Application Notes

Application Notes

ME00105B
 Application Notes

Soft Starter Ratings

Soft Starters must be rated so
that the junction temperature Start
of the SCR does not exceed Time
125oC. Start Frequency

Start Current
Current
Seven operating conditions
affect heat generated in, and
dissipated by the SCR.

- Start Current Off

- Start Time Time
- Start Frequency
- Off time Time
- Ambient Temperature
- Altitude
- Motor Current
 Application Notes

Soft Starter Ratings

AC53 utilisation code for soft
starters is specified by
256A: AC53a 4.5-30:70-10
IEC-947-4-2.

AC53a used for continously

connected soft starters.
Starts/Hour
AC53b used for soft starters
bypassed during run. On-load Duty Cycle
Start Time (seconds)
Start Current (multiple of FLC)
Starter Current Rating
 Application Notes

Soft Starter Ratings

AC53 utilisation code for soft
starters is specified by
IEC-947-4-2.
145A: AC53b 4.5-30:570

AC53b used for soft starters

bypassed during run.

Off Time
Start Time (seconds)
Start Current (multiple of FLC)
Starter Current Rating
 Application Notes

IMS2 Ratings
IMS2 Soft Starters have four
standard AC53a ratings and AC53a AC53b
four standard AC53b ratings.
(3 x FLC) (3 x FLC)
These are detailed in the AC53a 3-10:50-10 AC53b 3-10:350
Specification section of the
Users Manual. (3.5 x FLC) (3.5 x FLC)
AC53a 3.5-15:50-10 AC53b 3.5-15:345
The ratings are based on the
following additional
(4 x FLC) (4 x FLC)
parameters values:
AC53a 4-20:50-10 AC53b 4-20:340
- Ambient Temperature: 45oC
- Altitude: <1000 meters
(4.5 x FLC) (4.5 x FLC)
AC53a 4.5-30:50-10 AC53b 4.5-30:330
 Application Notes

IMS2 Ratings
In addition to the published
ratings, software is provided to
allow calculation of starter
current ratings under any
operating conditions.

Model Selection
IMS2 models can be selected
in three different ways.
- Standard model selection
- Advanced model selection
- Application Analysis
Application Notes
Standard Model Selection -
assumes typical motor and load
start performance characteristics.
Advanced Model Selection -
uses actual load and motor data
to determine required start current
requirements.
Application Analysis -
uses actual load and motor
speed/current and speed/torque
curves to fully model starting
performance.

Standard Model
Selection
Step
Uses typical figures for the
application type.
* If the application operates
outside standard IMS2
ratings refer to the selection
software instead of the
published Current Ratings
tables:
- 10 starts per hour
- 50% duty cycle
- 45oC
- <1000 meters
Application Notes
Action
1. Determine typical start current
using your experience or by consulting
the Appendix section of IMS2 Users
Manual.
2. Refer to the Current Ratings tables*
in the Specifications section of the Users
Manual, and use the typical start current
identified above to select a IMS2 model
with a FLC rating greater than or equal
to the motor FLC.
Note: Use the 3 Wire or 6 Wire rating
according to the intended connection
format.
 Application Notes

Standard Model Application: Submersible Water Pump

Selection Motor FLC = 80 Amps
3 Wire Connection
Example

88

WinSTART
For operating conditions outside the normal parameters use WinSTART
 Application Notes

Advanced Model Step Action

Selection 1. Determine required start torque
as a % of motor FLT.
Uses actual data for the motor Contact the machinery supplier
and load. for this data.

Use when typical figures not 2. Calculate start current required

certain enough. by the motor to produce the
required start torque.
Use for difficult loads and
TST
installations involving large IST = LRC x
motors. LRT
IST = Minimum required start
current
LRC = Motor Locked Rotor Current
LRT = Motor Locked Rotor Torque
TST = Required start torque
 Application Notes

Advanced Model Step Action

Selection 3. Refer to the Current Ratings
tables in the Specifications section
If the application operates of the Users Manual, and use the
outside standard IMS2 ratings
typical start current identified above
refer to the selection software
instead of the published
to select a IMS2 model with a FLC
Current Ratings tables: rating greater or equal to the motor
- 10 starts per hour FLC.
- 50% duty cycle
- 45oC
- <1000 meters
 Application Notes

Advanced Model Application:

Selection Screw Compressor, off load start (40% FLT)
Motor, FLC= 920A, LRC= 720%, LRT= 140%
TST 6 Wire Connection
IST = LRC x
LRT 40%
384% = 720 x
140%

956

WinSTART
For operating conditions outside the normal parameters use WinSTART
 Application Notes

Start Performance
Modelling
For critical application
circumstances motor
current/speed and
torque/speed curves can be
used with the load‘s
torque/speed curve to fully
model start performance.
 Application Notes

Ventilation
When installing IMS2 soft
starters in an enclosure
provision must be made for
adequate ventilation.

Soft starters dissipate 4.5

watts per amp.

The Users Manual includes a

table detailing required air
flows for various run currents.

WinSTART provides
calculation tool for enclsoure
ventilation.
 Application Notes

Line Contactors K1M

Not necessary for IMS2 M

operation.
S/S

May be required by local

regulations.

Increases personal safety by

providing a physical
disconnection when the motor
is not running or a fault has
occurred.

The Line Contactor must have

an AC3 rating equal to or
greater than the motor FLC.
 Application Notes

Line Contactors
Use of a line contactor also
eliminates the potential for
extreme supply voltage
disturbances to damage the
soft starter thyristors while they
are in the off state. Voltage
disturbances resulting from
supply resonance can typically
be expected on high
impedance supplies with
power factor correction. Use of
a line contactor is prudent in
such conditions.
 Application Notes

Bypass Contactors K1M

Not necessary for IMS2 operation.

Primarily used to avoid excessive

heat buid up when the IMS2 is M

installed in a totally sealed S/S

enclosure, eg: IP65 cabinet.

Can prevent soft starter thyristor

damage caused by excessive
overcurrent and contributes to a
small amount of energy saving.

The Bypass Contactor must have

an AC1 rating equal to or greater
than the motor FLC.
 Application Notes

Semiconductor Fuses
Optional item. Can be
expensive.

Must be selected to provide I2t

protection of the soft starter
thyristors and must be capable
of passing the motor start
current.

Fuses recommened in Users

Manual are apropriate for
normal use. Extreme or
unusual operating conditions
may require different fuse
selection.
 Application Notes

Input Interface Devices

Various types of switches and
contacts are used to interface
with the soft starter remote
control inputs. These signals
are used to control the motor
operation via the soft starter.
 Application Notes

Input Interface Devices

Commonly used devices are;

PLC signals are widely used in Building

Management Systems (BMS) and
automated control systems, eg: car
assembly plants.

Pushbuttons are used when the soft

starter is installed within an MCC and
for remote pendant stations.

Pressure, flow and limit switches are

widely used on various applications,
eg: pumps, conveyors, hoists, etc.
 Application Notes

Output Interface Devices

Various types of loads are used to
interface with the soft starter relay
outputs. These outputs provide
switching which operates under
assigned soft starter conditions,
eg: start/run, run, tripped, etc.
 Application Notes

Output Interface Devices

Common uses are;

Line, bypass and power factor

correction contactor coils can be
directly controlled.

Slave relays are used to interface with

external electrical systems for control
and indication.

Direct interfacing into PLCs for

indication and flagging.

Can be used for safety interlocking,

eg: to prevent personnel access.
 Application Notes

Advanced Soft Starter

Applications
There are many applications which
require the use of external switchgear
and control equipment. The most
common ones are;

 6 Wire (Inside Delta) connection

 Power Factor Correction

 Forward/Reverse motor control

 Soft Braking (Plug Braking)

 Dual Speed Dahlander motor

 Dual Winding motor

 Application Notes

6 Wire (Inside Delta)

Connection
If a motor has each end of its
winding available, the soft
starter can be configured for 6
wire connection. K1M
U1 U2

The soft starter rating is V1

M
V2

reduced to 66% of the motor S/S

W1 W2

FLC.
A line contactor or shunt trip
circuit breaker must be installed
for safety reasons.
Typically used to replace an
existing star/delta application.
 Application Notes

Power Factor
Correction
Power Factor Correction is K1M

used to improve the individual

power factor of a motor and
reduce the total current drawn
from the supply. MOTOR

Power Factor Correction must SOFT STARTER

K2M
be connected to the input of
the soft starter. Failure to do
so will result in SCR damage.
A dedicated contactor should
Power Factor Correction
be used to switch in the PFC Capacitors
capacitors once the soft
starter is providing full voltage
to the motor.
 Application Notes

Forward/Reverse
Motor Control
Forward/Reverse motor control is K2M

achieved using two external line

contactors.
To reverse the direction of motor K1M

rotation, the contactors are

configured to change over any two M

phases supplied to the motor. S/S

Typical applications are Winches

and Elevators.
 Application Notes

Soft Braking (Plug Braking)

This is the most effective form of K2M

motor braking with minimal motor

heating.
During braking, motor phase K1M

rotation is reversed using external

contactors until the motor is M

bought to a standstill. Motor speed S/S

and rotation are detected using a
shaft rotation sensor.
Soft starter secondary parameter
set can be used to provide
independent braking torque.
Typical application is a Bandsaw
(Headrig).
 Application Notes

Dual Speed
Dahlander Motor
A Dahlander motor has separated K3M

stator windings. These windings

are externally configured using
three contactors. K2M
T4

For low speed, the windings are T5

externally configured in delta. For T6

high speed, the windings are K1M

T1
TO DAHLANDER
DUAL SPEED MOTOR

externally configured in dual star. T2

The soft starter dual parameter S/S

T3

feature is used for low and high

speed motor operation.
Typical applications are
Compressors and Fans.
 Application Notes

Motor de 2 velocidades
Los dos devanados del estator del K2M

motor de dos velocidades, son

independientes entre ellos.
K1M
Cada velocidad debe ser ajustada
externamente vía contactores de 1U

M1
2U

diferentes KW si corresponde.
1V 2V

1W 2W
S/S

La función de doble parámetros

debe ser usada en el partidor
suave si correspondiera.