YDQ5 series liquid starter

Instruction manual

Catalog

Cover
Overview 2
Standard & criterion 2
Working condition 2
Type explanation 2
Characteristics 3
Structure 4
Installation 5
Commissioning 6
Maintenance 9
Packaging, transportation, storage and opening examination 9
How to order 10
Appendix 10
Back cover 11
 YDQ5 series liquid starter
Instruction manual
1 Overview
YDQ5 Series liquid starters (hereinafter referred to as starters) are the new kind of starting devices
developed for improving the starting feature of large- and medium sized wire-wound AC asynchronous motors.
Having solved the problems of frequency sensitive resistor starters which are high in impact current, difficult in
starting and not easy to operate, the starters of this series are suitable for the heavy-load starting of the motors of
ball grinding mills, air compressors, crushers, large-sized blast fans and large-sized pumps which are used in the
industrial branches of building materials, metallurgy, chemical industry, mining. They are the ideal substitutes
for frequency sensitive starters and metal resistor starters.

2 Standard & criterion

GB4720-1984 electric control devices part I low-voltage electric control devices
GB4942.2-1993 low-voltage electric devices shell protection grade
GB/T5226.1-1996 industrial mechanical electric devices part I general technical condition
GB/T13384-2008 mechanical electric products casing general technical condition
GB14048.4-2003 low-voltage switch devices and control devices
low-voltage mechanical electric contactors and motor starters

3 Working condition
Upper limit of ambient temperature is no more than +50 ℃, and lower limit is no less than -5 ℃.
The relative humidity is no more than 85 percent. The height above sea level is no more than 2000m.
It should be placed on an indoor place without obvious shake and impact, without fire and explosive
dangers and the vertical gradient is no more than 5º.
There must be no conductive dust and corrosive gas.
Power source is four-wire three-phase system of 380V/220V 20A, the undulation of voltage must be
guaranteed within 15 percent of rated voltage.
Note:1）The heater needs to be installed additionally when the ambient temperature is under 0 ℃ over a
long period of time, the user should explain it while ordering goods.
2）If the voltage of power source needs spcial design, the user should explain it while ordering goods.

4 Type explanation

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Instruction manual
4.1 Significance of auxiliary function code:
K Equipped with low voltage motor primary circuit
B Equpped with vacuum contactor
PC Using programmable controller
Various added codes can be combined to finish relevant functions 。 Only 0.2-0.4 series can be equipped
with low voltage motor primary circuit, and the heater needs to be installed additionally when the ambient
temperature is under 0℃ over a long period of time, PLC also can be adopted according with requirements.
4.2 See table 1 for suitable motor capacity
Table 1 technical parameters
Type Suitable motor Starting time(S) The number of Remark
capacity(KW) consecutive start
Light-load Overloading Light-load Overloading
(each (each (each (each
temperature temperature temperature temperature
5 ℃) 10 ℃) 5 ℃) 10 ℃)
YDQ5－0.2 ≤200
YDQ5－0.4 ≤400
YDQ5－0.6 ≤600
YDQ5－1 ≤1000
15 30 5 2-3
YDQ5－2 ≤2000
YDQ5－3 ≤3000
YDQ5－4 ≤4000
YDQ5－6 ≤6000

4.3 the starting time & starting course of motors are different because of different loads.

5 Characteristics
5.1 Fundamental Principle
Allow the relative distance between the two parallel plates in the conductive liquid to decrease
progressively up to zero through a mechanical driving device and make the resistance value run into the return
circuit of motor rotor decrease continuously, so as to realize the heavy-load smooth starting of large- and
medium-sized wire-wound motors.
5.2 Technical characteristics
5.2.1 The starting current is low but constant without impact on power network; the starting current is no more
than 1.3 times the rated current. Therefore the requirements of the heavy-load starting of motor for transformer
capacity can be decreased, reducing lump sum investment.
5.2.2 It is smooth in starting, so as to lower its impact on the mechanical equipment, and the service life of the
mechanical equipment and motor can be prolonged by about 30 percent.

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 YDQ5 series liquid starter
Instruction manual

5.2.3 It is high in its heat capacity, and it can start for 2~5 times continuously.
5.2.4 It can still start under low voltage state. Smooth start can be ensured so long as the voltage of the power
network can guarantee the motor to operate normally.

5.2.5 It is simple in structure, easy to maintain. Its reliability is more superior than that of frequency sensitive,
oil-soaked type resistors.

6 Structure
The starters of YDQ series are of cabinet type structure or according to the needs of customers. Basic
structure and external dimensions are shown in Figure 1 and Table 2.

Front elevation installation sketch drawing

Figure 1 YDQ5 structure sketch drawing
Table 2 Appearance & installation dimension of YDQ5 series
Appearance dimension mm Installation N.W. GCWR
Type dimension mm
KG KG
W D H A B Φ
YDQ5-0.2 700 800 2000 640 750 13 260 400

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Instruction manual
YDQ5-0.4 700 800 2000 640 750 13 260 400

YDQ5-0.6 700 1000 2000 640 950 13 290 525

YDQ5-1 800 1000 2000 740 950 13 320 600

YDQ5-2 1000 1200 2000 940 1150 13 400 900

YDQ5-3 1200 1200 2000 1140 1150 13 500 1300

YDQ5-4 1200* 1400 2200 1140 1350 13 670* 1850*

YDQ5-6 1500* 1400 2200 1440 1350 13 800* 2300*

Note：1)The dimension that marked with * should add 800mm if YDQ5-4、6 equipped with vacuum breakers.
7 Installation
7.1 It should be best if the liquid resistor cabinet body is to be installed on the concrete platform where can drain.

7.2 The foundation should be level, the cabinet body should be installed in vertical horizon plane.
7.3 Equipped with channel pedestal (figure 1)
7.4 The cable of rotor of motor should be connected to the lower end of the short contact of the rear side of
resistor cabinet (the lower end of short contact is connected to the fixed plate of liquid resistor).
7.5 If it is equipped with a phase advancer, the cable of rotor should first run to the phase advancer, and then is
connected into the resistor cabinet from phase advancer.

7.6 Control power source of liquid starter adopts cables of 3×2.5+1×1.5mm 2 that connected to the starter from
L1、L2、L3, N on the terminal array IV, and connecting the liquid starter to primary cabinet, DCS system or
other interlocking control line between the medium control system well according to the drawing.
7.7 The earth post should be fitted with green and yellow ground wire.

8 Commissioning
8.1 Preparation of liquid resistor：
8.1.1 It would be the best if the distilled water is used as the water for preparing liquid, soft water can also be
used, the lowest limit is to use daily-life water that the deposit has been taken off after purification.
8.1.2 Resistor solvent, i.e. resistor powder that our company will offer
8.1.3 Liquid starting resistor Ro should be determined using the formula：

where

U2e: is the open circuit voltage (V) of the circuit of motor rotor;
Ize: is rated current (A) of the circuit of motor rotor
KF: is abundance-capacity multiple of the power of motor. If actual operating value I 1 of the current of
motor stator is known, you may use K F= , where, I1e is the rated current of motor stator, if your equipment is

a new one that has not been put into operation, the I 1 is unknown, you may use , where, Ne is the rated
power of motor and N1 is the power required by load

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Instruction manual

Kt: Temperature multiple, if temperature of the solution prepared is about 30℃, Kt≈1.2;

KM: is starting torque multiple, that is , where MQ is the starting torque of motor during starting

and Me is the rated torque of motor. As for starting the mechanical equipment with full load, such as ball
grinding mills, KM≈1.1~1.3, we normally suggest that you use 1.1, if capacity of power network is large enough
and load torque is over large, you may use 1.3.

8.1.4 Preparation of resistor

①Turn the dynamic plate to the starting position (upper limit position) first, fill the water prepared to
approximately two-thirds of specified level in water tank, you should pay attention to that three liquid level
marks should be equal basically.
②Weigh a certain amount of electric liquid powder.
③Pour the water prepared into a vessel, such as basin or bucket first. The poured water shall be no more than
two-thirds of the total volume of the vessel. Take one-third of weighed electric liquid powder and put it into the
vessel slowly, and stir continuously till the electric liquid powder is dissolved fully. Then fill the solution into one
phase of resistor box, the part of electric liquid powder in block type that has not been dissolved shall be
dissolved through adding hot water. If there is still a little undissolved matter, you may give it away. If the vessel
is so small that the electric liquid powder cannot be dissolved one time, the electric liquid powder may be
dissolved by part to part.
④Repeat step for filling the dissolved electric liquid powder into other two phases of the resistor box.
⑤Add water to each phase of the resistor box respectively to specified level. (The resistor box is about 60mm
from liquid level).
⑥Turn on and turn off test button to make plate move up and down two or three times and allow resistor
liquid in box to be stirred evenly.
⑦Use clean cloth to wipe water drops off the external surface of the box.
⑧Measuring for the liquid resistor
After making its dynamic plate more to starting position, add electricity of 50Hz to the points between
dynamic plate and static plate each phase using a self-coupling transformer. The current I(A) shall be increased
from zero to about 5A gradually. Record the readings of ampere A, and measure the voltage-drop V(v) between

two plates at the same time. The measuring liquid resistance is and measuring circuit is as

following：

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Instruction manual

where
Fu: Fuse 2A; A: AC ampere 5A, Grade 0.5; B: voltage adjuster 5KVA; V: AC voltmeter Grade 0.5. The
resistance value gained from measuring shall be near the calculation value R 0, allowing an error of 0.5 percent.
⑨Adjustment of resistance: If the resistance is rather high, the concentration of the resistor liquid shall be
increased, otherwise, its concentration shall be decreased. The adjustment method is to take out a part of
liquid by using a piece of flexible pipe and add a certain amount of water or electric liquid powder to it.
Note: (1) Dynamic plate must be in the upper limit position and rotor circuit shall be separated from resistor box
when resistance is measured. (2) The resistor liquid shall not be measured until it is stirred evenly. (3) The phase
line and zero line of voltage adjuster must not be connected reversely.
8.2 Check the connection of control line and rotor cable
8.2.1 Check the connection of control line and rotor cable
8.2.2 Check whether the liquid starter uses a separate power source in three-phase four-wire system or not.
8.2.3 As for connection of control line, allow the liquid starter to be connected to primary cabinet, DCS system
or interlocking control line between the medium control system well according to the drawing.
8.2.4 Line of rotor should be connected to lower end of short contactor (line of rotor shall not be fixed until the
resistor is tested).
8.2.5 A careful check should be made on whether there are phenomenons of joint leakage, joint mistake and
looseness or not before it is powered on.
8.3 Action test of liquid starter
8.3.1 Make the dynamic plate be in the middle position from the upper limit position and lower limit one by
using the method running by hand, after the three phases of control power source is confirmed to be in a normal
state, let the “test” knob turn to operation position, turn on the air switch in the cabinet, at this moment, if the
plate goes upwards it should be in normal condition.
8.3.2 The travel switch of the upper limit position should stop going upwards if operating by hand, if the plate
goes down, the phase sequence should be mistaken. At this moment, turn off the power supply and change two
phases power source line.
8.3.3 Then, turn on the power supply and turn “test” knob rightward to “test” position, the plate runs down to the
lower limit position and stops, and KM2 sucks properly.
8.3.4 Turn “test” switch leftward, the plate is reset to the upper limit position, using a watch to count out time
when the plate runs from the upper limit position to the lower limit position, rectified start protection time is 2
seconds more than this time.
Note: Please determine the phase sequence according to above-mentioned method if work needs to change
the control power source.
8.4 Turn on power for commissioning
8.4.1 Turn on the control power source of the starting cabinet and again do an action test for the starting cabinet.
“Test” knob shall be turned to operation position if the action test is in normal condition.
8.4.2 Simulation commissioning
 Do not turn on the power source of the primary circuit of primary cabinet for the main motor, turn on the
control power source for primary cabinet and starting cabinet only.

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Instruction manual
 After “Allowable starting” indicating lamps of the starting cabinet lights, press down the turn-on button
of primary cabinet, the switch of primary cabinet is turned on this moment, “starting” indicating lamp on the
surface plate of the starting cabinet lights, at the same time, the plate moves from upper side to lower side to the
lower limit position, KM2 sucks properly. The “Start” indicating lamp goes out and “Run” indicating lamp goes
on. The above-mentioned conditions show that both starting and operation are in normal conditions.
 Press down the switch-off button of primary cabinet, the switch of primary cabinet is switched off, and
KM2 is turned off, “Run” indicating lamp goes out, the plate moves from upper side to lower side, at the same
time, “Reset” indicating lamp goes on. When the plate moves to upper limit position, “Reset” indicating lamp
goes out, “allowable starting” indicating lamp goes on. You should get ready for next start.
8.4.3 Starting commissioning
 Turn on the main power source of primary circuit and control power source of primary cabinet and
starting cabinet.
 Start motor in line with the order of simulation commissioning. Observe whether the starting current is in
specified range (1.1~1.3 I 1e) or not. If the starting current is too high at the beginning, it shows that the resistor is
low. The concentration of resistor liquid shall be decreased. The method is to take a part of liquid out of water
tank and fill the same amount of clear water, commission again after the liquid is stirred evenly. If the starting
current is too low at the beginning and impact is too high when QF2 (KM2) circuit breaker (contact) is turned
on, it shows that the resistor prepared is too high, so it shall be made lower. The concentration of the resistor
liquid shall be increased. The method is to take out a part of liquid and add a suitable amount of electric liquid
powder to it. Care shall be taken to that electric liquid powder shall not be added to water too much one time.
The electric liquid powder must be fully dissolved in water tank. And adjust the resistor until the starting current
is in normal condition.

8.5 Trouble shooting（table 3）

Table 3
Trouble Cause Check and treatment method
too low Liquid level a) Check whether liquid level switch loses efficacy or not

acousto-optical b) add water to initial level

alarm Too high liquid a) Check the thermometer setting value（about 75℃）
temperature b)continuous starting would lead liquid temperature too high

Overtime protection a)check winding of rotor short contactor

b) check auxiliary contact of rotor short contactor
Fault trip Too high impact a)check winding of rotor short contactor
current when switch to b) check auxiliary contact of rotor short contactor
full speed

9 Maintenance
9.1 Power source of the control cabinet must be turned on first before the equipment is started, it will not be
started until “allowable start” indicating lamp goes on.
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Instruction manual
9.2 Electrolytic liquid should be generally changed every 4 to 5 years, at the same time clean the plate and
insulation cabinet body before filling fresh electrolytic liquid. The plate should be again cleaned with clear water
after the conductive surface is first corroded with thin hydrochloric acid, the insulation cabinet body should be
dried in the air after it is first washed with clear water, then it will be coated with epoxy resin several times
(under general condition, it would be the best if you do not wash the insulation cabinet body through
disassembling, you should avoid it from shaking and impacting so as not to make the cabinet body crack when
you disassemble it).

10 Packaging, transportation, storage and opening examination

10.1 Packing can select the simple packing, domestic packing and exportation packing according to user’s
requirements.

10.2 Resistor cabinet cannot be laid down for handling, so as not to damage the gearing and insulating cabinet
body, The inclination of the cabinet body should not be more than 15º while conveying or storing.in order to
avoid impact, this equipment should be hoisted by fork truck or hoist according to the storage and transportation
marks.
10.3 storage should avoid solarization & drenching.
10.4 A check should be made on whether packing is in good condition or not before opening the box, if damage
is serious, you should negotiate with the transportation unit or contact our company. The wire should be hooked
on the 4 points of the hoisting ring when it is hoisted after opening the box.

11 How to order：
11.1 Type of starter
11.2 Motor power, stator voltage, stator current, rotor voltage, rotor current
11.3 Load type
11.4 Cabinet color
11.5 Short contactor or breaker

Appendix
weight of electrolyte powder for different resistance value（Kg）
type
Rema
YDQ5-0.2 YDQ5-0.4 YDQ5-0.6 YDQ5-1 YDQ5-2 YDQ5-3 YDQ5-4
resistance rk
valueΩ

0.3 2.9 2.7 4.5 5.1 8.8 17.3 27.9

0.4 2.5 2.5 4.3 4.8 8.3 12.9 21.7

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Instruction manual
0.5 2.1 2.4 4.1 4.5 7.8 10.4 17.7

0.6 1.8 2.2 3.7 4.2 7.5 8.5 14.6

0.7 1.4 2.0 3.2 3.9 6.2 7.3 12.4

0.8 1.1 1.6 3.0 3.6 5.5 6.6 10.6

0.9 0.7 1.2 2.4 3.3 5.2 6.0 9.6

1.0 0.65 1.0 2.2 3.0 4.9 5.4 8.7

1.1 0.6 0.8 2.0 2.7 4.6 4.7 7.8

1.2 0.5 0.6 1.9 2.4 4.2 4.4 7.1

1.3 0.4 0.5 1.6 2.1 3.9 4.1 6.5

1.4 0.3 0.4 1.5 1.8 3.6 3.8 6.2

1.5 0.25 0.35 1.2 1.5 3.3 3.5 5.9

1.6 1.2 2.9 3.3 5.6

1.7 2.6 3.2 5.3

1.8 2.3 2.8 5.0

1.9 2.0 2.5 4.7

2.0 1.6 2.2 4.3

note ： the data are tested under normal temperature, the water is distilled water and electrolyte powder is fully
dissolved.（only for reference）

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 YDQ5 series liquid starter
Instruction manual

XiangFan Big Pawer Electrical Co., Ltd.,

Renmin Road, No 45, Xiangfan, Hubei Province
TEL: 0710-3220078
FAX: 0710-3225414

Beijing Bigpawer Industrial Control Co.,Ltd

Jinyun Building, Block Broom 308-310, North Main Street No 43, Xizhimen, Haidian District, Beijing
TEL:010-62294288 010-62232358
FAX: 010-62232265

Edition Number：DLSYDQ2009-10
The product is subject to change without notice 。

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