Installation & Operating Procedures
Opal SS6
Series
SOLID STATE REDUCED VOLTAGE STARTER
FOR 3 PHASE INDUCTION MOTORS
OPAL SS6 Reduced Voltage St art ers
Opal SS6 SERIES
REDUCED VOLTAGE
SOLID STATE STARTERS
FOR 3 PHASE INDUCTION MOTORS
INSTALLATION & OPERATING PROCE DURE
Revision 1.08 - 07/2011
OPAL SS6 Reduced Voltage St art ers
FOR YOUR SAFETY
Only qualified personnel should install this equipment, after first reading and
understanding all the information in this manual. All instructions should be strictly
adhered to. The user should consult SAF Drives Inc. or a SAF OPAL Starters
supplier for clarification of the contents of this manual should any doubt or
questions arise.
The installation of this equipment must be conducted in accordance with all
national, regional and local electrical codes.
All drawings and technical representations included in this manual are for typical
installations and should not in any way be considered for specific applications or
modifications. Consult SAF OPAL Starters for supplemental instructions.
SAF Drives Inc. accepts no liability for any consequences resulting from
inappropriate, negligent or incorrect installation, application or adjustment of this
equipment.
The contents of this manual are believed to be correct at the time of printing. In
following with our commitment to the ongoing development and improvement of
our products SAF OPAL Starters reserves the right to change the specification of
this product and/or the content of this instruction manual without notice.
OPAL SS6 Reduced Voltage St art ers
TABLE OF CONTENTS
1.0 DESCRIPTION ......................................................................................................... 1
1.1 OVERVIEW .................................................................................................................... 1
1.1.1 STANDARD FEATURES ............................................................................................. 1
1.1.2 OPTIONAL FEATURES .............................................................................................. 2
1.2 APPLICATION NOTES ................................................................................................... 2
1.2.1 OPERATION MODES ................................................................................................. 2
1.2.2 CHOOSING STARTING MODE .................................................................................. 3
1.2.3 MOTOR AND LOAD TYPES ....................................................................................... 4
1.2.4 STARTING AC MOTORS I N PARALL EL .................................................................... 5
2.0 SPECIFICATIONS .................................................................................................... 6
2.1 POW ER RATING ............................................................................................................ 6
2.2 MAXI MUM RAT INGS ...................................................................................................... 6
2.3 SERVICE CONDITIONS ................................................................................................. 6
2.4 FUSE SIZING ................................................................................................................. 7
2.5 DIMENSIONS ................................................................................................................. 8
2.5.1 STANDARD UNIT ....................................................................................................... 8
2.5.2 REVERSING UNITS ................................................................................................... 9
2.6 SCR INSTALLATION SPECIF ICATIONS .......................................................................10
2.6.1 SCR TIGHTENING PROCEDURE .............................................................................10
3.0 CARD FUNCTIONS ................................................................................................ 12
3.1 CARD LAYOUT ..............................................................................................................12
3.2 ANNUNCIATION ............................................................................................................13
3.2.1 LED INDICATIONS ....................................................................................................13
3.2.2 NEON INDICATIONS .................................................................................................13
3.3 ADJUSTMENTS .............................................................................................................13
3.3.1 POTENTIOMETERS ..................................................................................................13
3.3.2 LINK SELECTION ......................................................................................................14
3.3.3 PUSHBUTTON AND SWITCHES ..............................................................................14
3.4 TERMINALS...................................................................................................................14
3.4.1 CUSTOMER TERMINALS..........................................................................................14
3.4.2 TERMINALS FOR INTERNAL USE ............................................................................15
3.5.1 OVER TEMPERATURE .............................................................................................15
3.5.2 MOTOR OVERLOAD .................................................................................................15
3.5.3 PHASE LOSS ............................................................................................................15
4.0 INSTALLATION AND START-UP .......................................................................... 16
4.1 INSPECTION .................................................................................................................16
4.2 SAFETY PRECAUTIONS ..............................................................................................16
4.5.1 BEFORE POWER-UP ................................................................................................17
4.5.2 WITH POW ER ON .....................................................................................................18
4.5.3 HEAVY DUTY CURRENT CALIBRAT ION TABLE .....................................................19
OPAL SS6 Reduced Voltage St art ers
5.0 OPAL OPTION CARDS .......................................................................................... 20
5.1 SOFT STOP ...................................................................................................................20
5.2 SOLID STATE REVERSING ..........................................................................................21
5.3 UP-TO-SPEED, SHEAR PIN, AND ENERGY SAVER ...................................................22
5.3.1 UP-TO-SPEED AND SCR BY-PASS ..........................................................................22
5.3.2 SHEAR PIN PROTECTION ........................................................................................23
5.3.3 ENERGY SAVER .......................................................................................................23
5.3.4 EXTENDED OVERLOAD ...........................................................................................23
5.4 SHORTED SCR DETECTION........................................................................................24
5.5 LINEAR ACCEL/DECEL OPTION ..................................................................................25
5.5.1 POTENTIOMETERS ..................................................................................................25
5.5.2 LINK SELECTION ......................................................................................................26
5.5.3 TERMINALS ...............................................................................................................26
5.5.4 START-UP .................................................................................................................26
6.0 TYPICAL CONNECTIONS ..................................................................................... 27
6.1 OPAL WITH 2-WIRE CONTROL A ND EXTERNAL RESET ..........................................28
6.2 OPAL WITH 3-WIRE CONTROL, OPTIONAL RUN AND READY P ILOT LIGHT ..........29
6.3 OPAL WITH SOFT STO P ..............................................................................................30
6.4 OPAL WITH SOLID STAT E REVERSI NG .....................................................................31
6.5 OPAL WITH BYPASS CONTACTOR FOR NEMA 4 OR 12 125A AND BELOW ...........32
6.6 OPAL WITH BYPASS CONTACTOR FOR NEMA 4 OR 12 200A AND ABOVE ............33
6.7 OPAL W ITH SHORTED SCR OPTION ..........................................................................34
6.8 OPAL W ITH LINEAR ACCEL/DECEL CARD .................................................................35
7.0 SPARE PARTS ...................................................................................................... 36
7.1 STANDARD UNIT ..........................................................................................................36
7.2 OPTION CARDS ............................................................................................................36
8.0 TROUBLESHOOTING ........................................................................................... 37
OPAL SS6 Reduced Voltage St art ers
1.0 DESCRIPTION
1.1 OVERVIEW
The OPAL series is a line of solid state reduced voltage starters for use with 3ø induction
motors. This series also includes various optional features that can be easily appended.
A solid state starter provides a step-less, thus smooth current ramp to the motor. This
characteristic elimi nates current surges and mechanical torque trans ients. Since these units
are solid state, we now eliminate the maintenance of moving contacts which are involved in
almost any other method of starting an AC induction motor.
1.1.1 STANDARD FEATURES
- 200-600 VAC 3ø Universal voltage, 50/60Hz with no adjustments
- Single controller card throughout the OPAL range
- Current regulated, closed loop
- Dual operation modes to match any application:
Constant Current mode for light loads or limited power supplies
Current Ramp mode for high inertia or heavy loads
- LED and NEON status and diagnostics
- Prevents starting with any phase missing
- Phase rotation insensitive
- Instantaneous electronic over-current trip
- Class 20 electronic motor overload
- Overload capacity:
500 % for 35 seconds
115 % continuous
- Form C dry fault contact
- N/O dry run contact
- Simple user set-up and current calibration by rotary switch
- Two or three wire control
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OPAL SS6 Reduced Voltage Starters
1.1.2 OPTIONAL FEATURES
- Solid State Reversing
Through the addition of 4 Silicon Controlled Rectifiers ( SCR's ) and a reversing card,
smooth motor reversing is achieved without having to stop the motor.
- Soft Stop
Motor deceleration is controlled to eliminate water hammer effect on pump applications.
- By-Pass Contactor
Once the motor has reached operational speed, the by-pass contactor is closed. This shorts
the SCR's which eliminates the voltage drop across the SCR's, in turn being more efficient
and ridding excess heat.
- Up-To-Speed Contact / Shear Pin Protection / Energy Saver
- Shorted SCR Sensor and Protection
Sensor detects shorted SCR and trips circuit breaker or contactor upstream.
- Linear Accel\Decel Card
Provides linear accel and decel independent of load with the use of speed feedback
- DC Injection Braking
Through the addition of 4 SCR's and a DC Injection card, adjustable braking of an AC motor
is performed. More information is provided in the OP-STOP, DC INJECTION manual.
- External Reset Push Button
- Start, Stop, Reverse Push Buttons
- NEMA 4 or NEMA 12 Enclosures
1.2 APPLICATION NOTES
1.2.1 OPERATION MODES
1.2.1.1 Constant Current Mode
Applications
*Compressors
*Empty Mixers
*Empty Crushers
*Chippers
*Pumps/Fans
*Centrifuges
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OPAL SS6 Reduced Voltage St art ers
1.2.1.2 Current Ramp Mode
Applications
* Conveyors
* Extruders
* Mixers
* Stamping
Machines
* Cranes
* Shredders
*Hammer Mills
1.2.2 CHOOSING STARTING MODE
With any induction motor the design is such that starting currents and torques are very high.
Across the line starting for a basic NEMA B design motor creates an in-rush current of
600% or more of the nameplate rating. Often these levels are so high that they cause
problems with mechanical or auxiliary electrical. An example of this is the high starting
torques which cause belt slip and high currents, creating large voltage dips. The basis of
choosing the correct starting mode is determining the problem to be solved.
Torque Reduction on heavy loads is accomplished by using the Current Ramp Mode.
The idea is to reduce starting current to just above the level which will produce enough
torque to get the motor to move. This is commonly referred to as "break-away torque". As
the current ramps up from this point, the torque also increases as time passes. If at the
initiation of start, the motor torque is less than the load, the motor will remain stalled until
the torque ramps to a sufficient level for acceleration.
Soft Startin g for light loads or reducin g starting current are accomplished by using the
Constant Current Mode.
On some applications the starting time is still too fast in the current ramp mode because the
load is too light. In this application it is best to select the constant current mode which will
allow the acceleration torque to be better controlled, actually kept constant.
If the available current is limited and causes significant voltage drops, the constant current
mode will allow flexibility in setting the current draw. Remember that the current level must
be great enough to provide acceleration torque and this level is determined by the load. For
all other applications, or if in doubt, select the Current Ramp Mode.
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OPAL SS6 Reduced Voltage Starters
1.2.3 MOTOR AND LOAD TYPES
1.2.3.1 Squirrel Cage Motors
Squirrel cage motors, with a single winding and of any NEMA design may be connected to
the OPAL starter.
1.2.3.2 Wound Rotor Motors
Wound Rotor Induction Motors (WRIM) and solid state starters make an excellent
combination for frequent starting, jogging, plug-stopping and reversing applications. These
WRIM motors use multiple steps of resistors to provide various speed torque characteristics.
This allows a high starting torque characteristic while providing low starting current when
compared to NEMA B designs.
One disadvantage has been the high maintenance costs of the resistor and shorting contactor
bank. The use of an OPAL allows an improvement to this arrangement by allowing the
current to be limited without use of the multiple steps. Usually the load characteristic is such
that this starting may be accomplished with only one or two starting steps. By eliminating
several contactors a major savings is realised that often pays for the installation cost.
The common method is to add only one step of resistance at 20% (Rotor volts divided by
Rotor Amps times 20%). This resistance value will provide relatively high starting torque
and the OPAL will be used to limit the current. As little as 200% of mot or full load current
can provide 100% starting torque unlike squirrel cage NEMA B motors which would require
500% current. The resistor bank may be shorted with a contactor at fu ll speed to reduce t he
slip and eliminate the watt losses in the resistors.
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OPAL SS6 Reduced Voltage St art ers
1.2.3.3 Other Types of AC Motors
OPAL starters may also be used to start 2-speed motors with multiple windings or
connections. Proper contactor selection and sequencing is required for the specific motor.
1.2.3.4 Resistive and Inductive Loads
The TRU-START is well suited for use as a phase controller or current regulator on resistive
or inductive loads such as heaters. When applied with a Temperature PI controller, the TRUSTART will maintain smooth control to avoid the overheating associated with on/off type
controllers. Improved temperature accuracy and longer heater elem ent life can be expected
over standard control methods.
1.2.4 STARTING AC MOTORS IN PARALLEL
OPAL SS6 starters can be used to start motors in parallel but they must have individual
overload devices added.
When the paralleled motors are also connected to the same load, mechanically or through the
material, then load sharing must be considered.
When the motors are mechanically tied, the load sharing is determined by how closely the
motor characteristics are to each other. It is important to keep the motors exactly t he same.
Even changing the manufacturers of the motors can cause some variations in load sharing.
The OPAL size is determined by the total of the motor current ratings.
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OPAL SS6 Reduced Voltage Starters
2.0 SPECIFICATIONS
2.1 POWER RATING
POWER 3ø, 200-600VAC, 50/60 Hz
CONTROL 115 VAC@50 Hz or 120 VAC@60 Hz, 12VA (fans are extra)
RATING See Section 2.2
All models have 1600V PIV SCR's
CONTACTS Run and fault relay contacts rated at 0.2A, 115VAC
PROTECTION Short circuit by HRC fuses or circuit breaker (supplied upon request)
Voltage surge protection by MOV's across the SCR's
2.2 MAXIMUM RATINGS
OPAL
MODEL
SS6-15 5 10 15
SS6-30 10 25 30
SS6-50 20 40 50
SS6-80 30 60 75
SS6-125 50 100 125
SS6-200 75 150 200
SS6-360 150 300 350
SS6-500 200 400 500
SS6-600 250 500 600
230V 460V 575V
HORESEPOWER
Page 6
SS6-800 300 600 800
2.3 SERVICE CONDITIO NS
ELEVATION For altitudes in excess of 2000 meters / 6600 feet above sea level, all
assemblies must be derated 1% for every 100 meters / 330 feet above
AMBIENT Do not install in areas where ambient temperature falls below
TEMPERATURE 0°C / 32°F or exceeds 40 °C / 104°F
HP
J FUSE AMPS
OPAL SS6 Reduced Voltage St art ers
2.4 FUSE SIZING
OPAL
MODEL
SS6-15
SS6-30
SS6-50
SS6-80
SS6-125
MOTOR
FLC
5
10
15
20
25
30
34
0
52
60
65
75
100
125
460V 575V FAST ACTING TME DELAYED
3
7.5
10
15
20
--
25
30
40
-50
60
75
100
5
10
15
20
25
30
30
40
50
60
--
75
100
125
15
25
40
50
60
70
70
80
100
125
150
150
200
250
10
15
25
30
40
50
50
60
80
90
90
100
150
175
SS6-200
SS6-360
SS6-500
150
180
200
250
300
360
400
500
125
150
--
200
250
300
--
400
150
--
200
250
300
--
400
500
300
400
400
500
600
--
--
--
200
250
300
350
400
500
500
600
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