Hoffman Controls 610-012A Series Manual

General
The 610-012A Motor Protector offers the latest technology
for providing positive and accurate overcurrent motor (load)
protection. Motor protection is accomplished by monitoring and
integrating the operating currents with current transformers in each
phase of the load. The unique design offers integration of sensed
overload conditions that occur as a result of electrical and mechan-
ical overload abnormalities. Fail-safe operation is provided by
protecting from excessive current in one or more of the following
individual or collective overload conditions:
Selecting protection (overload) at 8% above nominal FLA
(recommended) will provide both low and high voltage protection
indirectly. (See Figure 1, “Effects of Voltage Variation on Induction
Motor Characteristics”.) Other current conditions will be protected
directly by sensing current.
Important: This I&O Instruction only addresses "Across the
Line" motor protection. For "Part Winding Motor" protection
see Form # 173-0207-001.
Specifications
Voltage, Input (Select) 24, 120 or 208/240V AC
Power 2.5 VA
Frequency 60 Hz
Response Time To Trip
Minimum 2 Sec. @ LRA
Maximum 20 Min. @ 1.02% FLA
Trip Current Range
Min./Max. 20/175 Amps
Trip Level Setting Adjustable
Setting Range 0.2%
Trip Level Repeat Accuracy ± 1%
Relay Rating
Volts 24 to 240V AC
Current (Max.) 4 Amps
Ambient Temperature Range
Operating –30°C/65°C
Storage –30°C/65°C
Dimensions (L x W x H) 5.56” x 3.32” x 1.3”
Special Features
FAIL-SAFE — This instruction provides the installer with
the ability to prove that fail-safe motor protection is properly
functioning before the installer sets the required “trip level”. This
procedure assures the Controller has been properly installed/wired
and functions in a fail-safe mode. This assurance is important
when the protection of a motor or load is vital to the operation of
a system.
ACCURACY — A Standard Calibration procedure is detailed
on page 3 of this document. The Controller is capable of accuracy
as precise as the test instruments being used.
RESPONSE — The smaller the current tolerance selected
(above FLA), the more responsive the performance of the control
during overload conditions. Conversely, the larger the current toler-
ance selected (above FLA), the less responsive the control will be to
overload conditions. Response sensitivity may be adjusted above or
below the recommended, nominal 108% setting by changing the trip
current level.
610-012A Series
Overcurrent Motor Protector
with Single & 3∅ Motors
Electrical Overcurrent Mechanical Overload
Single Phase Wear
Phase Imbalance Binding
Low/High Voltage Friction
Locked Rotor Stall
Power Factor Torque




















     
Effects of Voltage Variation
on Induction Motor Characteristics
Figure 1
Hoffman|Controls
Installation & Operating
Instructions

2
Installation Instructions
1. Disconnect the power and all control voltage
serving the control panel when mounting the
610-012A Controller.
2. Mount the Controller on a non-vibrating, vertical surface
and ensure that access is available to the wiring terminals, test
points and “Trip Adj.” potentiometer.
3. Select the specific wiring diagram and wire the current trans-
formers for one of the following applications (see Figure 2):
a. Three phase, across the line.
b. Single phase
c. Three phase - part winding motors may be protected with
the use of two 610-012A units. See App Note 173-0207-
001 for wiring details.






Current Transformer C.T. Cross Section
Figure 3
Instruments Required
for Calibration
• Digital Voltmeter (DVM), 20 Volts DC scale
• Digital Amp Meter (DAM), Up to 175 amps
• Trim Pot Adjustment Tool (small screwdriver)
Pre-Installation Checklist
Verify the following before installation:
1. The motor (load) is operating normally and functioning with-
out fault.
2. Protection level required is within 20 to 175 amps.
3. The line voltage potential does not exceed 600V AC.
4. The Controller and C.T.s (current transformers) can be located
within a drip proof control panel, and meet the operating lim-
its of this specification.
5. One of the following single phase constant voltage sources are
available:
a. 24V AC
b. 120V AC
c. 208/240V AC




 

��
�



  
 
  











  


  



�
















 

��
�



  
 
  











 


 



�












610-012A Wiring Diagrams
Figure 2

3
CAUTION
To ensure accurate current monitoring the lines
should be strapped to the top of C.T. loop with
tie wrap provided. Stagger each C.T. to allow
maximum separation (minimum interaction).
4. Wire the selected control voltage to the appropriate 1/4” male
spade terminals marked:
a. 24V AC
b. Common and 120V AC
c. Common and 208/240V AC
5. Wire the safety control circuit of the contactor/starter through
isolated contacts N.O. and COM (4 amps max.).
NOTE: the N.O. contacts will close when power is applied
to the 610-12A.
6. Connect a separate DVM and install a separate DAM as fol-
lows: (See Figure 2)
a. Using DVM connect: Trip Volts (+) and Trip Volts-(–) test
posts, set scale to 20V DC.
b. Install DAM on: Line 1, set scale to anticipated current
value.
CAUTION
Do NOT adjust TRIP ADJ. (Amps) potentiom-
eter (15 turn); control is factory set to trip at 20
amps. Complete Fail-Safe Checkout first.
Fail-Safe Checkout
1. Apply line and control voltage to control panel to
start motor. Control circuit (N.O./COM) will close.
2. Motor should start, and control trip; stop motor momentarily.
a. Current observed should exceed 20 amps
b. Trip Volts observed should exceed 0 .25V DC.
3. When current exceeds values above:
a. Trip will occur. (Trip will vary from 2 seconds to 1 minute
(±) depending on the magnitude of current observed above
20 amps.)
b. Control circuit (N.O./COM) will open,
c. Load through contactor/starter will disconnect.
4. Installer may re-verify operation as observed in Item 2 above,
by resetting red RESET button.
5. Should “trip” fail to occur; check:
a. All wiring connections. (Items 3, 4, 5)
b. All voltage/amp reading. (Items 6a, 6b)
Standard Calibration
Procedure
This procedure provides an installer with the ability to deter-
mine the Trip (protection) Level required for the application. Trip
Level is described as a % of FLA as seen by the motor or Trip Volts
as seen by the 610-012A.
A range of motor protection from 5% to 15% above FLA is
typical. When 8% above FLA is selected (recommended), this
value will also provide protection for:
Low Voltage @ –10% (brown-out)
and
High Voltage @ +15% (over-voltage)
1. Disconnect power and control voltage to unit/motor.
2. Obtain the motor nameplate FLA. ________ Amps
If you have a part winding (6 lead) motor, divide the FLA rat-
ing by two (2). See App Note 173-0207-001 for wiring details.
3. Install jumper (shorting clip) across N.O./COM.
4. Connect DVM to:
a. TRIP VOLTS test post (+)
b. TRIP VOLTS test post (–)
c. Select appropriate DC Volts scale.
5. Apply power and control voltage to unit/motor. MOTOR
WILL START
6. Locate motor nameplate FLA in Table-1, Page-4, Column-1
and;
a. Select TRIP VOLTS, DC value in Table 1 (Column-2, 3,
or 4) for % overload required. (108% Recommended)
b. Adjust TRIP ADJ. (Amps) potentiometer (15 turn) CW
until TRIP VOLTS, DC value selected is obtained on
DVM.
7. Disconnect power and control voltage
8. Remove jumper (shorting clip) from N.O./COM.
9. Apply power and control voltage to unit/motor.
10. Fail-safe through N.O./COM is now under control.
11. Disconnect DVM and DAM. STANDARD CALIBRATION
PROCEDURE is complete.
Below 20 Amp FLA Use
The 610-012A Motor Protector may be applied where FLA
ratings do not normally exceed 20 amps. Wiring passed through
C.T.s may be “looped”, effectively providing a FLA multiplier, i.e.,
10 amp FLA rated motor leads passed through the C.T.s three (3)
times (first pass plus 2 loops) would be treated as approximately 30
amps FLA. Ensure all C.T. loops are formed equally, neatly and in
the same direction, perpendicular (at 90°) to the C.T. strap axis. See
�
�

Figure-3. Tie wrap or tape loops to ensure shape and proximity are
retained. Evaluate and Calibrate looped configuration using Table 1
to ensure adequate protection exists.
Amps/Trip Volts @ % Overload
Table 1
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
78
80
82
84
86
88
90
92
94
96
98
100
104
108
112
116
120
124
128
132
136
140
144
148
152
156
160
164
168
172
175
2.192
2.257
2.322
2.386
2.451
2.516
2.581
2.646
2.710
2.775
2.840
2.970
3.099
3.229
3.358
3.488
3.618
3.747
3.877
4.006
4.136
4.265
4.395
4.525
4.654
4.784
4.914
5.043
5.173
5.302
2.240
2.306
2.372
2.438
2.504
2.570
2.636
2.702
2.768
2.834
2.900
3.032
3.164
3.296
3.428
3.560
3.692
3.824
3.956
4.088
4.220
4.352
4.484
4.616
4.748
4.880
5.012
5.144
5.276
5.408
2.360
2.429
2.498
2.567
2.636
2.705
2.774
2.843
2.912
2.981
3.050
3.188
3.326
3.464
3.602
3.740
3.878
4.016
4.154
4.292
4.430
4.568
4.706
4.844
4.982
5.120
5.258
5.396
5.534
5.672
0.248
0.280
0.313
0.345
0.378
0.410
0.442
0.475
0.507
0.540
0.572
0.604
0.637
0.669
0.702
0.734
0.766
0.799
0.831
0.864
0.896
0.928
0.961
0.993
1.026
1.058
1.090
1.123
1.155
0.260
0.293
0.326
0.359
0.392
0.425
0.458
0.491
0.524
0.557
0.590
0.623
0.656
0.689
0.722
0.755
0.788
0.821
0.854
0.887
0.920
0.953
0.986
1.019
1.052
1.085
1.118
1.151
1.184
0.290
0.325
0.359
0.394
0.428
0.463
0.497
0.532
0.566
0.601
0.635
0.670
0.704
0.739
0.773
0.808
0.842
0.877
0.911
0.946
0.980
1.015
1.049
1.084
1.118
1.153
1.187
1.222
1.256
1.188
1.220
1.252
1.285
1.317
1.350
1.382
1.414
1.447
1.479
1.512
1.544
1.576
1.609
1.641
1.674
1.706
1.738
1.771
1.803
1.836
1.868
1.900
1.933
1.965
1.998
2.030
2.062
2.127
1.217
1.250
1.283
1.316
1.349
1.382
1.415
1.448
1.481
1.514
1.547
1.580
1.613
1.646
1.679
1.712
1.745
1.778
1.811
1.844
1.877
1.910
1.943
1.976
2.009
2.042
2.075
2.108
2.174
1.291
1.325
1.360
1.394
1.429
1.463
1.498
1.532
1.567
1.601
1.636
1.670
1.705
1.739
1.774
1.808
1.843
1.877
1.911
1.946
1.981
2.015
2.050
2.084
2.119
2.153
2.188
2.222
2.291
AMPS @ 108% @ 110% @ 115% AMPS @ 108% @ 110% @ 115% AMPS @ 108% @ 110% @115%
TRIP VOLTS DC Value TRIP VOLTS DC Value TRIP VOLTS DC Value
Reset — Fail-Safe Trip
When “trip” occurs, a RED LED pilot light will indicate a fail-
safe trip and manual lockout of the safety control interlock circuit
will occur.
The Controller can be RESET by either a local or remote proce-
dure. (Always install amp meter and observe current level when
re-starting after trip.)
Local: Push the red RESET button on the 610-012A
control. N.O. contacts will close, and if external
N.C. safety control contacts are closed, the motor
will restart.
Remote: Disconnect the power source to the control for 5
seconds and reconnect. N.O. contacts will close, and
if other N.C. safety control contacts are closed, the
motor will restart.
Hoffman|Controls
2463 Merrell Road, Dallas, Texas 75229 • Phone: [phone] • Fax: [phone] • Toll Free: 1-888-HCC-1190
www.hoffmancontrols.com Form: 173-0207-000 Rev A