Powtran PR5200 Series User manual

Foreword
Thank you very much for purchasing PR5200（C）soft starter.
This user’s manual provides the users with the instructions on the installation, parameter
setting, error diagnosis, routine maintenance and necessary precautions. Please read the manual
carefully before the installation of the product in order to ensure that it can be correctly installed
and operated.
Please contact Powtran's dealers or directly contact with the company if you have difficult
questions during the use of the soft starter , our professional staff is willing to serve for you.
Please leave this manual to the end user and keep it in good condition for the future
maintenance and other application occasions . Please fill in the warranty card then fax to the
distributor or fax to Powtran if there is quality problem during the warranty period.
During this product updating period, some details may be changed without prior notice. If you
want to get the latest information, please visit our website.
For other products’ information, please visit our homepage:http://www.powtran.com.

Contents
Foreword......................................................................................................................1
Contents.......................................................................................................................2
Section I The introduction of PR5200(C) soft starter..............................................1
1-1. The feature of the PR5200(C) soft starter.................... 1
1-2. The main function of the PR5200(C) soft starter......... 1
1-3. The main features of the PR5200(C) soft starter.......... 1
Section II Product model description and open - package inspection .....................3
2-1. Product model description............................................ 3
2-2. The steps of open - package inspection........................ 3
Section III The Conditions of use and installation requirements.............................4
3-1. The conditions of use of the soft starter....................... 4
3-2. The installation requirements of the soft starter........... 4
3-3. The appearance and installation dimension of the soft
starter 5
Section IV Main circuit and terminal wiring...........................................................8
4-1. The basic wiring diagram of the soft starter................. 8
4-2. Instruction of soft starter terminal wiring. ................... 8
4-3. PR5200C series integrative machine wiring diagram 10
4-4. PR5200C external terminal description ..................... 11
Section V Control panel and operation .................................................................13
5-1 Keyboard operational approach ................................. 13
5-2 Function parameters setting and description.............. 15
5-3 Programmable relay output functions........................ 16
5-4 Operation protection function of power on terminal.. 17
5-5 Other settings Description.......................................... 17

5-6 .Help and instructions................................................ 18
Section ⅥProtection and description......................................................................19
6-1 Protection functions and their parameters.................. 19
6-2 Protection level setting description............................ 20
Section VII Test runing and application................................................................22
7-1. Power test running .................................................... 22
7-2. PR5200(C) Series soft starter starting mode and
application 23
7-3. PR5200(C) series soft starter's stop mode and
application 25
7-4. Special application ..................................................... 26
7-5. Application examples................................................. 26
Section VIII Fault causes and treatment ...............................................................28
Section IX Soft-start model specifications and options ........................................30
Section X Quality Assurance................................................................................31
POWTRAN Technology Product Warranty Card ......................................................33

Precaution
Thanks for selecting intelligent motor soft starter products from Powtran technology Co.,
LTD., we will with excellent performance in return for your attention!
Please pay attention to the following matters during the soft starter installation, operation
and maintenance process
please be sure to read the operating instructions before installation
Must by professional technicians to install the soft starter
The specifications of the motor must match with the soft starter
Prohibit to connect the capacitors in soft starter output terminal (U, V, W)
The bare terminals must be wrapped by insulating tape after installation
Soft starter or related equipment should be reliable grounding
Input power must be cut off when equipment maintenance
Do not disassemble , modify, maintenance of this product personally.
Only trained people are allowed to operate this device, please read this manual
about the safety, installation, operation, and maintenance section before use of the
items. The safe application of this equipment depends on the correct transportation,
installation,operation and maintenance.

1
第
十
章
Section I The introduction of PR5200(C) soft
starter
1-1. The feature of the PR5200(C) soft starter
PR5200(C) series intelligent motor soft starter incorporates the latest motor control
theory and proprietary motor protection technology and advanced software technology
of new equipment, it is an ideal replacement of startup products which early used start
method of “Star to Triangle conversion”, “autoformer step-down voltage” and
“magnetic control step-down voltage” ; at present market ,Its performance is more
superior than other ordinary soft starter without using intelligent control technology.
1-2. The main function of the PR5200(C) soft starter
First: to reduce the motor starting current and reduce power distribution capacity,
avoid investment of expansion of power capacity.
The second: to reduce the starting stress of the motor and the load of the
equipment ; extend lifespan of the motor and related equipments.
Third: Its soft stop function can effectively solve the problem of parking vibration
of the inertial system,which is unable to realize by traditional starting equipment.
Fourth: to have six unique start-up modes adapts to the complex conditions of
motor and load, to perfect start effect.
Fifth: has the perfect and reliable protection function; effectively protect the motor
and the related production equipment use safety.
Sixth: motor soft starter intelligence, and network technology application makes
motor control technology to adapt to the rapid development of the electric power
automation technology in higher requirements.
1-3. The main features of the PR5200(C) soft starter
●Perfect human nature design:
Beautiful shape and reasonable structure
Perfect function and easy operation
Sturdy and reliable and compact structure
Industrial product excellence in the design of art.
●Reliable quality assurance:
Using the computer simulation design.
SMT placement production process.
Excellent electromagnetism compatibility.
The whole machine of aging, vibration test in high temperature before they
leave the factory
●Perfect and reliable protection function:
Voltage lose, lower voltage and over-voltage protection.
Soft starter motor overheating, lower load, too long starting time protection.
Input phase lose, output phase lose, three-phase unbalance protection.

Section I The introduction of PR5200（C）soft starter
2
Startup current, overload, short circuit protection.
●Proprietary intellectual property products:
Appearance design patent.
Independent software copyright.
Proprietary motor starting and protection technology.
Unique testing debugging equipment and process.
●Swift thoughtful after-sales service:
Reliable performance and quality lay the foundation of excellent service.
Provide excellent perfect supporting design scheme.
Timely and thoughtful use consultation.
Continuously improve product performance according to user opinion

3
第
十
章
Section II Product model description and open -
package inspection
2-1. Product model description
2-1-1. Instructions on nameplate
POWER
INPUT
OUTPUT
DALIAN POWTRAN TECHNOLOGY CO.,LTD.
MODEL
18.5kW
AC 3PH 380V 50Hz/60Hz ±10%
AC 0 37A 50Hz/60Hz3PH 380V
PR5200+ 018G3
ZPB1A0100001
2-1-2.Model designation
Powtran soft starter
PR 520+ 0 a 018 G 3
Model specification Input Voltage Level
3:Three-phase 380V-415V
4:Three-phase440V-460V
Rated Power:
Example：5R5: 5.5kW
011: 11kW
Class code:
0:normal configuration
1:special 1 configuration
2:special 2 configuration
Machine code:
a:General(omit)
C:Integrative machine
Function code
G：Gerneral
Output configuration
0：General configuration（omit）
2-2. The steps of open - package inspection
Each PR5200(C) series soft starter is under strict inspection and testing before they
leave the factory. Users received the products and unpacked, please follow the
inspection steps , if found problem, please contact the supplier promptly
Confirm the soft starter without any damage in transport process (machine body
damage or gap).
Check with the machine, the instruction manual,the warranty card
Check the product of the specifications of the enclosure panels, ensure that the
received goods match with you ordered products

4
第
十
章
Section III The Conditions of use and installation
requirements
PR5200(C) series soft starter should comply with the following conditions of use
and installation requirements; otherwise, the performance will not guarantee, it can
shorten life of soft starter even damage.
3-1. The conditions of use of the soft starter
3-1-1. Power supplies: the utility, self-power station, diesel generating sets three-
phase AC 380 V plus or minus 10%, frequency 50 Hz or 60 Hz, the power
supply capacity must meet soft starter motor starting to the requirement
3-1-2. Applicable motor: mouse cage type three-phase asynchronous motor, ac
motor rated power should be matching with soft starter rated power .
3-1-3. Start frequency: no demands, depending on the specific number load up.
3-1-4. Cooling way: air cooling.
3-1-5. The protective level: IP20.
3-1-6. Environmental conditions: Below elevation 3000 meters, the environment
Temperature between -25 ℃~ + 40 ℃, relative humidity below 90% RH, no
dewing, no inflammable, no explosive, no corrosive gas easily, have no
electrical conductivity dust, indoor and ventilated good, vibration is less than
0.5 G place.
We can offer under special conditions of use products, such as the explosion
proof type, low temperature, high pressure type type soft starter, its use
conditions will need further instructions.
3-2. The installation requirements of the soft starter
Installation direction and distance: in order to ensure that the soft starter in use
with good ventilation and cooling conditions, soft starter should be installed
vertically, and in the equipment with sufficient heat dissipation space all round,
as shown in chart 3.2 3.1, in the photo, to allow the minimum distance.
Soft starter install inside ark, in addition to the above requirements outside,
still must choose, under ventilated cabinet put oneself in another's position, as
shown in chart 3.3.
OUT
OUT
IN IN
AIR
50mm 50mm
150mm 150mm
Diagram 3.1 Diagram3.2

Section III The Conditions of use and installation requirements
5
PR5200(C) series integrative machine,wall-mounted(without cabinet
installation)and cabinet choose wall-mounted or landed installation,require
surroundings ventilated,without dust and other suspended solids.
3-3. The appearance and installation dimension of the soft starter
3-3-1. The appearance and installation dimension of the 5.5KW-55KW soft starter.
PR5200 series 75kW-400kW soft starter,the standard factory configuration is
three input and six out.
The rated power and rated current is max rated value of soft starter. Usually,
matching the corresponding parameter of motor shall not be more than this value.
W
b
a
d
b
W
d
L
L1
a
H
H1
Model
Rated
Power
(KW)
Rated
current
(A)
Base
No.
Dimension
Installation
Net(kg)
L1
L
W
H1
H
a
b
d
PR5200
5R5G3
5.5
11
5R1
-
288
146
-
159
270
115
Ø8
<4.8
PR5200
7R5G3
7.5
15
-
288
146
-
159
270
115
Ø8
<4.8
PR5200
011G3
11
22
-
288
146
-
159
270
115
Ø8
<4.8
PR5200
015G3
15
30
-
288
146
-
159
270
115
Ø8
<4.8
PR5200
18.5
37
-
288
146
-
159
270
115
Ø8
<4.8

Section III The Conditions of use and installation requirements
6
018G3
PR5200
022G3
22
44
-
288
146
-
159
270
115
Ø8
<4.8
PR5200
030G3
30
60
-
288
146
-
159
270
115
Ø8
<4.8
PR5200
037G3
37
74
-
288
146
-
159
270
115
Ø8
<4.8
PR5200
045G3
45
90
-
288
146
-
159
270
115
Ø8
<4.8
PR5200
055G3
55
110
-
288
146
-
159
270
115
Ø8
<4.8
PR5200
075G3
75
150
5R2
-
350
206
-
210
330
160
Ø9
<10
PR5200
090G3
90
180
-
350
206
-
210
330
160
Ø9
<10
PR5200
115G3
115
230
-
350
206
-
210
330
160
Ø9
<10
PR5200
132G3
132
264
5R3
-
420
256
-
250
400
210
Ø9
<18
PR5200
160G3
160
320
-
420
256
-
250
400
210
Ø9
<18
PR5200
185G3
185
370
-
420
256
-
250
400
210
Ø9
<18
PR5200
200G3
200
400
-
420
256
-
250
400
210
Ø9
<18
PR5200
250G3
250
500
5R4
-
490
360
-
290
465
290
Ø9
<32
PR5200
280G3
280
560
-
490
360
-
290
465
290
Ø9
<32
PR5200
320G3
320
640
-
490
360
-
290
465
290
Ø9
<32
PR5200
400G3
400
800
-
490
360
-
290
465
290
Ø9
<32
PR5200T
132G3
132
264
5R3T
530
460
300
245
191
435
240
Ø9
<22
PR5200T
160G3
160
320
PR5200T
185G3
185
370
PR5200T
200G3
200
400
PR5200T
250G3
250
500
5R4T
565
490
350
245
191
465
290
Ø9
<22
PR5200T
280G3
280
560
PR5200T
320G3
320
640
PR5200T
400G3
400
800
3-3-2. PR5200C series integrative machine appearance and installation dimensions,
the standard factory configuration is three input and three out.Wall-mounted
size chart(6R1-6R3).

Section III The Conditions of use and installation requirements
7
W
L
H
a
b
Cabinet size chart
W
L
H
b
a
d
Size table
Model
Rated power
（KW)
Rated
current(A)
Base
No.
Dimension
Installation
Net(kg)
L
W
H
a
b
d
PR5200C 015G3
15
30
6R1
620
400
220
600
250
10
PR5200C 018G3
18.5
37
620
400
220
600
250
10
PR5200C 022G3
22
44
620
400
220
600
250
10
PR5200C 030G3
30
60
620
400
220
600
250
10
PR5200C 037G3
37
74
620
400
220
600
250
10
PR5200C 045G3
45
90
620
400
220
600
250
10
PR5200C 055G3
55
110
620
400
220
600
250
10
PR5200C 075G3
75
150
6R2
980
534
278
852
275
12
PR5200C 090G3
93
180
980
534
278
852
275
12
PR5200C 115G3
115
230
980
534
278
852
275
12
PR5200C 132G3
132
264
980
534
278
852
275
12
PR5200C 160G3
160
320
6R3
1000
590
300
939
370
12
PR5200C 185G3
185
370
1000
590
300
939
370
12
PR5200C 200G3
200
400
1000
590
300
939
370
12
PR5200C 250G3
250
500
GGD 柜
1800
800
600
650
540
16
PR5200C 280G3
280
560
1800
800
600
650
540
16
PR5200C 320G3
320
640
1800
800
600
650
540
16
PR5200C 400G3
400
800
1800
800
600
650
540
16
PR5200C 450G3
450
900
1800
800
600
650
540
16
PR5200C 500G3
500
1000
1800
800
600
650
540
16
PR5200C 560G3
560
1120
1800
800
600
650
540
16
PR5200C 630G3
630
1260
1800
800
600
650
540
16

8
第
十
章
Section IV Main circuit and terminal wiring
PR5200(C) series soft starter has two kinds of wiring:
The main circuit wiring: three phase power input and output to the motor wiring
and coil in line circuit breaker, bypass contactor wiring.
External terminal wiring: by 14 small terminals derivation, including input, output
control lines and analog output signal lines.
4-1. The basic wiring diagram of the soft starter
4-2. Instruction of soft starter terminal wiring.
Output terminal like chart 4.2 illustration：
PR5200 Series
Soft Starter
3phase power input
Keyboard
control
M
3phase asynchronous mouse cage motor
Braker(QF)
chart
4.1
Connector(KM)
Note：six copper bar，below 3 for motor，upper 3 for contactor

Section IV Main circuit and terminal wiring
9
78910
Transient
stop
stop start common
3lines way
78910
Transient
stop
stop start common
2lines way:close K start
open K stop
K
12345678910 11 12
-+
Bypass
output
Programming
output
Fault
output 7.Instantaneous
stop
stop start public Analog output
13 14
BA
Communication
terminal
chart4.2
4-2-1.Terminal 1、2 is bypass output which is used to control bypass contactor.
Normally open terminalwill close. The terminal capacity is AC 250V/5A.
4-2-2.Terminal 3、4 is programable relay output, output model and function set by
“PE”parameter. This terminal is normally open passsive pot. Capacity is AC
250V/5A.
4-2-3.Terminal 5、6 is error output: which will colse when soft starter error or
power lose. Capacity is AC250V/5A.
4-2-4.Terminal 7 is transient stop input. This terminal must connect with terminal
10 when soft starter normally work. If Terminal 7 disconnect with terminal
10, softstart will transient stop and show error. This terminal can be
controled by normal close output terminal of outside protection device, set
PA to 0 (primary protection),this terminal funtion is prohibited.
4-2-5.Terminal 8、9、10 is for wiring of outside control start,stop button. There
are two type wiring way(3 lines and 2 lines) to choose proper way according
to demand. As chart 4.3.
4-2-6.Terminal 11、12 is 0～20mA、4～20mA DC anolog output. Which is used
to inspect the motor current. The max 20mA indicates motor current is 4
times of soft starter rated current. Which can be viewed by extra 0～
20mA、4～20mA current meter. The max resistor of output load is 300Ω.
Remark: the machine defaults to 4 ~ 20mA output, if need 0 ~ 20mA output
please explain in order.
4-2-7.Terminal 13, 14 for the RS485 communication terminal, 13 for the
communication terminal B, 14 for the communication terminal A.
4-2-8.The outside terminal should be correct connection, otherwise which will
damage this softstarter.
4-2-9.PR5200series soft starter main circuit diagram.

Section IV Main circuit and terminal wiring
10
RST
13 5 braker
（QF）
RST
135
L1 L2 L3
135
KH
bypass
electromagnetic
contactor
246
UVW
246
07 08 09 10 10 11 12 G
01 02 03 04 05 06
M
A
-+
anolog output
(DC 0～20mA）
KH/transient
stop stop start common
KM
N或L1
A1 A2
bypass
output
PR5200 series soft starter
Delay
output error
output
FU
(KM)
13 14
BA
Communication
terminal
4-3. PR5200C series integrative machine wiring diagram

Section IV Main circuit and terminal wiring
11
Motor
Three-phase
4-4. PR5200C external terminal description
4-4-1. Terminal 3,4 is programmable relay,output and function set by the setting
item PE，as normally open dry contact.Contact capacity is:AC 250V/5A.
4-4-2. Terminal 5，6 as fault output,when the soft starter failure or loss of power
closed，when the soft starter normal open，contact capacity is:AC 250V/5A
4-4-3. Terminal 11，12 as 0 to 20mA、4 to 20mA DC analog output，use for
real-time monitoring current,when the full scale is 20mA,the instruction motor current
is four times as the soft starter nominal rated current,you can external 0 to 20mA、4 to
20mA DC ammeterto observate，the output load resistance max value is 300 ohm.
Remark: the machine defaults to 4 ~ 20mA output, if need 0 ~ 20mA output please
explain in order.
4-4-4. PR5200C series main circuit wiring schematic diagram.

Section IV Main circuit and terminal wiring
12
start control panel
temperature controlled
switch
delay
output
fault
output
instant
stop
start
analog output
0～20mA、4～20mA
operation
keyboard
breaker
soft starter circuit diagram

13
第
十
章
Section V Control panel and operation
★PR5200(C)series soft starter has five kinds working
state:ready,running,error,start and stop. Ready、running、error has corresponding state
light.Startup indicates××××，softstop indicates —×××,and ×××××indicates motor
current.
5-1 Keyboard operational approach
JP3E5200 keyboard diagram
Ampere
Percentage
Second
Error light
Bypass
light
Colon
blank
Ready light
Three digitals
Two position
function code
Parameter Alternation
Key (acc/reduction key)
parameter
setting/shift
key
Rapid select/confirm
parameter setting
Running Key Stop/reset key
JP3E5200D keyboard diagram
Ampere
Percentage
Second
Error light
Bypass
light
Colon
blank
Ready light
Three digitals
Two position
function code
Parameter Alternation
Key (acc/reduction key)
parameter
setting/shift
key
Rapid select/confirm
parameter setting
Running Key
Stop/reset key

Section V Control panel and operation
14
5-1-1. startup state: when the indication ready light display 5200 or
,then softstater can start. The displaying 5200 means POWTRAN
5200 series softstarter. And means ready to start.
5-1-2. Delay state: ready or error state indication light flash means interval, display
dE×××and count down means startup delay.
5-1-3. Start and stop key:in the process of soft startup,the screen display ××××to
indicates motor current, and only Stop key is valid, and can not enter menu
to set parameter, and ready,running,error lights black out.In the process of soft
stop, the screen display××××to indicates motor current,and only RUN key is
valid, and can not enter menu to set parameter, and ready, running, error lights
black out, meanwhile the stop key has reset function.
5-1-4. PRG key , in the non-help mode, press the PRG key to enter the setup
menu,display PX: XXX,then press PRG key again, colon flashes, that means
can modify the parameters after colon.Press the Set key when the colon
flashes, if the data has been modified, it will display good and twice ring,
indicating that new data has been saved, and then exit. If you do not want to
save the new data, press the PRG key, colon will stop flashing and restoring
the original data, then press Set key or Stop key to exit.
5-1-5. Set key, in the non-setting state, press the set key to enter the help menu,
display HX: XXX, press the Set key or stop key to exit. In setting state, press
the set key to save the new setting of data and to exit the setting state.
5-1-6. Acceleration,deceleration key, in the setting menu, when the colon does not
flash ,press the acceleration or deceleration key to change the function number;
when colon flashes, press the acceleration or deceleration key to change the
data, press on the acceleration or deceleration key for more than 1 second, the
data will be increased or decreased continuously and quickly .In the help
menu, press the acceleration or deceleration key to change the function
number and the corresponding message.When the indicator light of bypass
operation is on, and did not enter the setting and help menu, display AXXXX,
that means the motor running current, then press the acceleration or
deceleration key to select display PXXXX or HXXXX.PXXXX indicates
motor apparent power;HXXXX indicates motor overloaded heat balance
coefficient. When indication value of HXXXX is more than 100%,soft starter
will be overload protection and display Err08.
5-1-7. When the data is more than 999, the last decimal point is bright, indicates the
mantissa + 0.
5-1-8. If the key operating is effective,there will be a voice tip, or this key does not
work in this state.
5-1-9. When the external control terminal connected to a 3-wire mode, the external
control start button and stop button have the equivalent function with start and
stop keys on the control panel.
5-1-10.The control panel with super anti-jamming design,and the outside connection

Section V Control panel and operation
15
distance is allow to be more than 3 m.
5-1-11.Keyboard digital display illustration
Display
letter
relative
letter
Display
letter
relative
letter
Display
letter
relative
letter
0
1
2
3
4
5
6
7
8
9或g
A或R
B
C
d或D
E
F
H
J
L
N
U或V
o
P
r
Y
RUN
Ver
READY
good
Err
M
N
5-2 Function parameters setting and description
Function parameters code in the following table
Code Setting Description
Code
Name
Range
of set
value
Factory
setting
Explanation
P0
Starting voltage
30-70%
30%
Voltage slope model is effective, the
starting voltage of current mode is
40%.
P1
Soft starting time
2-60S
16S
Limiting current mode does not
work.
P2
Soft stop time
0-60S
0S
Setting 0 means free stopping, please
set 0 for one with two onnections .
P3
Start delay
0-999S
0S
With a countdown delay, set to 0
without delay, starting immediately.
P4
Language selection
0、1
0
0 for Chinese display, 1 for the
English display.
P5
Starting current limit
50-
500%
280%
The current limiting mode is
effective; the maximum flow value
of the voltage slope mode is 400%.
P6
Load regulation rate
50-
200%
100%
Relative to the value of the rated
current PP.
P7
Under voltage
protection
40-
90%
80%
Protection below the set value.

Section V Control panel and operation
16
P8
Overvoltage
protection
100-
140%
120%
Protection is higher than the set
value.
P9
Starting mode
0-6
1
0 limit current; 1 voltage; 2 jump;
limit current; 3 jump + voltage; 4
current ramp; 5 double closed loop; 6
monitoring.
PA
Protection level
0-4
4
0 primary; 1 light load; 2 standard; 3
heavy load; 4 advanced.
PB
Control mode
0-6
1
0 keyboard; 1 keyboard + external
control; 2 external control; 3 external
control + communication; 4
keyboard + external control +
communication; 5 keyboard +
communication; 6 communication.
PC
Parameter
modification
allowed
0-3
1
See 5.5 other setup instructions.
PD
Correspondence
address
0-64
0
For MODBUS native slave address
setting.
PE
Programming output
0-19
7
See 5.3 programmable relay output
functions.
PF
Soft stop current
20-
100%
80%
See 7.3.1 soft stop mode.
PP
Motor rated current
11-
998A
Rated
value
Nominal rated current for input
motor.
PU
Bypass delay
0-40S
3S
Used to set bypass time delay.
PL
Three phase
unbalance
0、1
1
0 is prohibited, 1 is allowed.
PM
Current regulation
rate
50-150%
100%
Used to adjust the current value of
the display.
PN
Voltage regulation
rate
50-
150%
100%
Used to adjust the display voltage
value.
Note: 1, set the P6 load adjustment rate is calculated based on the load weight of the
motor in the number of PP based on the calculation of the maximum current, more than
this value will do the inverse time thermal protection.
2, setting the state, if more than 2 minutes without a button operation, will
automatically exit the setting state.
3, in the soft start and soft stop process can not set parameters, the other state can be set
parameters.
4, according to the confirmation key (PRG) on the power on the boot, can set
parameters to restore the factory value.
5-3 Programmable relay output functions
There are two programmable relay output function, programmable timing output
way and programmable state output way.
5-3-1. PE set from 0 to 4 items (10 ~ 14), programmable output work is timing
output way, the setting of output starting time as tabled below.