CD Automation STE Series User manual

USER’S MANUAL
Rev. 01/2007 ST
E
Enhanced Soft Starter

CONTENTS
1 Important warnings for safety..................................................................................... 5
2 Overview ..................................................................................................................... 6
2.1 Option CONTROL 6
2.2 Overall Features 7
2.3 Basic Connections 8
3 Quick Start .................................................................................................................. 9
4 Setting the Starter..................................................................................................... 10
4.1 Delivery of the SOFT START 10
4.2 Factory Setting 11
4.3 Mounting 12
4.4 Dimensions and Fixing holes 13
4.5 Size Family 14
4.6 Select Fuses 15
4.7 Removing the cover 16
5 How to connect the starter ........................................................................................ 17
5.1 Wiring details 17
5.2 Continuous service (no Bypass) Power Connections 18
5.3 Bypass Power Connections 19
5.4 Diagram of connection for Size 9 without Bypass 20
5.5 Diagram of connection for Size 9 with Bypass 22
5.6 Diagram of connection for Size 11/13/14 without Bypass 24
5.7 Diagram of connection for Size 11/13/14 with Bypass 26
6 Connection description .............................................................................................. 28
6.1 Access to the Electronic boards 28
6.2 Supply the Electronic Board 28
6.3 Analog Inputs 29
6.4 Analog Outputs 31
6.5 Digital Input 32
6.6 Digital Output 33
7 Led status and Alarms ............................................................................................... 34
7.1 LED Status Table 34
7.2 Critical Alarms 35
7.3 Not Critical Alarm 37
8 Control Panel ............................................................................................................. 38

9 Configuration Parameters.......................................................................................... 40
9.1 Operator Menu 40
9.2 Hardware Menu 42
9.3 Setup Menu 44
10 Typical Applications................................................................................................. 47
10.1 Example of starting curves in Voltage Ramp 48
10.2 Example of starting curves in Current Ramp 48
11 Maintenance ............................................................................................................ 49
11.1 Cooling Fans 49
11.2 Maintenance 49
11.3 Repairing procedure 49
11.4 Warranty condition 49
12 RS485 Serial Port .................................................................................................... 50
12.1 MODBUS communication 51
12.2 MODBUS RTU Protocol 51
12.3 Message Format 51
12.4 Read Holding Registers 53
12.5 Preset Multiple Registers 53
12.6 Error and exception responses 54
12.7 Address Configuration 54

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1Important warnings for safety
Before any operation on either the mechanical or electrical parts of the installation, check that power
and control cables of the unit are isolated from voltage sources.
During operation the motor can be stopped by cancelling the run command but the starter remaind
powered up.
If personnel safety requires prevention of sudden restarts, this electronic locking system is not
sufficient: fit a breaker on the power circuit.
The starter is fitted with safety devices which, in the event of a fault, can stop the starter and
consequently the motor.
The motor itself may be stopped by a mechanical blockage. Finally, voltage variations or line supply
failures can also cause shutdowns.
If the cause of the shutdown disappears, there is a risk of restarting which may endanger machines,
installation or personnel. In this case the user must take precautions against the possibility of restarts,
example cut off the power.
This starter must be installed and set up in accordance with both international and national standards.
Bringing the device into conformity is the responsibility of the systems integrator who must observe the
EMC directive among others within the European Union. The specifications contained in this document
must be applied in order to comply with the essential requirements of the EMC directive.
The STE Soft Starter must be considered as a component: it is neither a machine nor a device ready for
use in accordance with European directives (machinery directive and electromagnetic compatibility
directive). It is the responsibility of the final integrator to guarantee conformity to the relevant
standards.
Note
Warning: This icon is present in all the operational procedures where the Improper
operation may result in serious personal injury or death
Caution: This icon is present in all the operational procedures where the Improper
operation can cause damage for the SOFT STARTER.
CD Automation reserves the right to modify the own products and this manual without any
advise.

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2Overview
The STE Soft Starter is a third generation ,highly sophisticated Soft Starter for use with standard three
phase squirrel cage induction motor. It provides the best method of reducing current during motor
starting.
The STE starts the motor by supplying a slowly increasing voltage providing soft start and smooth
acceleration, while drawing the minimum current necessary to start the motor.
The STE can have an external by-pass contactor, which can be activated at the end of starting process.
After the starting process by-pass operating, the STE control the motor operating:
•Thermal Overload
•Measure of Currents, frequency, power
•Alarm and shutdown operation
Size S9 with Bypass Size S11, S13, S14 with Bypass
The electronic control of STE is Full Digital with an high performance 16 bit embebbed microprocessor in
connection with an 4 Digit Data Entry, for display and programming parameter's application.
The RS485 Communication with MODBUS protocol enables the soft starter to perform full control and
supervision: up 127 starters can be connected on a shield twisted pair to a host computer.
2.1 Option CONTROL
At the end of starting normally the grid supply the AC motor to full Votage:
with the option CONTROL in these condition the voltage can be reduced by a signal in the terminal box
(0÷10 Vdc or 4÷20 mA).
These feature is very useful for special loads (i.e. fans type load).
On obtein the speed variation by simply / economic voltage variation,in comparison with an inverter
solution.

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2.2 Overall Features
Starting the motor by different methods:
•Voltage ramp from INTITIAL VOLTAGE to RATED VOLTAGE (or nominal torque) with current limit.
•Current ramp.
•Kickstart (or voltage pulse) of 80 % UN without current limit intended for start high friction load
requiring high starting torque for a short time.
Deceleration the motor by different methods:
•Voltage ramp.
•Free wheel by shut down of contactor.

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2.3 Basic Connections
Star Connections (3 wires)
LSM III ==
3
L
M
V
V=
IL= Line current
IS= Soft Starter current
IM= Motor current (Winding)
VL= Line voltage
VM= Motor voltage
I
L
L1
L2
L3
M1
M2
M3
U1
V1
W1
U2
V2
W2
I
S
I
M
Delta Connections (3 wires)
3
L
M
I
I=LS II =LM VV =
IL= Line current
IS= Soft Starter current
IM= Motor current (Winding)
VL= Line voltage
VM= Motor voltage
I
L
L1
L2
L3
M1
M2
M3
U1
V1
W1
U2
V2
W2
I
S
I
M
Open Delta Connections (6 wires)
3
L
SM
I
II == LM VV =
IL= Line current
IS= Soft Starter current
IM= Motor current (Winding)
VL= Line voltage
VM= Motor voltage
I
L
L1
L2
L3
M1
M2
M3
U1
V1
W1
U2
V2
W2
I
S
I
M

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3Quick Start
Caution: this procedure must be performed only by qualified persons.
STE start ups should be performed by electrical technicians who are familiar with electronic soft starters
and their applications. This List covers the steps necessary for a basic start up:
1. Verify the Basic Connections. Making sure that the Soft Start current is in line with what you
really need.
(see par. 2.3)
2. Verify the Factory Setting
(see par. 4.2)
3. Verify the STE Soft Starter Mounting
(see par. 4.3)
4. Verify the Diagram of connection:
•All auxiliary connections must be done in line with wirings on this manual.
•Verify that there isn’t a short circuit on the load.
(see par. 5)
5. Now you are ready for Supply the Electronic boards
(see par. 6.2)
6. If not specified in the Order Code:
•Set the Full Load Current (In) of AC motor in the parameter P017 "':.
•Set the Limit Current in the parameter P018 3' (Refer to the Typical Applications par. 10).
(see par. 8)
7. Apply Start command. If the motor doesn't begin to turn, stop the unit, increase the Initial
Voltage (parameter P022 0:-/) and start again. Caution:Values too high of Initial Voltage can
cause inrush current and mechanical shock
8. When the Motor begins to turn, if the motor speed does not accelerate to the nominal value,
increase the Current Limit. If current during acceleration is too high, increase the Acceleration
Ramp (parameter P020 +):1)
9. Apply Stop command and wait until motor stops
The STE Soft Starter is ready to use.

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4Setting the Starter
4.1 Delivery of the SOFT START
Caution: Before to install, make sure that the SOFT START have not damages. If the
product has a fault, please contact the dealer from which you purchased the product.
The identification's label give all the information regarding the factory settings of the SOFT START unit,
this label is on the unit, like represented in figure.
Check that the starter reference printed on the label is the same as that on delivery notes corresponding
to the purchased order (see par. 4.2).

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4.2 Factory Setting
Model 1 2 3 4 5 6 7 8
STE
1 Nominal Current
3 wire connection
3 In pick 3,5 In pick 4 In pick 4,5 In pick
22A 19A 16A 14A
34A 30A 26A 24A
44A 38A 33A 30A
75A 65A 58A 50A
80A 70A 60A 52A
130A 110A 95A 90A
150A 140A 120A 110A
165A 150A 130A 120A
230A 200A 170A 150A
450A 450A 450A 450A
500A 500A 500A 500A
6 wire connection
3 In pick 3,5 In pick 4 In pick 4,5 In pick
38A 33A 28A 24A
59A 52A 45A 42A
76A 66A 57A 52A
130A 112A 100A 87A
138A 121A 104A 90A
225A 190A 164A 156A
260A 242A 208A 190A
285A 260A 225A 208A
398A 346A 294A 260A
779A 779A 779A 779A
865A 865A 865A 865A
2 Start Current
3 In 3,5 In 4 In 4,5 In
3 Supply Voltage
Specify this value to configure the unit in CD Automation
4 Voltage supply for the Electronic boards
110V From 100 to 130Vac 230V From 210 to 265Vac
5 Wiring
3W 3 wire connection 6W 6 wire connection
3WB 3 wire connection + bypass 6WB 6 wire connection + bypass
6 Start seconds
Specify this value to configure the unit in CD Automation
7 Off seconds
Specify this value to configure the unit in CD Automation
8 Option
3TA External 3TA MODULE (for size 9)
FUS External Fuse
CTRL option control

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4.3 Mounting
Caution: Check that no liquids, dust or conductive objects can fall into the starter.
The STE Soft Starter must be mounted vertically, allow sufficient space (at least 100 mm) above and
below the starter for suitable airflow.
Do not mount the starter near other heat sources. Surrounding air temperature in the cabinet should not
exceed 45°C, the starter is rated to operate over a temperature range of 0°C to +45°C.
Starter's heat dissipation while motor is running with by pass closed is minimal (i.e. 40 watt).
Without by pass heat dissipation is about 3 xIn watt.
During soft start the heat dissipation increase in the range 10/20 xIn watt, depending from start current.
If the motor is frequently started the cabinet should be designed for the higher heat dissipation with for
instance additional ventilation.
4.3.1 Environment
Ambient temperature 0°C to +45°C
Storage temperature -25°C to +70°C
Installation place Don’t install at direct sun light, where there are conductive dust,
corrosive gas, vibration or water and also in salty environmental.
Altitude Up to 1000 meter over sea level. For higher altitude reduce the
nominal current of 2% for each 100m over 1000m
Humidity From 5 to 95% without condense and ice

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4.4 Dimensions and Fixing holes
316mm
187mm
116mm
SIZE 9
Weight 5kg
290mm
96mm
104mm
5mm
7mm
440mm
270mm
137mm
SIZE 11
Weight 10,5kg
97mm
410
m
m
97mm
7mm
12mm
440mm
270mm
262mm
SIZE 13
Weight 18kg
410mm
222mm
222mm
7mm
12mm
460mm
270mm
262mm
SIZE 14
Weight 22,5kg
222mm
222mm
490mm
7mm
12mm

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4.5 Size Family
3 wire connection
Nominal Current
3 In pick
Nominal Current
3,5 In pick
Nominal Current
4 In pick
Nominal Current
4,5 In pick STE Size
22A 19A 16A 14A
34A 30A 26A 24A
44A 38A 33A 30A
75A 65A 58A 50A
80A 70A 60A 52A
130A 110A 95A 90A
SIZE 9
150A 140A 120A 110A
165A 150A 130A 120A
SIZE 11
230A 200A 170A 150A SIZE 13
450A 450A 450A 450A
500A 500A 500A 500A
SIZE 14
6 wire connection
Nominal Current
3 In pick
Nominal Current
3,5 In pick
Nominal Current
4 In pick
Nominal Current
4,5 In pick STE Size
38A 33A 28A 24A
59A 52A 45A 42A
76A 66A 57A 52A
130A 112A 100A 87A
138A 121A 104A 90A
225A 190A 164A 156A
SIZE 9
260A 242A 208A 190A
285A 260A 225A 208A
SIZE 11
398A 346A 294A 260A SIZE 13
779A 779A 779A 779A
865A 865A 865A 865A
SIZE 14

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4.6 Select Fuses
Caution: USE ONLY EXTRARAPID FUSE WITH APPROPRIATE I²T
Nominal Current Fuse
3 In pick 3,5 In pick 4 In pick 4,5 In pick Max Fuse I²T
(A²sec) Qty
22A 19A 16A 14A 3800 3
34A 30A 26A 24A 3800 3
44A 38A 33A 30A 7350 3
75A 65A 58A 50A 9050 3
80A 70A 60A 52A 15300 3
130A 110A 95A 90A 69000 3
150A 140A 120A 110A 102500 3
165A 150A 130A 120A 188000 3
230A 200A 170A 150A 245000 3
450A 450A 450A 450A 1050000 3
500A 500A 500A 500A 1050000 3
For 6 wire connection, the Soft Start current is the same of winding current, to have the line current
multiply by 1,73
Caution: The Fuses must have I²t 20% less than thyristor's I²t.
Caution: High speed fuses are used only for the thyristor protection and can not be used to
protect the installation.
Caution: The warranty of STE Soft Starter is null if no proper fuses are used. See tab.
Warning: The user installation must be protected by electromagnetic circuit breaker or by
fuse isolator.

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4.7 Removing the cover
SIZE 9
Remove the screw, if present Open the unit
Screw
Open
SIZE 11
Remove the screw, if present Remove the plastic cover Open the unit
Screw
Screw
Open
SIZE 13/14
Remove the screw Remove the plastic cover Open the unit
Screw
Screw
Screw
Screw
Open

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5How to connect the starter
Caution: this procedure must be performed only by qualified persons.
•The control line supply ensuring that is OFF.
•The power line supply ensuring is OFF.
•The motor ensuring that its coupling correspond to the suppy voltage.
•Select the cable sizing in accordance with instuctions of this manual.
•Connect the starter in details power and control following the application diagram.
5.1 Wiring details
Use copper cables and wires rated for use at 75°C only.
5.1.1 Power cable torque (suggested)
STE Size Connector
Type
Torque
Lb-in (N-m)
Wire
Range
AWG / kcmil
Wire
Terminal
SIZE 9 Terminal Block
M8 265 (30.0) 8 4/0
Copper wire
Compact (Solid) Stranded
SIZE 11 Bus Bar
with M8 screw 505 (57.0) 2 350
UL Listed (ZMVV)
Copper Tube Crimp. Lug
SIZE 13 Bus Bar
with M10 screw 505 (57.0) 1 600
UL Listed (ZMVV)
Copper Tube Crimp. Lug
SIZE 14 Bus Bar
with M10 screw 505 (57.0) Bus Bar 30x6mm Bus Bar 60x6mm
5.1.2 Power cable dimensions (suggested)
Current
Power Supply
Cable
Motor Cable
(Output)
Starter Bypass
(with Bypass) Earth
mm² AWG mm² AWG mm² AWG mm² AWG
14A÷45A 10 8 10 8 10 8 6 10
50A÷76A 35 2 35 2 35 2 16 4
80A÷95A 50 1/0 50 1/0 50 1/0 25 2
100A÷112A 75 3/0 75 3/0 75 3/0 35 2
120A÷170A 95 4/0 95 4/0 95 4/0 50 1/0
190A÷225A 2 x 75 2 x 3/0 2 x 75 2 x 3/0 2 x 75 2 x 3/0 95 4/0
230A÷346A Bus Bar 30 x 6 mm Bus Bar 30 x 6 mm Bus Bar 30 x 6 mm 2 x 75 2 x 3/0
398A÷450A Bus Bar 60 x 5 mm Bus Bar 60 x 5 mm Bus Bar 60 x 5 mm Bus Bar 30 x 6 mm
500A÷865A Bus Bar 60 x 6 mm Bus Bar 60 x 6 mm Bus Bar 60 x 6 mm Bus Bar 30 x 6 mm
5.1.3 Cable dimensions of the Command Terminals
Maximum connection capacity for all size: 1.5 mm2 (14 AWG)

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5.2 Continuous service (no Bypass) Power Connections
Warning: Before connecting or disconnecting the unit check that power and control cables
are isolated from voltage sources.
Terminal Description
L1 Line Input Phase 1
L2 Line Input Phase 2
L3 Line Input Phase 3
M1 Motor Output Phase U
M2 Motor Output Phase V
M3 Motor Output Phase W
SIZE 9
L1 L2 L3
M1 M2 M3
SIZE 11
L1 L2 L3
SIZE 13
L1 L2 L3
SIZE 14
L2L1 L3

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5.3 Bypass Power Connections
Warning: Before connecting or disconnecting the unit check that power and control cables
are isolated from voltage sources.
Terminal Description
L1 Line Input Phase 1
L2 Line Input Phase 2
L3 Line Input Phase 3
M1 Motor Output Phase U
M2 Motor Output Phase V
M3 Motor Output Phase W
B1 Bypass Output Phase U (not available for size 9)
B2 Bypass Output Phase V (not available for size 9)
B3 Bypass Output Phase W (not available for size 9)
SIZE 9
L1 L2 L3
M1 M2 M3
SIZE 11
L1 L2 L3
B1 B2 B3
SIZE 13
L1 L2 L3
B1 B2 B3
SIZE 14
L2L1 L3

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5.4 Diagram of connection for Size 9 without Bypass
Warning: Before connecting or disconnecting the unit check that power and control cables
are isolated from voltage sources.
Terminal Description
1 Voltage Supply for Electronic Boards (see par. 6.2)
2 Voltage Supply for Electronic Boards (see par. 6.2)
3 Not connected
4 Isolated output +12Vdc MAX 20mA
5 GND for Digital Input
6 Output +10Vdc MAX 5mA
7 GND for Analogue Input
8 (+)Analogue Input 1: Configurable (see par. 6.3)
9 (+)Analogue Input 2: PTC probes (see par. 6.3)
10 Analogue Output 1: Configurable (see par. 6.4)
11 RS485 A
12 RS485 B
13 Output relay 2: Run (Max 500mA, 125Vac)
14 Common of the contact relay Output 1
15 NPN Output 3: Configurable (12Vdc max 20mA)
16 NPN Output 4: Configurable (12Vdc max 20mA)
17 Digital Input 1: Stop
18 Digital Input 2: Start
19 Digital Input 3: Configurable
20 Digital Input 4: Configurable
(See par. 6)