Powtran PR5200 7R5G3, PR5200 018G3, PR5200 011G3, PR5200 015G3, PR5200 030G3 User Manual

Foreword

Thank you very much for purchasing PR5200（C）soft starter.

This user’s manual provides the users with the instructions on the installation, parameter
setting, error diagnosis, routine maintenance and necessary precautions. Please read the manual
carefully before the installation of the product in order to ensure that it can be correctly installed
and operated.

Please contact Powtran's dealers or directly contact with the company if you have difficult
questions during the use of the soft starter , our professional staff is willing to serve for you.

Please leave this manual to the end user and keep it in good condition for the future
maintenance and other application occasions . Please fill in the warranty card then fax to the
distributor or fax to Powtran if there is quality problem during the warranty period.

During this product updating period, some details may be changed without prior notice. If you
want to get the latest information, please visit our website.

For other products’ information, please visit our homepage:http://www.powtran.com.

Contents

Foreword ...................................................................................................................... 1

Contents ....................................................................................................................... 2

Section I The introduction of PR5200(C) soft starter .............................................. 1

1-1. The feature of the PR5200(C) soft starter .................... 1

1-2. The main function of the PR5200(C) soft starter ......... 1

1-3. The main features of the PR5200(C) soft starter .......... 1

Section II Product model description and open - package inspection ..................... 3

2-1. Product model description ............................................ 3

2-2. The steps of open - package inspection ........................ 3

Section III The Conditions of use and installation requirements ............................. 4

3-1. The conditions of use of the soft starter ....................... 4

3-2. The installation requirements of the soft starter ........... 4

3-3. The appearance and installation dimension of the soft

starter 5

Section IV Main circuit and terminal wiring ........................................................... 8

4-1. The basic wiring diagram of the soft starter ................. 8

4-2. Instruction of soft starter terminal wiring. ................... 8

4-3. PR5200C series integrative machine wiring diagram 10

4-4. PR5200C external terminal description ..................... 11

Section V Control panel and operation ................................................................. 13

5-1 Keyboard operational approach ................................. 13

5-2 Function parameters setting and description .............. 15

5-3 Programmable relay output functions ........................ 16

5-4 Operation protection function of power on terminal .. 17

5-5 Other settings Description .......................................... 17

5-6 .Help and instructions ................................................ 18

Section Ⅵ Protection and description ...................................................................... 19

6-1 Protection functions and their parameters .................. 19

6-2 Protection level setting description ............................ 20

Section VII Test runing and application ................................................................ 22

7-1. Power test running .................................................... 22

7-2. PR5200(C) Series soft starter starting mode and

application 23

7-3. PR5200(C) series soft starter's stop mode and

application 25

7-4. Special application ..................................................... 26

7-5. Application examples ................................................. 26

Section VIII Fault causes and treatment ............................................................... 28

Section IX Soft-start model specifications and options ........................................ 30

Section X Quality Assurance ................................................................................ 31

POWTRAN Technology Product Warranty Card ...................................................... 33

Only trained people are allowed to operate this device, please read this manual
about the safety, installation, operation, and maintenance section before use of the
items. The safe application of this equipment depends on the correct transportation,
installation,operation and maintenance.

Precaution

 Thanks for selecting intelligent motor soft starter products from Powtran technology Co.,

LTD., we will with excellent performance in return for your attention!

 Please pay attention to the following matters during the soft starter installation, operation

and maintenance process

please be sure to read the operating instructions before installation

Must by professional technicians to install the soft starter

The specifications of the motor must match with the soft starter

Prohibit to connect the capacitors in soft starter output terminal (U, V, W)

The bare terminals must be wrapped by insulating tape after installation

Soft starter or related equipment should be reliable grounding

Input power must be cut off when equipment maintenance

Do not disassemble , modify, maintenance of this product personally.

第
十

Section I The introduction of PR5200(C) soft
starter

1-1. The feature of the PR5200(C) soft starter

PR5200(C) series intelligent motor soft starter incorporates the latest motor control
theory and proprietary motor protection technology and advanced software technology
of new equipment, it is an ideal replacement of startup products which early used start

method of “Star to Triangle conversion”, “autoformer step-down voltage” and
“magnetic control step-down voltage” ; at present market ,Its performance is more

superior than other ordinary soft starter without using intelligent control technology.

1-2. The main function of the PR5200(C) soft starter

 First: to reduce the motor starting current and reduce power distribution capacity,

avoid investment of expansion of power capacity.

 The second: to reduce the starting stress of the motor and the load of the

equipment ; extend lifespan of the motor and related equipments.

 Third: Its soft stop function can effectively solve the problem of parking vibration

of the inertial system,which is unable to realize by traditional starting equipment.

 Fourth: to have six unique start-up modes adapts to the complex conditions of

motor and load, to perfect start effect.

 Fifth: has the perfect and reliable protection function; effectively protect the motor

and the related production equipment use safety.

 Sixth: motor soft starter intelligence, and network technology application makes

motor control technology to adapt to the rapid development of the electric power
automation technology in higher requirements.

1-3. The main features of the PR5200(C) soft starter

● Perfect human nature design:

 Beautiful shape and reasonable structure

 Perfect function and easy operation

 Sturdy and reliable and compact structure

 Industrial product excellence in the design of art.

● Reliable quality assurance:

 Using the computer simulation design.

 SMT placement production process.

 Excellent electromagnetism compatibility.

 The whole machine of aging, vibration test in high temperature before they

leave the factory

● Perfect and reliable protection function:

 Voltage lose, lower voltage and over-voltage protection.

 Soft starter motor overheating, lower load, too long starting time protection.

 Input phase lose, output phase lose, three-phase unbalance protection.

1

Section I The introduction of PR5200（C） soft starter

 Startup current, overload, short circuit protection.

● Proprietary intellectual property products:

 Appearance design patent.
 Independent software copyright.
 Proprietary motor starting and protection technology.
 Unique testing debugging equipment and process.

● Swift thoughtful after-sales service:

 Reliable performance and quality lay the foundation of excellent service.
 Provide excellent perfect supporting design scheme.
 Timely and thoughtful use consultation.
 Continuously improve product performance according to user opinion

2

第
十

POWER
INPUT
OUTPUT

DALIAN POWTRAN TECHNOLOGY CO.,LTD.

MODEL

18.5kW
AC 3PH 380V 50Hz/60Hz ± 10%

AC 0 37A 50Hz/60Hz3PH 380V

PR5200+ 018G3

ZPB1A0100001

Powtran soft starter

PR 520+ 0 a 018 G 3

Model specification

Input Voltage Level
3:Three-phase 380V-415V
4:Three-phase440V-460V

Rated Power:
Example：5R5: 5.5kW
011: 11kW

Class code:
0:normal configuration
1:special 1 configuration
2:special 2 configuration

Machine code:
a:General(omit)
C:Integrative machine

Function code
G：Gerneral

Output configuration
0：General configuration（omit）

Section II Product model description and open ­package inspection

2-1. Product model description

2-1-1. Instructions on nameplate

2-1-2.Model designation

2-2. The steps of open - package inspection

Each PR5200(C) series soft starter is under strict inspection and testing before they
leave the factory. Users received the products and unpacked, please follow the
inspection steps , if found problem, please contact the supplier promptly

 Confirm the soft starter without any damage in transport process (machine body

damage or gap).

 Check with the machine, the instruction manual,the warranty card
 Check the product of the specifications of the enclosure panels, ensure that the

received goods match with you ordered products

3

第
十

OUT

OUT

IN

IN

AIR

50mm

50mm

150mm

150mm

Section III The Conditions of use and installation
requirements

PR5200(C) series soft starter should comply with the following conditions of use
and installation requirements; otherwise, the performance will not guarantee, it can
shorten life of soft starter even damage.

3-1. The conditions of use of the soft starter

3-1-1. Power supplies: the utility, self-power station, diesel generating sets three-

phase AC 380 V plus or minus 10%, frequency 50 Hz or 60 Hz, the power
supply capacity must meet soft starter motor starting to the requirement

3-1-2. Applicable motor: mouse cage type three-phase asynchronous motor, ac

motor rated power should be matching with soft starter rated power .

3-1-3. Start frequency: no demands, depending on the specific number load up.
3-1-4. Cooling way: air cooling.
3-1-5. The protective level: IP20.
3-1-6. Environmental conditions: Below elevation 3000 meters, the environment

Temperature between -25 ℃ ~ + 40 ℃, relative humidity below 90% RH, no
dewing, no inflammable, no explosive, no corrosive gas easily, have no
electrical conductivity dust, indoor and ventilated good, vibration is less than

0.5 G place.

 We can offer under special conditions of use products, such as the explosion

proof type, low temperature, high pressure type type soft starter, its use
conditions will need further instructions.

3-2. The installation requirements of the soft starter

 Installation direction and distance: in order to ensure that the soft starter in use

with good ventilation and cooling conditions, soft starter should be installed
vertically, and in the equipment with sufficient heat dissipation space all round,
as shown in chart 3.2 3.1, in the photo, to allow the minimum distance.

 Soft starter install inside ark, in addition to the above requirements outside,

still must choose, under ventilated cabinet put oneself in another's position, as
shown in chart 3.3.

Diagram 3.1 Diagram3.2

4

Section III The Conditions of use and installation requirements

W

b

a

d

b

W

d

L

L1

a

H

H1

Model

Rated

Power

(KW)

Rated

current

(A)

Base

No.

Dimension

Installation

Net(kg)

L1 L W

H1 H a b d

PR5200

5R5G3

5.5

11

5R1

-

288

146 - 159

270

115

Ø8

<4.8

PR5200

7R5G3

7.5

15 - 288

146 - 159

270

115

Ø8

<4.8

PR5200

011G3

11

22 - 288

146 - 159

270

115

Ø8

<4.8

PR5200

015G3

15

30 - 288

146 - 159

270

115

Ø8

<4.8

PR5200

18.5

37 - 288

146 - 159

270

115

Ø8

<4.8

PR5200(C) series integrative machine,wall-mounted(without cabinet
installation)and cabinet choose wall-mounted or landed installation,require

surroundings ventilated,without dust and other suspended solids.

3-3. The appearance and installation dimension of the soft starter

3-3-1. The appearance and installation dimension of the 5.5KW-55KW soft starter.

PR5200 series 75kW-400kW soft starter,the standard factory configuration is
three input and six out.
The rated power and rated current is max rated value of soft starter. Usually,
matching the corresponding parameter of motor shall not be more than this value.

5

Section III The Conditions of use and installation requirements

018G3

PR5200

022G3

22

44 - 288

146 - 159

270

115

Ø8

<4.8

PR5200

030G3

30

60 - 288

146 - 159

270

115

Ø8

<4.8

PR5200

037G3

37

74 - 288

146 - 159

270

115

Ø8

<4.8

PR5200

045G3

45

90 - 288

146 - 159

270

115

Ø8

<4.8

PR5200

055G3

55

110 - 288

146 - 159

270

115

Ø8

<4.8

PR5200

075G3

75

150

5R2

-

350

206 - 210

330

160

Ø9

<10

PR5200

090G3

90

180 - 350

206 - 210

330

160

Ø9

<10

PR5200

115G3

115

230 - 350

206 - 210

330

160

Ø9

<10

PR5200

132G3

132

264

5R3

-

420

256 - 250

400

210

Ø9

<18

PR5200

160G3

160

320 - 420

256 - 250

400

210

Ø9

<18

PR5200

185G3

185

370 - 420

256 - 250

400

210

Ø9

<18

PR5200

200G3

200

400 - 420

256 - 250

400

210

Ø9

<18

PR5200

250G3

250

500

5R4

-

490

360 - 290

465

290

Ø9

<32

PR5200

280G3

280

560 - 490

360 - 290

465

290

Ø9

<32

PR5200

320G3

320

640 - 490

360 - 290

465

290

Ø9

<32

PR5200

400G3

400

800 - 490

360 - 290

465

290

Ø9

<32

PR5200T

132G3

132

264

5R3T

530

460

300

245

191

435

240

Ø9

<22

PR5200T

160G3

160

320

PR5200T

185G3

185

370

PR5200T

200G3

200

400

PR5200T

250G3

250

500

5R4T

565

490

350

245

191

465

290

Ø9

<22

PR5200T

280G3

280

560

PR5200T

320G3

320

640

PR5200T

400G3

400

800

3-3-2. PR5200C series integrative machine appearance and installation dimensions,

the standard factory configuration is three input and three out.Wall-mounted
size chart(6R1-6R3).

6

Section III The Conditions of use and installation requirements

W

L

H

a

b

W

L

H

b

a

d

Model

Rated power

（KW)

Rated

current(A)

Base

No.

Dimension

Installation

Net(kg)

L W H a b

d

PR5200C 015G3

15

30

6R1

620

400

220

600

250

10

PR5200C 018G3

18.5

37

620

400

220

600

250

10

PR5200C 022G3

22

44

620

400

220

600

250

10

PR5200C 030G3

30

60

620

400

220

600

250

10

PR5200C 037G3

37

74

620

400

220

600

250

10

PR5200C 045G3

45

90

620

400

220

600

250

10

PR5200C 055G3

55

110

620

400

220

600

250

10

PR5200C 075G3

75

150

6R2

980

534

278

852

275

12

PR5200C 090G3

93

180

980

534

278

852

275

12

PR5200C 115G3

115

230

980

534

278

852

275

12

PR5200C 132G3

132

264

980

534

278

852

275

12

PR5200C 160G3

160

320

6R3

1000

590

300

939

370

12

PR5200C 185G3

185

370

1000

590

300

939

370

12

PR5200C 200G3

200

400

1000

590

300

939

370

12

PR5200C 250G3

250

500

GGD 柜

1800

800

600

650

540

16

PR5200C 280G3

280

560

1800

800

600

650

540

16

PR5200C 320G3

320

640

1800

800

600

650

540

16

PR5200C 400G3

400

800

1800

800

600

650

540

16

PR5200C 450G3

450

900

1800

800

600

650

540

16

PR5200C 500G3

500

1000

1800

800

600

650

540

16

PR5200C 560G3

560

1120

1800

800

600

650

540

16

PR5200C 630G3

630

1260

1800

800

600

650

540

16

Cabinet size chart

Size table

7

第
十

PR5200 Series

Soft Starter

3phase power input

Keyboard

control

M

3phase asynchronous mouse cage motor

Braker(QF)

chart

4.1

Connector(KM)

Note：six copper bar， below 3 for motor，upper 3 for contactor

Section IV Main circuit and terminal wiring

 PR5200(C) series soft starter has two kinds of wiring:

The main circuit wiring: three phase power input and output to the motor wiring
and coil in line circuit breaker, bypass contactor wiring.

External terminal wiring: by 14 small terminals derivation, including input, output
control lines and analog output signal lines.

4-1. The basic wiring diagram of the soft starter

4-2. Instruction of soft starter terminal wiring.

Output terminal like chart 4.2 illustration：

8

Section IV Main circuit and terminal wiring

7

8

9

10

Transient
stop

stop

start

common

3lines way

7

8

9

10

Transient
stop

stop

start

common

2lines way:close K start
open K stop

K

1

2

3

4

5

6

7

8

9

10

11

12

-

+

Bypass

output

Programming
output

Fault
output

7.Instantaneous
stop

stop

start

public

Analog output

13

14

B

A

Communication
terminal

chart4.2

4-2-1.Terminal 1、2 is bypass output which is used to control bypass contactor.

Normally open terminalwill close. The terminal capacity is AC 250V/5A.

4-2-2.Terminal 3、4 is programable relay output, output model and function set by

“PE”parameter. This terminal is normally open passsive pot. Capacity is AC
250V/5A.

4-2-3.Terminal 5、6 is error output: which will colse when soft starter error or

power lose. Capacity is AC250V/5A.

4-2-4.Terminal 7 is transient stop input. This terminal must connect with terminal

10 when soft starter normally work. If Terminal 7 disconnect with terminal
10, softstart will transient stop and show error. This terminal can be
controled by normal close output terminal of outside protection device, set
PA to 0 (primary protection),this terminal funtion is prohibited.

4-2-5.Terminal 8、9、10 is for wiring of outside control start,stop button. There

are two type wiring way(3 lines and 2 lines) to choose proper way according
to demand. As chart 4.3.

4-2-6.Terminal 11、12 is 0～20mA、4～20mA DC anolog output. Which is used

to inspect the motor current. The max 20mA indicates motor current is 4
times of soft starter rated current. Which can be viewed by extra 0
20mA、4～20mA current meter. The max resistor of output load is 300Ω.
Remark: the machine defaults to 4 ~ 20mA output, if need 0 ~ 20mA output
please explain in order.

4-2-7.Terminal 13, 14 for the RS485 communication terminal, 13 for the

communication terminal B, 14 for the communication terminal A.

4-2-8.The outside terminal should be correct connection, otherwise which will

damage this softstarter.

4-2-9.PR5200series soft starter main circuit diagram.

9

～

Section IV Main circuit and terminal wiring

R

S

T

1

3 5

braker

（QF）

R

S

T

1

3

5

L1

L2

L3

1

3

5

KH

bypass

electromagnetic

contactor

2

4

6

U

V

W

2

4

6

07

08

09

10

10

11

12

G

01

02

03

04

05

06

M

A

-

+

anolog output

(DC 0～20mA）

KH/transient

stop

stop

start common

KM

N或L1

A1

A2

bypass

output

PR5200 series soft starter

Delay

output

error

output

FU

(KM)

13

14

B

A

Communication

terminal

4-3. PR5200C series integrative machine wiring diagram

10

Section IV Main circuit and terminal wiring

Motor

Three-phase

4-4. PR5200C external terminal description

4-4-1. Terminal 3,4 is programmable relay,output and function set by the setting

item PE，as normally open dry contact.Contact capacity is:AC 250V/5A.

4-4-2. Terminal 5，6 as fault output,when the soft starter failure or loss of power

closed，when the soft starter normal open，contact capacity is:AC 250V/5A

4-4-3. Terminal 11，12 as 0 to 20mA、4 to 20mA DC analog output，use for

real-time monitoring current,when the full scale is 20mA,the instruction motor current
is four times as the soft starter nominal rated current,you can external 0 to 20mA、4 to
20mA DC ammeterto observate，the output load resistance max value is 300 ohm.
Remark: the machine defaults to 4 ~ 20mA output, if need 0 ~ 20mA output please
explain in order.

4-4-4. PR5200C series main circuit wiring schematic diagram.

11

Section IV Main circuit and terminal wiring

start control panel

temperature

controlled

switch

delay

output

fault

output

instant

stop

start

analog output

0～20mA、4～20mA

operation

keyboard

breaker

soft starter circuit diagram

12

第
十

Ampere
Percentage
Second

Error light

Bypass
light

Colon
blank

Ready light

Three digitals

Two position

function code

Parameter Alternation
Key (acc/reduction key)

parameter
setting/shift
key

Rapid select/confirm
parameter setting

Running Key

Stop/reset key

Ampere
Percentage
Second

Error light

Bypass
light

Colon
blank

Ready light

Three digitals

Two position
function code

Parameter Alternation
Key (acc/reduction key)

parameter
setting/shift
key

Rapid select/confirm
parameter setting

Running Key

Stop/reset key

Section V Control panel and operation

★PR5200(C)series soft starter has five kinds working
state:ready,running,error,start and stop. Ready、running、error has corresponding state
light.Startup indicates××××，softstop indicates —ЧЧЧ ,and ЧЧЧЧЧindicates motor
current.

5-1 Keyboard operational approach

JP3E5200 keyboard diagram

JP3E5200D keyboard diagram

13

Section V Control panel and operation

5-1-1. startup state: when the indication ready light display 5200 or

,then softstater can start. The displaying 5200 means POWTRAN

5200 series softstarter. And means ready to start.

5-1-2. Delay state: ready or error state indication light flash means interval, display

dE××× and count down means startup delay.

5-1-3. Start and stop key:in the process of soft startup,the screen display ×××× to

indicates motor current, and only Stop key is valid, and can not enter menu
to set parameter, and ready,running,error lights black out.In the process of soft
stop, the screen display×××× to indicates motor current,and only RUN key is
valid, and can not enter menu to set parameter, and ready, running, error lights
black out, meanwhile the stop key has reset function.

5-1-4. PRG key , in the non-help mode, press the PRG key to enter the setup

menu,display PX: XXX,then press PRG key again, colon flashes, that means
can modify the parameters after colon.Press the Set key when the colon
flashes, if the data has been modified, it will display good and twice ring,
indicating that new data has been saved, and then exit. If you do not want to
save the new data, press the PRG key, colon will stop flashing and restoring
the original data, then press Set key or Stop key to exit.

5-1-5. Set key, in the non-setting state, press the set key to enter the help menu,

display HX: XXX, press the Set key or stop key to exit. In setting state, press
the set key to save the new setting of data and to exit the setting state.

5-1-6. Acceleration,deceleration key, in the setting menu, when the colon does not

flash ,press the acceleration or deceleration key to change the function number;
when colon flashes, press the acceleration or deceleration key to change the
data, press on the acceleration or deceleration key for more than 1 second, the
data will be increased or decreased continuously and quickly .In the help
menu, press the acceleration or deceleration key to change the function
number and the corresponding message.When the indicator light of bypass
operation is on, and did not enter the setting and help menu, display AXXXX,
that means the motor running current, then press the acceleration or
deceleration key to select display PXXXX or HXXXX.PXXXX indicates
motor apparent power;HXXXX indicates motor overloaded heat balance
coefficient. When indication value of HXXXX is more than 100%,soft starter
will be overload protection and display Err08.

5-1-7. When the data is more than 999, the last decimal point is bright, indicates the

mantissa + 0.

5-1-8. If the key operating is effective,there will be a voice tip, or this key does not

work in this state.

5-1-9. When the external control terminal connected to a 3-wire mode, the external

control start button and stop button have the equivalent function with start and
stop keys on the control panel.

5-1-10. The control panel with super anti-jamming design,and the outside connection

14

Section V Control panel and operation

Display

letter

relative

letter

Display

letter

relative

letter

Display

letter

relative

letter

0 1 2 3 4 5 6 7 8

9 或 g

A 或 R

B

C

d 或 D

E

F H J

L N

U 或 V

o P r Y RUN

Ver

READY

good

Err

M N

Code Setting Description

Code

Name

Range
of set
value

Factory
setting

Explanation

P0

Starting voltage

30-70%

30%

Voltage slope model is effective, the
starting voltage of current mode is
40%.

P1

Soft starting time

2-60S

16S

Limiting current mode does not
work.

P2

Soft stop time

0-60S

0S

Setting 0 means free stopping, please
set 0 for one with two onnections .

P3

Start delay

0-999S

0S

With a countdown delay, set to 0
without delay, starting immediately.

P4

Language selection

0、1

0

0 for Chinese display, 1 for the
English display.

P5

Starting current limit

50-

500%

280%

The current limiting mode is
effective; the maximum flow value
of the voltage slope mode is 400%.

P6

Load regulation rate

50-

200%

100%

Relative to the value of the rated
current PP.

P7

Under voltage
protection

40-

90%

80%

Protection below the set value.

distance is allow to be more than 3 m.

5-1-11. Keyboard digital display illustration

5-2 Function parameters setting and description

 Function parameters code in the following table

15

Section V Control panel and operation

P8

Overvoltage
protection

100­140%

120%

Protection is higher than the set
value.

P9

Starting mode

0-6

1

0 limit current; 1 voltage; 2 jump;
limit current; 3 jump + voltage; 4
current ramp; 5 double closed loop; 6
monitoring.

PA

Protection level

0-4

4

0 primary; 1 light load; 2 standard; 3
heavy load; 4 advanced.

PB

Control mode

0-6

1

0 keyboard; 1 keyboard + external
control; 2 external control; 3 external
control + communication; 4
keyboard + external control +
communication; 5 keyboard +
communication; 6 communication.

PC

Parameter
modification
allowed

0-3

1

See 5.5 other setup instructions.

PD

Correspondence
address

0-64

0

For MODBUS native slave address
setting.

PE

Programming output

0-19

7

See 5.3 programmable relay output
functions.

PF

Soft stop current

20-

100%

80%

See 7.3.1 soft stop mode.

PP

Motor rated current

11-

998A

Rated

value

Nominal rated current for input
motor.

PU

Bypass delay

0-40S

3S

Used to set bypass time delay.

PL

Three phase
unbalance

0、1

1

0 is prohibited, 1 is allowed.

PM

Current regulation
rate

50-150%

100%

Used to adjust the current value of
the display.

PN

Voltage regulation
rate

50­150%

100%

Used to adjust the display voltage
value.

Note: 1, set the P6 load adjustment rate is calculated based on the load weight of the
motor in the number of PP based on the calculation of the maximum current, more than
this value will do the inverse time thermal protection.
2, setting the state, if more than 2 minutes without a button operation, will
automatically exit the setting state.
3, in the soft start and soft stop process can not set parameters, the other state can be set
parameters.
4, according to the confirmation key (PRG) on the power on the boot, can set
parameters to restore the factory value.

5-3 Programmable relay output functions

There are two programmable relay output function, programmable timing output

way and programmable state output way.

5-3-1. PE set from 0 to 4 items (10 ~ 14), programmable output work is timing

output way, the setting of output starting time as tabled below.

16

Section V Control panel and operation

PE setting
value

0(10)

1(11)

2(12)

3(13)

4(14)

Programming
output time

Initiate action
command

Starting at the
beginning

Bypass
operation

Stop action
command

Stopping is
complete

PE set value

5(15)

6(16)

7(17)

8(18)

9(19)

state of output
indication

Motor fault
conditions

Running

Readiness

Start state

Bypass state

(1)This way of working contains a 999 seconds timer which setted by the setting item P4.
If P4 is not 0, the start timing is according to the initial setting time setted by PE , when
the time is up changing the output state, if P4 is 0, changing the output state immediately.
The output of the reset time is to sustain 1 seconds after finishing the time delay setted by
P4 and in the state of readiness.

(2)The control cycle of programmable output timing is according to one starting
process, if re-start the motor , the last programming output process is automatically
stopped and re-started the programming process.

5-3-2. PE is from 5 to 9 (15 ~ 19), the programmable output work is state output

mode, the setting of the working state output as tabled below：

(1)Programmable state output to indicate the working state of the soft starter, the time
setted by P4 is invalid in this mode. The factory setting of PE is 7, which indicates the
preparation state of soft starter, can start the motor in this state; programmable output is
in the failure state, which indicates the fault of the motor(Err05, Err06, Err07, Err08,
Err12, Err15 ), which is different from the function of ⑤, ⑥ fault output terminals;
running state refers to non preparation or fault condition, which includes 3 process of
start, bypass, soft-stop.

(2)When PE> 9, the reset state of the programmable output (③, ④ No. external pin)
changed from normally open to closed, that is inverted output. Flexible using the
function of programmable relay output, which can effectively simplify the external
control logic circuit。

5-4 Operation protection function of power on terminal

The jumper mode is selected, divided into two states.

Status 1: power terminal operation effective protection: external control starting
terminal before the power is in a closed state, soft does not respond to run the command
must first run the command to remove a and run the command again after the effective
soft response.

Soft fault reset time command to run effectively, soft nor the response command to
run, we must first run the command removed to eliminate the operation state of
protection.

Status 2: on the terminal operation protection is not valid: on the power, if the
external control starting terminal is in a closed state, then the automatic starting motor,
which is allowed to start on.

The J14 2, 3 short connected to state 1, J14 1, 2 short connected to state 2.

5-5 Other settings Description

17

Section V Control panel and operation

Display

Explanation

AC：XXX

Three digital voltmeter, to monitor three-phase AC power supply voltage.

45A-380V

The soft starter specifications for 45A/380V.

H1：E05

Last occurred fault information Err05.

H2：E01

There had been a fault information Err01.

H3：E06

There had been a fault information Err06.

H9：E00

There was no fault information.

Uer3.0

The software version of this product is Ver3.0. With the software upgrade,
version with the increase.

LXXXX

Total number of successful starting.

RUNXX

The spending time (seconds) of last soft starting (starting successfully) .

Note: H1 ~ H9 with recursive way to storage newly happened nine fault information.





5-5-1. set item PC to modify the parameters to allow the selection of items, there are

three options:

(1) when the item PC is 0, no parameters are modified.
(2) when the item PC is 1, the, P6, PD, PE, PP, PP, PU, and P4 parameters are

forbidden to modify the settings.

(3) when the item PC is 2, the parameters of all settings are allowed.

5-6 .Help and instructions

 Help information as following table：

⑴ In the non-soft start and non-soft stop state, and did not enter the setting mode,

press the set key, can enter the help menu, and then press the acceleration or
deceleration key to select message。

⑵ In the help state, press the set key or stop button to exit help state。

18

第
十

Section Ⅵ Protection and description

PR5200(C) series soft starter with complete protection to protect the safety of soft
starter and motor. During the application, appropriate protection parameters and level
should be setted based on different situation.

6-1 Protection functions and their parameters

6-1-1. Soft starter over-temperature protection: the temperature rose to 80 ℃ ± 5 ℃

over-temperature protection, when the temperature dropped to 55 ℃ (the
lowest), no over-temperature protection。

6-1-2. Input phase protection lag time : <3 seconds。
6-1-3. Three-phase unbalance protection lag time: <3 seconds.
6-1-4. Three-phase unbalance protection lag time: <3 seconds.It is based on the

deviation of all phase current greater than 50% ± 10% . When the load current
is lower than 30% of the nominal rating of soft starter, the benchmark
deviation will increase.

6-1-5. start over current protection time: the duration is greater than the set P6 load

regulation rate for the benchmark 5 times the protection time see table 6.1.

6-1-6. Running overload protection time: to set the P6 load regulation rate as the

benchmark for anti time thermal protection, protective tripping time curve as
shown in Figure 6.1.

6-1-7. The protection lag time of much too low supply voltage, when the power

supply voltage is lower than the 40% of limit, the protection time <0.5
seconds, or the protection time <3 seconds if it is lower than the setting value.

6-1-8. The protection lag time of much too high supply voltage : when the power

supply voltage is lower than the 140% of limit, the protection time <0.5
seconds, or the protection time <3 seconds if it is higher than the setting
value.

6-1-9. The protection delay time of load short-circuit : <0.1 seconds, the current is

10 times more than soft starter nominal rated current. This protection can not
replace fuse short-circuit protection device.

6-1-10. Motor under load protection, the current range is 10% to 90% of motor rated

current, the protection action delay from 5 to 90 seconds。

These time parameters are from tested effective signal to a tripping protection
instructions, and the parameters just for reference. All the protection functions of

19

Section Ⅵ Protection and description

PA setting

0(Primary)

1(Light load)

2(standard)

3(heavy load)

4(high

grade)

Description

Running overload
Level of protection

no

2 level

10 level

20 level

10 level

According to
IEC60947

-4-2 Standard

Start over-current
Protection time

no

3 seconds

15 seconds

30 seconds

15 seconds

Starting current for
more than P6setting
5times calculation

Overload trip time
running list

Current
multiple (I/Ie)

3 4 5 3 4 5 3 4 5 3 4

5

Typical values

for the table

Trip time
(seconds)

4.5

2.3

1.5

23

12

7.5

46

23

15

23

12

7.5

PR5200(C) series soft starter can be verified through the actual or simulation method. If
it can't meet the user's requirements, special protection device should be added to ensure
safety。

6-2 Protection level setting description

6-2-1. In order to adapt to different applications, PR5200(C) series soft starter has

five protection level, there are 0: primary, 1: light load, 2: Standard 3: heavy, 4:
Advanced, it setted by PA setting. Among them,

(1)Primary protection is against to the function of external terminal instantaneous
stop, meanwhile only remains the overheating, short circuit and main circuit fault
protection, it can be applied to needed emergency start in unconditional occasion, such
as fire systems, etc.

(2)The three protection level of light load, standard load and overload have the
complete protection function. The difference is the time curves of motor overloaded
thermal protection are not the same. The time parameters of motor thermal protection
are as Table 6.1 and Chart 6.1.

(3)High level of protection standards is stringent at start. Other protection features
parameters keep the same with standard protection set.

6-2-2. Protection level and thermal protection time according to PA setting is as the

diagram below：

Diagram 6.1

6-2-3. According to IEC60947-4-2 standard curve of the motor thermal protection

tripping time is as follows:

Chart 6.1

20

Section Ⅵ Protection and description

Protection tripping time curve (thermal state)

21

第
十

Test running

Make sure the supplying power voltage is

in the rated input voltage range of soft

starter

Follow 4-1 wiring diagram of soft starter, make

sure phase sequence connection of the bypass

contactor is correct, then power is on.

Setting PP according to the input rated current

of the motor plate

Press the Run Key to starting motor

The direction of motor rotation

is correct.

To stop the machine immediately, and cut off

the input power and changing the reversing

wiring of the main loop.

Stop for ending the test running.

N

Y

Section VII Test runing and application

 Double-check before power running according to the following terms:

Whether the soft starter power match with the motor rated power.
Whether the motor insulation satisfy the requirements.
Whether the Input and output main circuit wiring is correct.
Whether all the terminal screws are tightened.

7-1. Power test running

22

Section VII Test runing and application

T

I

I1

Ie

0

Chart 7.1

7-1-1. If the motor starter status is not satisfactory, refer to 7.2 of the soft starter

starting mode and application to select appropriate starting model.

7-1-2. If the motor starting torque is not enough, you can change the starting voltage

(voltage mode) or current-limiting value (current mode), to improve the motor
starting torque.

7-1-3. When soft starter power on, do not open the cover, to avoid electric shock.
7-1-4. In the power test of running, if appearing unusual phenomena, such as

abnormal noise, smoke or odor, etc., should be quickly cut off the power and
make further investigation.

7-1-5. If power on or when starting, appearing failure light and display ErrXX, you

can find the reason according to the displayed fault code and the
corresponding chapter of the cause.Press the stop button or external stop
button to reset the fault status.

 Note：

⑴ When the ambient temperature is below -10 ℃, should power on for more

than 30 minutes to warm-up before starting.

⑵ When the soft starter drive the motor successfully, the operation status

indicator on the middle panel lights, that proves the bypass is in running status.
If at this time, the motor stop by bypass contactor without actuation,y ou
should check the bypass contactor and associated wiring connection.

7-2. PR5200(C) Series soft starter starting mode and application

PR5200(C) series soft starter has Seven models to suit a variety of complex starter

motor and load conditions, the user can choose it as different application.

7-2-1 Current limit starting mode

When setting PB to 0, set the start mode for this

mode.

Chart 7.1 shows the current limit mode of the
motor starting current waveform changes. I1 is
starting current limit by setting, when the motor
starts, the output voltage rapidly increases, till the
motor current reaches the current limit value I1, and
maintain the motor current is not higher than this
value, then gradually as the output voltage increased,
gradually accelerate the motor, when the motor
reaches the rated speed, the bypass contactor make actuation, output current rapidly
dropped to or below the motor rated current Ie, starting process is complete.

When the motor is lightly loaded or setting the current limit highly, the
maximum starting current may not reach the set limit value is normal.

23

Section VII Test runing and application

T

U

Ue

U1

0

t

Chart 7.2

T

C

Un100%

U1

0

100ms

T

C

Un100%

U1

0

100ms

Chart 7.4

Chart 7.3

Current limit starting mode is generally used for a strictly limited starting

current requirements of the occasion.

7-2-2 Voltage ramp start model

When P9 setting item is 1, start

mode is for this mode.

Chart 7.2 shows the output voltage
waveform as voltage ramp start voltage
waveform. U1 is the initial starting
voltage of starting, when the motor start,
the motor current does not exceed 400%
of rated range, the output voltage of soft
starter quickly rise to U1, then the output
voltage gradually increase by the start
parameters setting, the motor is in smooth acceleration according to voltage
continuously rise, when the voltage reach the rated voltage Ue, the rated motor speed,
bypass contactor act, starting process is complete.

Starting time t is based on standard load obtained in the standard experimental
conditions, control parameters, PR5200(C) series soft starter is based on this
parameter benchmark, by controlling the output voltage, make the motor speed up
in a smooth start-up process, not a mechanical control, regardless of time t.
Acceleration is smooth. In view of this, when the load is light, set the start time often
less than the starting time, as long as a smooth start is normal.

In general, the voltage ramp start mode is suit to not strict starting current
requirement and strict demanding of a
smooth start of the occasion.

7-2-3 Kickstart mode

P9 setting item set to 2 or 3, starter
model is for this mode.

Chart 7.3 and Chart 7.4 shows the
kickstart mode waveform of the output.
In some heavy load situations, due to
mechanical effects of static friction,
when it can not start the motor, you can
use this start mode. At the start, imposing
a high fixed voltage to the motor first
and last for a limited period of time, to

24

Section VII Test runing and application

T

I

I1

Ie

0

T1

Chart 7.5

Before using this model, start motor with non-sudden jump model, if the motor
can not move due to static friction, then use this model; otherwise avoid to start this
mode to reduce the unnecessary high current impact.

7-2-4 Current ramp start mode

P9 items set 4, start mode is for this mode.

Chart 7.5 shows the current ramp start mode
output current waveform, which I1 is the current limit
set P6, T1 value is the time set by P1.

Current ramp start mode has a strong acceleration
ability, for bipolar motors, can also shorten the start-up
time within a certain range.

7-2-5 The voltage limiting double loop start mode

Set P9 as 5 to set start mode for this mode.

Double loop starting voltage limiting mode adopt voltage ramp and current limit
dual closed-loop control model, is both stable requires and strict current limiting
demanding, the integrated starter-limiting mode, it uses the prediction algorithm to
estimate the work status of the motor.

In this start mode, output voltage waveform will be based on the motor and load
conditions vary.

7-2-6 Monitor start mode

Started in this mode will run in direct starting, can monitor the operation of the
motor current and other parameters, when running overload, overvoltage or
undervoltage, fault output 5,6 terminal to cut output, also shows the corresponding
fault information.

7-3. PR5200(C) series soft starter's stop mode and application

PR5200(C) series soft starters, there are two stop modes, soft-stop mode and free
stop mode.

7-3-1 Soft stop mode

When Setting item P2 is not zero, set the stop mode for this mode.

In this stop mode, the motor power start from the bypass contactor and switch to
the output of soft starter thyristor, soft starter output voltage decrease steadily from
the total pressure, reducing the motor speed steady in order to avoid mechanical
shock, till the motor stops running. Soft stop output cut-off voltage equal to the initial
voltage of starting.

Soft stop mode can reduce and eliminate the surge of pump type load.

Soft stop mode can use setting item PF to set the soft stop current limit, in soft
stop, reduce the impact of high current, pay attention that, this soft start current limit
is a percentage calculated on the basis of starting current limit value.

7-3-2 Free stop mode

25

Section VII Test runing and application

Item P2 is set to 0, set stop mode for this mode.

In this stop mode, when the soft starter receive the stop command, immediately
disconnect the bypass contactor and ban soft starter thyristors voltage output, motor
gradually stop as load inertia. In the situation of one drive two(more) wiring, should
set soft starter stop mode as this, in order to avoid of the phase fault reporting when
output switching.

Under normal circumstances, if not necessary soft stop, stop mode should be
free stop model, to extend the life of the soft starter.

As stop model completely ban the instantaneous output, can avoid an
instantaneous high-current impact in special applications.

7-4. Special application

7-4-1 Motors in parallel Start：

If not exceed the rated power limit of the soft starter, the motor can be connected
in parallel (motors sum current can not exceed the power of soft starter, the type
selected depending on the application rated current), but at this time should provide
additional thermal protection devices for each motor.

7-4-2 Two-speed motor start：

PR5200(C) series soft starter can start with two-speed motor, before changing
from low speed to high speed, must be solved by delayed magnetic period, to avoid a
very large reverse current between the line and the motor.

7-4-3 Long cable：

As the resistance of the cable causes, a very long motor cables could cause
voltage landing, if the voltage drop is very obvious, it will affect the current
consumption and starting torque, when choosing motor and soft starter, must consider
this.

7-4-4 soft starters parallelled with the same one power line：

If in a power line, installed several soft starters, should install the input reactor
between the wiring of the soft starter and transformer, to the middle of the line should
be . Reactor should be installed between each feeder circuit breaker and soft starter.

7-4-5 Surge protection Device (SPD) application：

In the applications which may suffer from lightning or other causes that lead to
overvoltage, overcurrent, surge interference, should consider installing a surge
protector, detailed application methods instructions, refer to POWTRAN company
"surge protector (SPD)" Product sample or other relevant data.

7-5. Application examples

Under different load conditions, parameter settings for example shown in table

7.2. Data in the table is only for reference, should be adjusted according to actual
situation

26

Section VII Test runing and application

Type of load

Start time
(seconds)

The initial

voltage

Voltage starting

(maximum current limit)

Limit Start

Ball

30

60% 4 4.5

Fans

26

30% 4 3.5

Centrifugal pump

16

40% 4 2.5

Piston compressor

16

40% 4 3

Enhance the

mechanical

16

60% 4 3.5

Mixer

16

50% 4 3

Crusher

16

50% 4 3.5

Screw compressor

16

40% 4 3

Screw conveyor

20

40% 4 2

Light load motor

16

30% 4 3

Belt conveyors

20

40% 4 2.5

Heat pump

16

40% 4 3

Table 7.2

27

第
十

Display

Description

Problems and treatment methods

Err00

Failure has been

solved

Just happened undervoltage, overvoltage or
overheating, instantaneous stop terminals are open,
such failures, now has been normal, this time to
prepare lights, reset to start the motor.

Err01

External terminal
momentary
open circuit

Short-circuit connection with the external
Instantaneous stop terminal⑦and public terminal⑩,
or connecting to other protective devices normally
closed contact.

Err02

Soft starter
overheating

Start too often or the motor power do not match
with the soft starter.

Err03

Starting times

too longer than

60 seconds

Starting parameter settings is inadequate or the load is
too heavy, the power capacity is not enough, etc.

Err04

Input phase lost

Check the input or main circuit failure, whether the
bypass contactor is stuck in the closed position and
whether the SCR is in open circuit and so on.

Err05

Output phase lost

Check the input or main circuit failure, whether the
bypass contactor is stuck in the closed position and
whether the SCR is in open circuit and so on.

Err06

Three-phase
unbalanced

Check whther the input three-phase power supply
and the load motor is normal.

Err07

Start over-current

Whether the load is too heavy or motor power does
not match with soft starter.

Err08

Running overload
protection

Whether the load is too heavy or setting items P6,
PP parameters set incorrectly.

Err09

Supply voltage is
too low

Check the input voltage or setting item P7
parameter set incorrectly.

Err10

Supply voltage is
too high

Check the input voltage or setting item P8
parameter set incorrectly.

Err11

Set the parameters
error

Modify the settings, or pressing the Enter key on
power to restore the factory values.

Err12

Load short-circuit

Check whether overloading or thyristor short circuit.

Err13

Automatic re-start

wiring error

Check whether the outside the control start and stop
terminal is connected to 2-wire mode.

Err14

External stop
terminal wiring
error

When you allow external control mode, the external
control stop terminal is in the open state, which can
not start the motor.

Err15

Motor underload

Check the motor shaft and load faults.

Section VIII Fault causes and treatment

Fault codes and treatment as following table：

28

Section VIII Maintenance and Repair

Note: some fault phenomena are interrelated, as the report Err02, may be
related with soft starter overheating or load short current, so when checking fails,
consideration should be comprehensive, accurately determine the point of failure.

29

第
十

Soft starter model

Rated

Power

(KW)

Rated

current

(A)

Supporting

circuit breaker

model (QF)

Supporting the
bypass
contactor
model

pporting the

bypass
contactor type
(KM)

A line size

Remarks

PR5200 5R5G3

5.5

11

16A

25A

2.5mm2 Cable

Rated power and
rated current is the
maximum rating of
the soft starter,
matching circuit
breaker and the
bypass contactor
should match the
size of motor
specification.

PR5200 7R5G3

7.5

15

20A

25A

4mm2 Cable

PR5200 011G3

11

22

32A

40A

6mm2 Cable

PR5200 015G3

15

30

40A

63A

10mm2 Cable

PR5200 018G3

18

37

50A

63A

10mm2 Cable

PR5200 022G3

22

44

63A

63A

16mm2 Cable

PR5200 030G3

30

60

80A

100A

25mm2 Cable

PR5200 037G3

37

74

100A

160A

35mm2 Cable

PR5200 045G3

45

90

125A

160A

35mm2 Cable

PR5200 055G3

55

110

160A

160A

35mm2 Cable

PR5200 075G3

75

150

180A

250A

30*3mm2 Cable

PR5200 090G3

90

180

225A

250A

30*3mm2 Cable

PR5200 115G3

115

230

315A

400A

30*3mm2 Cable

PR5200 132G3

132

260

315A

400A

30*4mm2 Cable

PR5200 160G3

160

320

350A

630A

30*4mm2 Cable

PR5200 185G3

185

370

400A

630A

40*4mm2 Cable

PR5200 200G3

200

400

500A

630A

40*4mm2 Cable

PR5200 250G3

250

500

630A

630A

40*4mm2 Cable

PR5200 280G3

280

560

630A

1000A

40*4mm2 Cable

PR5200 320G3

320

640

800A

1000A

40*4mm2 Cable

PR5200 400G3

400

800

1000A

1000A

40*4mm2 Cable

Section IX Soft-start model specifications and
options

9-1 PR5200(C) series soft starter (5.5KW-55KW) list of the external parts of the
specification reference：

30

第
十

Section X Quality Assurance

The product quality shall comply with the following provisions:

1. Warranty terms
1-1. The product from the user the date of purchase, the warranty period of 12

months (limited to domestic market).

1-2. Export products and non-standard products warranty period is 12 months

or according to the agreement of warranty execution.

1-3. The product from the user the purchase date, guarantee to return,

replacement, repair service, within one month after the date of shipment.

1-4. The product from the user the date of purchase, replacement, repair within

three months after the date of shipment.

1-5. The product from the user the purchase date, enjoy lifelong compensable

service.

2. Exceptions clause
If belongs to the quality problems caused by following reasons products, not

within the warranty.

2-1. The user is not in accordance with the "products manual" is used method of

operation caused the failure.

2-2. Users without permission to repair or alteration caused by product failure.
2-3. Users beyond the standard specifications require the use of the inverter

caused by product failure.

2-4. Users to buy and then fell loss or damage caused by improper handling.
2-5. Because the user use environment device caused by aging lead to product

failure.

2-6. Due to the fault cause of earthquake, fire, lightning, wind or water disaster,

abnormal voltage irresistible natural disasters.

2-7. Damaged during shipping (Note: the transport mode specified by the

customer, the company to assist to handle cargo transfer procedures).

3. The following conditions, manufacturers have the right not to be warranty
3-1. No product nameplate or product nameplate blurred beyond recognition.
3-2. Not according to the purchase contract agreement to pay the money.
3-3. For installation, wiring, operation, maintenance and other users can not

describe the objective reality to the company's technical service center.

4. In return, replacement, repair service, shall be returned the company,

confirmed the attribution of responsibility, can be returned or repair

31

Section IX Soft-start model specifications and options

32

第
十
章

Product type： Producing number：

Warranty Period：

Purchasing date： _____ Day _____ Month _____ Year

Invoice No.：

Customer Name：
(Or Company Name)

Address：

Postcode： Tel： Fax：

Dealers Name：

Address：

Postcode： Tel： Fax：

Dealers Seal

POWTRAN Technology Product Warranty Card

Thank you very much for purchasing POWTRAN product.
The product has passed the strict quality inspection by POWTRAN technology.

According to the guarantee card, in the warranty period, if he product has quality
problem caused by the hardware malfunction during the normal using condition, the
company will be responsible for free maintenance.

33

第
十
章

Applicatio

n

Motor

KW pole type

When

happens

Continuous operation Acceleration slow down power supply
others（ ）

What
displays

Alarm display（ ）with or without keyboard display（ ）
output voltage（YES NO）

Running
after rest

Yes No Resetting way Keyboard Panel Terminal Power
Others( )

The control

terminal

01,02 03,04 05,06 07 08 09 10 11,12
Others( )

Working

hours

frequency

Installatio

n place

Whether

the power

is off

Yes

No

Whether the

machine is

abnormal

YES

No

Whether it

has fault

before

Yes( Times）

No

Customer feedback form of soft starter fault

Dear customer: In order to provide our best service to you ,please fill in the table
below

34

The first
time

Maintenance

Agency Name

Tel

Address

Postcode

Maintenance bill

number

Maintenance

staff sign

The
second
time

Maintenance

Agency Name

Tel

Address

Postcode

Maintenance bill

number

Maintenance

staff sign

The
third
time

Maintenance

Agency Name

Tel

Address

Postcode

Maintenance bill

number

Maintenance

staff sign

The following table is filled in by service agencies

Maintenance Record：

Product information feedback

Dear users：

Thank you for your attention and purchasing POWTRAN technology products! In order to
serve you better, we hope to get your personal general information about using POWTRAN
technology products, your now and future demand on POWTRAN technology products, gain for
your valuable feedback. To facilitate as early as possible when you need our services, please visit
the company website POWTRAN technology Http://www.powtran.com "technologies and
services" and "Downloads" section for information feedback.

1) Download and update you product manual

2) Access to products, technical information, such as instructions, size characteristics, and

frequently asked questions

3) Application Case Share.

4) Technical consulting, on-line feedback

5) Feedback by the form of e-mail on product information and user needs information

6) For the latest products, access to all kinds of additional services and extended warranty.