ABB PSTX30 Guide

Softstarters Type PSTX30...PSTX370
Installation and commissioning manual
1SFC132081M0201 EN, Rev A

This is the Installation and commissioning manual for Softs-
tarters Type PSTX30…PSTX370.
Document number: 1SFC132081M0201
Revision: A
Issue date: 2014-06-27
Data can be changed without notice.
We reserve all rights to this document, even in the event that
a patent is issued and a different commercial proprietary right
is registered. Improper use, in particular reproduction and dis-
semination to third parties, is not permitted.
This document has been carefully checked. If the user detect
an error, he or she is kindly asked to notify us as soon as pos-
sible.
The data contained in this manual is intended solely for the
product description and is not to be deemed to be a state-
ment of guaranteed properties. In the interests of our cus-
tomers, we constantly seek to ensure that our products are
developed to the latest technological standards. As a result,
there may be some differences between the softstarter and
the information in this manual.
Author’s address:
ABB AB
Control Products
Low Voltage Products
SE-721 61 VÄSTERÅS, Sweden
© Copyright 2014. All rights reserved. Data can be changed
without notice.
Original instruction

Thank you for selecting this ABB PSTX softstarter.
Carefully read and make sure that you understand all
instructions before you mount, connect, configure the
softstarter.
This manual is intended for installation and advanced
usage of the PSTX softstarter. For quick and easy
installation, see 1SFC132082M9901 - Softstarters Type
PSTX30...PSTX370User Manual short form. The manual is
available on ABB website.
When this manual refers toABB website: Select the link
Control Products, continue to Softstarters and type in
the specified reference in the search field.
•Only authorized and appropriately trained personnel are
allowed to install and make the electrical connection
of the softstarter in accordance with existing laws and
regulations.
•Only authorized personnel are allowed to do service and
repair on the softstarter.
•Unauthorized repair will effect the warranty.
•ABB personell have to obey the instructions in ABB
CISE 15.4.
•This manual is a part of the PSTX softstarter.
Always keep this manual available when working with
the PSTX softstarter.
•Examine the softstarter and the package when you
unpack your new PSTX softstarter. If there are damages,
please contact the transportation company or the ABB
reseller/ofceimmediately.
•Do not lift the softstarter by the connection bars, as this
can do damage to the softstarter.
Saftey notes
In this user manual, these symbols are used:
CAUTION
Caution symbol indicates the presence of a
hazard which could result in personal injury.
WARNING
Warning symbol indicates the presence of a
hazard which could result in damage to equipment
or property.
INFORMATION
Information sign alerts the reader to relevant facts
and conditions.
Modicationstodatainthismanualcanbeappliedwithout
notice.
General saftey information
CAUTION
Only authorized and appropriately trained
personnel are allowed to install and make
the electrical connection of the softstarter in
accordance with existing laws and regulations.
WARNING
Examine the softstarter and the package when
you unpack your new PSTX softstarter. If there
are damages, please contact the transportation
company or the ABB reseller/office immediately.
WARNING
Do not lift the softstarter by the connection bars,
as this can damage the softstarter.
WARNING
Only authorized and appropriately trained service
personnel are allowed to do service and repair on
the softstarter. Note: unauthorized repair will effect
the warranty.
Read this first
Warning and saftey


11
5
9
3
7
11
2
6
10
4
8
12
1 Introduction
2 Quick start
3 Description
4 Mounting
5 Connection
6 Human machine interface (HMI)
7 Functions
8 Communication
9 Maintenance
10 Troubleshooting
11 Wiring diagrams
12 Revisions
Softstarters Type PSTX
Installation and commissioning manual


1
1.1 Documentation for softstarter PSTX30...PSTX370
8
1.1.1 Installation and commissioning manual
1.2 Intended audience 9
1.3 Revision notes and other documents 9
1.4 Acronyms and abbreviations 9
1.4 Acronyms and abbreviations 9
1 Introduction

1.1.1 Installation and commissioning
manual
This manual, “Softstarters Type PSTX30...PSTX370
Installation and comissioning manual”, contains
instructions on how to install, commission and maintain
the softstarter. It covers procedures for mechanical and
electrical installation, and installation of communication
devices. It also covers energizing, settings and
configuration.
To start quickly, read chapter 2 Quick start
or use the short form manual (1SFC132082M9901).
For chapter content,
see Table 2 Chapter contents below:
Table 2 Chapters contents
Chapters Description
1. Introduction Introduces the reader to this manual.
2. Quick start Contains information on how to, in the
quickest way, install the softstarter and get it
into operation.
3. Description Describes the softstarter with specifications
and list of functions.
4. Mounting Contains information of the delivery, how to
unpack and mount the softstarter.
5. Connection Contains instructions on how to make the
electrical connections, as well as connections
for communication devices.
6. Human-Machine
Interface
Describes the local Human-Machine
Interface, how it works and what it contains.
Describes all settings and how to navigate
the menu systems.
7. Functions Describes all functions included in the
softstarter, with their minimum, maximum
and default values. This chapter is intended
for the experienced user.
8. Communication Describes the communication ports of the
softstarter.
9. Maintenance Describes what maintenance is needed and
how to do it.
10. Troubleshooting Contains instructions on how to quickly find
and correct the most common faults.
11. Wiring diagrams Contains electrical and application diagrams
for the softstarter.
12. Revision Shows all revisions of the manual
13. Index Index of the content of this manual.
1.1.2 Installation and commissioning
manual - Short form
The “Softstarters Type PSTX30...PSTX370 Installation
and comissioning manual - Short form” contains brief
information about the softstarter:
-Installation
-Electrical connections
-Basic funtions
-Troubleshooting
The short form contains the languages shown in
Table 1 Languages. The short form has document ID
1SFC132082M9901.
This chapter describes the softstarter documentation.
It describes manuals and its chapters, releases, intended
audience and it explains concepts.
1.1 Documentation for softstarter
PSTX30...PSTX370
For the softstarter types PSTX30...PSTX370, the following
manuals and catalogs are available:
1SFC132081M0201
This document. Installation and comissioning manual
(English version). See chapter 1.1.1 Installation and
commissioning manual more information.
1SFC132082M9901
Installation and comissioning manual - Short form.
See chapter 1.1.2 Installation and commissioning
manual - Short form for more information.
1SFC132009C0201
Catalog Softstarters Type PSTX and PSTB.
These documents are available online in PDF format.
A printed version of the “Installation and comissioning -
Short form” is included with the softstarter.
The following manuals will be available as online PDF-files:
Table 1 Languages
Document ID Language
1SFC132081M1301 AR Arabic
1SFC132081M2001 ZH Chinese
1SFC132081M4601 CS Czech
1SFC132081M0101 DE German
1SFC132081M0201 EN English
1SFC132081M0701 ES Spanish
1SFC132081M1801 FI Finnish
1SFC132081M0301 FR French
1SFC132081M0901 IT Italian
1SFC132081M3101 NL Dutch
1SFC132081M4001 PL Polish
1SFC132081M1601 PT Portuguese
1SFC132081M1101 RU Russian
1SFC132081M3401 SV Swedish
1SFC132081M1901 TR Turkish
These documents will be found at: ABB Website. Select
the link Control Products on the site, and then
continue to Softstarters.
1

1.2 Intended audience
1.2.1 General
The Installation and commissioning manual is intended for
authorized installation, commissioning, and maintenance
personnel.
1.2.2 Requirements for personnel
The installation personnel must have a basic knowledge
in handling electric equipment. The commissioning and
maintenance personnel must be well experienced in
using electric equipment. ABB personell have to obey the
instructions in ABB CISE 15.4.
1.3 Revision notes and other
documents
For latest information on revisions and other
documents related to the PSTX softstarters, please
check ABB Website. Select the link Control Products on
the site, and then continue to Softstarters.
1.4 Acronyms and abbreviations
The acronyms and abbreviations described in table 3 are
used in this manual.
Table 3 Acronyms and abbreviations
Acronym/
abbreviation
Description
BP By-pass
DOL Direct-on-line
EOL Electronic overload
FB Fieldbus
FBP Fieldbus Plug
HMI Human-Machine Interface
IeRated operational current
IT Information Technology
LED Light Emitting Diode
PCBA Printed Circuit Board Assembly
PLC Programmable Logic Controller
PTC Positive Temperature Coefficient
SC Short Circuit
SCR Silicon Controlled Rectifier (thyristor)
TOR Top of Ramp (full voltage/Full-On)
UcRated control circuit voltage, used for
controlling the softstarter. *
UeRated operational voltage on the motor (three
phase main voltage feeding the motor). *
UsRated control supply voltage, feeding the
electronics in the softstarter. *
*) For definition see IEC 60947-1 edition 5.0
1

2
2.1 Connection
12
2.2 Configuration
14
2.2.1 Basic set-up 14
2.2.2 Application set-up 14
2.3 How to start/stop the motor
15
2 Quick start

This chapter is a short guide on how to connect, configure
and start the softstarter in an easy way.
This product has been carefully manufactured and tested,
but there is a risk that damage can occur from abnormal
handling during transportation. Therefore, the instructions
below must be followed:
CAUTION
Hazardous voltage: Can cause death or serious
injury. Always turn off and lock out all power that
supply this device before you start to work on the
equipment.
WARNING!
Mounting and fastening of electrical connections
must be made by authorized personnel and in
accordance with existing laws and regulations.
WARNING!
Before you connect the softstarters PSTX30...
PSTX170tooperationalvoltageforthersttime,
apply control supply voltage in order to open the by-
pass relays. (see step 6 in chapter 2.1 Connection).
Opening the by-pass relays is necessary to avoid
unintentional starting of the equipment while it is
being connected to operational voltage.
INFORMATION
ABB personell have to obey the instructions in
ABB CISE 15.4.
2.1 Connection
1. Mount the softstarter according to chapter 4
Mounting.
INFORMATION
PSTX softstarters can be connected both In Line
1and Inside Delta 2, see Figure 1.
2. Connect the main circuit: terminals 1L1 - 3L2 - 5L3
to the line side 1, and terminals 2T1 - 4T2 - 6T3
to the motor side 2, see Figure 2. Use wire
connection for PSTX30-105, see Figure 2
and terminal connection for PSTX 142-370,
see Figure 3.
3. Connect the line side to terminals 1L1, 3L2, 5L3.
see 1Figure 2 and 3. Connect the motor to
terminals 2T1, 4T2, 6T3 on the motor side, see 2
Figure 2 and 3
INFORMATION
Use only wires of the same dimension when you
connect 2 wires to each terminal. (Possible for
PSTX30...105 only).
Figure 1: In Line (1) and Inside Delta (2) connection
1
PSTX PSTX
12
1SFC132081M0201
Figure 2: Terminal connection clamps.
2
1SFC132081M0201
1
2
Line side
1L1
3L2
5L3
6T3
4T2
2T1
Motor side
3
Line side
2T1
4T2
6T3
5L3
3L2
1L2
Motor side
1
2
1SFC132081M0201
Figure 3: Terminal connection bars
2

4. Connect the control supply voltage (100-250V
50/60Hz) to terminal 1 and 2 .
5. Connect the functional earth (terminal 22), to an
earthing point close to the softstarter.
See Figure 4.
The earthing is not a protective earth, it is a
functional earth. The earthing cable should be
as short as possible. Maximum length is 0.5 m.
The earthing cable should be connected to the
mounting plate were the softstarter is mounted,
which should also be earthed.
6. Look at the diagram, see Figure 5, and connect
the start/stop circuits: terminal 13, 14, 18, 19 and
20/21, with the internal 24V DC terminal. When
using internal 24 V DC (terminals 20 or 21), the
terminals 18 and 19 should be connected to each
other. For external control circuit voltage,
see chapter 5.1.2.3 Start and Stop - terminals
13, 14, 18, 19, 20, 21.
WARNING
Use 24V DC only when you connect terminal 13, 14,
15, 16 and 17. Other voltages can cause damage
to the softstarter and the warranty will no longer be
valid. For more information about terminal 15, 16 and
17, see chapter 5.1.2.4 Programmable inputs -
terminals 15, 16 and 17.
7. Connect terminals 4, 5, 6, 7, 8, 9, 10, 11 and 12
to use the signal output relays. These are potential
free contacts for maximum 250 V AC, 1.5 A AC-15
and 30 V DC, 5 A DC-12. See Figure 6.
8. Check that the operational voltage and control
supply voltage corresponds to the softstarter
ratings.
9. Switch on the control supply voltage.
10. The green “Ready” LED will flash on the HMI, as in
Figure 7.
11. After switching on the softstarter the language
settings will appear on the display, choose your
language and press selection softkey “OK”. The
HMI will now download language data from the
softstarter. Which may take several minutes. When
this is completed the HMI will switch to Home view.
12. Configure applicable parameters as given in
chapter 7 Functions or use the assistants as
described in chapter 2.2 Configuration.
Figure 4: Functional earth, terminal 22.
4
1SFC132081M0201
5
22
L1
L2
L3
N
KM1
1L1 3L25L3
2T14T2 6T3
UVW
19 201815 1617141321 21
M
3
Stop
Star 24 V DCt
LN
121110987654
22
2014 18 1913
Start Stop
1SFC132081M0201
Figure 5: Circuit diagram PSTX30...PSTX370
(Fuse and contactor version)
6
22
L1
L2
L3
N
1L1 3L25L3
2T14T2 6T3
UVW
19 201815 1617141321 21 22
M
3
Stop
Star 24 V DCt
LN
121110987654
22
2014 18 1913
Start Stop
1SFC132081M0201
Figure 6: Circuit diagram PSTX30...PSTX370 ( MCCB version)
PSTX
L
100-250V
50/60 Hz K4 K4 K4 StartStopReset In1In2 DGND DND +24V GND
N
7
1SFC132081M0201
Figure 7: Flashing “Ready” LED
2

2.2 Configuration
For a quick configuration of the softstarter, you can use
the Assistants menu.
The Assistants menues are divided into:
•Basic set-up
- The Basic set-up menu is divided into four steps:
1. Language
2. Date and time
3. Motor data
4. System configuration
•Application set-up
- The Application set-up is divided into three steps:
1. Application set-up
2. Keep/Change values
3. Tune settings
2.2.1 Basic set-up
This set-up will automatically appear when you start the
softstarter. It can be turned off so that it does not start
automatically. See step 6 below.
1. Find the Assistants menu by pressing “Menu”
and then scroll to Assistants with the Navigation
keys. Press “Select” to enter the Assistants
menu.
2. Scroll to the Basic set-up menu by using the
Navigation keys and then enter the menu by
pressing “Select”.
3. The Basic set-up will start with step 1, Language.
Press “Edit” to change language. Use the
Navigation keys to select language and then press
“Save”.
4. Press to enter step 2, Date and time. Press
“Edit” and use the Navigation keys to edit date and
time, then press “Save”.
5. Press to enter step 3, Motor data.
Press “Edit” to change the Motor rated current
Ie. Use the Navigation keys to change the value
and then press “Save”.
6. Press to enter step 4, System configuration.
Here it is possible to set if the softstarter shall
enter the Basic set-up at power on or not. Use the
Navigation keys to select Yes or No and then press
“Save”.
7. Press and then Press “Done” to finish the
Basic setup. For more settings, enter Application
set-up.
2.2.2 Application set-up
1. Find the Assistants menu from the Home view by
pressing “Menu” and scroll to Assistants with
the Navigation keys. Press “Select” to enter
the Assistants menu.
2. Scroll to the Application set-up menu by using
the Navigation keys and then enter the menu by
pressing “Select”.
3. The Application set-up will start with step 1,
Application type. Scroll to the appropriate
application type and then press “Select”. For a
full Application list see chapter 7.21.1 Application
settings list.
4. Press to enter step 2, Values. You can choose to
“Keep actual values” or “Change to recommended
values”. Scroll to the selection of your choice and
Press “Select” to apply.
WARNING!
Note that previously saved parameter values will be
lost if you select “Change to recommended values”.
5. Press to enter step 3, Tune settings. In most
cases the recommended values work well, but
sometimes fine tuning is needed. For fine tuning,
press “Edit” and then use the navigation keys
to set:
-Start ramp time: 1 - 120s
-Stop ramp time: 1 - 120s
-Start ramp initial level: 10 - 99%
-Stop ramp end level: 10 - 99%
-Current limit level: 1.5 - 7.5 xIe
-Start mode: Voltage ramp, Torque ramp or Full
voltage start
-Stop mode: No ramp, Voltage ramp, Torque ramp,
DC brake or Soft brake
6. Press and then press “Done” to finish the
Application set-up. If needed, fine tuning can also
be made in the Parameters menu.
2

2.3 How to start/stop the motor
CAUTION
Hazardous voltage: Can cause death or serious
injury. Turn off and lock out all power that
supply this device before you start work on the
equipment.
WARNING!
Mounting and fastening of electrical connections
must be made by authorized personnel and in
accordance with existing laws and regulations.
WARNING!
Before you connect the softstarters PSTX30...
PSTX170tooperationalvoltageforthersttime,
apply control supply voltage in order to open the by-
pass relays. (see step 6 in chapter 2.1 Connection).
Opening the by-pass relays is necessary to avoid
unintentional starting of the equipment while it is
being connected to operational voltage.
INFORMATION
ABB personell have to obey the instructions in
ABB CISE 15.4.
1. Switch on the operational voltage.
2. To start the softstarter from the keypad, press the
R/L-key to select local control, then press the Start
key. Press Stop to stop the softstarter
3. To start from hard wire control, press the R/L-key
to select hard wire control, then press the Start
key. Press Stop to stop the softstarter
2

3
3 Description
3.1 Overview
18
3.1.1 Operation functions 18
3.1.2 Protection functions 18
3.1.2.1 User defined protection 19
3.1.3 Warning functions 19
3.1.4 Fault detection functions 19
3.1.5 Softstarter overview 20
3.1.6 Type designation 21
3.1.7 Environmental influence 21
3.1.8 Specifications 21
3.2 Technical data
22
3.2.1 General 22
3.2.2 Technical data for external keypad 22
3.2.3 Semi-conductor fuses 22
3.2.4 Weights 22
3.2.5 Softstarter ratings 23
3.2.6 Dimensions 24

•Dual current limit
•Ramp current limit
•Kick start
•Slow speed
•Motor heating
•Sequence start
•Automatic restart
•Small motor mode
•Fire mode
•Limp mode
•Pump cleaning
3.1.2 Protection functions
The PSTX softstarter is equipped with a number of
protection functions to protect the softstarter, motor
and other equipments. All protections can be set to
have automatic reset or manual reset. Protection can be
enabled or disabled by the user.
Available protections are listed below:
•EOL protection
•Locked rotor protection
•Phase reversal protection
•Current imbalance protection
•Over voltage protection
•Under voltage protection
•Earth fault protection
•Voltage imbalance protection
•Voltage outputs protection
•External thermal sensor - PT100 protection
•External thermal sensor - PTC protection
•Power factor underload protection
•Current underload protection
•User defined protection
•Too long current limit protection
•By-pass open protection
•Fieldbus failure protection
•Extension IO failure protection
•HMI failure protection
•Limit number of starts
This chapter describes the softstarter in general,
specifications as well as available accessories and spare
parts.
3.1 Overview
The PSTX softstarter is designed with the latest
technology for soft start and soft stop of squirrel cage
motors. The softstarter has several advanced motor
protection features as standard.
Bypass
Softstarter range PSTX30...370 have integrated by-pass
components. For PSTX210...370, this is a three phase
by-pass contactor. In an emergency case, it is possible to
start the motor DOL with this contactor.
User interface
The keypad on the front is designed with Navigation keys,
Selection softkeys, Start and Stop keys, Local or Remote
key, Information key and a clear information display. It is
possible to choose between 15 different user languages.
The softstarter can be controlled in three different ways:
•Hardwire inputs control
•Keypad control (either attached to the softstarter front
or detached and connected with the cable included)
•Fieldbus communication interface (by built in Modbus,
Anybus module or the FieldBusPlug with adapter)
Only one type of control method can be enabled
simultaneously. Default selection is hardware inputs
control.
Keypad control has the highest priority and
overrides all other control methods.
Fans
The integrated fans for cooling are running only during
ramping (start/stop) and when the heat sink temperature
is above a certain level. The temperature is monitored by
a thermistor.
3.1.1 Operation functions
Available functions are listed below:
•Voltage ramp start
•Voltage ramp stop
•Torque ramp start
•Torque ramp stop
•Full voltage start
•Direct stop
•Stand still brake
•Normal current limit
3

3.1.2.1 User defined protection
Programmable digital input can be used in combination
with external device/sensor to provide to the customer the
possibility of handling own defined protection.
The protection is activated when the input signal reaches
high level (fieldbus or physical I/O).
3.1.3 Warning functions
The softstarter is equipped with a number of warning
functions that signal potential risks, before activating a
protection.
The difference between a warning and a protection is that
a warning can not stop the softstarter and that a reset of
a warning is not necessary.
The warning level and other parameters needed to enable
and configure the warning are settable. Warnings will be
logged in the event list when it occurs.
Available warnings are listed below:
•Current imbalance warning
•Over voltage warning
•Under voltage warning
•EOL time-to-trip warning
•EOL warning
•Total Harmonic Distortion (THD) warning
•Voltage imbalance warning
•Power factor underload warning
•Current underload warning
•Faulty Fans warning
•Locked rotor warning
•Thyristor overload warning
•Short circuit warning
3.1.4 Fault detection functions
The softstarter is equipped with a number of fault
detection functions to signal malfunctioning at
softstarter, motor or power network level. The softstarter
differentiates between external and internal faults. Fault
detection functions can not be disabled by the user.
Available faults are listed below:
•Phase loss fault
•High current fault
•Low supply voltage fault
•Bad network fault
•Thyristor overload fault
•Short circuit fault
•Shunt fault
•Unspecified fault
•Heat sink overtemperarure fault
•Open circuit thyristor fault
•Faulty usage
•Faulty connection
3

3.1.5 Softstarter overview
Settings can be done via Keypad and Fieldbus
communication.
With the keypad, settings can be set as individual
parameter settings or as a selection of predefined
parameters for different applications.
Most parameters have one possible setting, but some
parameters have extra settings for sequence start. The
default parameter settings are stored in the unit so that a
reset to default can be done at any time.
When the fieldbus communication is selected, most
parameters can also be modified from this interface.
Overview, See Figure 8.
Ready
Run Fault
Protection
Com1 Com2
4T22T1 6T3
3L21L1 5L3
PSTX
L
100-250V
50/60 Hz K4 K5 K6
Start StopIn1 In2DGND+24VGND
N
In0
8
1SFC132081M0201
Figure. 8: Softstarter overview
Symbol for
Torque control
Anybus
connection
(Com2)
Supply voltage Us
Order code
Technical data
according to UL 508
Fieldbus connection (Com1)
Motor side connection
Terminal marking of
control circuits
Line side connection
Display
Keypad
Mini USB
Country of origin
Utilization code
Approvals
Terminal marking of
control circuits
Protection (Yellow)
Fault (Red)
Technical data
accordning to
IEC 60 947-4-2
Ready (Green)
Run (Green)
3
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3
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12
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