motortronics XLS-78, XLS-120, XLS-92, XLS-150, XLS-180 Installation & Operation Manual

XLS Series Solid State Soft Starter 39 - 1250A

XLS SERIES

Solid State Soft Starter

39 - 1250 A

INSTALLATION & OPERATION

MANUAL

Motortronics

- 23 -

REV 2
08110601MN

XLS Series Solid State Soft Starter 39 - 1250A

Motortronics

- 24 -

XLS Series Solid State Soft Starter 39 - 1250A

Table of Contents

XLS Series
Solid State Soft Starter
39 - 1250A

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

1.1 General

1.2 Specifications and Performance Features

Chapter 2: Installation.......................................................2

2.1 Receiving and Unpacking

2.2 Location

2.3 Initial Unit Inspection

2.4 Warning

2.5 Mounting and Cleaning

2.6 Power Terminal Wire Range and Tightening Torque

2.7 Dimensions

Chapter 3: Motor Overload Protection............................5

3.1 Thermal Overload Relay

3.2 Overload Relay

3.3 FLA Dial Adjustment

3.4 Manual/Automatic Reset

3.5 Test for Trip Indication

Chapter 4: Connections ................................................... 6

4.1 Power Connections

4.2 Control Connections

Chapter 5: Adjustments ....................................................9

5.1 Introduction

5.2 Acceleration Adjustments

5.3 Deceleration Adjustments

Chapter 6: Start-Up .........................................................1 2

6.1 Start-up Check List

6.2 Sequence of Operation

Chapter 7: Status Indicator LEDs ..................................13

7.1 LED Functions

Chapter 8: Troubleshooting ...........................................14

8.1 Failure Analysis

8.2 SCR Testing Procedure

8.3 Replacing SCR Devices

8.4 Replacing Printed Circuit Boards

Chapter 9: Main Control Board ......................................20

Motortronics

- 25 -

XLS Series Solid State Soft Starter 39 - 1250A

Motortronics

- 26 -

XLS Series Solid State Soft Starter 39 - 1250A

Chapter 1 - Introduction

1.1 General

The XLS Series solid state reduced voltage soft starter is a six SCR
design which features a voltage/current ramp with an anti-oscillation
circuit for smooth load acceleration. The SCRs are sized to withstand
starting currents of 500% for 60 seconds (compared to 350% for 30
seconds from other manufacturers). The XLS Series features smooth,
stepless ramp control which reduces motor inrush current and excessive
wear on the mechanical drive train components. In addition to having
easy to understand diagnostic lights, the XLS Series can be set up for
the ideal starting cycle. Starting voltage, ramp time, current limit, and
decel control are standard adjustments on the XLS Series. The starting
electrical characteristics of the motor can be matched to the mechanical
characteristics of the drive train for controlled acceleration of the load,
by simply adjusting the unit’s starting torque, ramp time and current
limit potentiometers. The XLS Series includes adjustable overload
protection, shorted SCR detection and phase loss detection. It is factory
wired for 120VAC control voltage (or 240VAC for 415 VAC and 380
VAC units) and three-wire start/stop control. Auxiliary contacts and
provisions for interlocking are also included.

1.2 Specifications and Performance Features

Motortronics

- 1 -

XLS Series Solid State Soft Starter 39 - 1250A

Chapter 2 - Installation

2.1 Receiving and Unpacking

Upon receipt of the product you should immediately do the following:

• Carefully unpack the unit from the shipping carton and inspect it for

shipping damage (if damaged, notify the freight carrier and file a
claim within 15 days of receipt).

• Verify that the model number on the unit matches your purchase

order.

• Confirm that the ratings sticker on the unit matches or is greater

than the motor’s HP and current rating.

2.2 Location

Proper location of the XLS Series is necessary to achieve specified
performance and normal operation lifetime. The XLS Series should
always be installed in an area where the following conditions exist:

• Ambient operating temperature:

Chassis unit: 0 to 50°C (32 to 122°F)
Enclosed unit: 0 to 40°C (32 to 104°F)

• Protected from rain and moisture

• Humidity: 5 to 95% non-condensing

• Free from metallic particles, conductive dust and corrosive gas

• Free from excessive vibration (below 0.5G)

• Open panel units must be mounted in the appropriate type of

enclosure. Enclosure size and type must be suitable to dissipate
heat generated by the soft starter. Contact factory for assistance in
sizing enclosures.

2.3 Initial Unit Inspection

• Make a complete visual check of the unit for damage which may
have occurred during shipping and handling. Do not attempt to continue
installation or start up the unit if it is damaged.

• Check for loose mechanical assemblies or broken wires which may
have occurred during transportation or handling. Loose electrical
connections will increase resistance and cause the unit to function
improperly.

• Prior to beginning the installation, verify that the motor and XLS unit
are rated for the proper amperage and voltage.

2.4 Warning!

Do not service equipment with voltage applied! The unit can be
the source of fatal electrical shocks! 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.

Motortronics

- 2 -

XLS Series Solid State Soft Starter 39 - 1250A

2.5 Mounting and Cleaning

When drilling or punching holes in the enclosure, cover the electrical
assembly to prevent metal filings from becoming lodged in areas which
can cause clearance reduction or actually short out electronics. After
work is complete, thoroughly clean the area and reinspect the unit for
foreign material. Make sure there is sufficient clearance (six inches)
all around the unit for cooling, wiring and maintenance purposes. To
maximize effective air flow and cooling, the unit must be installed with
its heat sink ribs oriented vertically and running parallel to the mounting
surface.

Warning!

Remove all sources of power before cleaning the unit.

In dirty or contaminated atmospheres the unit should be cleaned on a
regular basis to ensure proper cooling. Do not use any chemicals to
clean the unit. To remove surface dust use 80 to 100 psi, clean, dry
compressed air only. A three inch, high quality, dry paint brush is
helpful to loosen up the dust prior to using compressed air on the unit.

2.6 Power Terminal Wire Range and Tightening Torque

Note: All wiring must be sized according to NEC standards.

Motortronics

- 3 -

XLS Series Solid State Soft Starter 39 - 1250A

y

y

y

y

2.7 Dimensions

Enclosure

XLS-6 to XLS-32 12.8 10.9 5.5 12.3 10.3 0.28

XLS-39 to XLS-120 16.5 10 10 15.9 9 0.28

XLS-150 to XLS-180 20 20.1 12 18.5 17.5 0.44

PANEL

NEMA1

NEMA 4/4X

NEMA12

XLS-220 to XLS-288 27 20.1 11.2 25.5 17.5 0.44
XLS-360 to XLS-550 29.5 20.1 11.5 25.5 17.5 0.44

XLS-718 to XLS-1006 45 33 12.8 43.3 31.3 0.44

XLS-1150 to XLS-1250 33 33 15.2 31.2 31.2 0.44

XLS-6 to XLS-32

XLS-39 to XLS-120 16.5 10 10 15.9 9 0.28
XLS-150 to XLS-180 32.3 24.3 13.3 31.3 18 0.44
XLS-220 to XLS-288 38.3 24.3 13.3 37.3 18 0.44
XLS-360 to XLS-550 44.3 30.3 13.3 43.3 24 0.44

XLS-718 to XLS-1006 50.2 36.3 15.5 49.3 30 0.4

XLS-1150 to XLS-1250

XLS-6 to XLS-11 11.7 8.9 9 9 8.4 0.28

XLS-18 to XLS-78 15.7 12.2 10 12 11 0.28

XLS-92 to XLS-120 24 24 12.9 22.5 22.5 0.5
XLS-150 to XLS-288 36 30 16.9 34.5 28.5 0.5
XLS-360 to XLS-550 48 36 16.9 46.5 34.5 0.5

XLS-718 to XLS-1006 72.1 48.1 20

XLS-1150 to XLS-1250

Model

Number

Overall

Dimensions

Mounting

Dimensions

ABCDEF

Not Available Not Available

Contact Factor

Contact Factor

Contact Factor

Floor Mounted

Contact Factor

Motortronics

- 4 -