delay: The amount of time that the frequency drift condition must exist beyond the window

before a trip occurs.

SP3.16 Power Factor Lead Alarm: Typically used to indicate a leading power factor.

• Power Factor Lead Alarm Delay: The amount of time that the power factor lead condition must exist beyond the

window before an alarm occurs.

SP3.17 Power Factor Lead Trip: The acceptable amount of power factor lead before a trip is generated.

• Power Factor Lead Delay: The amount of time that the power factor lead condition must exist beyond the window

before a trip will occur.

SP3.18 Power Factor Lag Alarm: Typically used to indicate a lagging power factor.

• Power Factor Lag Alarm Delay: The amount of time that the power factor lagging condition must exist beyond the

window before an alarm occurs.

SP3.19 Power Factor Lag Trip: The acceptable mount of power factor lag before a trip is generated.

• Power Factor Lag Delay: The amount of time that the power factor lag condition must exist beyond the window

before a trip will occur.

SP3.20 Power Demand Period: The Soft Starter monitors the demand of the motor based on several parameters
(current, kW, kVAR, kVA). Monitoring the demand of the motor assist in the energy management program where
processes can be altered or scheduled to reduce overall demand. Demand is calculated by taking samples of the
output current, kW, kVAR and kVA over a period of time, then averaged and stored into memory.

Motortronics Inc. Page 45

Page 4

Relay Assignment

MENU

I/B TRIP
1ST: TRIP

S/C TRIP
1ST: TRIP ONLY

OVERCURRENT TRIP
1ST: TRIP

STATOR RTD TRIP
1ST: NONE

NON-STATOR RTD TRIP
1ST: NONE

G/F HI SET TRIP
1ST: TRIP

G/F LO SET TRIP
1ST: TRIP

PHASE LOSS TRIP
1ST: TRIP

ACCEL. TIME TRIP
1ST: TRIP ONLY

START CURVE TRIP
1ST: TRIP ONLY

OVER FREQUENCY TRIP
1ST: NONE

UNDER FREQUENCY TRIP
1ST: TRIP

I*I*T START CURVE
1ST: TRIP

O/L TRIP
1ST: TRIP ONLY

PHASE REVERSAL
1ST: TRIP

OVERVOLTAGE TRIP
1ST: TRIP

UNDERVOLTAGE TRIP
1ST: TRIP

POWER FACTOR TRIP
1ST: NONE

TACH ACCEL TRIP
1ST: NONE

INHIBITS TRIP
1ST: TRIP

SHUNT TRIP
1ST: NONE

BYPASS DISCREPANCY
1ST: NONE

TCB FAULT
1ST: TRIP

EXTERNAL INPUT #2
1ST: NONE

DUAL RAMP
1ST: NONE

THERMOSTAT
1ST: TRIP

O/L WARNING
1ST: ALARM

OVERCURRENT ALARM
1ST: ALARM

SCR FAIL SHUNT ALARM
1ST: NONE

MOTOR RUNNING
1ST: AUX3

I/B ALARM
1ST: ALARM

STATOR RTD ALARM
1ST: NONE

NON-STATOR RTD ALARM
1ST: NONE

RTD FAILURE ALARM
1ST: NONE

SELF-TEST FAIL
1ST: TRIP

THERMAL REGISTER
1ST: ALARM

U/V ALARM
1ST: ALARM

O/V ALARM
1ST: ALARM

POWER FACTOR ALARM
1ST: NONE

KW DEMAND ALARM
1ST: NONE

KVA DEMAND ALARM
1ST: NONE

KVAR DEMAND ALARM
1ST: NONE

AMPS DEMAND ALARM
1ST: NONE

LEARNED START CURVE
1ST: TRIP

GROUND FAULT ALARM
1ST: ALARM

UNDERCURRENT ALARM
1ST: NONE

TIMED OUTPUT
1ST: NONE

RUN DELAY TIME
1ST: NONE

AT SPEED
1ST: AUX4

Range: TRIP (AUX1),

ALARM (AUX2), AUX3,
AUX4

(DOWN ARROW 3
TIMES)

LOW CONTROL VOLTAGE
1ST: TRIP ONLY

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SP.4 Relay Assignment (Setpoint Page 4)

(Security Level 2)

Motortronics Inc. Page 46

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SP.4 Relay Assignment (Setpoint Page 4) – Continued

(Security Level 2)

All of the protective functions of the Soft Starter are user programmable to an output relay. The factory will ship with all
tripping functions assigned to TRIP (AUX1) relay, and all alarm functions to ALARM (AUX2) relay.

Note: AUX1 - 4 are Factory Set and should not be changed.
SP4.1 The following is a list of all the user programmable functions.

Note: The 1st Relay Assignments are factory defaults and should not be changed.

RELAY ASSIGNMENTS
FUNCTIONS 1st 2nd 3rd

OVERLOAD TRIP TRIP ONLY NONE NONE
IMBALANCE TRIP TRIP (AUX1) NONE NONE
SHORT CIRCUIT TRIP TRIP ONLY NONE NONE
OVERCURRENT TRIP TRIP (AUX1) NONE NONE
STATOR RTD TRIP NONE NONE NONE
NON-STATOR RTD TRIP NONE NONE NONE
GROUND FAULT HI SET TRIP* TRIP (AUX1) NONE NONE
GROUND FAULT LO SET TRIP* TRIP (AUX1) NONE NONE
PHASE LOSS TRIP TRIP (AUX1) NONE NONE
ACCEL TIME TRIP TRIP ONLY NONE NONE
START CURVE TRIP TRIP ONLY NONE NONE
OVER FREQUENCY TRIP NONE NONE NONE
UNDER FREQUENCY TRIP TRIP (AUX1) NONE NONE
I*I*T START CURVE TRIP (AUX1) NONE NONE
LEARNED START CURVE TRIP (AUX1) NONE NONE
PHASE REVERSAL TRIP (AUX1) NONE NONE
OVERVOLTAGE TRIP TRIP (AUX1) NONE NONE
UNDERVOLTAGE TRIP TRIP (AUX1) NONE NONE
POWER FACTOR TRIP NONE NONE NONE
TACH ACCEL TRIP NONE NONE NONE
INHIBITS TRIP ALARM (AUX2) NONE NONE
SHUNT TRIP NONE NONE NONE
BYPASS DISCREPANCY TRIP ONLY NONE NONE
LOW CONTROL VOLTAGE TRIP ONLY NONE NONE
TCB FAULT TRIP (AUX1) NONE NONE
EXTERNAL INPUT 2 NONE NONE NONE
DUAL RAMP NONE NONE NONE
THERMOSTAT TRIP (AUX1) NONE NONE
OVERLOAD WARNING ALARM (AUX2) NONE NONE
OVERCURRENT ALARM ALARM (AUX2) NONE NONE
SCR FAIL SHUNT ALARM ALARM (AUX2) NONE NONE
GROUND FAULT ALARM* ALARM (AUX2) NONE NONE
UNDERCURRENT ALARM NONE NONE NONE
MOTOR RUNNING AUX3 NONE NONE
IMBALANCE ALARM ALARM (AUX2) NONE NONE
STATOR RTD ALARM NONE NONE NONE
NON-STATOR RTD ALARM NONE NONE NONE
RTD FAILURE ALARM NONE NONE NONE
SELF TEST FAIL TRIP (AUX1) NONE NONE
THERMAL REGISTER ALARM (AUX2) NONE NONE
U/V ALARM ALARM (AUX2) NONE NONE
O/V ALARM ALARM (AUX2) NONE NONE
POWER FACTOR ALARM NONE NONE NONE
KW DEMAND ALARM NONE NONE NONE
KVA DEMAND ALARM NONE NONE NONE
KVAR DEMAND ALARM NONE NONE NONE
AMPS DEMAND ALARM NONE NONE NONE
TIMED OUTPUT NONE NONE NONE
RUN DELAY TIME NONE NONE NONE
AT SPEED AUX4 NONE NONE

*Ground fault option must be installed

Motortronics Inc. Page 47

TRIP (AUX1) RELAY
FAIL-SAFE: NO

AUX 3 RELAY
FAIL-SAFE: NO

AUX4 RELAY
FAIL-SAFE: NO

AUX5 RELAY
FAIL-SAFE: NO

AUX6 RELAY
FAIL-SAFE: NO

AUX7 RELAY
FAIL-SAFE: NO

AUX8 RELAY
FAIL-SAFE: NO

ALARM (AUX2) RELAY
FAIL-SAFE: NO

TRIP (AUX1) RELAY
LATCHED: YES

AUX3 RELAY
LATCHED: NO

AUX4 RELAY
LATCHED: NO

AUX5 RELAY
LATCHED: NO

AUX6 RELAY
LATCHED: NO

AUX7 RELAY
LATCHED: NO

AUX8 RELAY
LATCHED: NO

ALARM (AUX2) RELAY
LATCHED: NO

Page 5

Relay Configuration

MENU

Option: Yes or No

(DOWN ARROW 4 TIMES)

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SP.5 Relay Configuration (Setpoint Page 5)

(Security Level 2)

In Setpoint Page 5 the user can configure the four output relays as either fail-safe or non fail-safe and latching or non­latching.

SP5.1 When a relay has been configured for "Fail Safe" and power is applied to the unit the relay will energize and its
contacts will change state. The relay will then de-energize and its contacts revert back when an event occurs of if power is
removed.

NOTE: The relays in the soft starter will not prevent a start sequence unless they are wired in as interlocks. If power is
lost, the motor power is also lost. Do not change the programming for AUX 1-4. These are for factory use only. AUX 5-8
are user defined outputs.

SP5.2 A relay configured as non-latching will reset itself when the cause of the trip event is not continuous. The TRIP
(AUX1) relay should always be programmed for latching, because this trip should require a visual inspection of the motor
and starter before issuing a manual reset to release the relay after a trip has been stored.

Motortronics Inc. Page 48

TACHOMETER SCALE
SELECTION: DISABLED

ANALOG OUTPUT #1
:RMS CURRENT

TACH ACCEL TRIP MODE
SELECT: DISABLED

MANUAL TACH SCALE

4.0 mA: 0 RPM

TACH RAMP TIME
: 20 SEC

TACH UNDERSPEED TRIP
PT: 1650 RPM

TACH OVERSPEED TRIP
PT: 1850 RPM

TACH ACCEL TRIP
DELAY: 1 SEC

ANALOG OUTPUT #1
4ma: 0

ANALOG OUTPUT #1
4ma: 0 20mA: 250

MANUAL TACH SCALE

20.0 mA: 2000 RPM

Page 6

User I/O Configuration

MENU

Option: Enabled or

Disabled

(DOWN ARROW 5 TIMES)

Range: 0-3600RPM

Increments of 5

Range: 0-3600RPM
Increments of 5

ENABLED

Option: Underspeed,

Overspeed or Disabled

Range: 0-65535
Increments of 1

Range: 1-120 SEC.,Disabled
Increments of 1

Range: 0-3600RPM
Increments of 5

Range: 0-3600RPM
Increments of 5

Range: 1-60 SEC.
Increments of 1

Range: 0-65535
Increments of 1

Range:

Analog Output Range
RPM 0 - 3600
Hottest Bearing 0 - 200°C
Hottest Stator RTD 0 - 200°C
RMS Current 0 - 6500A
% Motor Load 0 - 1000%
KW 0-30000 KW
OFF
Increments of 1

ANALOG OUTPUT #2
:% MOTOR LOAD

ANALOG OUTPUT #2
4mA: 0

ANALOG OUTPUT #2
20mA: 1000

Range: 0-65535

Increments of 1

Range: 0-65535
Increments of 1

Range: See Analog Output#1
Increments of 1

USER PROGRAMMABLE
EXTERNAL INPUTS

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

(Security Level 2)

Motortronics Inc. Page 49

Continue on page 51

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

(Security Level 2)

The Soft Starter can be configured to accept a tachometer feedback signal using the 4-20mA input.

SP6.1 The first screen of Setpoint page 6 is TACHOMETER SCALE SELECTION. When this is set to ENABLED, the
user will need to input the tachometer scale of the 4-20mA input range.

 Manual Tach Scale 4.0 mA: The unit is looking for an RPM value to assign to the lowest point on the scale. This

Value should represent the motor at zero speed.

 Manual Tach Scale 20.0 mA: The unit is looking for an RPM value to assign to the highest point on the scale. This

value should represent the motor at full speed.

SP6.2 Tach Accel Trip Mode Select: When enabled, the underspeed or overspeed must be selected for the Tach Accel
Trip. If underspeed is selected, only the Tach Underspeed Trip Point will be used. If overspeed is selected, only the Tach
Overspeed Trip Point will be used.

 Tach Ramp Time: This is the duration of time before the starter begins sampling the tachometer.

 Tach Underspeed Trip: Defines the minimum motor speed using the Tach feedback. When the underspeed trip

mode is enabled and the motor speed falls below this level for the time specified by the Tach Accel Trip Delay an
underspeed trip occurs.

 Tach Overspeed Trip: Defines the maximum allowed motor speed using the Tach feedback. When the overspeed

trip mode is enabled and the motor speed exceeds this level for the time specified by the Tach Accel Trip Delay an
overspeed trip occurs.

 Tach Accel Trip Delay: The duration of time that the Tach Accel trip condition must persist before a trip is generated.

SP6.3 The controller provides two 4-20mA analog outputs. Each analog output is independent of the other and can be

assigned to monitor different functions. The available output ranges are; RPM, Hottest Non-Stator (Bearing) RTD, Hottest
Stator RTD, RMS current, and % Motor Load.

 Analog Output #1 – Select a function from the available five options to be transmitted from the 4-20mA output.

Note: If selecting RPM, the Tachometer feedback input signal must be present in order for the controller to give proper
output. If selecting RTD, the RTD option must be installed and an RTD input signal must be present for a proper output to
be given from the analog output.

 Analog Output #1 (4 mA): Enter a value that the 4mA level will represent for the selected function; typically this value

should be 0.

 Analog Output #1 (20 mA): Enter a value that the 20mA level will represent for the selected function.

SP6.4 Analog Output #2 – All of the Setpoints and setup screens for Analog Output #2 are the same as those for

Analog Output #1.

Motortronics Inc. Page 50

USER

PROGRAMM-

ABLE

EXTERNAL

INPUTS

TCB FAULT
SELECT: ENABLED

EXTERNAL INPUT #2
SELECT: DISABLED

DUAL RAMP
SELECT: DUAL RAMP

THERMOSTAT
SELECT: ENABLED

Options: Enabled or

Disabled

(Continued)

NAME EXT INPUT #2

NAME EXT INPUT #3
SECOND RAMP

See Text for
Instructions

NAME EXT INPUT #4
THERMOSTAT

TCB FAULT
TYPE: N.O.

EXTERNAL INPUT #2
TYPE: N.O.

DUAL RAMP
TYPE: N.O.

THERMOSTAT
TYPE: N.C.

NAME EXT. INPUT #1
TCB FAULT

Options: Enabled or

Disabled

Options: Enabled,
Disabled or Dual Ramp

Options: Enabled or
Disabled

See Text for
Instructions

See Text for
Instructions

See Text for
Instructions

Options: N.O. or N.C.

Options: N.O. or N.C.

Options: N.O. or N.C.

Options: N.O. or N.C.

TCB FAULT
TIME DELAY: 1 SEC.

EXTERNAL INPUT #2
TIME DELAY: 0 SEC.

DUAL RAMP
TIME DELAY: 0 SEC.

Range: 0 - 60 SEC

Increments of 1

Range: 0 - 60 SEC

Increments of 1

THERMOSTAT
TIME DELAY: 1 SEC.

Range: 0 - 60 SEC

Increments of 1

Range: 0 - 60 SEC

Increments of 1

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

(Security Level 2)

SP6.5 User Programmable External Inputs: The controller provides up to 4 digital external inputs which are individually
programmable. A description name can be assigned to each individual input for easy identification.

 External Input #1: Factory programmed for TCB Fault.

 External Input #2: If used, this Setpoint must be enabled.

 Name Ext. Input #2: The user can assign a description name to the input to easily identify the cause of external trip or

alarm. Up to 15 characters including spaces can be used to assign the name.

 External Input #2 Type: The external input can be set as either a normally open or normally closed contact.

 External Input #2 Time Delay: Upon a change in contact setting, the unit will wait the programmed amount of time

before generating an output. If no delay is needed, then input 0 seconds. The controller will post an event upon
seeing a change in state.

 External Input #3: The setup screens and Setpoints for External Input #3 includes the option of being configured for

Dual Ramp. In Dual Ramp mode, the initial contact setting is the same as the START RAMP #1. Upon a change in
input contact state, the controller will switch over to START RAMP #2 and use that setting for start control mode.

Note: The start RAMP types should only be switched while the motor is stopped. In Setpoint Page 4 Relay Assignments
do not assign any output relay to this function. The controller is programmed with External input #3 programmed for dual
ramp. If it is not needed, disable the dual ramp.

• External Input #4 – These input screens are for the thermostat input and can be enabled or disabled.

Note: It is recommended that this function remain enabled. If the thermostat indicates an over temperature condition, the
controller will trip the motor.

Motortronics Inc. Page 51

CURVE A RAMP
TIME 1: 2 SEC

CURVE A VOLTAGE
LEVEL 2: 30%

Range: 0 - 100%

Increments of 1

Range: 1 - 60 SEC
Increments of 1

CURVE A RAMP
TIME 2: 2 SEC.

CURVE A VOLTAGE
LEVEL 3: 37%

CURVE A RAMP
TIME 3: 2 SEC.

CUSTOM CURVE A

CURVE A VOLTAGE
LEVEL 4: 45%

CURVE A RAMP
TIME 4: 2 SEC.

CURVE A VOLTAGE
LEVEL 5: 55%

CURVE A RAMP
TIME 5: 2 SEC.

CURVE A VOLTAGE
LEVEL 6: 67%

CURVE A RAMP
TIME 6: 2 SEC.

CURVE A VOLTAGE
LEVEL 1: 25%

Range: 0 - 100%

Increments of 1

Range: 1 - 60 SEC
Increments of 1

Range: 0 - 100%
Increments of 1

Range: 1 - 60 SEC
Increments of 1

Range: 0 - 100%
Increments of 1

Range: 1 - 60 SEC
Increments of 1

Range: 0 - 100%
Increments of 1

Range: 1 - 60 SEC
Increments of 1

Range: 0 - 100%
Increments of 1

Range: 1 - 60 SEC
Increments of 1

CURVE A VOLTAGE
LEVEL 7: 82%

CURVE A RAMP
TIME 7: 2 SEC.

Range: 1 - 60 SEC

Increments of 1

Range: 0 - 100%
Increments of 1

(Continued on next page)

Page 7

Custom Acceleration Curve

MENU

CUSTOM ACCEL CURVE
: DISABLED

Range: DISABLED,

CURVE A, B or C

(DOWN
ARROW
six times)

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SP.7 Custom Acceleration Curve (Setpoint Page 7)

(Security Level 3)

SP7.1 Setpoint Page 7 allows the user to
custom design the acceleration curve (start
curve) for a specific application. The custom
design setup allows for up to three different
curves in the Soft Starter. Only one curve can
be active (enabled) at any given time. Each of
the three curves allow for eight voltage plotting
points, with corresponding ramp times and a
current limit setting.

Note: Each successive voltage level must be
programmed to a voltage level equal to or
greater than the previous level. All eight
voltage levels must be programmed and the
eighth level has been preset at 100%.

• If Custom Accel Curve has been set to curve

A, B or C on this page, the Soft Starter will
override the Start Control Mode selected in
Setpoint Page 2, (even if Start Control Mode in
Setpoint Page 2 has not been set to Custom
Accel Curve).

Motortronics Inc. Page 52

CUSTOM

CURVE A

CURVE A VOLTAGE
LEVEL 8: 100%

CURVE A RAMP
TIME 8: 2 SEC

CURVE A CURRENT
LIMIT: 350% FLA

Range: 0 - 100%

Increments of 1

CURVE B VOLTAGE
LEVEL 1: 25%

(Continued from Prev. page)

Range: 1 - 60 SEC

Increments of 1

Range: 200 - 500%
Increments of 10

Range: 0 - 100%
Increments of 1

CURVE B RAMP
TIME 1: 2 SEC.

CURVE B VOLTAGE
LEVEL 2: 30%

CURVE B RAMP
TIME 2: 2 SEC.

Range: 1 - 60 SEC

Increments of 1

CURVE B VOLTAGE
LEVEL 3: 37%

Range: 0 - 100%

Increments of 1

Range: 0 - 100%
Increments of 1

Range: 1 - 60 SEC
Increments of 1

CURVE B RAMP
TIME 3: 2 SEC.

CURVE B VOLTAGE
LEVEL 4: 45%

CURVE B RAMP
TIME 4: 2 SEC.

Range: 1 - 60 SEC

Increments of 1

CURVE B VOLTAGE
LEVEL 5: 55%

Range: 0 - 100%

Increments of 1

Range: 0 - 100%
Increments of 1

Range: 1 - 60 SEC
Increments of 1

CUSTOM

CURVE B

CUSTOM

CURVE B

Cont.

CURVE B VOLTAGE
LEVEL 6: 67%

CURVE B RAMP
TIME 5: 2 SEC.

Range: 1 - 60 SEC

Increments of 1

CURVE B RAMP
TIME 6: 2 SEC.

CURVE B VOLTAGE
LEVEL 7: 82%

CURVE B RAMP
TIME 7: 2 SEC.

Range: 1 - 60 SEC

Increments of 1

CURVE B VOLTAGE
LEVEL 8: 100%

Range: 0 - 100%

Increments of 1

Range: 0 - 100%
Increments of 1

Range: 1 - 60 SEC
Increments of 1

CURVE B CURRENT
LIMIT: 350% FLA

Range: 200 - 500%

Increments of 10

Range: 0 - 100%
Increments of 1

CUSTOM
CURVE C

CURVE C VOLTAGE
LEVEL 1: 25%

CURVE C RAMP
TIME 1: 2 SEC.

CURVE C VOLTAGE
LEVEL 2: 30%

CURVE C RAMP
TIME 2: 2 SEC.

Range: 1 - 60 SEC

Increments of 1

CURVE C VOLTAGE
LEVEL 3: 37%

Range: 0 - 100%

Increments of 1

Range: 0 - 100%
Increments of 1

Range: 1 - 60 SEC
Increments of 1

CURVE C RAMP
TIME 3: 2 SEC.

Range: 1 - 60 SEC

Increments of 1

Range: 0 - 100%
Increments of 1

(Continued on next page)

CTi Automation - Phone: [phone] - Fax: [phone] - Web: www.ctiautomation.net - Email: [e-mail]

SP.7 Custom Acceleration Curve (Setpoint Page 7) - Continued

(Security Level 3)

Motortronics Inc. Page 53

CUSTOM

CURVE C

Cont.

CURVE C VOLTAGE
LEVEL 4: 45%

CURVE C RAMP
TIME 4: 2 SEC.

CURVE C VOLTAGE
LEVEL 5: 55%

CURVE C RAMP
TIME 5: 2 SEC.

Range: 1 - 60 SEC

Increments of 1

CURVE C VOLTAGE
LEVEL 6: 67%

Range: 0 - 100%

Increments of 1

Range: 0 - 100%
Increments of 1

Range: 1 - 60 SEC
Increments of 1

CURVE C RAMP
TIME 6: 2 SEC.

Range: 1 - 60 SEC

Increments of 1

Range: 0 - 100%
Increments of 1

CURVE C VOLTAGE
LEVEL 7: 82%

Range: 0 - 100%

Increments of 1

CURVE C RAMP
TIME 7: 2 SEC.

Range: 1 - 60 SEC

Increments of 1

CURVE C VOLTAGE
LEVEL 8: 100%

CURVE C RAMP
TIME 8: 2 SEC.

CURVE C CURRENT
LIMIT: 350% FLA

Range: 200 - 500%

Increments of 10

Range: 1 - 60 SEC
Increments of 1

Range: 0 - 100%
Increments of 1

(Continued from prev. page)

CTi Automation - Phone: [phone] - Fax: [phone] - Web: www.ctiautomation.net - Email: [e-mail]

SP.7 Custom Acceleration Curve (Setpoint Page 7) - Continued

(Security Level 3)

Motortronics Inc. Page 54

RUN CURVE LOCKED
ROTOR TIME: O/L CLASS

COAST DOWN TIMER
TIME: DISABLED

Range:1 - 60 MIN, DISABLED

Increments of 1

BASIC RUN
OVERLOAD CURVE

Range: 400-800%

Increments of 1

PAGE 8

OVERLOAD CURVE

CONFIGURATION

MENU

(DOWN
ARROW 7
TIMES)

BASIC RUN
OVERLOAD CURVE

Range: 1-30 SEC,

O/L Class Increments of 1

RUN LOCKED ROTOR
CURRENT: 600% FLA

START CURVE LOCKED
ROTOR TIME: O/L CLASS

ACCELERATION TIME
LIMIT: 30 SEC

Range:1 – 300 SEC,

DISABLED
Increments of 1

Range: 1-30 SEC,
O/L Class Increments of 1

NUMBER OF STARTS PER
HOUR: DISABLED

TIME BETWEEN STARTS
TIME: 5 MIN

Range:1 - 60 MIN,

DISABLED
Increments of 1

Range: 1 - 6, DISABLED
Increments of

MAX I*I*T START
: 368 FLA*FLA*SEC

Range:1 - 2500, FLA*Time

(Sec) Increments of 1

LEARNED START CURVE
BIAS: 10%

Range: 5 - 40%

Increments of 1

START LOCKED ROTOR
CURRENT: 600% FLA

Range: 400-800%

Increments of 10

Range: 400-800%
Increments of 10

TIME FOR SAMPLING
: 30 SEC

CURRENT OVER
CURVE: DISABLED

Options: DISABLED,
LEARN or ENABLED

AREA UNDER CURVE
PROTECTION: DISABLED

Options: ENABLED or
DISABLED,

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SP.8 Overload Curve Configuration (Setpoint Page 8)

(Security Level 3)

Configures the unit’s start and run protection mode. The unit has independent start and run curve protection and the
settings can be based on the OL Class or set by the motor’s locked rotor current and time.

SP8.1 Basic Run Overload Curve

• Run Curve Locked Rotor Time: Set the locked rotor time to the OL Class default chosen in Setpoint Page 1 or set the

time in seconds. This is the time the locked rotor condition exists before a trip occurs.

• Run Locked Rotor Current: The current the motor draws with full voltage on the windings and no rotor movement (as a

percent of motor FLA). Refer to the nameplate data or contact the motor manufacturer.

• Coast Down Timer: If enabled, this prevents the motor from restarting for the programmed amount of time, after a stop

command is given.

Motortronics Inc. Page 55

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SP8.2 Basic Start Overload Curve

 Start Curve Locked Rotor Time: The locked rotor time can be set to the OL Class default chosen in Setpoint Page 1

or to a specific time. The overload condition must exist for the programmed amount of time before a trip occurs.

 Start Locked Rotor Current: The current the motor draws with full voltage on the windings and no motor movement

(as a percent of motor FLA). Refer to the motor nameplate data or contact the motor manufacturer.

 Acceleration Time Limit: If the motor does not enter run mode (reach “at speed”) within the preset time, the unit trips

on acceleration time limit.

 Number of Starts per hour: If enabled, this limits the maximum number of starts permitted per hour. This Setpoint

allows a maximum of 6 starts per hour. Contact the motor manufacturer for further information regarding number of
starts per hour.

 Time Between Starts: If enabled, the soft starter prevents another start attempt until the programmed time has

expired.

SP8.3 Area Under Curve Protection: If enabled, this secondary start protection uses both the basic start protection and
the area under the curve protection.

 Max I*I*T Start: The maximum I²t allowed during start. If the I²t to start exceeds this number then the Soft Starter will

generate a trip.

SP8.4 Current Over Curve: Learns the motor’s starting characteristics and protects the motor based upon the learned
curve. It is useful when commissioning a new motor.

 Learn: The unit reads the motor’s starting characteristics. Start the motor and allow it to come to full speed. The start

feedback enables the motor protection based on the learned start curve.

 Learned Start Curve Bias: The maximum allowed deviation above or below the start curve before a trip is generated.

 Time for sampling: The time the soft starter continues to sample the start curve characteristic during learn mode.

Motortronics Inc. Page 56

Page 9

RTD CONFIGURATION

MENU

STATOR PHASE A1
TYPE : OFF

# OF RTD’S USED
FOR STATOR: 4

Options: ENABLED

or DISABLED

(DOWN ARROW 8 TIMES)

RTD VOTING
: DISABLED

Range: 0 - 6

Increments of 1

Options: ENABLED
or DISABLED

RTD # 1 DESCRIPTION
STATOR PHASE A1

STATOR PHASE A1
ALARM LEVEL: OFF

STATOR PHASE A1
TRIP LEVEL: OFF

STATOR PHASE A2
TYPE : OFF

RTD # 2 DESCRIPTION
STATOR PHASE A2

STATOR PHASE A2
ALARM LEVEL: OFF

STATOR PHASE A2
TRIP LEVEL: OFF

Range: *

Range: *** Range: ** Range: **

Range: **

Range: **

Range: *** Range: *

STATOR PHASE B1
TYPE : OFF

RTD # 3 DESCRIPTION
STATOR PHASE B1

Range: **

Range: **

Range: *** Range: *

STATOR PHASE B1
ALARM LEVEL: OFF

STATOR PHASE B1
TRIP LEVEL: OFF

STATOR PHASE B2
TYPE : OFF

RTD # 4 DESCRIPTION
STATOR PHASE B2

Range: **

Range: **

Range: *** Range: *

STATOR PHASE B2
ALARM LEVEL: OFF

STATOR PHASE B2
TRIP LEVEL: OFF

STATOR PHASE C1
TYPE : OFF

RTD # 5 DESCRIPTION
STATOR PHASE C1

Range: **

Range: **

Range: *** Range: *

STATOR PHASE C1
ALARM LEVEL: OFF

STATOR PHASE C1
TRIP LEVEL: OFF

STATOR PHASE C2
TYPE : OFF

RTD # 6 DESCRIPTION
STATOR PHASE C2

Range: **

Range: **

Range: *** Range: *

STATOR PHASE C2
ALARM LEVEL: OFF

STATOR PHASE C2
TRIP LEVEL: OFF

END BEARING TYPE
: OFF

RTD #7 DESCRIPTION
END BEARING

Range: **

Range: **

Range: *** Range: *

END BEARING
ALARM LEVEL: OFF

END BEARING
TRIP LEVEL: OFF

RTD # 9 TYPE
: OFF

RTD # 9 DESCRIPTION
RTD # 9

Range: **

Range: **

Range: *** Range: *

RTD # 9 ALARM
LEVEL: OFF

RTD # 9 TRIP
LEVEL: OFF

RTD # 10 TYPE
: OFF

Range: **

Range: **

Range: *** Range: *

RTD # 10 ALARM
LEVEL: OFF

RTD # 10 TRIP
LEVEL: OFF

RTD # 11 TYPE
: OFF

Range: **

Range: **

Range: *** Range: *

RTD # 11 ALARM
LEVEL: OFF

RTD # 11 TRIP
LEVEL: OFF

RTD # 12 TYPE
: OFF

Range: **

Range: **

Range: *** Range: *

RTD # 12 ALARM
LEVEL: OFF

RTD # 12 TRIP
LEVEL: OFF

RTD # 10 DESCRIPTION
RTD # 10

RTD # 11 DESCRIPTION
RTD # 11

RTD # 12 DESCRIPTION
RTD # 12

RANGES:
* 120 OHM NICKEL (NI)

100 OHM NICKEL (NI)
10 OHM COPPER (CU)
100 OHM PLATINUM (PT)
OFF

**OFF or 0 - 240C (32-464F) Example: ### C = ### F

Increments of 1

***STATOR A1, STATOR A2, STATOR B1, STATOR B2, STATOR C1,

STATOR C2, FRONT BEARING, BACK BEARING, BEARING BOX,
AMBIENT, NONE

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Motortronics Inc. Page 57

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SP.9 RTD Option Configuration (Setpoint Page 9)

(Security Level 3)

Note: The RTD is an option. Contact factory for additional information.

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

SP9.1 Use NEMA Temp for RTD Value:

When this Setpoint is enabled, the Soft Starter will use the NEMA design insulation class to limit the maximum allowed
range of the alarm and trip level. The maximum allowed temperature range is 240° C or (464°F).

SP9.2 Number Of RTD’S Used for Stator:

Up to six RTDs can be assigned to monitor the stator of the motor.

SP9.3 RTD Voting:

When this is enabled, the Soft Starter will not post a trip until 2 RTD’s have exceeded the trip level. This prevents
nuisance RTD tripping.

SP9.4 RTD Setup:

Each of the 12 RTDs is configured in the following manner. The first column is the RTD type, the second column is the
RTD description, the third column is the alarm level, and the fourth column is the trip level. The first six RTDs have been
pre-programmed with a description name for the STATOR, with two RTDs per phase.

RTDs #1 & #2 have been named STATOR PHASE A1 and A2 respectively. RTDs #3 & 4 are named STATOR PHASE B1
and B2, RTDs #5 & 6 are named STATOR PHASE C1 and C2.

If other description names are required, press the right arrow button from the RTD Type screen to go the RTD description
screen. If no alarm or trip level is required these Setpoints can be turned off.

RTD Available Settings:

RTD TYPE:

 120 OHM NICKEL (NI)
 100 OHM NICKEL (NI)
 10 OHM COPPER (CU)
 100 OHM PLATINUM (PT)

 OFF

ALARM LEVEL: OFF or 0 - 240C (32-464F) Example: ### C = ### F, Increments of 1

RTD DESCRIPTION:

STATOR A1, STATOR A2, STATOR B1, STATOR B2, STATOR C1,
STATOR C2, FRONT BEARING, BACK BEARING, BEARING BOX,
AMBIENT, NONE

Motortronics Inc. Page 58

Page 9

RTD CONFIGURATION

MENU

STATOR PHASE A1
TYPE : OFF

# OF RTD’S USED
FOR STATOR: 4

Options: ENABLED

or DISABLED

(DOWN ARROW 8 TIMES)

RTD VOTING
: DISABLED

Range: 0 - 6

Increments of 1

Options: ENABLED
or DISABLED

RTD # 1 DESCRIPTION
STATOR PHASE A1

STATOR PHASE A1
ALARM LEVEL: OFF

STATOR PHASE A1
TRIP LEVEL: OFF

STATOR PHASE A2
TYPE : OFF

RTD # 2 DESCRIPTION
STATOR PHASE A2

STATOR PHASE A2
ALARM LEVEL: OFF

STATOR PHASE A2
TRIP LEVEL: OFF

Range: *

Range: *** Range: ** Range: **

Range: **

Range: **

Range: *** Range: *

STATOR PHASE B1
TYPE : OFF

RTD # 3 DESCRIPTION
STATOR PHASE B1

Range: **

Range: **

Range: *** Range: *

STATOR PHASE B1
ALARM LEVEL: OFF

STATOR PHASE B1
TRIP LEVEL: OFF

STATOR PHASE B2
TYPE : OFF

RTD # 4 DESCRIPTION
STATOR PHASE B2

Range: **

Range: **

Range: *** Range: *

STATOR PHASE B2
ALARM LEVEL: OFF

STATOR PHASE B2
TRIP LEVEL: OFF

STATOR PHASE C1
TYPE : OFF

RTD # 5 DESCRIPTION
STATOR PHASE C1

Range: **

Range: **

Range: *** Range: *

STATOR PHASE C1
ALARM LEVEL: OFF

STATOR PHASE C1
TRIP LEVEL: OFF

STATOR PHASE C2
TYPE : OFF

RTD # 6 DESCRIPTION
STATOR PHASE C2

Range: **

Range: **

Range: *** Range: *

STATOR PHASE C2
ALARM LEVEL: OFF

STATOR PHASE C2
TRIP LEVEL: OFF

END BEARING TYPE
: OFF

RTD #7 DESCRIPTION
END BEARING

Range: **

Range: **

Range: *** Range: *

END BEARING
ALARM LEVEL: OFF

END BEARING
TRIP LEVEL: OFF

RTD # 9 TYPE
: OFF

RTD # 9 DESCRIPTION
RTD # 9

Range: **

Range: **

Range: *** Range: *

RTD # 9 ALARM
LEVEL: OFF

RTD # 9 TRIP
LEVEL: OFF

RTD # 10 TYPE
: OFF

Range: **

Range: **

Range: *** Range: *

RTD # 10 ALARM
LEVEL: OFF

RTD # 10 TRIP
LEVEL: OFF

RTD # 11 TYPE
: OFF

Range: **

Range: **

Range: *** Range: *

RTD # 11 ALARM
LEVEL: OFF

RTD # 11 TRIP
LEVEL: OFF

RTD # 12 TYPE
: OFF

Range: **

Range: **

Range: *** Range: *

RTD # 12 ALARM
LEVEL: OFF

RTD # 12 TRIP
LEVEL: OFF

RTD # 10 DESCRIPTION
RTD # 10

RTD # 11 DESCRIPTION
RTD # 11

RTD # 12 DESCRIPTION
RTD # 12

RANGES:
* 120 OHM NICKEL (NI)

100 OHM NICKEL (NI)
10 OHM COPPER (CU)
100 OHM PLATINUM (PT)
OFF

**OFF or 0 - 240C (32-464F) Example: ### C = ### F

Increments of 1

***STATOR A1, STATOR A2, STATOR B1, STATOR B2, STATOR C1,

STATOR C2, FRONT BEARING, BACK BEARING, BEARING BOX,
AMBIENT, NONE

CTi Automation - Phone: [phone] - Fax: [phone] - Web: www.ctiautomation.net - Email: [e-mail]

SP.9 RTD Option Configuration (Setpoint Page 9) - Continued

(Security Level 3)

Motortronics Inc. Page 59

Page 10

SECURITY SET

PASSWORD

MENU

SET LEVEL 2
PASSWORD: 100

(DOWN ARROW 9 TIMES)

Range: 000 - 999

SET LEVEL 3
PASSWORD: 1000

Range: 0000 - 9999

Page 11

COMMUNICATIONS

MENU

SET FRONT BAUD
RATE: 9.6 KB/SEC

(DOWN
ARROW 10
TIMES)

Range: 2.4, 4.8, 9.6,

19.2 38.4 KB/SEC

REMOTE START/
STOP: DISABLED

Option: Enabled or

Disabled

SET MODBUS BAUD
RATE: 9.6 KB/SEC

Range: 2.4, 4.8, 9.6,

19.2 38.4 KB/SEC

MODBUS ADDRESS
NUBBER: 247

Range: 1- 247

Increments of 1

SET ACCESS CODE
CODE: 1

Range: 1- 999

Increments of 1

SET LINK BAUD
RATE: 9.6 KB/SEC

Range: 2.4, 4.8, 9.6,

19.2 38.4 KB/SEC

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SP.10 Set Password (Setpoint Page 10)

(Security Level 3)

The soft starter has three levels of user programmable setpoint screens. Level one setpoints do not require a password
because the data contained in level one is basic nameplate data and starter control. Level two setpoint screens require a
three-digit password to configure the protection schemes. Level three setpoint screens require a four-digit password to
access the full range of protection and starter schemes.

SP10.1 Set Level 2 Password: This level uses a 3-digit password. The default level 2 password is 100.

SP10.2 Set Level 3 Password: Level three uses a 4-digit password. The default level 3 password is 1000.

SP.11 Communications (Setpoint Page 11)
(Security Level 3)

SP11.1 Set Front Baud Rate: Configures the RS232 communications baud rate.

SP11.2 Set Modbus Baud Rate: Configures the Modbus communications baud rate

SP11.3 Modbus Address Number: Assigns a Modbus address to the unit.

SP11.4 Set Access Code: Assigns an access code to the Modbus addressing. This is typically not used

SP11.5 Set Link Baud Rate: Configures the RS422 communications baud rate between the keypad operator and the

CPU board (For applications with remote keypad only).

SP11.6 Remote Start/Stop: Allows the RS485 Modbus communications to start and stop the motor. Contact factory for
details.

Motortronics Inc. Page 60

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SP.12 System Setpoints (Setpoint Page 12)

(Security Level 3)

SP12.1 Default Display Screen: This Setpoint group allows the user to choose the default screen the Soft Starter
displays while the motor is running. Select the metering page number (1-3), then, select the metering screen number. The
range varies depending on the selected page. To display a default screen, program the following two Setpoints:

 Metering Data Page#: Range is Page 1 - 3.

 Metering Data Screen#: If Page 1 is selected as the default page, then Screens 1- 10 are available. If Page 2

Screens 1-29 are available. If Page 3 is selected then Screens 1-6 are available. (See Metering Menu, MP.1, for
screen number assignment.)

SP12.2 Alarms: Configures the RTD failure alarm (when RTD option is included) and the thermal register alarm.

 RTD Failure Alarm: If enabled, and an RTD shorts or open, an alarm occurs. (Only if RTD option is installed).

 Thermal Register Alarm: Sets a level in the thermal register to generate an alarm when the Thermal Register

Capacity Used has exceeded this level.

 Thermal Alarm Delay: The amount of time that the Thermal Register Used must exceed the Setpoint before an alarm

condition will occur.

SP12.3 Thermal Register Setup Information: This Setpoint group will configure the thermal register and indicate to the
soft starter which inputs to use when thermal modeling.

 Cold Stall Time: Enter the time from the motor manufacturer’s specification sheet or use the time defined by the OL

Class. This Setpoint is used to define the thermal capacity of the motor.

 Hot Stall Time: Enter the amount of time specified by the motor manufacturer or use half of the time defined by the

OL Class.

 Stopped Cool Down Time: The time the motor needs to cool down after it has stopped. Use only the data provided

by the motor manufacturer. This Setpoint is used to configure the cooling rate of the thermal register.

 Running Cool Down Time: The amount of time the motor needs to cool down while running. Use only the data

provided by the motor manufacturer.

 Relay Measured Cool Rates: When the RTD option is supplied, the Soft Starter can be configured to use the

measured cooling rates from the RTDs instead of the programmed settings. This Setpoint should only be enabled
when the RTD option is present.

 Thermal Register Minimum: Sets the value in the thermal register which represents a motor running at the

nameplate current (with no overheating or negative sequence currents present).

 Motor Design Ambient Temperature: Use the data from the motor manufacturer’s specifications. When RTD option

is supplied, this Setpoint will be the base point for the RTD biasing of the Thermal Register.

 Motor Design Run Temperature: Use the data from the motor manufacturer’s specifications. This Setpoint defines

the operating temperature rise of the motor at full load amps or 100% load.

 Motor Stator Max Temperature: This represents the maximum temperature the stator insulation will withstand. The

user may choose to use the temperature setting of the insulation class (selected in Setpoint Page 1) or enter a
specific maximum temperature. This value should not exceed the stator’s insulation temperature. This maximum
temperature represents 100% thermal capacity.

 U/B Input to Thermal Register: Always enabled. It allows the soft starter to use the line current imbalance

information to bias the Thermal Register.

Motortronics Inc. Page 61

DEFAULT
DISPLAY SCREEN

PAGE 12

SYSTEM SETPOINTS

MENU

(DOWN ARROW 11 TIMES)

METERING DATA
PAGE #: 1

Enter Metering Page (1 - 4)
Number for display

METERING DATA
SCREEN #: 1

Enter Metering Screen
Number for display

ALARMS

RTD FAILURE ALARM
ALARM: DISABLED

Option: Enabled or

Disabled

Range: Off, 40 - 95%
Increments of 1

THERMAL REGISTER
ALARM: 90%

THERMAL ALARM
DELAY: 10 SEC.

Range: 1 - 20 SEC.

Increments of 1

HOT STALL TIME
: 1/2 O/L CLASS

COLD STALL TIME
: O/L CLASS

Range: O/L CLASS,

4 - 40 SEC
Increments of 1

Range: 1/2 O/L CLASS,
4 - 40 SEC
Increments of 1

RUNNING COOL DOWN
TIME: 15 MIN

STOPPED COOL DOWN
TIME: 30 MIN

Range: 10 - 300 MIN

Increments of 1

Range: 10 - 300 MIN
Increments of 1

RELAY MEASURED COOL
RATES: DISABLED

THERMAL REGISTER
MINIMUM: 15%

Range: 10 – 50% ,Off

Increments of 1

Option: Enabled or
Disabled

MOTOR DESIGN AMBIENT
TEMPERATURE: 40 C

MOTOR DESIGN RUN
TEMPERATURE: 80% MAX

Range: 50 - 100% of Motor

Stator Max Temp.
Increments of 1%

Range: 10 - 90 C
Increments of 1

MOTOR STATOR MAX
TEMPERATURE: INS CLS

I/B INPUT TO THERMAL
REGISTER: ENABLED

Range: Insulation Class

10 - 240 C
Increments of 1

Option: Enabled or
Disabled

USE CALCULATED K OR
ASSIGN: 7

Range: 1 - 50, ON

THERMAL
REGISTER
SETUP
INFORMATION

PRESS ENTER TO
CLR THERMAL
REGISTER

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 User Calculated K or Assign: When the Setpoint is set to ON, the soft starter will calculate the k constant factor for

biasing the thermal register, or the user may choose to assign the k value.

 SP12.4 Press Enter to CLR Thermal Register: Allows the level three password user to clear the thermal register for

emergency restarts.

Motortronics Inc. Page 62

SET DATE AND TIME
##/##/## ##:##

PAGE 13

CALIBRATION &

SERVICE

MENU

(DOWN ARROW 12 TIMES)

MODEL #: ######
FIRMWARE REV. #: ######

ENTER DATE (DDMMYYYY)
##/##/####

Range: D = 1 - 31, M = 1-12,

Y = 1970 – 2069
Increments of 1

ENTER TIME (hh:mm)
:##:##

Range: H = 00 - 23,

M = 0 - 59
Increments of 1

PRESS ENTER TO ACCESS
FACTORY SETTINGS

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SP.13 Calibration & Service (Setpoint Page 13)

(Security Level 3)

Certain screens are displayed for user information only, such as Current date and time, Model number and Firmware
revision number. Setpoint changes in this page will only be accessible to factory personnel.

SP13.1 Set Date and Time: Displays the date and time.

 Enter Date (DDMMYYYY): Allows the factory personnel to program the date for the soft starter in the format shown.

 Enter Time (HH:MM): Allows the factory personnel to program the time for the soft starter.

SP13.2 Model & Firmware #: Displays the model number and firmware revision in the soft starter.

SP13.3 Press Enter to Access Factory Settings: Available to qualified personnel.

Motortronics Inc. Page 63

Metering

Page

Description of Display

Screen

PAGE 1

Metering Menu & Data

Phase A, B, C and Ground Fault (Option)

1

Average current of the % of imbalance and the motor's RPM (Tach Option)

2

Motor load as a percentage of motor FLA

3

Line frequency and present phase sequence

4

Percentage of remaining Thermal Register

5

Thermal capacity required to start the motor

6

Average time required to start

7

Average current during start

8

Measured I2T required to start the motor

9

Amount of time required to start the motor during the last successful start

10

Metering

Page

Description of Display

Screen

PAGE 2

Metering

Phase A, B, C currents and Power Factor

1

Phase A, B, C currents and Ground Fault (Option)

2

Displays KW and KVA

3

Displays KVAR and Power Factor

4

Displays Peak ON and KW Demand

5

Displays Peak ON and KVA Demand

6

Displays Peak ON and KVAR Demand

7

Displays Peak ON and Amps Demand

8

Clears Demand values

9

Displays Megawatt hours used

10

Press enter to clear statistics on MWH values

11

Metering

Page

Description of Display

Screen

PAGE 3

RTD Values

Hottest stator RTD (#1 - 6)

1

Hottest non-stator RTD (#7 - 12)

2

Temperature of start phase A1 in °C and °F

3

Maximum temperature for RTD #1

4

Same as Screens 3 - 4 for RTDs #2 - 12

5 - 26

Clear the maximum temperature register (Level 3 password required)

27

Measured running thermal stabilization time of motor (in minutes)

28

Measured stopped cooling time (to ambient) of motor (in minutes)

29

Metering

Page

Description of Display

Screen

PAGE 4

Status

Current status

1

Amount of time remaining before an overload trip occurs

2

Amount of time remaining from a thermal inhibit signal

3

Coast down time remaining

4

Amount of time remaining before a start command can be given

5

Excessive number of starts per hour

6

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Chapter 6 - Metering Pages

The Soft Starter offers performance metering which gives the user the ability to view information about the motor and the unit.

6.1 Metering Page List

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

6.1.1 Metering Menu & Data (Metering Page 1)

6.1.2 Metering (Metering Page 2)

6.1.3 RTD Option Values (Metering Page 3)

6.1.4 Status (Metering Page 4)

Motortronics Inc. Page 64

Metering

Page

Description of Display

Screen

PAGE 5

Event

Recorder

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

1

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

1A

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

1B

Metering

Page

Description of Display

Screen

PAGE 6

Last Trip

Cause of last trip

1

Measured phase current

2

Measured voltage and power factor

3

Imbalance percentage, the frequency and the kW

4

Hottest stator RTD temperature

5

Hottest non-stator RTD temperature

6

Metering

Page

Description of Display

Screen

PAGE 7

Statistics

Total Megawatt Hours

1

Accumulated Total Running Hours

2

Clear the Total Running Hour Count

3

Total Number of Trips / Number of Short CircuitTrips

4

Number of Start and Run Overload Trips since the last statistical data clearing

5

Number of frequency and Current Imbalance trips

6

Number of Over Current Trips

7

Stator and Non-Stator RTD Trips

8

Ground Fault Hiset and Loset Trips

9

Acceleration Time Trips

10

Start Curve Trips

11

I2T Start Curve Trips

12

Learned Start Curve Trips

13

Shunt Trip Trips

14

Phase Loss Trips

15

Tach Acceleration Trips

16

Undervoltage and Overvoltage Trips

17

Power Factor Trips

18

Phase Reversal Trips

19

Low Control Voltage Trips

20

Ext Inp #1 Trips

21

Ext Inp #2 Trips

22

Ext Inp #3 Trips

23

Ext Inp #4 Trips

24

Press ENTER to Clear Statistics

25

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6.1.5 Event Recorder (Metering Page 5)

6.1.6 Last Trip (Metering Page 6)

6.1.7 Statistics (Metering Page 7)

Motortronics Inc. Page 65

METERING PAGE 1
CURRENT METERED DATA

METERING PAGE 2
VOLTAGE & POWER DATA

MENU

METERING PAGE 3
RTD VALUES

METERING PAGE 4
STATUS

METERING PAGE 5
EVENT RECORDER

METERING PAGE 6
LAST TRIP

METERING PAGE 7
STATISTICS

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6.2 Metering Menu and Explanation

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

Motortronics Inc. Page 66

IA: ###### IB: ######
IC: ###### G/F: #####

I (AVG): ####
I/B: ## % RPM: ####

MENU

MOTOR LOAD % OF FLA
FLA: ### %

LINE FREQUENCY:: ##.##
PHASE ORDER: ###

THERMAL REGISTER
REMAINING: ### %

THERMAL CAPACITY
TO START: ### %

AVERAGE START TIME
TIME: ##.# SECS

METERING PAGE 1
CURRENT METERED DATA

AVG START CURENT
: ###### AMPS

I*I*T TO START
I*I*T: #######

LAST START
TIME: ##.# SEC

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MP.1 Metering (Metering Page 1)

Displays basic current metering data.

Screen 1: Phase A, B, C and ground fault (option) current.

Screen 2: Displays the average current, the percent of imbalance and the motor’s

RPM (available with tachometer input)

Screen 3: Displays the motor load in percent of motor FLA.

Motortronics Inc. Page 67

Screen 4: Displays the line frequency and the present Phase Order.

Screen 5: Displays the percent of the remaining thermal register. In order for the

motor to successfully start, the percentage must be greater than the thermal
capacity required for a successful start.

Screen 6: Displays the thermal capacity required to successfully start the motor.

Screen 7: Displays the average time required to start.

Screen 8: Displays the average current during start.

Screen 9: Displays the measured I2T required to start the motor.

Screen 10: Displays the amount of time required to start the motor during the last

successful start.

Vab: ### Vbc: ###
Vca: ### P/F: ## #.##

IA: ##### IB: #####
IC: ##### G/F:###.#

MENU

kW: #####
kVA: #####

kVAR: #####
P/F: ## #.##

PEAK ON: ##/## ##:##
kW: #####

PEAK ON: ##/## ##:##
kVA: #####

PEAK ON: ##/## ##:##
kVAR: #####

METERING PAGE 2
VOLTAGE & POWER DATA

PEAK ON: ##/## ##:##
AMPS: #####

PRESS ENTER TO CLEAR
DEMAND VALUES

MWH USED
: #####

PRESS ENTER TO CLEAR
MWH VALUES

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MP.2 Metering (Metering Page 2)

Displays the soft starter statistical voltage metering information

Screen 1: Displays Phase A, B, C and Power Factor.

Note: P/F: N/A Motor stopped

P/F: LG #.## (Lagging)
P/F: LD #.## (Leading)

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

Screen 3: Displays kW and kVA.

Screen 4: Displays kVAR and Power Factor.

Screen 5: Displays Peak On and kW demand.

Screen 6: Displays Peak On and kVA demand.

Screen 7: Displays Peak On and kVAR demand.

Screen 8: Displays the average current during start.

Motortronics Inc. Page 68

Screen 9: Clears Demand Values.

Screen 10: Displays the Megawatt hours used.

Screen 11: Press Enter to clear statistics on MWH values.

HOTTEST STATOR
RTD#: # @ ### C

METERING PAGE 3
RTD VALUES

MENU

(DOWN
ARROW 2
TIMES)

HOTTEST NON-STATOR
RTD#: # @ ### C

STATOR PHASE A1
RTD #1: ### C = ### F

STATOR PHASE A2
RTD #2: ### C = ### F

STATOR PHASE B1
RTD #3: ### C = ### F

STATOR PHASE B2
RTD #4: ### C = ### F

STATOR PHASE C1
RTD #5: ### C = ### F

STATOR PHASE C2
RTD #6: ### C = ### F

SHAFT BEARING
RTD #8: ### C = ### F

RTD #9
RTD #9: ### C = ### F

RTD #10
RTD #10: ### C = ### F

RTD #11
RTD #11: ### C = ### F

RTD #12
RTD #12: ### C = ### F

PRESS ENTER TO
CLEAR MAX TEMP REGS

MEASURED RUN COOL
TIME: ### MIN

MEASURED STOPPED
COOL TIME: ### MIN

MAX TEMP SINCE
CLEAR RTD #1: ### C

MAX TEMP SINCE
CLEAR RTD #2: ### C

MAX TEMP SINCE
CLEAR RTD #3: ### C

MAX TEMP SINCE
CLEAR RTD #4: ### C

MAX TEMP SINCE
CLEAR RTD #5: ### C

MAX TEMP SINCE
CLEAR RTD #6: ### C

MAX TEMP SINCE
CLEAR RTD #7: ### C

MAX TEMP SINCE
CLEAR RTD #8: ### C

MAX TEMP SINCE
CLEAR RTD #9: ### C

MAX TEMP SINCE
CLEAR RTD #10: ### C

MAX TEMP SINCE
CLEAR RTD #11: ### C

MAX TEMP SINCE
CLEAR RTD #12: ### C

END BEARING
RTD #7: ### C = ### F

Screen 1

Screen 2

Screen 3 Screen 4

Screen 5

Screen 6

Screen 7

Screen 8

Screen 9

Screen 10

Screen 11

Screen 12

Screen 13

Screen 14

Screen 15

Screen 16

Screen 17

Screen 18

Screen 19

Screen 20

Screen 21

Screen 22

Screen 23

Screen 24

Screen 25

Screen 26

Screen 27

Screen 28

Screen 29

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MP.3 Metering (Metering Page 3)

Displays the RTD information (When RTD option is installed)

Screen 1: Displays the hottest stator RTD
(#1 – 6 depending upon number of RTDs used for stator).

Screen 2: Displays the hottest non-stator RTD (#7-12 if
#1-6 is used for stator).

Screen 3: Displays the temperature of stator phase A1 in
°C and °F.

Screen 4: Displays the maximum temperature for RTD #1
since the last command to clear the thermal register.

Screen 5 - 26: Same as Screens 3 - 4 for RTDs # 2 - 12.

Screen 27: Allows the user to clear the maximum

temperature register upon entering the setpoint level 3
password.

Screen 28: Displays the measured run cool time in
minutes.

Screen 29: Displays the measured stopped cool time in
minutes.

Motortronics Inc. Page 69

METERING PAGE 4
STATUS

MENU

O/L TIME LEFT TO TRIP
TRIP: ###### SEC

THERM INH TIME LEFT
: #### MIN

COAST DOWN TIMER
TIME LEFT: #:## MIN

TIME BETWEEN STARTS
TIME: #:## MIN

STARTS PER HOUR TIME
## ## ## ## ## ## ##

*(CURRENT STATUS)

Screen 3

Screen 4

Screen 5

Screen 6

Screen 1

Screen 2

MOTOR STOPPED
READY TO START

MOTOR STARTING
MULT. OF FLA

MOTOR RUNNING
AT ###.## X FLA

LAST TRIP CAUSE
NONE (or trip cause)

PROGRAMMING
SETPOINTS

MOTOR STATUS
UNKNOWN STATE ###

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MP.4 Metering (Metering Page 4)

Displays the present status of the soft start

*Screen 1: Displays the present state of the unit as follows:

Screen 2: Displays the amount of time remaining before an overload trip will

occur.

Screen 3: Displays the amount of time remaining from a thermal inhibit. The inhibit
time comes from the amount of thermal register remaining versus the amount of
thermal capacity required to start.

Screen 4: Displays the coast down time remaining (Backspin time). The time
remaining depends upon the user setting in Setpoint Page 8, Coast Down Time.

Screen 5: Displays the amount of time remaining before a start command can be
given. The time remaining depends upon the setting in Setpoint page 5.

Screen 6: If the number of starts per hour has exceeded the setting in Setpoint
page 8.

* NOTE: Screen 1 CURRENT STATUS Screens include:

(Displays relay state upon error)

Motortronics Inc. Page 70

METERING PAGE 5
EVENT RECORDER
(60 events)

MENU

(DOWN ARROW 4 TIMES)

:<cause of event>
:##/##/## ##:##

Screen 1

IA: ###### IB: ######
IC: ###### G/F: ####

Screen 1a

Vab: ###### Vbc: ######
Vca: ###### P/F: ####

Screen 1b

1st Event

:<cause of event>
:##/##/## ##:##

IA: ###### IB: ######
IC: ###### G/F: ####

Vab: ###### Vbc: ######
Vca: ###### P/F: ####

2nd Event

:<cause of event>
:##/##/## ##:##

Screen 1

IA: ###### IB: ######
IC: ###### G/F: ####

Screen 1a

Vab: ###### Vbc: ######
Vca: ###### P/F: ####

Screen 1b

59th Event

:<cause of event>
:##/##/## ##:##

IA: ###### IB: ######
IC: ###### G/F: ####

Vab: ###### Vbc: ######
Vca: ###### P/F: ####

60th Event

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MP.5 Metering (Metering Page 5)

Displays the present status of the soft start

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

Screen 1a: Displays the current at Phase A, B, C and the ground fault at the time of the trip. (Note: Ground fault option

must be present)

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

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

NOTES-

Motortronics Inc. Page 71

MENU

METERING PAGE 6
LAST TRIP

Ia: #### Ib: ####
Ic: #### G/F: ####.#

Vab: ###### Vbc: ######
Vca: ###### P/F: ######

I/B: ## % Hz: ##.#
KW: #######

HOTTEST STATOR
RTD# # @ ### C

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

(CAUSE OF TRIP)
(VALUE AT TIME OF TRIP)

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MP.6 Metering (Metering Page 6)

Displays the last trip information

Screen 1: Displays the cause of the last trip.

Screen 2: Displays the measured phase current at the time of the trip.

Screen 3: Displays the Vab, Vbc, Vca and power factor at the time of trip.

Screen 4: Displays the imbalance percentage, the frequency and the kW at the

time of the trip.

Screen 5: Displays the hottest stator RTD temperature (when RTD option present)
at time of the trip.

Screen 6: Displays the hottest non-stator RTD temperature (when RTD option
present) at the time of the trip.

Motortronics Inc. Page 72

MWH TOTAL
: ###

METERING PAGE 7
STATISTICS

MENU

(DOWN ARROW 6 TIMES)

RUNNING HOURS TOTAL
TIME: ## ## HOURS

TOTAL TRIPS: ###
S/C TRIPS: ###

START O/L TRIPS: ###
RUN O/L TRIPS: ###

FREQUENCY TRIPS: ###
I/B TRIPS: ###

OVERCURRENT
TRIPS: ###

G/F HISET TRIPS: ###
G/F LOSET TRIPS: ###

ACCELERATION TIME
TRIPS: ###

START UNDER CURVE
TRIPS: ###

START OVER CURVE
TRIPS: ###

I*I*T START CURVE
TRIPS: ###

LEARNED START CURVE
TRIPS: ###

FAIL SHUNT TRIP
TRIPS: ###

PHASE LOSS TRIP
TRIPS: ###

TACH ACCEL TRIP
TRIPS: ###

PRESS ENTER TO
CLEAR RUN HOURS

U/V TRIPS: ###
O/V TRIPS: ###

POWER FACTOR
TRIPS: ###

PHASE REVERSAL
TRIPS: ###

LOW CONTROL VOLTAGE
TRIPS: ###

EXT INP #1: ###

EXT INP #3: ###

EXT INP #2: ###

Screen 1

Screen 2

Screen 3

Screen 4

Screen 5

Screen 6

Screen 7

Screen 8

Screen 9

Screen 10

Screen 11

Screen 12

Screen 13

Screen 14

Screen 15

Screen 16

Screen 17

Screen 18

Screen 19

Screen 20

Screen 21

Screen 22

Screen 23

Screen 24

Screen 25

STATOR TRIPS: ###
NON-STATOR TRIPS: ###

PRESS ENTER TO
CLEAR STATISTICS

Screen 26

LEVEL 2 Password required

EXT INP #4: ###

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MP.7 Statistics (Metering Page 7)

Displays the statistical trip information

Screen 1: Displays the total of megawatt hours.
Screen 2: Displays the accumulated total running hours.
Screen 3: Clears the total running hour count.
Screen 4: Displays the total number of trips since the

last clearing of the statistical data and the
total number of short circuit trips.
Screen 5: Displays the number of start overload and run
overload trips since the last clearing of the
statistical data.
Screen 6: Displays the number of frequency trips and
Imbalance trips.

Screen 7: Displays the number of overcurrent trips
Screen 8: Displays the number of Stator and non-Stator

RTD Trips
Screen 9: Displays the number of Ground Fault Hi and
Lo Set trips
Screen 10: Displays the number of acceleration time
trips.
Screen 11: Displays the number of start under curve
trips

Screen 12: Displays the number start over curve trips
Screen 13: Displays the number of I2T start curve trips
Screen 14: Displays the number of learned start curve

trips.

Screen 15: Displays the number of fail shunt trips.
Screen 16: Displays the number of phase loss trips.
Screen 17: Displays the number of tachometer

acceleration trips.
Screen 18: Displays the number of undervoltage and
overvoltage trips.

Screen 19: Displays the number of power factor trips.
Screen 20: Displays the number of phase reversal trips.
Screen 21: Displays the number of low control voltage
trips.
Screen 22: Displays the number of external input #1

trips.
Screen 23: Displays the number of external input #2
trips.
Screen 24: Displays the number of external input #3
trips.
Screen 25: Displays the number of external input #4
trips.
Screen 26: Requires a Security Level 2 password to
clear the statistics.

Motortronics Inc. Page 73

Problem

CPU LCD

Display

LED

AUX

Relay

Possible Cause

Solutions

One of the main fuses
blows or circuit breaker
opens when the power
is applied or disconnect
is closed.

TCB FAULT
TRIP

Trip

AUX1

Short circuit between
the inputs

Locate and remove short

Faulty SCRs

Remove power and test SCR(s).
Refer to Section 7.1.1 for the SCR
testing procedure

Short Circuit Trip

SHORT
CIRCUIT TRIP

Trip

AUX1

Short circuit or ground
fault in motor/cabling

Locate and remove short or ground

Phase Loss

Repair cause of phase loss

Branch circuit
protection not correctly
sized

Verify correct sizing of branch
circuit protection

Faulty main circuit
board

Remove power and replace main
circuit board.

Faulty SCRs

Remove power and test SCR(s).
Refer to Section 7.1.1 for the SCR
testing procedure

Single Phase Trip

SINGLE
PHASE TRIP

(Check LCD
display for
possible fault
indicators)

Trip

AUX1

Single phase incoming
power

Correct problem with incoming
power

Faulty SCRs

Remove power and test SCR(s).
Refer to Section 7.1.1 for the SCR
testing procedure

Environment
Temperature over 122°
F (ambient temperature
for chassis units) or
over 104°F (ambient
temperature for
enclosed version

Place unit in environment
temperature less than 122°F for
panel version or less than 104°F for
enclosed version.

Bypass failed to close

Check bypass contactor and wiring.
The "At Speed" delay is incorrectly
programmed. Reprogram back to
factory default value.

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Chapter 7 - Maintenance and Troubleshooting

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

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

7.1 Failure Analysis

When a fault occurs, the LCD will display the fault error while the listed LED and AUX Relay will be lit. Please clear all faults
before attempting to restart the unit.

Note: If the problem persists after the required programming changes have been made, and all corrective action has

been taken, please contact the factory for assistance.

Motortronics Inc. Page 74

Problem

CPU LCD

Display

LED

AUX

Relay

Possible Cause

Solutions

Phase Loss

PHASE LOSS

Trip

AUX1

Loss of 1 or more
phases of power from
utility or generated
power.

Check power source.

Blown power fuses

Check for short circuits.

Overload

OVERLOAD
TRIP

Trip

AUX1

Improper programming

Check motor nameplate versus
programmed parameters.

Possible load damage
or jammed load

Check motor currents.

Stall prevention

ACCEL TIME
TRIP

Trip

AUX1

Improper setting for
motor load condition

Verify current limit setting.
Damaged load

Check for load failure.

Under Voltage
Trip

UNDER
VOLTAGE
TRIP

Trip

AUX1

Improper programming

Check Setpoint settings.

Wrong position of
disconnect or breaker

Check disconnect or open breaker

Main contactor failed to
close

Check internal connections

Transformer too small

Reduce current limit setting,
saturation or
sagging power supply transformer

Unloaded motor

Check load

Self-test Failure

SELF-TEST
FAILURE

Trip

AUX1

Failed CPU or Main
Firing Board

Contact factory
Vibration

Check internal wiring connections

Line Frequency
Trip

OVER OR
UNDER
FREQUENCY
TRIP

Trip

AUX1

Generator Power
Problem or grid change

Troubleshoot and repair generator

Contact utility company

Main board failure

Three phase power removed from
Main

Any Ground Fault
Trip

GROUND
FAULT
HI-SET OR
LO-SET

Trip

AUX1

Improper programming

Check Setpoint settings

Any wire going to
ground (I.e. stator
ground, motor ground,
soft start ground)

Check with megger or Hi-pot motor
leads and motor

High vibration or loose
connections

Check internal connections

Short Circuit Trip

Check for fault
indication

Trip

AUX1

!

WARNING

This is a serious fault condition. Ensure that the fault condition
is cleared on the load side before attempting to restart the
motor.

Load shorted

Remove power and repair.

Faulty main circuit
board

Replace the main circuit board

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7.1 Failure Analysis - Continued

Motortronics Inc. Page 75

Problem

CPU LCD

Display

LED

AUX

Relay

Possible Cause

Solutions

Control circuit fuses
blow after control
power is applied.

None

None

None

Short in Control Circuit

Remove Power, locate and remove
the short.

Wrong Control Voltage

Apply the correct voltage to the
control circuit.

Motor will not start

Any fault
indication
message

Trip

AUX1

No Control Voltage applied
to Control Board

Apply control voltage to TCB
board.

Control Power Transformer
failure or CPT Fuse failure

Remove power and replace the
power transformer or the CPT fuse

Start Circuit Wired
Incorrectly

Remove power and correct the
start circuit wiring.

No Start Command

Apply the start command.

No 3 Phase Line Voltage

Apply 3 phase line voltage to the
unit.

Shorted SCR in Starter

Remove power and Test SCR(s).
Refer to Sec. 7.1.1 for the testing
procedure.

Faulty Control Logic

Remove power and repair the
Control Logic.

Failure of Main Circuit
Board

Replace the Main Circuit Board.

Motor vibrates /
Motor growls while
starting or
extremely
unbalanced motor
currents run mode

IMBALANCE
TRIP

Trip

AUX1

Faulty Motor

Check the Motor and the Motor
connections.

Faulty SCR(s)

Remove Power and perform the
SCR device checks.

Faulty Gate / Cathode on
SCR(s)

Remove Power and Test SCR(s).
Refer to Sec. 7.1.1 for the testing
procedure.

Faulty Main Circuit Board.

Replace the Main Circuit Board.

IMBALANCE
ALARM

Alarm

AUX2

Faulty Motor / Wiring

Troubleshoot and repair / replace
wiring.

Faulty Main Circuit Board

Replace the Main Circuit Board.

Test Points

OHM Meter Reading

Test Results

From Position A to
Position B

Greater than 10K Ohm

Pass

Less than 5K Ohm

Fail

From Position B to
Position C

Greater than 10K Ohm

Pass

Less than 5K Ohm

Fail

Gate (G) to Cathode
(K) for each SCR

8 to 50 Ohms

Pass (Typical 8 to 20 Ohms)

Less than 8 or greater
than 50 Ohms

Fail

Notes

1 - Allow 15 minutes after shutdown for DV/DT network to discharge.

2 - Voltage sharing resistors may need to be disconnected to obtain correct readings
for tests between positions A, B & C...

K

K

G

G

Red

Red White

White

Gate Drive Board

A

C

B

CTi Automation - Phone: [phone] - Fax: [phone] - Web: www.ctiautomation.net - Email: [e-mail]

7.1 Failure Analysis - Continued

7.1.1 - SCR Testing Procedure

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

Motortronics Inc. Page 76