Eaton Cutler-Hammer Easy-Start ES Series User manual

Easy-Start ES
Solid State Reduced Voltage Motor Starter
Easy-Start ES
Solid State Reduced Voltage Motor Starter
Cutler-Hammer
Instruction Manual
For Model Easy-Start ES Solid State Reduced Voltage Motor Starter
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This product discussed in this literature is subject to terms and conditions outlined
in appropriate Cutler-Hammer selling policies. The sole source governing the
rights and remedies of any purchaser of this equipment is the relevant Cutler-
Hammer selling policy.
NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF
FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OR WAR-
RANTIES ARISING FROM COURSE OF DEALING OR USAGE OF TRADE, ARE
MADE REGARDING THE INFORMATION, RECOMMENDATIONS AND
DESCRIPTIONS CONTAINED HEREIN. In no event will Cutler-Hammer be
responsible to the purchaser or used in contract, in tort (including negligence),
strict liability or otherwise for any special, indirect, incidental or consequential dam-
age or loss whatsoever, including but not limited to damage or loss of use of equip-
ment, plant or power system, cost of capital, loss of power, additional expenses in
the use of existing power facilities, or claims against the purchaser or user by its
customers resulting from the use of the information, recommendations and
descriptions contained herein.
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Table of Contents
Easy-Start ES Instruction Manual
i
Page
Safety ...............................................S-1
The Meaning of Safety Statements ................S-2
Easy-Start ES Safety Statements..................S-2
Introduction .........................................1-1
Installation...........................................2-1
Pre-Installation ....................................2-3
Drawings..........................................2-19
Specifications .....................................2-45
Operation ............................................3-1
Operation .........................................3-2
Adjustments.......................................3-2
DIP Switch Settings ...............................3-3
Options ..............................................4-1
Available Options..................................4-2
Application Notes..................................4-13
Drawings..........................................4-21
Troubleshooting .....................................5-1
Troubleshooting Guide ............................5-2
SCR Diagnostics Tests ............................5-5
Renewal Parts List ................................5-13
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Figure Description Page
2-1 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
2-2 System Schematic
(Hevi-Duty Co. - Multi Volt Transformer Connections) . . . . . . . . . . . . . 2-21
2-3 System Schematic (Cutler-Hammer Transformer Connections) . . . . . . . . . 2-22
2-4 Logic Board Terminal Block TB1 Functions . . . . . . . . . . . . . . . . . . . . . . . . 2-23
2-5 Derate Curve For Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
2-6 Momentary Contact Start/Stop Pushbuttons . . . . . . . . . . . . . . . . . . . . . . . . 2-25
2-7 Hand-Off-Auto Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
2-8 Start-Stop Pushbuttons with Hand-Off-Auto Selector Switch . . . . . . . . . . . 2-27
2-9 Power Connections with Options
(Hevi-Duty Co. Multi Volt Transformer) . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
2-10 Power Connections with Options (Cutler-Hammer Transformer) . . . . . . . . 2-29
2-11 Dimension and Installation Open Panel ES045-_EP, ES070-_EP,
ES120-_EP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
2-12 Dimension and Installation Open Panel Slim Line Motor Control Center
ES070-_EC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
2-13 Dimension and Installation NEMA-12 Regular Enclosure
ES045-_ER, ES070-_ER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
2-14 Dimension and Installation NEMA-12 Large Enclosure
ES045-_EL, ES070-_EL, ES120-_EL . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
2-15 Dimension and Installation Open Panel ES180-_NP, ES260-_NP,
ES560-_NP, ES250-_EP, ES360-_EP, ES500-_EP . . . . . . . . . . . . . . . 2-34
2-16 Dimension and Installation Open Panel Slim Line
Motor Control Center ES120-_EC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
2-17 Dimension and Installation Open Panel Slim Line
Motor Control Center ES180-_NC, ES250-_NC . . . . . . . . . . . . . . . . . . 2-36
List of Illustrations
Easy-Start ES Instruction Manual
iii
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List of Illustrations
iv
Easy-Start ES Instruction Manual
Figure Description Page
2-18 Dimension and Installation NEMA-1 Regular Enclosure
ES180-_NR, ES260-_NR, ES560-_NR . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
2-19 Dimension and Installation NEMA-1 Large Enclosure, ES180-_NL,
ES260-_NL, ES560-_NL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
2-20 Dimension and Installation Open Panel ES750-_NP . . . . . . . . . . . . . . . . . 2-39
2-21 Dimension and Installation NEMA-1 Large Enclosure ES750-_NL . . . . . . 2-40
2-22 Dimension and Installation NEMA-12 Large Enclosure ES250,
ES360-_EL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
2-23 Dimension and Installation NEMA-12 Large Enclosure ES500-_EL . . . . . . 2-42
2-24 Dimension and Installation NEMA1 ES950-_NL . . . . . . . . . . . . . . . . . . . . . 2-43
2-25 Dimension and Installation Open Panel ES950-_NP . . . . . . . . . . . . . . . . . 2-44
3-1 Over-Load Time-Current Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
4-1 NEMA-1 Current Vs. Time Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4-2 NEMA-12 Current Vs. Time Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4-3 Extended Start Time with By-Pass Contactor . . . . . . . . . . . . . . . . . . . . . . . 4-24
4-4 Option E1- Extended Start Time with Ramp-Up Door Light . . . . . . . . . . . . 4-25
4-5 Smooth Stop with By-Pass Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
4-6 Smooth Stop ÒS1Ó Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
4-7 Smooth Stop with Remote Maintained 2-Wire Contact . . . . . . . . . . . . . . . . 4-28
4-8 Jam DIP Switch Trip Point Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
4-9 Jam Trip Time Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
4-10 Underload DIP Switch Trip Point Settings . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
4-11 Underload Trip Time Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
4-12 Options J1, J2 Jam-Underload with Red Trip Lights . . . . . . . . . . . . . . . . . . 4-31
4-13 Daughter Board Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
4-14 Printed Circuit Logic Board Component Layout . . . . . . . . . . . . . . . . . . . . . 4-33
4-15 Option E - Printed Circuit Board Component Layout -
Extended Start Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
4-16 Option S - Printed Circuit Board Component Layout - Smooth-Stop . . . . . 4-35
4-17 Option J - Printed Circuit Board Component Layout - Jam-Underload . . . . 4-36
4-18 Option U - Printed Cirucit Board Component Layout - Shorted
SCR Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
4-19 Option D - Printed Circuit Board Component Layout - Daughter Board . . . 4-38
4-20 Dimension For Logic Board, Daughter Board, Cover Board Assembly . . . 4-39
5-1 Typical SCR Clamp Used in ES180, ES260 . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5-2 Typical SCR Clamp Used In ES180, ES250, ES260: 1 Leaf
ES360, ES500, ES560: 2 Leaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5-3 Assembly Sink-Device Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5-4 Stack Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
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List of Tables
Easy-Start ES Instruction Manual
v
Table Description Page
2-1 Starts-Per-Hour ES045 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2-2 Starts-Per-Hour ES070 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2-3 Starts-Per-Hour ES120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2-4 Starts-Per-Hour ES180 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2-5 Starts-Per-Hour ES250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2-6 Starts-Per-Hour ES260 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2-7 Starts-Per-Hour ES360 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2-8 Starts-Per-Hour ES500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2-9 Starts-Per-Hour ES560 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2-10 Starts-Per-Hour ES750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2-11 Starts-Per-Hour ES950 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
3-1 Dip Switch Setting Multipliers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-2 Dip Switch Ampere Settings ES045 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3-3 Dip Switch Ampere Settings ES070 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3-4 Dip Switch Ampere Settings ES120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3-5 Dip Switch Ampere Settings ES180 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-6 Dip Switch Ampere Settings ES250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-7 Dip Switch Ampere Settings ES260 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3-8 Dip Switch Ampere Settings ES360 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3-9 Dip Switch Ampere Settings ES500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3-10 Dip Switch Ampere Settings ES560 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3-11 Dip Switch Ampere Settings ES750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3-12 Dip Switch Ampere Settings ES950 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3-13 Voltage Plugs and Jumper Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
4-1 Thermal-Magnetic Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4-2 Magnetic Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4-3 Circuit Breaker Interrupting Rating and Terminal Sizes . . . . . . . . . . . . . . . . 4-7
5-1 J4 Connector Test Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
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Safety
Easy-Start ES Instruction Manual
S-1
Cutler-Hammer has made every effort to provide you with the
safest motor starters on the market but wishes to point out how to
safely operate and troubleshoot your starter.
After you review this section you will:
¥ Understand the meaning of the Safety Alert Symbol, Danger,
Warning, Caution, and Notice safety statements.
¥ Know what safety statements you should be aware of when
you operate and troubleshoot Cutler-Hammer motor starters.
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S-2
Easy-Start ES Instruction Manual
The Meaning of Safety Statements
You will find various types of safety information
on the following pages and on the labels
attached to the equipment. This section explains
their meaning.
Notice - means that failure to follow these
instructions could cause damage to the
equipment or cause it to operate improperly.
Easy-Start ES Safety Statements
The following safety statements relate to the
installation, operation and troubleshooting of
Cutler-Hammer Motor Starters.
Notice - Make sure you read and understand
the installation procedures in this manual
before you attempt to operate or troubleshoot
the equipment.
Notice - Select proper voltage plug and install
into socket J5 on the logic board.
Danger means that failure to follow this safety
statement
will result in serious personal injury
or death.
Safety
Danger
Warning means that failure to follow this
safety statement
could result in serious
personal injury or death.
This instruction manual should be used for
proper installation, operation and maintenance
of the equipment. Improperly installing and
maintaining these products can result in death
or serious personal injury. Before attempting
installation or maintenance, read and
understand all instructional materials related to
the product. If further information is required,
you should consult Cutler-Hammer Corporation.
The Safety Alert Symbol means
ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLVED!
Caution means that failure to follow this
safety statement
may result in minor or
moderate personal injury or property damage.
Warning Warning
Caution
Non-isolated heat sink frames are electrically
hot when line voltage is connected, which may
result in death or personal injury if touched. Do
not touch heat sink frames unless line side
power is disconnected and locked out.
Danger High Voltage
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Notice - Power factor capacitors: Do not
connect power factor correcting capacitors to the
load side of the starter. They will cause the
starter to fail. If capacitors are used they must
be connected to the line side of the starter, at
least 10 feet upstream of the starter.
Safety
S-3
Easy-Start ES Instruction Manual
Isolated heat sink frames must be grounded with
the grounding lugs provided.
All electrical codes must be followed which may
require additional conduit and enclosure
grounding.
Danger
There can be line voltage potential at the motor
load terminals even with the starter in the off-
state. This is due to the RC snubber network
across the SCRÕs and leakage across SCRÕs.
Always disconnect input power before servicing
starter or motor.
Danger High Voltage
Do not connect any additional control circuits,
such as lamps and relays, across K2 coil (TB1-4
and TB1-12 on the logic board).
Caution
The fan control power transformer is pre-wired
at the factory (refer to Section 2). Be sure to
check compatibility to line voltage before
applying line power to the Easy-Start.
Caution
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SECTION 1
Introduction
Easy-Start ES Instruction Manual
1-1
Congratulations! You have purchased one of the most
sophisticated Solid State Reduced Voltage Starters in the
industry. Models are available from 45 to 950 Amp applications.
This manual provides a check list, drawings, specifications and
pre-installation information, and the various available options to
help you select the right equipment and properly install your Easy-
Start ES Reduced Voltage Starter.
To assure successful installation, thoroughly read and understand
the material presented in each section before you attempt to
install the drive. If this is your first installation, we suggest that you
read each section in the sequence they are presented since they
assume you know the material presented previously. Once you
are an experienced installer, you can use the manual as a source
of reference.
Easy-Start ES Solid State Reduce Voltage Starters are designed
to provide reduced voltage starting of three phase motors. The
Easy-Start ES has standard features which can be adjusted to
tailor your starterÕs performance to suit your needs.
About This Manual
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About This Manual
SECTION 1
1-2
Easy-Start ES Instruction Manual
Note that throughout the manual, titles of sections and specific
parameters are shown in
italics . Items in bold italics are important.
If you have any questions or comments, please feel free to contact us.
We at Cutler-Hammer are proud to have you as a customer and can
assure you that you will have many productive years from your new
Easy-Start ES Solid State Reduced Voltage Starter.
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SECTION 2
Installation
Easy-Start ES Instruction Manual
2-1
This section of the Easy-Start ES Instruction manual provides pre-
installation information, drawings and specifications to help you
properly install your Easy-Start ES Solid State Reduced Voltage
Starter.
To ensure successful installation, thoroughly read and understand
the material presented in this section before you attempt to install
the Starter. If this is your first installation, we suggest that you
read these sections in the sequence they are presented. Once
you are an experienced installer, you can use this section as a
source of reference.
About This Section
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Easy-Start ES Instruction Manual
2-3
This part of the Installation section of this Instruction Manual
provides guidelines to consider
before you install your drive :
¥ Description.
¥ Easy-Start ES Model Designation.
¥ Application Considerations.
¥ Considerations for Field Wiring.
Pre-Installation
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2-4
Description
The Easy-Start ES solid state unit is a complete
reduced voltage 3-phase AC motor starter with
motor protection. It is available in basically 9
different sizes, NEMA-12/NEMA-1:
45 Amps...........................NEMA-12
70 Amps...........................NEMA 12 Each size
120 Amps.........................NEMA-12 is rated
180 Amps...........................NEMA-1 for a
250/260 Amps ...NEMA-12/NEMA-1 starting
360 Amps.........................NEMA 12 duty
500/560 Amps ...NEMA-12/NEMA-1 for 20
750 Amps...........................NEMA-1 seconds.
950 Amps...........................NEMA-1
There are 3 AC line voltage combinations for
each size:
208/230/460V 50/60 Hz
380/415V 50/60 Hz
460/500/575V 50/60 Hz
This solid state starter incorporates 6 SCRÕs in
the power section. It provides a soft-start for 3-
phase induction motors either with voltage ramp,
or current ramp mode, and with current limit over
ride.
A built in energy saving circuit reduces the motor
voltage and current at light loads, and saves
power.
Block Diagram Description (Figure 2-1)
System Schematic (Figures 2-2 and 2-3)
The line current is sensed by using three
current
transformers . These AC signals are converted
to DC through a rectifier. Also, each phase
current is signal conditioned to produce a DC
signal for that phase or power line.
DIP switches are used to calibrate the current
rating and match it to the motor name plate for
these functions:
A. Current Feedback for energy saving load
sensing.
B. Over-Current protection:
1. Inverse-Time Trip
2. Instantaneous Trip
C. Current Limit
By using voltage feedback , the Easy-Start ES
senses the motor load and slip-speed and
adjusts the motor voltage and current to conserve
power whenever the motor is lightly loaded. Line
voltage is also sensed in order to give motor
voltage regulation; this is especially useful at high
line voltages which could cause excess motor
temperature rises.
Easy-Start ES Instruction Manual
Pre-Installation
INSTALLATION
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Pre-Installation
INSTALLATION
2-5
Description
Sensing the line voltage provides important
information for diagnostics and motor protection.
The features include the following:
Phase Rotation Protection:
Inhibits starting of the motor unless rotation is
A-B-C.
Phase Loss Protection:
Trips starter off line if one or more phases are
lost.
Under-Voltage Protection:
Trips starter off line if line voltage drops
below 75% of nominal rating.
The Easy-Start ES has a built-in adjustable
ramp which can be used in either voltage mode
or current mode. It also has an adjustable initial
step which represents initial voltage or initial
current depending on the position of the
voltage/current ramp DIP switch ÒDS3-1.Ó The
ramp and initial step functions are in the circuit
only in the start mode.
The ramp and voltage/current signals are fed into
a main
amplifier . This amplifier is biased by an
adjustment marked MIN. This adjustment is used
to set the minimum motor voltage at no load. It is
factory set to about 50% of nominal line voltage.
The amplifier also has a stability adjustment
which can be used to handle difficult motor load
applications. It is marked STAB and is factory
set to approximately midpoint.
A
digital trigger is used on the SCR gates. It
gives near perfect balance of motor voltage
between phases. Its hard firing and fast rise-time
gate pulses insure positive firing of the SCRÕs. Its
wide range insures motor voltage control from
zero to full line voltage with power factors from
0.1 to 1.0.
The current unbalance circuit senses each line
current and the signals are sent to comparators.
The circuit senses when the line currents are
unbalanced and trips the starter off line whenever
the unbalance is greater than 20% from the
average. This feature is useful in diagnostics and
will be covered more in the troubleshooting
section of this manual.
The lockout is an input to the digital trigger. It is
at a logic ÒhighÓ during normal operation. It is
forced to a logic ÒlowÓ by any one of the
protective or alarm functions. In this low state the
gates of the digital trigger are inhibited or Òlocked
outÓ to prevent firing of the SCRÕs.
Easy-Start ES Instruction Manual
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Easy-Start ES Instruction Manual
Pre-Installation
INSTALLATION
2-6
Model Designation
E S 1 2 0 - 4 E L - - - -
Options
Easy-Start 120-
Type Enclosure/Panel:
Ampere Rating:
ER Regular NEMA-12
NR Regular NEMA-1
EL Large NEMA-12
045 NL Large NEMA-1
070 EP Open Panel Isolated Heat Sink *
120 NP Open Panel Non-Isolated Heat Sink
180 Line Volts: EC Open Panel Isolated Heat Sink 14.0" Wide
250 3 380/415V NC Open Panel Non-Isolated Heat Sink 18.5" Wide
260 4 208/230/460V
360 5 460/500/575V
500
560
750
950
Notice -
* ES045_EP, ES070_EP, EC, and ES120_EP, EC are isolated heat sinks.
All other open panel models are non-isolated heat sinks.
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Easy-Start ES Instruction Manual
Pre-Installation
INSTALLATION
2-7
Application Considerations
Installation
1. Ventilated NEMA 1 enclosures should be
mounted so that enough clearance is
available for air to enter and exit the
enclosure. Specific clearance requirements
are shown on enclosure dimension drawings.
2. NEMA 12 enclosures should be mounted so
that heat sink fins are vertical. For wall
mounted units a minimum clearance of 6" on
top and bottom is required.
3. Open panel units should be mounted in a box
so the temperature inside the box does not
exceed 50¡C (122¡F).
For sizing the enclosure the heat loss in watts
can be estimated at 3 times the full load
current.
EXAMPLE: For ES180-4N the maximum
current rating is 180 amps. The approximate
watts loss at maximum current rating is
3 x 180 = 540 watts.
For units with non isolated heat sinks, all the watt
loss must be dissipated thru box surface.
For units with isolated heat sinks; the heat sink
fins should be brought out in open air thru a
properly gasketed cut out in the enclosure.
Approximately 50% watt loss is dissipated thru
the heat sinks and the remaining 50% should be
dissipated thru the remainder of the box surface,
not counting the heat sink.
Ambient Temperature
Easy-Start ES is rated for 40¡C (104¡F) ambient
temperature. For above 40¡C derate by 5% for
every 5¡C rise over 40¡C up to 50¡C (122¡F)
max.
EXAMPLE: ES180-4N is rated 180 Amps @
40¡C. For 50¡C the rating would be 180 x 0.9
= 162 Amps
Altitude
Easy-Start ES is rated for 3300 ft. [1000 meters].
Use Figure 2-5 for derating above 3300 ft.
Multi-Motor Operation
Easy-Start ES can be used to control multiple
motors if the following conditions are met:
The current rating of Easy-Start ES should be
equal to or greater than the total of individual
motor full load amps and DIP switches must
be set for the cumulative full load amps of the
motors.
Individual motor overcurrent protection is
provided by others.
Energy Saver circuit should be turned OFF.
The motors should not be mechanically
coupled together, i.e. two motors on same
shaft.
NEC and local code requirement for
individual motor protection and branch circuit
protection are met.
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Easy-Start ES Instruction Manual
The percent off-time is therefore 12/60 X 100 =
20%. We next look at the starts per hour Table
2-2 for a 70 amp starter (ES070). We can see
that the model ES070 can do only 40 starts per
hour at 350 amps with a start time of 5 seconds
and an off-time of 20%.
Therefore, we need to use the next larger size
starter, (ES120). From Table 2-3 we can see that
80 starts per hour are allowed at a starting
current of 360 amps with a start time of 5
seconds and a 20% off-time, by using the model
ES120.
Notice - The Easy-Start ES may trip due to
overcurrent, if repeated starts at high current and
long starting times, are used.
Starting Torque
The reduced voltage applied to the motor results
in reduced inrush current and soft start.
However, it reduces the starting torque of the
motor. The relationship is as follows:
Torque at Reduced
=
Current at Reduced
Current Voltage
2
Torque at Full Current Current at Full Voltage
EXAMPLE: A 100 HP 1800 RPM 460V NEMA B
motor draws six times full load amps for starting
and starting torque is 150% of full load torque.
If the same motor is started with Easy-Start ES at
300% current limit.
Starting Torque at 300% Current Limit = 300
2
600
x starting torque at 600% current = 1/4 x 150%
full load torque = 37.5% full load torque
Pre-Installation
INSTALLATION
2-8
Application Considerations
Frequent Starting/Stopping
The number of starts and stops depends upon
many factors. The most important ones are:
1. Position of current limit potentiometer which
can be anywhere from 200-500% of the
current rating set by the DIP switches.
2. Start time.
3. Run time.
4. Off time before next start.
The following tables (Table 2-1 thru Table 2-11)
can be used for guidance in frequent
starting/stopping application. These tables are
based on worst case condition that the controller
will be running at the indicated starting current
during the entire start time.
The number of starts-per-hour in the following
tables is based on the current carrying capacity
of the Easy-Start ES. If a high number of multiple
starts is used, the starter may trip due to the
inverse-time overload current protection function.
If a trip should occur, due to multiple starts, it is
advisable to wait a period of 10 minutes before re
starting to avoid damage to the Easy-Start ES.
Notice - The motor manufacturer should be
consulted about the effect of a high number of
multiple starts on motor life.
Zero % off-time in the starts per hour tables,
indicates jog duty.
EXAMPLE: If an application requires 1 start per
minute, 60 starts per hour, for a 460V, 50 HP, 70
Amp motor; the cycle time is 60 seconds
between starts. Assume a start time of 5
seconds, at a starting current of 500% (350
amps) is needed, with an off-time between run
and start of 12 seconds, and a run time of 43
seconds.
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Easy-Start ES Instruction Manual
Pre-Installation
INSTALLATION
2-9
Application Considerations
NEMA Design C and D Motors, Wound
Rotor Motors
These motors are used due to their high starting
torque characteristics. When high starting
currents and high starting torques are required,
the extended time current option must be
supplied and the unit must be oversized (see
Section 4).
Reversing Starters
If all the limitations are understood and accepted
the Easy-Start ES can be used on line side of an
electro mechanical reversing starter. The
operation should be to start the motor in forward
or reverse after a complete stop. Plug reversing
i.e. going from forward to reverse directly will
damage the starter. It is recommended that
enough time delay be built into the reversing
starter circuit (by others) to prevent restarting
until the motor has come to complete stop.
Wye Delta (Six Lead) Motors
These should be connected in Delta and can
then be started with Easy-Start ES.
Part Winding Motors
Part winding motors are started by applying full
voltage to part of the winding and after a time
delay full voltage is applied to the remaining
winding.
For part winding motors the Easy-Start ES can
be used by connecting the two windings in
parallel.
2-Speed 2-Winding Motor
If all the limitations are understood and accepted
Easy-Start ES may be used on the line side of a
electromechanical 2-speed 2-winding motor but
will provide soft start only if the motor is started in
either speed from complete stop. The ramp (soft
start) can be optimized for one speed only.
Going directly from low speed to high speed or
high speed to low speed would not give smooth
transition and may cause a current surge. It is
recommended that enough time delay be built
into the 2-speed 2-winding starter circuit (by
others) to prevent changing speeds without
coming to full stop.
Another way is to connect Easy-Start ES
between low speed contactor of
electromechanical 2-speed starter and low speed
winding of the motor. This will provide a soft start
on low speed only.
2-Speed Single Winding Motors
The Easy-Start ES is not recommended for use
with 2-speed single winding motors.
Capacitors
Notice - Power factor correction capacitors
should not be connected between load side of
Easy-Start ES and the motor. This will cause
damage to the starter.
When the Easy-Start ES is operating at reduced
voltage on the motor, there may be small
amounts of harmonic current drawn from the AC
power line. There may be a resonant circuit
caused by capacitors across the line. The
capacitors may therefore have a higher
temperature rise than normal. This situation can
be minimized by the following:
- If a contactor is used to switch the capacitors,
it should have a time delay built in the circuit
so that the contactor closes after the Easy-
Start ES has ramped up to full voltage.
- The capacitors should be mounted as far
upstream from the solid state starter as
possible. If capacitors must be used they
must be connected on the line side of the
Easy-Start ES with at least 10 feet of cable
between starter and the capacitors.
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Easy-Start ES Instruction Manual
Pre-Installation
INSTALLATION
2-10
Application Considerations
Starting Time
The Easy-Start ES is designed to operate at
500% of its current calibration setting, (set by the
DIP switches) for 20 seconds. If longer starting
times are used, the Easy-Start ES will trip due to
the overcurrent protection feature; (see Figure
3-1).
If longer starting times are required, the extended
start-time option must be purchased. This option
inhibits the inverse-time current trip during the
extended start time.
Notice - Consult Motor Manufacturer for Effect
of Longer Starting Time on Motor Life.
Suppose we have a 150 HP, 180 FLA motor
which is driving a load with 120 second start time
and the current limit is set for 500%, i.e. 900
amps. From Figure 4-1, Model ES180 will supply
900 amps but only for 40 seconds; therefore a
larger unit such as ES260 is required. Using
Figure 4-1, we see that ES260 will handle 900
amps for almost 200 seconds. So ES260 with
extended start time option can be used for this
application.
Circuit Breakers
The Easy-Start ES is capable of 500% current
limit for 20 seconds. The circuit breakers, or
protective devices used upstream, should be
sized so that they can handle the maximum
current for 20 seconds, or longer where extended
start times are required.
Automatic Reset
Automatic reset normally is not used with the
Easy-Start ES due to its 5 cycle ride-through
capability. The control is wired for manual reset
as standard.
Model Number ES045 Starts-Per-Hour
Curr. Starting Start Percent Off-Time
Limit Current Time
AC Amps Sec. 0% 10% 20% 30%
2 180 240 360 480
250% 113 5 80 120 160 200
10 50 70 85 100
20 20 30 40 50
2 150 220 300 360
300% 135 5 60 100 130 150
10 40 50 60 70
20 16 25 30 35
2 100 160 200 240
400% 180 5 40 60 80 100
10 20 30 40 50
20 10 16 20 24
2 80 120 150 180
500% 225 5 30 40 50 60
10 12 16 20 24
20 1 4 8 12
Starts-Per-Hour ES045
Table 2-1
Model Number ES070 Starts-Per-Hour
Curr. Starting Start Percent Off-Time
Limit Current Time
AC Amps Sec. 0% 10% 20% 30%
2 180 240 320 480
250% 175 5 80 120 150 180
10 40 60 70 80
20 20 30 35 45
2 120 200 240 320
300% 210 5 40 60 100 120
10 20 30 40 60
20 8 16 20 30
2 60 120 160 200
400% 280 5 30 40 60 80
10 12 20 30 40
20 4 8 16 20
2 40 80 120 140
500% 350 5 12 24 40 60
10 4 8 16 20
20 - 4 8 12
Starts-Per-Hour ES070
Table 2-2
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