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
Page 1
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
Page 2
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.
Page 3
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.
Page 4
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.
Page 5
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
Page 7
OPAL SS6 Reduced Voltage Starters
2.5 DIMENSIONS
This is a general guideline for dimensions as they may change slightly based on different
options used.
2.5.1 STANDARD UNIT
OPAL
MODEL
SS6-15
SS6-30
SS6-50
SS6-80
SS6-125
SS6-200
Height × Width × Depth
CHASSIS NEMA 1 NEMA 12
33cm × 22cm × 15cm
13" × 8.5" × 6"
41cm × 22cm × 15cm
16" × 8.5" × 6"
43cm × 27cm × 19cm
17" × 10.5" × 7.5"
43cm × 27cm × 22cm
17" × 10.5" × 8.5"
53cm × 27cm × 24cm
21" × 10.5" × 9.5"
34cm × 52cm × 27cm
13.5" × 20.5" × 10.5"
33cm × 22cm × 18cm
13" × 8.5" × 7"
41cm × 22cm × 18cm
16" × 8.5" × 7"
43cm × 30cm × 27cm
17" × 12" × 10.5"
43cm × 30cm × 27cm
17" × 12" × 10.5"
53cm × 30cm × 27cm
21" × 12" × 10.5"
76cm × 61cm × 41cm
30" × 24" × 16"
33cm × 22cm × 18cm
13" × 8.5" × 7"
61cm × 50cm × 30cm
24" × 20" × 12"
43cm × 30cm × 27cm
17" × 12" × 10.5"
43cm × 30cm × 27cm
17" × 12" × 10.5"
53cm × 30cm × 27cm
21" × 12" × 10.5"
122cm × 91cm × 41cm
48" × 36" × 16"
Page 8
SS6-360
SS6-500
SS6-600
SS6-800
48cm × 56cm × 28cm
19" × 22" × 11"
50cm × 64cm × 34cm
19.5" × 25" × 13.5"
50cm × 64cm × 34cm
19.5" × 25" × 13.5"
65cm × 71cm × 42cm
25.5" × 28" × 16.5"
91cm × 76cm × 41cm
36" × 30" × 16"
107cm × 91cm × 41cm
42" × 36" × 16"
107cm × 91cm × 41cm
42" × 36" × 16"
122cm × 91cm × 51cm
48" × 36" × 20"
122cm × 91cm × 41cm
48" × 36" × 16"
152cm × 122cm × 41cm
60" × 48" × 16"
152cm × 122cm × 41cm
60" × 48" × 16"
152cm × 152cm × 51cm
60" × 60" × 20"
OPAL SS6 Reduced Voltage St art ers
2.5.2 REVERSING UNITS
OPAL
MODEL
SS6-15R
SS6-30R
SS6-50R
SS6-80R
SS6-125R
SS6-200R
Height × Width × Depth
CHASSIS NEMA 1 NEMA 12
33cm × 22cm × 17cm
13" × 8.5" × 6.5"
41cm × 22cm × 17cm
16" × 8.5" × 6.5"
43cm × 27cm × 20cm
17" × 10.5" × 8"
43cm × 27cm × 22cm
17" × 10.5" × 8.5"
53cm × 27cm × 24cm
21" × 10.5" × 9.5"
34cm × 52cm × 28cm
13.5" × 20.5" × 11"
33cm × 22cm × 18cm
13" × 8.5" × 7"
41cm × 22cm × 18cm
16" × 8.5" × 7"
43cm × 30cm × 27cm
17" × 12" × 10.5"
43cm × 30cm × 27cm
17" × 12" × 10.5"
53cm × 30cm × 27cm
21" × 12" × 10.5"
91cm × 76cm × 41cm
36" × 30" × 16"
33cm × 22cm × 18cm
13" × 8.5" × 7"
61cm × 50cm × 30cm
24" × 20" × 12"
43cm × 30cm × 27cm
17" × 12" × 10.5"
43cm × 30cm × 27cm
17" × 12" × 10.5"
53cm × 30cm × 27cm
21" × 12" × 10.5"
122cm × 91cm × 41cm
48" × 36" × 16"
SS6-360R
SS6-500R
SS6-600R
SS6-800R
48cm × 56cm × 29cm
19" × 22" × 11.5"
50cm × 64cm × 36cm
19.5" × 25" × 14"
50cm × 64cm × 36cm
19.5" × 25" × 14"
65cm × 71cm × 42cm
25.5" × 28" × 16.5"
122cm × 76cm × 41cm
48" × 30" × 16"
122cm × 91cm × 41cm
42" × 36" × 16"
122cm × 91cm × 41cm
42" × 36" × 16"
152cm × 91cm × 51cm
60" × 36" × 20"
122cm × 91cm × 41cm
48" × 36" × 16"
152cm × 122cm × 41cm
60" × 48" × 16"
152cm × 122cm × 41cm
60" × 48" × 16"
183cm × 152cm × 51cm
72" × 60" × 20"
Page 9
OPAL SS6 Reduced Voltage Starters
2.6 SCR INSTALLATION SPECI FICATIONS
2.6.1 SCR TIGHTENING PROCEDURE
2.6.1.1 Clean both heat sink and SCR surfaces.
2.6.1.2 Apply a thin layer of joint compound (Noalox) to both SCR surfaces.
2.6.1.3 Observe correct SCR polarity.
2.6.1.4 Install SCR so that roll pins engage dimples on both sides of the SCR.
2.6.1.5 Tighten clamp bolts evenly until finger-tight.
2.6.1.6 Tighten each bolt according to table below (based on number of spring bars
and size of bars).
* Note: SMALL clamps are 4.25 inches / 10.5 cm and LARGE clamps are 5 inches / 12.5 cm.
CLAMP SIZE SPRING BARS
BOLT TURNS PAST
FINGER TIGHT
SMALL 1 0.75
SMALL 2 1
LARGE 3 1.75
LARGE 4 1.75
Page 10
OPAL SS6 Reduced Voltage St art ers
Page 11
OPAL SS6 Reduced Voltage Starters
3.0 CARD FUNCTIONS
3.1 CARD LAYOUT
Page 12
CA392 - OPAL CONTROLLER CARD
OVER
TEMP
On when unit is faulted because of an open Over
Temperature switch at the OT terminal
MOTOR
OVRLD
When lit an IOC (instantaneous over-current) or
an inverse time overload fault exists
Should be lit during stop and extinguished when the motor is
up to speed. This represents the status of SCR 1 and 2
Indicates voltage is present on L1
Should be lit during stop and extinguished when the motor is
up to speed. This represents the status of SCR 3 and 4
Indicates voltage is present on L2
Should be lit during stop and extinguished when the motor is
SETTING
Adjusts the time of the current ramping
CW rotation decreases the time
Adjusts the starting current or breakaway
CW increases the torque (current)
OPAL SS6 Reduced Voltage St art ers
3.2 ANNUNCIATION
3.2.1 LED INDICATIONS
LED NAME COLOUR DESCRIPTION
LD1
RED
LD2 READY GREEN This LED is illuminated when there are no faults
LD3 RUN GREEN Indication of run commanded to starter
LD4
RED
LD5 +15V GREEN Illuminated when +15V power supply is okay
3.2.2 NEON INDICATIONS
NEON NAME DESCRIPTION
NE1 SCR 1,2
NE2 L1 ON
NE3 SCR 3,4
NE4 L2 ON
NE5 SCR 5,6
up to speed. This represents the status of SCR 5 and 6
NE6 L3 ON Indicates voltage is present on L3
3.3 ADJUSTMENTS
3.3.1 POTENTIOMETERS
POT NAME RANGE
RV1 RATE 2-3 SEC 50%
RV2 STEP 150-350%
DEFAULT
50%
DESCRIPTION
torque
Page 13
Shipped from factory with no jumper
RV1 has no bearing
This selects current ramp mode which is
BURDEN
Calibrates current for nameplate rating of motor
115 VAC supplied to this input will enable the unit
Common Fault relay contact. The relay is energized
when a fault exists
Normally open Fault relay contact
Normally closed Fault relay contact
Dry run contact for external use or sealing contact for
start pushbutton with three wire control
115 VAC control voltage input
250 VAC
A contact closure across these terminals will reset
For local panel door use, low voltage control.
OPAL SS6 Reduced Voltage Starters
3.3.2 LINK SELECTION
LINK NAME POSITION DESCRIPTION
With no jumper present, heavy duty mode
selected
Selects constant current mode
dependent on RV1
JP1 DUTY
JP3 RATE
NO
JUMPER
OFF
ON
*Note : JP2 does not exist on this version
3.3.3 PUSHBUTTON AND SWITCHES
SWITCH NAME DESCRIPTION
SW1 RESET Resets IOC or inverse time overload fault
SW2
SELECT
Refer to current table on starter or Section 4.5.3.
3.4 TERMINALS
3.4.1 CUSTOMER TERMINALS
TERMINAL NO. DESCRIPTION
1
to run
2
3
TB
4
5 115 VAC supplied for control logic
6,7
AC AC1, N
TB1 RESET
AC1, N AC1 input is protected with internal fuse, 3A
any faults that exist.
Page 14
This two pin connector is for an over temperature switch on
units with fans and must be shorted if an OT switch is not used
OPAL SS6 Reduced Voltage St art ers
3.4.2 TERMINALS FOR INTERNAL USE
TERMINAL DESCRIPTION
OT
FAN Fused 115 VAC for fan connection
SCR1-6 Gate lead connections for SCR firing
OPT Provided for ribbon cable link to SAF's OPAL option cards
3.5 FAULTS
Any OPAL fault energizes the fault relay and shuts down the starter. Whenever any fault exists, the
READY LED will be off indicating the starter won't run. Once the fault is cleared, READY will be
illuminated if no other faults exist. Terminal TB-2 to 3 will be open when no fault exists and closed
during a fault condition, TB2 to 4 is vice versa.
3.5.1 OVER TEMPERATURE
OPAL units with fans have over temperature switches fastened to the heatsink(s). This switch or
switches in series, are connected in the OT terminal on the control card. Units without fans have
a jumper installed. In the case where there is a fan failure or fan blockage and the heatsink
temperature exceeds 85°C / 185°F ± 5°C / 41°F, the over temperature switch opens, faulting the
OPAL. This fault is indicated by LD1, OVERTEMP. When the heatsink cools enough, creating
switch closure, the OVER TEMP LED will extinguish.
3.5.2 MOTOR OVERLOAD
This fault has two conditions, instantaneous over current (IOC) or inverse timed overload. Both
of these faults are indicated by LD4, MOTOR OVRLD. If started into a short, the OPAL should
trip on an IOC dependent upon the impedance of the incoming lines. This condition is resettable
instantly by the RESET button. The inverse time overload is a class 20 overload that simulates
the heating of the motor.
This electronic circuitry begins to integrate whenever the current to the motor exceeds 115% of
the current setup with SW2. This current calibration switch should be setup to the name plate
current rating of the motor. Once the overload circuitry reaches the trip level, the unit faults and
shuts down. This trip is allowed to be cleared with the RESET button after a time period of
approximately 5-7 minutes. This time allows for the motor to cool before restarting.
3.5.3 PHASE LOSS
If any of the incoming lines are not present before starting the OPAL will be faulted. Each line is
indicated by a corresponding neon lamp. Once the missing phase(s) is/are present and no other
faults exist, the unit will be ready to run.
Page 15
CAUTION
machinery, touch motor terminals or control equipment pa rts.
OPAL SS6 Reduced Voltage Starters
4.0 INST A LLATION A ND ST A RT-UP
4.1 INSPECTION
The OPAL has been packaged to protect it from damage caused by normal handling during
shipment; however mishandling may cause damage to the OPAL. Unpack the unit as soon as
it is received and check for any shipping or storage damages.
If damage is found, notify the carrier. Any damage claim must be filed by the customer since
all shipments are F.O.B. SAF plant unless otherwise specified.
If the OPAL is not installed when received, store it in a clean, dry, well ventilated area, free
from heat, humidity, oil, dust, and metal particles.
4.2 SAFETY PRECAUTIONS
Equipment is at line voltage when AC power is connected.
Pressing "STOP" pushbutton does not remove AC mains potential.
All phases must be disconne cted before it is safe to work on
The electrical code requires all equipment, starter, motor, operator station, etc. to be
grounded properly.
An incoming circuit breaker or disconnect switch must be locked open before wiring or
servicing this starter, motor, or other related equipment. This equipment must be installed
and serviced only by qualified personnel, familiar with this starter.
The user is responsible for ensuring that proper short circuit protection is provided by either
a circuit breaker or HRC fuses.
4.3 MOUNTING GUIDELINES
Standard Nema 1 OPAL Starters must be installed indoors in a well ventilated area, free
from heat, humidity, oil, dust and metal particles.
One foot of clearance must be kept all around in a natural cooled unit. The equipment must
be mounted away from any heat source. See Section 2 for additional specifications.
Be aware that the heatsink may reach 70° C / 158°F during normal operation. Do not install
the starter in contact with any material that can not accept this temperature.
The starter must be mounted vertically and where it will not experience excessive shock or
vibration.
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OPAL SS6 Reduced Voltage St art ers
4.4 WIRING GUIDELINES
The electrical code requires that an approved circuit disconnecting device be installed in the
incoming AC supply, mounted in a location readily accessible to personnel installing or servicing
this equipment.
Power factor correcting capacitors MUST NOT be connected to the OPAL output. If desired, they
must be added ahead of the starter. Cap acitors can be connected before startin g or after the motor
has reached full speed. It is recommended that the Up-to-Speed option card be used to connect the
capacitors after full speed has been reached.
In-line contactors are not required; however they can be used on the line side or the motor side
without detriment to the starter. It is recommended that the contactor be sequenced to open and
close under no-load conditions to prolong the life of the contacts.
Size the power wiring as per local code. On long wire runs it is recommended to use a larger wire
size.
All three phases of the incoming power wires must pass through the same hole in the enclosure.
This rule also applies to all phases of the outgoing or motor wires.
If an electro-mechanical brake is used in the system, it must be powered from the line side of the
starter, to ensure full voltage to the brake.
For short-circuit fuse protection, we suggest referencing the table in Section 2.
4.5 START-UP
4.5.1 BEFORE POWER-UP
4.5.1.1 Ensure that all electrical connections are completed as shown on the schematics, and
that connections are properly tightened.
4.5.1.2 Read motor full load current from the nameplate and rotate SW2 to match the motor
full load current, according to the label attached or the current chart in Section 4.5.3.
4.5.1.3 Check 120 VAC control voltage to the OPAL unit.
4.5.1.4 Set RV1 and RV2 to mid-position, for 15 sec ramp time and 250% starting current.
4.5.1.5 Check link positions. The factory settings are current ramp mode and no jumper for
heavy duty.
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OPAL SS6 Reduced Voltage Starters
4.5.2 WITH POWER ON
4.5.2.1 With the motor connected and power on, all neon lamps should be illuminated and
no faults should exist.
4.5.2.2 Once start has been initiated the motor must start rotating immediately, it must not
stall. Increase the starting current if necessary by rotating RV2, STEP, clockwise.
4.5.2.3 The RATE could be re-adjusted to extend or decrease the accelerating time. To
speed up the acceleration rate, turn RV1 clockwise. The actual motor accelerating
time depends on the motor current as well as the mechanical load. This setting has
no effect when constant current mode has been selected. Refer to diagram below.
4.5.2.4 The RATE adjusts the time from the STEP setting to 500% of motor full load
current.
4.5.2.5 Some readjustments may be required when the motor is started to suit specific
applications.
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OPAL SS6 Reduced Voltage St art ers
4.5.3 HEAVY DUTY CURRENT CALIBRATION TABLE
SW2
OPAL MODEL (SS6 -)
POSITION
15 30 50 80 125 200 360 500 600 800
0 1 12 24 47 77 103 150 286 420 494
1 2 13 26 50 80 109 164 300 432 514
2 3 15 28 52 84 116 178 315 444 535
3 4 16 30 54 87 122 192 330 456 555
4 5 17 32 56 90 129 206 343 468 576
5 6 19 34 58 93 135 220 357 480 596
6 7 20 36 61 96 142 234 372 492 616
7 8 22 38 63 100 148 248 386 504 637
8 9 23 40 65 103 155 262 400 516 657
9 10 24 42 67 106 161 276 415 528 678
A 11 6 44 69 109 168 290 429 540 698
B 12 27 46 72 112 174 304 443 552 718
C 13 29 48 74 116 181 318 458 564 739
D 14 30 51 76 119 187 332 472 576 759
E 15 31 53 78 122 194 346 486 588 780
F 16 33 55 80 125 200 360 500 600 800
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OPAL SS6 Reduced Voltage Starters
5.0 OPAL OPTION CARDS
Re fer to Section 6 for typica l connections of any of the options listed in this se c tion.
5.1 SOFT STOP
CA390 - SOFT STOP CARD
This option has been designed to provide a controlled stop, to eliminate the water hammering effect
a ss ociated with fluid pumping applications.
The Soft St op card w ork s in the opposite fashion as t he OPAL start ing. W hen stop is commanded,
t he OPAL out put voltage drops t o a level set by STEP, RV2, and begins to ramp down following a
rate set by t he pot enti ometer D ECEL, RV 1, The OPA L wi l l remai n on unti l t he mot or t ermi nal
v o l tag e h as d ec reased t o a s et vo ltage l evel, at w h i c h tim e th e starter s w i tc h es o ff. T he maximum
ramp ti me i s l i mi t ed t o a maxi mum 15-20 seconds. T hi s i s the ti me that t he r el ay i n t he OPA L
controller card, CA392, is maintained ene rgize d.
The ma jority of AC induction motors expe rience a region of instability when phased back or volta ge
i s reduced. T he STEP potentiomet er shoul d be adj usted to a l evel , w hi ch is j ust bel ow this poi nt.
Fully counter-clockwise provides little decrease in voltage step when stop is commanded.
Clockwise rotation of RV1 slows the ramp down from this point.
T h e v olt ag e l ev el ju mp er , J1 , set at L O c eases st ar t er o perat i o n at 1 5 % v o ltag e w hi le at H 1 , t he
OPAL stops a t 20% line voltage.
Terminals 1 and 2 on t his option car d are prov ided to w ir e an ex ternal selector swit ch to enable or
di sable t he sof t st op mode. W hen terminal s 1 and 2 of T B 1 are shor ted, t he OPA L will coast t o a
res t when stop is commanded.
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OPAL SS6 Reduced Voltage St art ers
5.2 SOLID STATE REVERSING
CA388 - SOLID STATE REVERSING CARD
This option provides a smooth, current controlled, motor rotation reversal without any current surge
or torque jerk. Motor stopping is not required. Additions to the OPAL include a reversing card,
CA388, plus four additional SCR's.
Terminal block AC, terminals 1 and 2 are to be connected to 115 VAC control voltage. An external
switch or contact must be connected to AC, terminals 3 and 4 of this card. The forward brid ge is
selected with the switch closed. With the switch open the starter will fire the reverse bridge.
Terminal block J1 is a form C dry contact rated at 0.2A, 115 VAC for an indication of the direction
selected and by-pass contactor sequencing for a reverse/by-pass combination. The red LED, LD1
indicates the reverse selection and the green LED, LD2 annunciates that the forward bridge is
chosen.
A REVERSING DELAY TIME potentiometer, RV1, sets the time the OPAL remains off when
switching directions, from 1 to 10 seconds. Clockwise rotation increases dwell time. The factory
default setting is 1 second.
When the motor is running and the forward/reverse switch changes states, the OPAL turns all SCR's
off. After an adjustable time delay set up by RV1, the OPAL is switched back on, triggering a
different set of SCR's. This effectively switches two output lines, decelerates the motor down to
zero speed, and continues to accelerate it to full speed in the opposite direction. The motor reversal
is performed under complete current control via the RAMP and STEP potentiometers on the
CA392.
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OPAL SS6 Reduced Voltage Starters
5.3 UP-TO-SPEED, SHEAR PIN, AND ENERGY SAVER
5.3.1 UP-TO-SPEED AND SCR BY-PASS
A three pole contactor used in conjunction with the Up-To-Speed contact eliminates the
SCR losses by shorting them out after the motor has reached full speed. This feature is a tru e
Watt Saver modification and permits the use of the OPAL in a NEMA 4 or NEMA 12
enclosure. The by-pass contactor is switched on only after the motor has reached fu ll speed
and as such sees only motor full load current. At stop, the by-pass contactor is opened while
the SCR's are triggered fully on, limiting the power contacts opening voltage. The SCR's are
then switched off without having any voltage surge.
When a by-pass contactor is used in conjunction with reversing, the FWD/REV contacts of
the CA388 must be connected in series for proper sequencing of the contactor(s).
When the motor reaches full speed, the Up-To-Speed relay is energized and the red UP-TOSPEED LED, LD3 is illuminated. A form C dry relay contact rated at 1A, 120VAC, is
provided on J1 terminals 1, 2 and 3 for by-pass sequencing. Large contactors require a
control relay to handle the high in rush current to the coil.
Page 22
CA391 - MULTI OPTION CARD
OPAL SS6 Reduced Voltage St art ers
5.3.2 SHEAR PIN PROTECTION
This feature has been designed to provide motor jam protection, similar to a mechanical
shear pin.
Once the motor has reached full speed, indicated by LD3 being on, the OPAL will trip if the
motor current increases to 300%. The red SHEAR TRIP LED, LD2 will indicate this trip and
is resettable via the red RESET pushbutton on the option card. Link JP2 enabl es or disables
this optional feature.
5.3.3 ENERGY SAVER
This option is designed to phase back the SCR's under light load, and keep them fully phased
on under medium to full load. This optional feature is intended for use on small motors in
applications where the motor runs under no load for an extensive time but can not be
switched off. The energy save is not effective on motors over 25 HP. The OPAL starter is
designed for repeated starting and stopping. The most efficient operation is to switch the
motor off when ever possible.
Link JP1 enables or disables this optional feature. The red ENERGY SAVE LED, LD1 will
come on to announce that this feature is active. To calibrate this feature, turn RV1, PHASE
BACK ADJUST pot clockwise until the motor starts to become unstable. Once this occurs,
turn the pot slightly counter-clockwise until the motor is again stable. Energy save is not
operational with the use of a bypass contactor.
5.3.4 EXTENDED OVERLOAD
With a high inertia load such as a chipper, a Class 20 overload may not allow enough time
for the motor to reach full speed without nuisance overload tripping.
In such a scenario an extended overload option can be implemented. This allows the motor
500% current for a longer period of time. This option only affects the overload when the
motor is started.
The extended overload is not a factory option and must be specifically requested. Consult
factory for more details.
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OPAL SS6 Reduced Voltage Starters
5.4 SHORTED SCR DETECTION
CA395 - SHORTED SCR CARD
This option provides protection against the unlikely event of a shorted Silicon Controlled Rectifier
(SCR). This card only functions when the OPAL is not running and should be used in conjunction
with a shunt trip circuit breaker or an in-line contactor.
In the event of a shorted SCR, it is not sufficient to merely trip the starter. The incoming 3ø power
must be removed. The danger associated with a shorted SCR is that even when the starter is not
running, current may pass freely through the motor.
If a shorted SCR is detected, the Shorted SCR relay is energized. The form C relay contact rated at 1
Amp, 120 VAC on terminals 1, 2 and 3 of J1, is provided for means of opening the circuit breaker
or contactor used. Large contactors require a control relay to handle the high in rush current to the
coil. A red LED, LD1 will illuminate during this condition of a shorted device.
The CA395 will indicate a shorted SCR if the motor is not connected. In reversing applications, two
shorted SCR cards must be used. When using an OPAL with an integral DC Injection option, the
DCI contact from the OP-STOP must be used in conjunction with the shorted SCR contact to
eliminate erroneous trips during DC injection.
Page 24
Sets up speed feedback for the regulator by adjusting voltage at TP1
OPAL SS6 Reduced Voltage St art ers
5.5 LINEAR ACCEL/DECEL OPTI O N
CA385 - LINEAR ACCEL/DECEL CARD
This option card combined with a 60 tooth magnetic pulse pick-up or a tachometer provides
linear acceleration and deceleration independent of load. The ramp reference can be via
internal ramp generator or an auxi liary reference. A form C dry contact indicating when the
unit is running is available for external use and illuminated via LD1.
5.5.1 POTENTIOMETERS
POT NAME DESCRIPTION
RV1 STAB Adjustment for stability of the ramping transition
RV2
TACH
SCALE
RV3 DECEL Adjusts decel time of ramp, 5 - 50 seconds, CW increases time
RV4 ACCEL Adjusts accel time of ramp, 5 - 50 seconds, CW increases time
(below JP2), CW decreases voltage at TP1
For internal ramp set TP1 for -9.2V or less at full speed
For aux ref set TP1 = maximum reference -0.667 or slightly less at
full speed
Page 25
PULSE
FEEDBACK
Common point for pulse pick up feedback
and auxiliary reference
Input for auxiliary reference when JP1 is at AUX
Range is 0 - 15V maximum
ramp reference or auxiliary input reaches 0V
FEEDBACK
Scaled by resistor at J3
Scaling resistor for tach feedback
OPAL SS6 Reduced Voltage Starters
5.5.2 LINK SELECTION
LINK NAME DESCRIPTION
AUX Reference from auxiliary input
JP1
INT Internal reference from ramp generator
PULSE Feedback from magnetic pick-up input on J1
JP2
TACH Feedback from tachometer input on J2
5.5.3 TERMINALS
TERMINAL
NO. NAME DESCRIPTION
1
2 COMMON
J1
3 AUX REF
4 NO Normally open starter status contact
5 NC Normally closed starter status contact
6 COM
J2
J3 CAL R
5.5.4 START-UP
TACH
Connection point for pulse pick up feedback
Common of ramp status form C contacts
Energized when unit started and de-energized when
Input for tachometer feedback
Resistor should be 1 Watt or greater
CAL R = (max. tach volts -13.4) ÷ 12 in kilo-ohms
5.5.4.1 STEP (RV2) should be set at 0 and the RATE jumper (JP3) must be OFF or
removed on the CA392 control card. Ensure SW2 is in correct position.
5.5.4.2 Set JP1 and JP2 on CA385 at settings for your application. If tach feedback is being
used, install resistor as per above procedure in TERMINALS.
5.5.4.3 Set all pots to 50%.
5.5.4.4 Start unit and adjust speed feedback according to the procedure in the table
POTENTIOMETERS, RV2 description when at full speed. If accel or decel is too
slow adjust appropriate pot. If motor does not seem to get up to full speed, reduce
the level at TP1 by turning RV2 clock-wise.
Page 26
OPAL SS6 Reduced Voltage St art ers
6.0 TYPICAL CONNECTIONS
Listed in this section are diagrams containing typical single option connections. Notice that
multi-option connections are possible, meaning a combination of a starter with two or more
options attached. The only connection difference between the various sized OPAL power
units, other than the obvious sizes and ratings of devices, is the location of the current
transformers. This should be of no concern because any modification involving this
configuration should be done at the factory or be consulted by SAF Drives Inc.
Page 27
OPAL SS6 Reduced Voltage Starters
6.1 OPAL WITH 2-WIRE CONTROL AND EXTE RNAL RE S E T
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OPAL SS6 Reduced Voltage St art ers
6.2 OPAL WITH 3-WIRE CONTROL, O P TIONAL RUN AND READY PILOT LIGHT
Page 29
OPAL SS6 Reduced Voltage Starters
6.3 OPAL WITH SOFT STOP
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OPAL SS6 Reduced Voltage St art ers
6.4 OPAL WITH SOLID STATE REV E RS ING
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OPAL SS6 Reduced Voltage Starters
6.5 OPAL WITH BYPASS CONTACTOR FOR NE MA 4 O R 1 2 125A AND BELOW
Page 32
OPAL SS6 Reduced Voltage St art ers
6.6 OPAL WITH BYPASS CONTACTOR FOR NE MA 4 O R 1 2 200A AND ABOVE
Page 33
OPAL SS6 Reduced Voltage Starters
6.7 OPAL WITH SHORTED SCR OPTION
Page 34
OPAL SS6 Reduced Voltage St art ers
6.8 OPAL WITH LINEAR ACCEL/DECE L CARD
Page 35
C/T
NO.
MULTI
SOLID STATE
SOFT
SHORTED
LINEAR
OPTION
CARD
OPAL SS6 Reduced Voltage Starters
7.0 SPARE PARTS
7.1 STANDARD UNIT
OPAL
MODEL
C/T
RATIO
PART
SCR
PART NO.
MOV PART
NO.
CONROL
CARD
SS6-15 1500:1 T261122 N10SP03 O210050 CA392
SS6-30 1500:1 T261122 N10SP03 O210050 CA392
SS6-50 1500:1 T261122 N10SP06 O210050 CA392
SS6-80 2500:1 T262320 N10SP16 O210050 CA392
SS6-125 2500:1 T262320 N20SP06 O210050 CA392
SS6-200 2500:1 T262320 N728452 O210050 CA392
SS6-360 5000:1 T265320 N718133 O210050 CA392
SS6-500 8500:1 T268320 N718552 O210050 CA392
SS6-600 8500:1 T268320 --- O210050 CA392
SS6-800 10000:1 T261321 --- O210050 CA392
Page 36
7.2 OPTION CARDS
DESCRIPTION
OPTION
CA391 CA388 CA390 CA395 CA385
REVERSING
STOP
SCR
ACCEL/DECEL
Fan failure
Replace fan
Fan blockage
Clear blockage
Replace jumper, units without fans
only
READY (LD2)
not lit
Does not start &
doesn't illuminate
Shorted motor or output
Check motor and output
SW2 not calibrated for
motor
Refer to current calibration chart on
unit
Burden pack not installed
or not installed correctly
Install burden pack and/or correctly
Confirm SW2 is setup for the motor
connected
RAMP and STEP setup or
necessary
Check control voltage and FU1 on
control card
Motor runs in
direction
Measure continuity between line and
Motor not connected
Connect motor
Neons 2, 4, or 6
not lit
Motor sounds
starting
Confirm good connections and all gate
card are secure
try CONSTANT CURRENT mode
Incoming lines must be connected to
OPAL SS6 Reduced Voltage St art ers
8.0 TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE CORRECTION
OVER TEMP
(LD1) lit
Jumper missing from OT
Fault present Refer to section 3.5 FAULTS
RUN (LD3)
Control wiring
MOTOR OVRLD
(LD4) lit
Motor overload
SW2 setup may be wrong
trips before motor
is up to speed
extended overload
+15V (LD5) not lit Control voltage not present
wrong
Neons 1, 3, or 5
Phase reversal
Shorted SCR
not lit at stop
Refer to section 6 TYPICAL
CONNECTIONS and check wiring
Increase RV1 and RV2, refer to
section 4
Interchange any two incoming or
motor leads
output terminals
3ø supply Check incoming line voltage
rough when
Loose connections or gate
leads
Lightly loaded
Motor starts
similar to
across the line
Incorrect line, terminal and
bypass connections
leads to SCR's and the CA392 control
Decrease STEP and RAMP or maybe
L1, L2, L3
Motor must be connected to T1, T2,T3
Bypass contactor must be connected to
BPM L1-3, BPM T1-T3
Page 37
OPAL SS6 Reduced Voltage Starters
Page 38
SAF Drives Inc. www.safdrives.com
18 Neville Street, Unit C www.opalstarters.com
Tel: 519-662-6489 Email: answers@opalstarters.com
Fax: 1-866-280-5247 Toll Free: 1-800-3-ASK-SAF
18 Neville Street, Unit C
New Hamburg, ON N3A 4G7
Tel: 519-662-6489
Fax: 1-866-280-5247
www.safdrives.com
www.opalstarters.com
email: answers@opalstarters.com
(Replies given within 24 hours)
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