LS ELECTRIC LSLV-SSM Series User manual

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Soft Starter
LSLV-SSM series Service Manual

Product Identification
This service manual applies to LS Electric SSMe and SSMi soft starters.
Product description Soft starter name
Basic model SSMe
Advanced model SSMi
Spare parts may vary depending on the soft starter model or rating.
For the latest manuals and software, please visit our website.

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Contents
1About this manual ............................................................................................................. 2
2Caution statements ........................................................................................................... 3
3Identifying the serial number and version number ......................................................... 4
3.1 Unit serial number and version......................................................................................................................4
3.2 Date of manufacture......................................................................................................................................4
3.3 PCB serial number ........................................................................................................................................4
4Diagnostics........................................................................................................................ 5
4.1 Power Circuit Test .........................................................................................................................................5
4.2 Basic Functionality Test ................................................................................................................................5
4.3 Review the Event Log ...................................................................................................................................5
4.4 Run Simulation Test ......................................................................................................................................6
4.5 Control Input Test..........................................................................................................................................6
4.6 Start/Run Performance Test..........................................................................................................................7
4.7 After Repair Tests .........................................................................................................................................7
5Troubleshooting ................................................................................................................ 8
5.1 Trip messages...............................................................................................................................................8
5.2 SCRs ...........................................................................................................................................................10
6Service instructions ........................................................................................................ 11
6.1 Frame sizes.................................................................................................................................................11
6.2 0024B~0042B..............................................................................................................................................12
6.3 0052B~0135B..............................................................................................................................................13
6.4 0184B ~ 0250B............................................................................................................................................14
6.5 0352B ~ 0580B............................................................................................................................................15
6.6 0835B ~ 1250B............................................................................................................................................16
6.7 0735C~1220C .............................................................................................................................................17
6.8 0202E~1092E..............................................................................................................................................18
7Firmware updates............................................................................................................ 19
7.1 Overview .....................................................................................................................................................19
7.2 Firmware versions .......................................................................................................................................19
7.3 Loading new firmware .................................................................................................................................19
7.4 Reusing boards from other starters.............................................................................................................21
7.5 Model name, model rating, serial number, parameter defaults ...................................................................21
7.6 Model ratings...............................................................................................................................................21
8Spare parts ...................................................................................................................... 22
8.1 Enclosure Opening Tools ............................................................................................................................22
8.2 User interface board....................................................................................................................................23
8.3 Motor control board .....................................................................................................................................25
8.4 Bypass driver board ....................................................................................................................................27
8.5 Gate drive board..........................................................................................................................................28
8.6 SCRs ...........................................................................................................................................................29
8.7 Phase arms .................................................................................................................................................30
8.8 Fans ............................................................................................................................................................31
8.9 Current transformers ...................................................................................................................................32
8.10 Internal bypass contactor ............................................................................................................................34
8.11 Snubber assemblies....................................................................................................................................36
9Appendix.......................................................................................................................... 38
9.1 Bolt Tightening Torques ..............................................................................................................................38

About this manual Soft starter
2/38
1 About this manual
WARNING
Indicates a hazard that may cause personal injury or death.
CAUTION
Indicates a hazard that may damage the equipment or installation.
NOTE
Provides helpful information.

Soft starter Caution statements
3/38
2 Caution statements
WARNING – ELECTRICAL SHOCK HAZARD
The equipment contains dangerous voltages when connected to mains voltage. Only a qualified
electrician should carry out the electrical installation. Improper installation of the motor or the
soft starter may cause equipment failure, serious injury or death. Follow this manual and local
electrical safety codes.
WARNING
The AC supply must be disconnected from the starter using an approved isolation device before
any cover is removed from the starter or before any servicing work is performed.
CAUTION
Many electronic components are sensitive to static electricity. Voltages so low that they cannot
be felt, seen or heard, can reduce the life, affect performance, or completely destroy sensitive
electronic components. When performing service, proper ESD equipment should be used to
prevent possible damage from occurring.
NOTE
The servicing technician is responsible for ensuring that all electrical safety tests have been
completed in accordance with local regulations.
Disposal instructions
Equipment containing electrical components may not be disposed of together with
domestic waste.
It must be collected separately as electrical and electronic waste according to local
and currently valid legislation.

Identifying the serial number and version number Soft starter
4/38
3 Identifying the serial number and version number
3.1 Unit serial number and version
The soft starter's serial number can be identified from the silver label on the starter.
The soft starter version number is the last two digits of the first part of the serial number (xxxxVV-xxx).
-0105B-V5-C1-H S/N: 123456-789
3 phase, 200-525 VAC, 50/60 Hz 105 A: AC53b:3-10:590, 55kW(75HP) 400 VAC
Enclosure rating: IP 20, U LOpen Type Pollution degree: 3.
WARNING - The opening of the branch circuit protective device is an indication thatthe
fault current has been interrupted. To reduce the risk of fire or electric shock the
controller should be examined and replaced if damaged.
REFER TO USER MANUA LFOR TECHNICA LSPECIFIC ATIONS
M/R: 0085 Made in New Zealand
18753.B
1
Serial number
3.2 Date of manufacture
The date of manufacture is the last three digits of the unit serial number (xxxxxx-WWY).
•Y represents the last digit of the year of manufacture ("1" is 2001, 2011, 2021)
•WW represents the number of the week within that year
3.3 PCB serial number
Each PCB is labelled with an individual serial number.
For boards with a barcode, the serial number is
written below the barcode.
For boards with no barcode, the serial number is a
six digit number on a white label.

Soft starter Diagnostics
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4 Diagnostics
NOTE
The basic model controls the current across 1/L1-2/T1 and 5/L3-6/T3. When taking
measurements across each phase, do not measure 3/L2-4/T2.
NOTE
Before changing any parameter settings, save the current parameter set to a file using
WinMaster or the soft starter's Save User Set function (see the soft starter user manual for more
information).
4.1 Power Circuit Test
This procedure tests the soft starter's power circuit, including the SCRs, motor control board and user
interface board.
1. Isolate the soft starter from the incoming mains supply and the motor, and remove the control voltage.
2. Using a 500 VDC insulation tester on the 200 ohm scale or a standard multimeter, check the
resistance across each phase of the soft starter in both directions.
•Advanced model: 1/L1 to 2/T1, 2/T1 to 1/L1, 3/L2 to 4/T2, 4/T2 to 3/L2, 5/L3 to 6/T3 and 6/T3 to
5/L3.
•Basic model: 1/L1 to 2/T1, 2/T1 to 1/L1, 5/L3 to 6/T3 and 6/T3 to 5/L3.
The readings should be similar one all phases, in both directions. If any reading is less than 200 ohms,
the SCR or internal bypass has failed short circuit and must be replaced.
4.2 Basic Functionality Test
This procedure tests that the soft starter is receiving control voltage.
1. Remove all external wiring from the soft starter control inputs.
•xxxxX-xx-C1 (110~120 VAC): A1, A2
•xxxxX-xx-C1 (220~240 VAC): A2, A3
•xxxxX-xx-C2 (24 VAC/VDC): A1, A2
2. The keypad should display the Welcome message. The Ready, Run, Trip, and Local LEDs should
illuminate.
If the keypad or LEDs do not illuminate, replace the user interface board.
If the Ready LED flashes and the screen displays the message "Not Ready", the reset input may be
active. Check the setting of parameter 7I Reset/Enable Logic.
4.3 Review the Event Log
The event log stores details about the starter's 384 most recent events (actions, warnings and trips). For
trips, the log also includes details such as supply voltage and frequency, and current to the motor.
•To review the event log on the soft starter's keypad, use Menu > Logs > Event Log.
•To export the event log as a CSV file for analysis away from the starter, use Menu > USB Save &
Load > Save Params and Logs.

Diagnostics Soft starter
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4.4 Run Simulation Test
The run simulation simulates a motor starting, running and stopping, and can help identify faults within the
soft starter.
•If the starter does not respond to commands correctly, the user interface board may be faulty.
•If you do not hear the internal bypass open and close, the internal bypass or power circuit may be
faulty.
NOTE
The soft starter must be disconnected from mains voltage.
The simulation is only available when the soft starter is in Ready state.
To use the run simulation:
1. Ensure the soft starter is in Ready state.
•If necessary, place a link across the reset input 10, 11 or change parameter 7I Reset/Enable
Logic.
2. Press MENU/ENTER to open the menu then select Setup Tools.
3. Scroll to Run Simulation and press MENU/ENTER.
4. Apply a start command from the selected command source. The soft starter simulates its pre-start
checks and closes the main contactor relay.
•The 'Run' LED flashes.
•The fan starts to operate (models 0052 and larger).
•Use a multimeter to check that the main contactor output 33, 34 is closed.
5. Press MENU/ENTER. The soft starter simulates starting.
•Use a multimeter to measure the resistance across 1/L1-2/T1, 3/L2-4/T2, 5/L3-6/T3. The
resistance should be less than 0.2 Ω.
6. Press MENU/ENTER. The soft starter simulates running.
•The 'Run' LED stops flashing and stays on.
•Internally bypassed models: The internal bypass closes.
•Non-bypassed models: The bypass contactor output closes.
7. Apply a stop command from the selected command source. The soft starter simulates stopping.
•The 'Run' LED flashes.
•The internal bypass opens
8. Press MENU/ENTER. The Ready LED flashes and the main contactor relay opens.
9. Press MENU/ENTER. The starter activates then deactivates each programmable output.
•Use a multimeter to check each output relay operates as expected.
10. Press MENU/ENTER to end the simulation.
4.5 Control Input Test
This procedure tests the condition of the soft starter control inputs. This test is performed using a wire link.
1. Disconnect all external wiring from the soft starter's control inputs.
2. Control voltage must still be connected to the soft starter.
3. Navigate to the soft starter's Digital I/O Status screen.
•The top line of the screen shows the status of the start/stop, reset and programmable inputs.
4. Connect a wire link between each input.
•If the displayed status of the input changes, the input is operating correctly.
•If the displayed status does not change, the user interface board is damaged.

Soft starter Diagnostics
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4.6 Start/Run Performance Test
This procedure tests that the starter operates correctly during a soft start.
1. Connect the starter to mains voltage, control voltage and to a motor.
2. Set parameter 1B Motor Full Load Current to match the motor.
3. Set parameter 2A Start Mode to 'Constant Current'.
4. Set parameter 2D Current Limit to a level which will supply enough start current for the connected
motor to easily accelerate to full speed.
5. Use an AC voltmeter to measure the voltage across each controlled phase (1/L1-2/T1, 3/L2-4/T2,
5/L3-6/T3). This should be close to the nominal mains voltage (phase voltage for in-line connection
and line voltage for inside delta connection).
•If the voltage is zero, the SCR on that phase may have failed.
•If the voltage is not equivalent to the nominal mains voltage, the internal bypass may be
damaged and should be replaced.
6. Calculate expected start current by multiplying Motor Full Load Current by Current Limit.
7. Scroll to the motor current screen on the keypad then initiate a start.
•If the displayed current is equal to the calculated start current on all three phases, the soft starter
is performing correctly.
8. When the soft starter is starting, measure the voltage across each phase.
•The voltage should be less than 0.5 VAC when the starter reaches Run mode.
•If the voltage remains near nominal mains voltage, the SCR is not firing correctly. Check the
connections between the motor control board and SCRs.
4.7 After Repair Tests
NOTE
The servicing technician is responsible for ensuring that all electrical safety tests have been
completed in accordance with local regulations.
To test that the soft starter functions correctly after reassembly:
1. Apply control power to the soft starter.
2. Ensure that the welcome screen displays the correct firmware version.
3. Perform a Run Simulation test using both the local keypad and remote switches.
4. Connect mains supply and motor. Test that the soft starter functions as expected.
To test the operation of the soft starter with a small motor (a motor with a current rating which is much
lower than that of the soft starter):
5. Use Setup Tools > Load/Save Settings to load the factory default parameter values into the soft
starter.
6. Disable parameter 5C Undercurrent.
7. Connect a small motor to the output terminals of the soft starter. Test that the soft starter functions as
expected.
NOTE
Reset parameter 5C Undercurrent to its default value after conducting tests.

Troubleshooting Soft starter
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5 Troubleshooting
5.1 Trip messages
Display
Possible cause/Suggested solution
2 Phase - Damaged
SCR
This message is displayed if the soft starter tripped on “Lx-Tx shorted” during the
pre-start checks and PowerThrough is enabled. It indicates that the starter now
operates in PowerThough mode (2-phase control only).
Check for either a shorted SCR or a short within the bypass contactor.
See "Lx-Tx shorted".
Battery/clock
A verification error has occurred on the real time clock, or the backup battery
voltage is low. If the battery is low and the power is off, date/time settings will be
lost. The starter will continue to soft start and soft stop correctly.
The battery is not removable. In order to replace the battery, the user interface
board must be replaced.
Reprogram the date and time.
Current
imbalance
Current imbalance can be caused by:
•a faulty current transformer. Check the resistance of each CT. The resistance
should be between approximately 5 Ω~ 20 Ωand similar for both CTs.
•a poor connection between a current transformer and the motor control board.
Check the connections are sound.
•an SCR that has failed open circuit. A failed SCR can only be definitely
diagnosed by replacing the SCR and checking the starter's performance.
Current Read Err
Lx
Where 'X' is 1, 2 or 3.
Internal fault. The output from the CT circuit is not close enough to zero when the
SCRs are turned off.
This trip can be caused by:
•a faulty current transformer. Check the resistance of each CT. The resistance
should be between approximately 5 Ω~ 20 Ωand similar for both CTs.
•a poor connection between a current transformer and the motor control board.
Check the connections are sound.
•a faulty motor control board.
EEPROM fail
An error occurred loading data from the EEPROM to RAM when the keypad
powered up.
Replace the user interface board.
Firing Fail Px
Where 'X' is phase 1, 2 or 3.
The SCR did not fire as expected. The SCR may be faulty or there may be an
internal wiring fault.
•check the resistance of each SCR. The resistance of a healthy SCR should be
≥0.2 MΩ.
•check the SCR firing looms are connected correctly.
•check the SCR gate resistance. The SCR gate resistance should be between
approximately 5 Ω≤25 Ω.
•Replace the motor control board.
Heatsink
overtemperature
•Check that the internal bypass contactors are operating. Use the run
simulation to operate the starter and measure resistance across each
controlled phase. Resistance should be > 0.2 MΩ when the bypass contactor
is open, and < 0.2 Ω when the bypass contactor is closed.
•Measure the voltage across 1/L1-2/T1, 3/L2-4/T2, 5/L3-6/T3 while the starter
is running. If the bypass contactor has closed the voltage should be
≤0.5 VAC. If the bypass contactor does not close, the voltage should be
approximately 2 VAC.
•
Check that cooling fans are operating (if fitted).
Internal fault 84
The model rating is not correct for the hardware.
•If the motor control board has recently been replaced, check that the correct
part was use and cycle control power. Enter the correct model rating code,
as printed on the silver label on the side of the unit.
Update the starter with the latest firmware. If the problem persists, contact your
local distributor.
Internal fault 85
Internal fault 86
Internal fault 87
Internal fault 89
Internal processing error.
Replace the motor control board.

Soft starter Troubleshooting
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Display
Possible cause/Suggested solution
Internal fault 88
The soft starter has detected a mismatch between its firmware and hardware.
•The wrong firmware may be loaded in the starter.
•The starter may not be detecting the hardware correctly.
•The current pulse may be too low during pre-start checks (<2 A, or < 20% of
the setting of parameter 1B Motor Full Load Current).
Update the starter with the latest firmware. If the problem persists, contact your
local distributor.
Internal fault 90
Internal fault 91
Internal fault 92
Internal fault 93
Internal processing error.
Replace the motor control board. If the problem persists, replace the user interface
board.
Internal fault 94
Internal fault 95
Internal fault 96
Internal processing error.
Check that all connectors are firmly in place.
Internal fault x
Where 'X' is a number.
Contact The Manufacturer with the fault code.
L1-T1 shorted
L2-T2 shorted
L3-T3 shorted
During pre-start checks the starter has detected a shorted SCR or a short within
the bypass contactor as indicated.
To identify which phase is shorted, use a multimeter to measure the resistance
between the input and output terminations on each phase. The resistance of a
healthy SCR should be ≥0.2 MΩ.
Once the affected phase has been identified, test the SCR and bypass contactor
separately.
•check the SCR firing looms are connected correctly.
•check the SCR gate resistance. The SCR gate resistance should be between
approximately 5 Ω≤25 Ω.
•check that the internal bypass contactors are operating. Use the run
simulation to operate the starter and measure resistance across each
controlled phase. Resistance should be > 0.2 MΩwhen the bypass contactor
is open, and < 0.2 Ω when the bypass contactor is closed.
•measure the voltage across 1/L1-2/T1, 3/L2-4/T2, 5/L3-6/T3 while the starter
is running. If the bypass contactor has closed the voltage should be ≤0.5
VAC. If the bypass contactor does not close, the voltage should be
approximately 2 VAC.
Low Control Volts
The soft starter has detected a drop in the internal control voltage.
•Check the external control supply (A1, A2, A3) and reset the starter.
If the external control supply is stable:
•the 24 V supply on the motor control board may be faulty.
•the bypass driver board may be faulty.
Unplug the bypass driver board and begin the run simulation. If the fault persists,
replace the user interface board. If the starter operates correctly, replace the
bypass driver board.
This protection is not active in Ready state.
Motor thermistor
•Use the Thermistor Reset function to disable the thermistor circuit
•Check for a short circuit across terminals B4, B5.
Not ready
•The reset input may be active. If the reset input is active, the starter will not
operate. Check parameter 7I Reset/Enable Logic.
•The soft starter may be waiting for the restart delay to elapse. The length of
the restart delay is controlled by parameter 5A Restart Delay.
Power loss
If testing the soft starter with a small motor, it must draw at least 10% of the
starter's programmed FLC setting on each phase.
Thermistor
circuit
The motor thermistor circuit is not functioning correctly. Replace the motor control
board.

Troubleshooting Soft starter
10/38
5.2 SCRs
SCR damage is generally caused by overcurrent, overvoltage or overtemperature. To prevent future
damage, check that the soft starter has been installed properly. Common causes of SCR problems
include:
Overcurrent:
•cable fault on soft starter output
•motor fault
•start current and/or start time exceeds the soft starter's rating
•starts per hour exceed the soft starter rating
Overvoltage:
•power supply transient or surge
•lightning strike (direct or indirect) on power supply
•motor fault
•loose connection in power circuit, before or after the starter
•power factor correction connected to the output of the soft starter
•over-corrected bulk power factor correction on a lightly loaded system causing severe ringing
voltages
Overtemperature:
•blocked heatsinks or restricted ventilation
•inadequate ventilation
•excessive ambient temperatures
•bypass relay fails to close during running (internally bypassed starters only)
Protecting SCRs
Modern SCRs are generally rugged and reliable. However, the risk of SCR damage can be reduced by
using semiconductor fuses and/or a main contactor.
•Semiconductor Fuses
Semiconductor fuses reduce the potential for SCR damage caused by short circuits on the output of the
starter.
Protection systems such as circuit breakers or HRC fuses do not operate quickly enough to protect SCRs
from short circuits.
•Main Contactors
SCRs are most vulnerable to overvoltage damage when voltage is applied to their input terminal while
they are off. In this condition the SCR is blocking the full line voltage. Using a main contactor to remove
voltage from the SCR input when the starter is off eliminates the risk of SCR damage due to overvoltage.

Soft starter Service instructions
11/38
6 Service instructions
6.1 Frame sizes
The soft starters can be grouped into general layout configurations as follows:
Frame Size
Build
configuration
Models
0024B
0042B
0052B
S1B
F1
0064B
0069B
0105B
0115B
0135B
0184B
F2
0200B
0229B
0250B
S2B
0352B
F3
0397B
0410B
F4
0550B
0580B
0835B
0940B
S3B
F5
1070B
1230B
1250B
0735C
0830C
S3C
F5
1025C
1170C
1220C
0202E
0287E
0387E
S3E
F12
0564E
0629E
0857E
1092E

Service instructions Soft starter
12/38
6.2 0024B~0042B
1
2
4
6
3
5
7
11
10
12
8
9
19782.A
1
Cover
7
Current transformers
2
User interface board
8
Expansion port cover
3
Motor control board
9
Internal bypass
4
Upper skeleton
10
SCRs
5
Snubbers
11
Heatsink
6
Busbars
12
Lower skeleton

Soft starter Service instructions
13/38
6.3 0052B~0135B
1
2
4
5
3
6
7
9
10
8
11
12
13
19783.A
1
Cover
8
Expansion port cover
2
User interface board
9
Internal bypass
3
Motor control board
10
Fan
4
Upper skeleton
11
SCRs
5
Snubbers
12
Heatsink
6
Busbars
13
Lower skeleton
7
Current transformers

Service instructions Soft starter
14/38
6.4 0184B ~ 0250B
1
2
4
6
3
5
8
7
11
10
14
15
9
12
13
19784.A
1
Cover
9
Expansion port cover
2
User interface board
10
Fan
3
Motor control board
11
Air duct
4
Upper skeleton
12
SCRs
5
Internal bypass
13
Heatsink
6
Snubbers (V7 models only)
14
Lower skeleton
7
Busbars
15
End grille
8
Current transformers

Soft starter Service instructions
15/38
6.5 0352B ~ 0580B
1
2
6
4
5
3
7
8
9
12
13
10
14
11
19785.A
1
Cover
8
Expansion port cover
2
User interface board
9
Bypass driver board
3
Motor control board
10
Snubbers (V7 models only)
4
Internal bypass
11
Fan
5
Upper skeleton
12
Phase arm
6
Busbars
13
Lower skeleton
7
Current transformers
14
End grille

Service instructions Soft starter
16/38
6.6 0835B ~ 1250B
21951.A
1
3
4
6
7
9
2
8
15
11
12
10
16
17
18
13
14
5
1
User interface board
10
Cover
2
Motor control board
11
PCB support
3
Bypass driver board
12
PCB insulating sheet
4
Busbars
13
EMC and PCB support plate
5
Bypass contactor
14
Insulating sheet
6
Phase arm
15
Mounting foot
7
Current transformers
16
Expansion port cover
8
Chassis
17
Top cover
9
Bottom cover
18
Fan

Soft starter Service instructions
17/38
6.7 0735C~1220C
21952.A
1
3
4
5
6
2
7
13
9
10
8
14
15
16
17
11
12
1
User interface board
10
PCB insulating sheet
2
Motor control board
11
EMC and PCB support plate
3
Bypass driver board
12
Insulating sheet
4
Busbars
13
Mounting foot
5
Phase arm
14
Expansion port cover
6
Current transformers
15
Top cover
7
Bottom cover
16
Fan
8
Cover
17
Chassis
9
PCB support

Service instructions Soft starter
18/38
6.8 0202E~1092E
23384.A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
1
User interface board
9
PCB insulating sheet
2
Motor control board
10
PCB chassis
3
Gate drive board
11
Insulating sheet
4
Phase arm
12
Expansion port cover
5
Current transformers
13
Top cover
6
Bottom cover
14
Fan
7
Cover
15
Chassis
8
PCB support