FAIRFORD ELECTRONICS LIMITED DFE-30 User manual

page 1 M-7A87-F 090710
Digital Soft Starters
230Amp to 500Amp
Soft Starters and Energy
Optimising Soft Starters
FAIRFORD
ELECTRONICS
DFE-30 132kW @ 400V 230Amp
DFE-32 160kW @ 400V 280Amp
DFE-34 200kW @ 400V 350Amp
DFE-36 250kW @ 400V 430Amp
DFE-38 280kW @ 400V 500Amp
Installation Instructions
Montageanweisung
Notice d’installation
Istruzioni per il montaggio
Instrucciones de montaje
This device is suitable for use in industrial
environments. EN 55011/22 Class A
Das Gerät ist für den industriellen Einsatz
geeignet EN 55011/22 KlasseA.
L’appareil a été conçu pour l’emploi en milieu
industriel EN 55011/22 classeA.
L’apparecchio è adatto per uso in ambienti
industriali EN 55011/22 ClasseA.
El aparato es adecuado para uso en ambiente
industrial EN 55011/22 claseA.
Electric shock risk. Danger
Only skilled or instructed persons may carry
out the following operations.
Lebensgefahr durch elektrischen Strom!
Nur Elektrofachkräfte und elektrotechnisch
unterwiesene Personen dürfen die im Folgenden
beschriebenen Arbeiten ausführen.
Tension électrique dangereuse !
Seules les personnes qualifées et averties doivent
exécuter les travaux ci-après.
Tensione elettrica: Pericolo di morte!
Solo persone abilitate e qualificate possono eseguire le
operazioni di seguito riportate.
¡Corriente eléctrica! ¡Peligro de muerte!
Eltrabajoacontinuacióndescritodebeserrealizadopor
personas cualificadas y advertidas.
Manual
Further information available
from the Fairford website
www.fairford.co.uk
Dfe
The DFE is also available in smaller
sizes from the DFE-02 at 22Amp to
the DFE-26 at 195Amp

page 2 M-7A87-F 090710
295
300
320
204
160
M8 clearance
M10 Earth
55 55
104
200
DFE-30 to DFE-38 132kW to 280kW
Dimensions – Abmessungen – Dimensioni – Dimensiones
Unitweights
DFE30 & DFE32 9.7kg
DFE34 to DFE3813.5kg
All Electrical connections are M10
UnitmountingssuitableforM8fixings.
160mm x 300mm centres

page 3 M-7A87-F 090710
X1, X2 A1, A2
13, 14 23, 24
mm AWG mmNmmm
2
1 x 0.75 – 2.5 18 – 12 6 0.8 0.5 x 3.5
2 x 0.75 - 1 18 – 16 11 0.8 0.5 x 3.5
X1 X2 A1 A2 13 14 23 24
Control
supply
24VDC
Start/stop
24VDC/110VAC
3Amp NO
AC11 230VAC
0 +24V
Control cables –Steuerleitungen
Conducteurs de commande –
Cavi comandi -
Conductores de mando
Power cables/Leistungsleitungen/Conducteurs de puissance/Cavi di potenza/
Conductores de potencia
Mounting position -
Einbaulage - Position de
montage - Posizione di
montaggio - Posición de
montaje
30° max
5mm
55mm
55mm
1L1,3L2,5L3
2T1,4T2,6T3
2x 150mm
2x 4/0AWG
2
PE
M10 - 14Nm
25x 10
2x 95mm
2x 2/0AWG
2
M10 - 14Nm
25x 5
DFE-30 & DFE-32
DFE-32to DFE-38

page 4 M-7A87-F 090710
Standard connection – Standardanschluss – Raccordement standard –
Collegamento standard – Conexión estándar
K2.1
S2
S1
A1
K1M
A2
Z1
A1
K2
A2
13
14
+ 24VDC
0 VDC
X2
X1
+24VDC
or 110VAC
0VDC or N
K2.2
A1
A2
3 wire control 24 VDC/110VAC
Soft starter with mains contactor - Softstarter mit Netzschütz – Démarreur progressif avec contacteur réseau –
Softstarter con contattore di rete – Arrancador suave con contactor red
Where several conductors are to be connected, the difference between the wires/cables
used must not exceed one DIN Standard size level.
Bei Mehrleiteranschluss darf maximal ein DIN-Normgrößen-Sprung zwischen den
verwendeten Leitern liegen.
En cas de raccordement de plusieurs conducteurs, il faut 1 écartement normalisé max.
entre les conducteurs.
In caso di collegamento a più conduttori, è ammesso al massimo un salto di grandezze
DIN standard fra i conduttori utilizzati.
En caso de conexión de múltiples conductores puede haber como máximo un salto de
magnitud normalizada DIN entre los conductores utilizados.
M
3~
U1
V1 V2
W2
W1
U2
2T1
6T3
4T2
M
3~
U1
V1 V2
W2
W1
U2
2T1
6T3
4T2
Make the Delta
at the motor Make the Delta at the DFE
F1
K1M
M
3~
2T1
6T3
4T2
M1
Z1
L1
L2
L3
PE
1L1
5L3
3L2
23 24
ready
/fault
13 14
run
X1
-X2
+A1 A2
PFC
start/stop
<100m
24VDC
DFE
DFE
DFE
DFE
DFE DFE

page 5 M-7A87-F 090710
+24VDC
or 110VAC
0VDC or N
S1
Z1
A1
01
A2
+ 24VDC
0 VDC
X2
X1
2 wire control element
24 Volt within cabinet,110 Volt external
I>
U>
I> I>
j
F1
Q1
M
3~
2T1
6T3
4T2
M1
Z1
L1
L2
L3
PE
1L1
5L3
3L2
23 24
ready
/fault
13 14
run
X1
-X2
+A1 A2
PFC
start/stop
<100m
24VDC
Semiconductor contactor – Halbleiterschütz – Contacteur à semi-conducteurs –
Contattore a semiconduttori – Contactor semiconductor
Q1 = Cable protection - Leitungsschutz - Protezione di linea -
Protección de cable - Protection de câbles
K1M = Main contactor - Netzschütz - Contattore di rete - Contactor red -
Contacteur réseau
Z1 = Overload relay - Überlastrelais - Relè termico - Relé de sobrecarga -
Relais thermique
F1 = Semiconductor fuse for type 1 coordination, in addition to Q1 -
Halbleitersicherung für Zuordnungsart 1, zusätzlich zu Q1 -
Per avere la protezione del semiconduttorein coordinamento di tipo 1, è
necessario un fusibile in aggiunta a Q1 -
Fusible semiconductor para tipo de coordinación 1, adicionalmente a Q1 -
Fusible pour semi-conducteurs pour coordination de type 1, additionnel à Q1
= Soft Starter - Halbleiterschütz - Contactor semiconductor - Contattore a
semiconduttori - Contacteur à semi-conducteurs
A1-A2 = Start/Stop - Start/Stopp - Start/Stop - Arranque/Parada -
Démarrage/Arrêt
= EMERGENCY-STOP - NOT-AUS - ARRESTO D’EMERGENZA -
PARADA DE EMERGENCIA - ARRET D’URGENCE
SERVICING
WARNING NEVER CARRY OUT ANY WORK ON ELECTRICAL OR
MECHANICAL EQUIPMENT BEFORE ISOLATING ALL POWER
SUPPLIES.THEDFEDOESNOTPROVIDEISOLATION.
LIVE OUTPUTS MAY BE PRESENT WITHOUT MOTOR ROTATION
1Undervoltage release with early-make
auxiliary contact - Unterspannungsauslöser
mit voreilendem Hilfsschalter - Déclencheur à
manque de tension avec contact auxiliaire à
action avancée - Sganciatore di minima
tensione con contatto ausiliario anticipato -
Disparador de baja tensión con interruptor
auxiliar adelantado
DFE
DFE
DFE
DFE

page 6 M-7A87-F 090710
Green
On Ready
Off
Fault
1SCR / supply
2Thermal
3Uc < 24V
4Bypass relay failure
5Shearpin
6Overload
Rapid Overcurrent
Flash Red (fault)
Settings - Einstellungen - Réglages - Regulazioni - Regulaciones
Start
Stop
Uini
10
30
030
30% 100%
Pedestal Voltage:- 30% for standard rating
100% for high breakaway loads
Soft Stop time:- 0 = default range 0S to 30 S
Soft Start time:- ~12 = default range 1S to 30S
☺ LED green - LED grün – DEL vert – LED verde -
LED verde
On Ready for operation – Betriebsbereit – Prêt à
fonctionner – Pronto al funzionamento – En
condiciones para funcionamiento
Off Fault – Fehler – erreur – errore – error
Fault LED red – Fehler LED rot – DEL erreur
rouge – LED errore rosso –LED error rojo
flashes
1 SCR or supply
2 Toohot
3 Control supply low volts
4 Bypass relay failure
5 Shearpin ( I> 4.5 x Ie )
6 Overload -see chart on page10
Green/Orange Flash Tripped & Reset, Ready
Rapid
flashes Overcurrent. >300% starting, > 110% running
Following a trip the LED will continue to flash until until the next start is initiated.

page 7 M-7A87-F 090710
EMC EMISSION AND IMMUNITY LEVELS
ESD immunity IEC 61000-4-2 4kV contact.
8kV air discharge
R F immunity IEC 61000-4-6 140dBuV over 0.15-80MHz
R F immunity EC 61000-4-3 10V/m over 80 -1000MHz
Fast Transient immunity IEC 61000-4-4 2kV/5kHz
Surge immunity IEC 61000-4-5 2kV line to ground
1kV line to line
Conducted RF emissions EN 55011 Class A
Radiated RF emissions EN 55011 Class A
Rated Impulse
withstand Voltage (Uimp) 2.5kV
Rated Insulation Voltage (Ui) 500V
Pollution Degree 2
Short Circuit Co-ordination* Type1
Ambient Temperature 0°C to 40°C. Above 40°C de-rate linearly by 2% of unit
FLC per °C to a derate of 40% at 60°C
Transport and Storage -25°Cto+60°C
Altitude 1000m. Above1000m de-rate linearly by1% of unit FLC
per 100m to a max. altitude of 2000m.
Humidity max.85% non-condensing, not exceeding50%at 40°C
IP Rating IP00
DesignStandards
IEC60947-4-2;
EN60947-4-2 “ACSemiconductor MotorControllers and Starters”
*When protected byrecommendedsemiconductor fuse.
A1,A2
UT1, T2, T3
X1, X2
~½ second
UL1, L2, L3
with circuit breaker with contactor
23, 24
13, 14

page 8 M-7A87-F 090710
Sizing Guide
TheDFEis designedforgeneral purposeapplicationsandwherea traditionalStar/Deltais
currentlyused, or would beconsidered to be appropriate. Generallythe motor will startoff
load, and the time to accelerate to full speed will be in the region of a few seconds.
Thestandard DFErange is suitablefor the majorityof cases,andconforms toTrip Class5,
which means it is capable of withstanding 3 times Full Load Current for 5 second starts.
Howeverthere are instances wherea different start is requiredand to satisfy thissituation
theDFEhas fourfurtherratings, Class10B,Class 10,Class20 andClass30.These ratings
correspond to IEC thermal / electronic overload trip classes, and the DFE must be used
with an over current protection device that has a rating corresponding to the Trip Class
selected.
When using the following tables to select the most appropriate model of DFE please note
· The DFE is not suitable for very high inertia loads such as centrifuges or
loaded crushers with starts > 30 seconds (Fairford has other ranges of Soft
Starter for these applications)
· Do not use the Class 5 rating when there is possibility of the motor starting
with a significant load.
· 2-pole motors may take longer to start, use a minimum of Trip Class 10B.
Attention!
Within the scope of the EU Directives, the DFE soft starters and their accessories may be
commissioned only provided it is established that the machine fulfils the protective
requirements of Machine Directive 89/392/EWG.
Achtung!
Im Geltungsbereich der EG-Richtlinien dürfen die Softstarter der Reihe DFE und deren
ZubehörnurdanninBetriebgenommenwerden,wennfestgestelltwird, dassdieMaschine
dieSchutzanforderungender Maschinenrichtlinie89/392/EWG erfüllt.
¡Atención!
Enel campo deaplicación de la normativaCE, los arrancadoressuavesde la serieDFE y
suscorrespondientesaccesoriossólo deberánponerseenmarcha cuandoseasegureque
lamáquina cumple conlas exigencias de seguridadde la normativa demáquinas 89/392/
CE.
Attention !
Enapplication des directiveseuropéennes, les démarreursprogressifsde la gammeDFE
et leurs accessoires ne doivent être mis en service que s’il a été vérifié que la machine
répondbien aux exigences dela directive machines 89/392/EWG.
Attenzione!
Nel campo di validità delle direttive CEE i softstarter della serie DFE e i loro accessori
possono essere messi in esercizio solamente se è verificato che la macchina soddisfai
requisitidi sicurezza delle direttivemacchine 89/392/CEE.

page 9 M-7A87-F 090710
Common applications, used as a guide to determine appropriate Trip Class.
Trip
Class 30
4-29: 1171
(3/Hr)
230 A 132 KW 190 HP
280 A 160 KW 230 HP
350 A 200 KW 290 HP
430 A 250 KW 350 HP
500 A 280 KW 400 HP
Ie
(A)
400V Inline KW 400V Inline HP 460V
Trip Class 5
3-5: 355
(10/Hr)
(Standard)
Trip
Class 10B
3.5-12: 1188
(3/Hr)
Trip
Class 10
3-23: 1177
(3/Hr)
Trip
Class 20
4-19: 1181
(3/Hr)
132 A 75 KW 110 HP
195 A 110 KW 160 HP
160 A 90KW 130 HP
DFE-22 *
DFE-24 *
DFE-26 *
DFE-30
DFE-32
DFE-34
DFE-36
DFE-38
DFE-26 *
DFE-30
DFE-30
DFE-32
DFE-34
DFE-38
----
----
DFE-26 *
DFE-30
DFE-32
DFE-34
DFE-36
DFE-38
----
----
DFE-30
DFE-32
DFE-34
DFE-36
DFE-38
----
----
----
Application Trip
Class
Start
Time
(s) Notes
Standard 5 5 Suitable for Star / Delta applications with
<5sStartime, motor starts off load
Heavy 10B 12 Suitable for Star / Delta with applications
< 12 s Star time
High Torque 20 12 Requires more starting torque than a
Star / Delta
Centrifugal Pump 10 10 Generally easy to start when pumping water
Positive
displacement Pump 10 12 Can be difficult to start
Off load Conveyor 5 5 Unloaded at start
Heavy conveyor 20 12 Loaded at start
High inertia fan 10 23 Generally fans greater or equal to 45KW
Off load
Compressor 5 5 Special circuits ensure motor starts off load
Loaded
Compressor 10 12 Some compressor systems can be difficult
to start
Off load Mixer 5 5 No material in basin, off load
Heavy Mixer 20 12 Material in basin
Trip Class table
*Thebasic guide for theDFE-24 and DFE-26 isavailable as partNo.M-7A49-F.
For ratings covered by the shaded areas please contact Fairford Electronics
DFE-32
DFE-34
DFE-36
DFE-38
----
----
----
----

page 10 M-7A87-F 090710
1
10
100
1.1
1.5 22.5 3 3.5 44.5
Trip Level Current (Amps)
Seconds to Trip
2
3
4
5
6
7
8
9
20
30
40
50
60
70
80
90
253 345 460 575 690 805 920 1035
308 420 560 700 840 980 1120 1260
385 525 700 875 1050 1225 1400 1575
473 645 860 1075 1290 1505 1720 1935
230A
280A
350A
430A
500A 550 750 1000 1250 1500 1750 2000 2250
xIe
40°C 3 start/Hr
rated
current
The DFE can be used at ratings other than those stated. Use the above trip curves to
ascertain the required unit for the duty.
Asan examplethe DFE-32will runa 160kWmotor (280Amp)as themaximum continuous
runningcurrentand willallow anoverload of3 x280Amp (840Amp) for12 seconds3 times
per hour. The unit would also allow a 3.5 x overload (980Amp) for approx 5½ seconds 3
timesper hour.
Followingan overloadtrip subsequent restartscan berestricteddue toa cooling time.The
severityof overload determines thecooling time which hasa max value of10minutes.
Model
DFE-30
DFE-32
DFE-34
DFE-36
DFE-38

page 11 M-7A87-F 090710
Operational Voltage (Ue) 230-460 VAC rms 3-Phase (-15% +10%)
Rated Frequency 50 - 60Hz +/- 2Hz
Form Designation Form 1 Bypassed Controller
Index Rating Class 5 AC53b: 3-5: 355
Internallybypassed
Control Supply 24VDC approx12VAsupplied externallytoterminals X1-X2.
DFE-30to DFE-38 need a power supply capableof4Amps
for250ms.
Asuitable power supplykit is availablefrom Fairford
Over Current Trip Singlephase sensing, Non adjustable.See trip curve.
Start/Soft Stop Control 24V DC/110VAC galvanically isolatedterminalsA1-A2
Auxiliary Circuits (relays) Run - 13/14, Ready - 23/24. 230VAC 3A, AC11.
Indication Multifunction LED onfrontpanel
Start Time 1 to 30 seconds.
Stop Times 0 to 30 seconds
Start Duty S1 according to IEC 34-1 and VDE0530 Part 1.
3 x FLC for 5 seconds 10/Hr - standard rating (Class5, 40°C)
Up to 10 starts per hour. Soft stop = start for duty purposes
For other duties see pages 9 & 10 or consult
FairfordElectronics
Power Terminals Input 1/L1, 3/L2 & 5/L3 output 2/T1, 4/T2 6/T3.
Externalbusbars (unit is IP00)
Earth Terminal External stud M10
ModelName
400/460V
Range
Class 10A @40°C
3x FLC for 12seconds
3 starts per Hr
Ferraz Fuse for
Type 1 coordination
short circuit
protection
Rated Short
Circuit
Current
(Iq)
Ie
(Arms) Motor kW at 400V
230A 132kW 6,9 URD 32
D08A 0630 18kA
280A 160kW 18kA
350A 200kW 6,9 URD 33
D08A 1100
18kA
430A 250kW 30kA
500A 280kW 30kA
DFE-30
DFE-32
DFE-34
DFE-36
DFE-38

page 12 M-7A87-F 090710Copyright © Fairford Electronics Ltd 2009 Document No. FD7A8707-F
Fairford Electronics Limited, Coombe Works, Derby Road, Kingsbridge, Devon TQ7 1JL, UK
TEL: + 44 (0) 1548 857494 FAX: + 44 (0) 1548 853118
EMAIL: [email protected] WEB: www.fairford.co.uk
Registered No.: 1559267 England VAT No.: GB 367 2844 24