Instruction Manual For Model Easy-Start ES Solid State Reduced Voltage Motor Starter Easy-Start ES Solid State Reduced Voltage Motor Starter Easy-Start ES Solid State Reduced Voltage Cutler-Hammer Motor Starter
This product discussed in this literature is subject to terms and conditions outlined in appropriate Cutler-Hammer selling policies. The sole source governing the rights and remedies of any purchaser of this equipment is the relevant CutlerHammer selling policy.
Table of Contents Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-1 The Meaning of Safety Statements . . . . . . . . . . . . . . . . S-2 Easy-Start ES Safety Statements. . . . . . . . . . . . . . . . . . S-2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Pre-Installation . . . . . . . . . . . . .
List of Illustrations Figure 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9 2-10 2-11 2-12 2-13 2-14 2-15 2-16 2-17 Description Page Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 System Schematic (Hevi-Duty Co. - Multi Volt Transformer Connections) . . . . . . . . . . . . . 2-21 System Schematic (Cutler-Hammer Transformer Connections) . . . . . . . . . 2-22 Logic Board Terminal Block TB1 Functions . . . . . . . . . . . . . . . . . . . . . . . .
List of Illustrations Figure 2-18 2-19 2-20 2-21 2-22 2-23 2-24 2-25 3-1 4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8 4-9 4-10 4-11 4-12 4-13 4-14 4-15 4-16 4-17 4-18 4-19 4-20 5-1 5-2 5-3 5-4 Description Dimension and Installation NEMA-1 Regular Enclosure ES180-_NR, ES260-_NR, ES560-_NR . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37 Dimension and Installation NEMA-1 Large Enclosure, ES180-_NL, ES260-_NL, ES560-_NL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Tables Table Description Page 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9 2-10 2-11 3-1 3-2 3-3 3-4 3-5 3-6 3-7 3-8 3-9 3-10 3-11 3-12 3-13 4-1 4-2 4-3 5-1 Starts-Per-Hour ES045 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Starts-Per-Hour ES070 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Starts-Per-Hour ES120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Starts-Per-Hour ES180 . . . . .
Safety Cutler-Hammer has made every effort to provide you with the safest motor starters on the market but wishes to point out how to safely operate and troubleshoot your starter. After you review this section you will: ¥ Understand the meaning of the Safety Alert Symbol, Danger, Warning, Caution, and Notice safety statements. ¥ Know what safety statements you should be aware of when you operate and troubleshoot Cutler-Hammer motor starters.
Safety The Meaning of Safety Statements Easy-Start ES Safety Statements You will find various types of safety information on the following pages and on the labels attached to the equipment. This section explains their meaning. The following safety statements relate to the installation, operation and troubleshooting of Cutler-Hammer Motor Starters.
Safety Caution Danger Isolated heat sink frames must be grounded with the grounding lugs provided. Do not connect any additional control circuits, such as lamps and relays, across K2 coil (TB1-4 and TB1-12 on the logic board). All electrical codes must be followed which may require additional conduit and enclosure grounding. Caution Danger High Voltage There can be line voltage potential at the motor load terminals even with the starter in the offstate.
SECTION 1 Introduction About This Manual Congratulations! You have purchased one of the most sophisticated Solid State Reduced Voltage Starters in the industry. Models are available from 45 to 950 Amp applications. This manual provides a check list, drawings, specifications and pre-installation information, and the various available options to help you select the right equipment and properly install your EasyStart ES Reduced Voltage Starter.
About This Manual SECTION 1 Note that throughout the manual, titles of sections and specific parameters are shown in italics. Items in bold italics are important. If you have any questions or comments, please feel free to contact us. We at Cutler-Hammer are proud to have you as a customer and can assure you that you will have many productive years from your new Easy-Start ES Solid State Reduced Voltage Starter.
SECTION 2 Installation About This Section This section of the Easy-Start ES Instruction manual provides preinstallation information, drawings and specifications to help you properly install your Easy-Start ES Solid State Reduced Voltage Starter. To ensure successful installation, thoroughly read and understand the material presented in this section before you attempt to install the Starter. If this is your first installation, we suggest that you read these sections in the sequence they are presented.
Pre-Installation This part of the Installation section of this Instruction Manual provides guidelines to consider before you install your drive: ¥ Description. ¥ Easy-Start ES Model Designation. ¥ Application Considerations. ¥ Considerations for Field Wiring.
Pre-Installation INSTALLATION Description The Easy-Start ES solid state unit is a complete reduced voltage 3-phase AC motor starter with motor protection. It is available in basically 9 different sizes, NEMA-12/NEMA-1: 45 Amps...........................NEMA-12 70 Amps ...........................NEMA 12 120 Amps.........................NEMA-12 180 Amps...........................NEMA-1 250/260 Amps ...NEMA-12/NEMA-1 360 Amps .........................NEMA 12 500/560 Amps ...NEMA-12/NEMA-1 750 Amps............
Pre-Installation INSTALLATION Description Sensing the line voltage provides important information for diagnostics and motor protection. The features include the following: Phase Rotation Protection: Inhibits starting of the motor unless rotation is A-B-C. Phase Loss Protection: Trips starter off line if one or more phases are lost. Under-Voltage Protection: Trips starter off line if line voltage drops below 75% of nominal rating.
Pre-Installation INSTALLATION Model Designation ES 120 - 4EL ---Options Easy-Start 120Type Enclosure/Panel: Ampere Rating: 045 070 120 180 250 260 360 500 560 750 950 Line Volts: 3 380/415V 4 208/230/460V 5 460/500/575V ER NR EL NL EP NP EC NC Regular NEMA-12 Regular NEMA-1 Large NEMA-12 Large NEMA-1 Open Panel Isolated Heat Sink * Open Panel Non-Isolated Heat Sink Open Panel Isolated Heat Sink 14.0" Wide Open Panel Non-Isolated Heat Sink 18.
Pre-Installation INSTALLATION Application Considerations Installation 1. Ventilated NEMA 1 enclosures should be mounted so that enough clearance is available for air to enter and exit the enclosure. Specific clearance requirements are shown on enclosure dimension drawings. Ambient Temperature Easy-Start ES is rated for 40¡C (104¡F) ambient temperature. For above 40¡C derate by 5% for every 5¡C rise over 40¡C up to 50¡C (122¡F) max. EXAMPLE: ES180-4N is rated 180 Amps @ 40¡C.
Pre-Installation INSTALLATION Application Considerations The number of starts and stops depends upon many factors. The most important ones are: The percent off-time is therefore 12/60 X 100 = 20%. We next look at the starts per hour Table 2-2 for a 70 amp starter (ES070). We can see that the model ES070 can do only 40 starts per hour at 350 amps with a start time of 5 seconds and an off-time of 20%. 1.
Pre-Installation INSTALLATION Application Considerations NEMA Design C and D Motors, Wound Rotor Motors These motors are used due to their high starting torque characteristics. When high starting currents and high starting torques are required, the extended time current option must be supplied and the unit must be oversized (see Section 4). Reversing Starters If all the limitations are understood and accepted the Easy-Start ES can be used on line side of an electro mechanical reversing starter.
Pre-Installation INSTALLATION Application Considerations Starting Time The Easy-Start ES is designed to operate at 500% of its current calibration setting, (set by the DIP switches) for 20 seconds. If longer starting times are used, the Easy-Start ES will trip due to the overcurrent protection feature; (see Figure 3-1). amps. From Figure 4-1, Model ES180 will supply 900 amps but only for 40 seconds; therefore a larger unit such as ES260 is required.
Pre-Installation INSTALLATION Application Considerations Model Number ES120 Curr. Limit 250% 300% 400% 500% Starts-Per-Hour Model Number ES180 Starting Current AC Amps Start Time Sec.
Pre-Installation INSTALLATION Application Considerations Model Number ES250 Curr. Limit 250% 300% 400% 500% Starts-Per-Hour Model Number ES260 Starting Current AC Amps Start Time Sec.
Pre-Installation INSTALLATION Application Considerations Model Number ES360 Curr. Limit 250% 300% 400% 500% Starts-Per-Hour Model Number ES500 Starting Current AC Amps Start Time Sec.
Pre-Installation INSTALLATION Application Considerations Model Number ES560 Curr. Limit 250% 300% 400% 500% Starts-Per-Hour Model Number ES750 Starting Current AC Amps Start Time Sec.
Pre-Installation INSTALLATION Application Considerations Model Number ES950 Curr. Limit 250% 300% 400% 500% Starts-Per-Hour Starting Current AC Amps Start Time Sec.
Pre-Installation INSTALLATION Considerations For Field Wiring The Easy-Start ES requires the following basic electrical connections: (Refer to Section 2 for connection diagrams.) 1. Three-phase line power. (Install proper voltage plug, see Section 3.) 2. Three-phase AC motor connection. 3. Ground connections. 4. 120 VAC control power, and RESET Pushbutton. 5. Check CPT connections on fan cooled models. The three-phase line power can be from a suitable disconnect switch or a circuit breaker.
Pre-Installation INSTALLATION Considerations For Field Wiring Hevi-Duty Company - Multi Volt Transformer Connections Wiring Practices The fan CPT is factory connected as follows: Easy-Start ES Voltage Rating Voltage Rating Used For Transformer Connections 208/230/460 380/415 460/500/575 460V 380V 575V If the incoming line voltage is different than the factory connected rated voltage shown in previous paragraph, reconnect the multi-voltage transformer primary and secondary as follows for Hevi-Duty Co
Pre-Installation INSTALLATION Considerations For Field Wiring Cutler-Hammer Transformer Connections The fan CPT is factory connected as follows: Easy-Start ES Voltage Rating Voltage Rating Used For Transformer Connections 208/230/460 380/415 460V 380V If the incoming line voltage is different than the factory connected rated voltage shown in previous paragraph, reconnect the multi-voltage transformer primary and secondary as follows for Cutler-Hammer transformers: Line Voltage Primary FU-2 Connection
Drawings This part of the Installation section of this Instruction Manual presents the following series of drawings: ¥ Overload Characteristics. ¥ Control Connection and Schematic Diagrams. ¥ Outline dimensions and options for mounting each chassis.
Drawings INSTALLATION Easy ES-001 Block Diagram Figure 2-1 Easy-Start ES Instruction Manual 2-20
Drawings Easy ES-002 INSTALLATION System Schematic (Hevi-Duty Co.
Drawings (230V-460V) (XF HR) (208V-380V-415V XF HR) Easy ES-003 INSTALLATION System Schematic (Cutler-Hammer Transformer Connections) Figure 2-3 Easy-Start ES Instruction Manual 2-22
Drawings Easy ES-004 INSTALLATION Logic Board Terminal Block TB1 Functions Figure 2-4 Easy-Start ES Instruction Manual 2-23
Drawings Derate Factor INSTALLATION 1.0 T= 4 0° C 0.9 0.8 0.7 0.6 0.5 Conversion factor—multiply altitude in feet by 0.3048 to obtain altitude in meters 0.4 0.3 0.2 0.
Drawings Easy ES-006 INSTALLATION Momentary Contact Start/Stop Pushbuttons Figure 2-6 Easy-Start ES Instruction Manual 2-25
Drawings Easy ES-007 INSTALLATION Hand-Off-Auto Selector Switch Figure 2-7 Easy-Start ES Instruction Manual 2-26
Drawings Easy ES-008 INSTALLATION Start-Stop Pushbuttons With Hand-Off-Auto Selector Switch Figure 2-8 Easy-Start ES Instruction Manual 2-27
Drawings Easy ES-009 INSTALLATION Power Connections with Options (Hevi-Duty Co.
Drawings Easy ES-010 INSTALLATION Power Connections with Options (Cutler-Hammer Transformer) Figure 2-10 Easy-Start ES Instruction Manual 2-29
Drawings Easy ES-011 INSTALLATION Dimension and Installation Open Panel ES045-_EP, ES070-_EP, ES120-_EP Figure 2-11 Easy-Start ES Instruction Manual 2-30
Drawings INSTALLATION NOTES 1. PANEL MATERIAL: 14 GA (.074) STEEL FINISH: ASA 61 LIGHT GRAY 2. PANEL SHOULD BE MOUNTED IN A VERTICAL POSITION TO PROVIDE PROPER COOLING. 3. WHEN DAUGHTER BD. OPTION IS USED DEPTH IS 7.50". FIELD WIRING LUGS WEIGHT LBS WIRE GAUGE RANGE MODEL LINE / LOAD LUGS GROUND LUGS ES070-_EC 50 AWG 14-1 0 AWG 14-2 2.00 0.00 3.75 6.25 14.00 B B 13.69 13.25 B B #4 AWG (6´ FT LG) B #4 AWG (6´ FT LG) 10.13 .219 DIA. B B B B .68 B B B B 3.88 .75 .31 0 .50 0 3.42 4.
Drawings Easy ES-013 INSTALLATION Dimension and Installation NEMA-12 Regular Enclosure ES045-_ER, ES070-_ER Figure 2-13 Easy-Start ES Instruction Manual 2-32
Drawings Easy ES-014 INSTALLATION Dimension and Installation NEMA-12 Large Enclosure ES045-_EL, ES070-_EL, ES120-_EL Figure 2-14 Easy-Start ES Instruction Manual 2-33
Drawings Easy ES-015 INSTALLATION Dimension and Installation Open Panel ES180-_NP, ES260-_NP, ES560-_NP, ES250-_EP, ES360-_EP, ES500-_EP Figure 2-15 Easy-Start ES Instruction Manual 2-34
Drawings INSTALLATION FIELD WIRING LUGS WEIGHT LBS WIRE GAUGE RANGE MODEL LINE / LUGS GROUND LUGS ES120-_EC AWG #6-250MCM 60 AWG 14-2 13.69 14.00 9.25 0 .31 .68 4.75 NOTES 1. EACH INCOMING LINE CABLE MUST PASS THRU THE CORRESPONDING CURRENT TRANSFORMER. 2. PANEL MATERIAL: 14 GA (.074) STEEL FINISH: ASA 61 LIGHT GRAY 3. PANEL SHOULD BE MOUNTED IN A VERTICAL POSITION TO PROVIDE PROPER COOLING. 4. USER MUST PROVIDE LOAD LUGS. 5. WHEN DAUGHTER BD. OPTION IS USED DEPTH IS 7.50". .000 .25 .38 6.38 .
Drawings INSTALLATION Easy ES-017 Dimension and Installation Open Panel Slim Line Motor Control Center ES180-_NC, ES250-_NC Figure 2-17 Easy-Start ES Instruction Manual 2-36
Drawings INSTALLATION Easy ES-018 Dimension and Installation NEMA-1 Regular Enclosure ES180-_NR, ES260-_NR, ES560-_NR Figure 2-18 Easy-Start ES Instruction Manual 2-37
Drawings Easy ES-019 INSTALLATION Dimension and Installation NEMA-1 Large Enclosure ES180-_NL, ES260-_NL, ES560-_NL Figure 2-19 Easy-Start ES Instruction Manual 2-38
Drawings INSTALLATION Easy ES-020 Dimension and Installation Open Panel ES750-_NP Figure 2-20 Easy-Start ES Instruction Manual 2-39
Drawings Easy ES-021 INSTALLATION Dimension and Installation NEMA-1 Large Enclosure ES750-_NL Figure 2-21 Easy-Start ES Instruction Manual 2-40
Drawings Easy ES-022 INSTALLATION Dimension and Installation NEMA-12 Large Enclosure ES250, ES360-_EL Figure 2-22 Easy-Start ES Instruction Manual 2-41
Drawings Easy ES-023 INSTALLATION Dimension and Installation NEMA-12 Large Enclosure ES500-_EL Figure 2-23 Easy-Start ES Instruction Manual 2-42
Drawings Easy ES-024 INSTALLATION Dimension and Installation NEMA-1 ES950-_NL Figure 2-24 Easy-Start ES Instruction Manual 2-43
Drawings Easy ES-025 INSTALLATION Dimension and Installation Open Panel ES950-_NP Figure 2-25 Easy-Start ES Instruction Manual 2-44
Specifications This part of the Installation section of this Instruction Manual presents the following specifications: ¥ General Specifications.
Specifications INSTALLATION EASY-START ES SPECIFICATIONS: Current Ratings: Isolated Sink Suitable for NEMA-12 45 Amps 70 120 250 500 Non-Isolated Sink Suitable for NEMA-1 180 Amps 260 560 750 950 AC Supply Voltage: Three voltage combinations for each current rating: 208/230/460 +10% - 15% 50/60 Hz 3-PH 380/415 +10% - 15% 50/60 Hz 3-PH 460/500/575 +10% - 15% 50/60 Hz 3-PH Output Stage: 6-SCRÕs....
Specifications INSTALLATION EASY-START ES SPECIFICATIONS: Starting Current Limit: Continuous 3-phase sensing, adjustable from 200 to 500%. Energy Saving: The Easy-Start ES senses the motor load and slip speed and adjusts the motor voltage to conserve power whenever the motor is lightly loaded. Power Wiring: Straight through configuration. Undervoltage Protection: Trips at 75% of nominal line voltage. Time delay 2 seconds approximately.
SECTION 3 Operation About This Section This section of the Instruction Manual provides information about the operation of the Easy-Start ES solid state reduced voltage motor starter. After you review this section you will understand: ¥ Operation of the Easy-Start ES Motor Starter. ¥ Adjustments.
Operation SECTION 3 Operation There are primarily two basic modes of operation. 1. Voltage Ramp - The motor voltage is increased linearly from an initial step voltage, until it reaches full line voltage. This is done by the use of the two adjustments, time and initial step. The initial step adjustment is used to get the motor turning upon a start command. At very low initial step voltage settings, the motor may not begin to turn for several seconds.
Operation SECTION 3 DIP Switch Settings DS1 POSITIONS DS2 123 123 123 123 123 123 123 123 1 2 3 4 000 001 010 011 100 101 110 111 0 0 0 0 0.282 0.247 0.223 0.201 0.179 0.164 0.153 0.142 0 0 0 1 0.364 0.321 0.291 0.263 0.234 0.215 0.202 0.187 0 0 1 0 0.432 0.382 0.348 0.315 0.282 0.260 0.243 0.227 0 0 1 1 0.501 0.445 0.407 0.369 0.331 0.306 0.287 0.268 0 1 0 0 0.544 0.485 0.444 0.404 0.363 0.336 0.316 0.295 0 1 0 1 0.
Operation SECTION 3 DIP Switch Settings For complete DIP switch calibration AC current tables of all Models, see the following tables (Tables 3-2 thru 3-12). DS1 POSITIONS DS2 123 123 123 123 123 123 123 123 1 2 3 4 000 001 010 011 100 101 110 111 0 0 0 0 12.7 11.1 10.1 9.0 8.0 7.4 6.9 6.4 0 0 0 1 16.4 14.4 13.1 11.8 10.5 9.7 9.1 8.4 0 0 1 0 19.4 17.2 15.6 14.2 12.7 11.7 10.9 10.2 0 0 1 1 22.5 20.0 18.3 16.6 14.9 13.8 12.9 12.
Operation SECTION 3 DIP Switch Settings DS1 POSITIONS DS2 1 2 3 4 123 000 123 001 123 010 123 011 123 100 123 101 123 110 123 111 0 0 0 0 19.7 17.3 15.6 14.1 12.5 11.5 10.7 9.9 0 0 0 1 25.5 22.4 20.4 18.4 16.4 15.1 14.1 13.1 0 0 1 0 30.2 26.8 24.3 22.0 19.7 18.2 17.0 15.9 0 0 1 1 35.1 31.2 28.5 25.8 23.2 21.4 20.1 18.8 0 1 0 0 38.1 34.0 31.1 28.3 25.4 23.5 22.1 20.6 0 1 0 1 42.4 37.9 34.8 31.8 28.6 26.5 24.9 23.
Operation SECTION 3 DIP Switch Settings DS1 POSITIONS DS2 1 2 3 4 123 000 123 001 123 010 123 011 123 100 123 101 123 110 123 111 0 0 0 0 50.8 44.5 40.2 36.2 32.1 29.5 27.6 25.6 0 0 0 1 65.5 57.7 52.4 47.3 42.1 38.8 36.3 33.7 0 0 1 0 77.8 68.8 62.6 56.7 50.7 46.7 43.8 40.8 0 0 1 1 90.2 80.2 73.2 66.5 59.6 55.1 51.7 48.2 0 1 0 0 97.9 87.3 79.9 72.7 65.3 60.4 56.8 53.1 0 1 0 1 108.9 97.5 89.4 81.7 73.5 68.2 64.1 60.
Operation SECTION 3 DIP Switch Settings DS1 POSITIONS DS2 1 2 3 4 123 000 123 001 123 010 123 011 123 100 123 101 123 110 123 111 0 0 0 0 73.3 64.2 58.1 52.3 46.4 42.6 39.8 37.0 0 0 0 1 94.6 83.4 75.6 68.3 60.9 56.0 52.4 48.7 0 0 1 0 112.3 99.4 90.4 81.9 73.2 67.5 63.2 59.0 0 0 1 1 130.3 115.8 105.8 96.0 86.1 79.6 74.6 69.7 0 1 0 0 141.4 126.2 115.4 104.9 94.3 87.3 82.0 76.7 0 1 0 1 157.3 140.8 129.1 118.0 106.2 98.5 92.
Operation SECTION 3 DIP Switch Settings DS1 POSITIONS DS2 1 2 3 4 123 000 123 001 123 010 123 011 123 100 0 0 0 0 141.0 123.5 111.7 100.5 89.3 0 0 0 1 182.0 160.3 145.4 131.4 117.0 0 0 1 0 216.0 191.2 173.9 157.5 140.8 0 0 1 1 250.5 222.7 203.4 184.6 165.6 0 1 0 0 272.0 242.6 222.0 201.8 0 1 0 1 302.5 270.7 248.4 226.9 0 1 1 0 328.0 294.5 270.9 0 1 1 1 354.5 319.8 294.6 1 0 0 0 371.5 335.8 1 0 0 1 395.0 358.
Operation SECTION 3 DIP Switch Settings DS1 POSITIONS DS2 1 2 3 4 123 000 123 001 123 010 123 011 123 100 123 101 123 110 123 111 0 0 0 0 211.5 185.3 167.5 150.8 133.9 122.9 114.8 106.6 0 0 0 1 273.0 240.5 218.1 197.1 175.5 161.6 151.2 140.6 0 0 1 0 324.0 286.7 260.8 236.2 211.2 194.7 182.4 170.1 0 0 1 1 375.8 334.0 305.1 276.9 248.4 229.6 215.3 201.0 0 1 0 0 408.0 363.9 332.9 302.7 272.1 251.7 236.6 221.1 0 1 0 1 453.8 406.
Operation SECTION 3 The plugs are stamped with voltage ratings according to Table 3-13; and upon initial inspection. DIP Switch Settings 2. DIP Switch 3 (DS3) DS3-1 Set to OPEN position for voltage ramp mode. Set to CLOSED position for current ramp mode. DS3-2 Set to OPEN position for energy saving ON. Set to CLOSED position for energy saving OFF. The DS3 switch is factory set with: DS3-1 OPEN DS3-2 OPEN 3.
Operation SECTION 3 DIP Switch Settings 4. Time - The ramp time is adjustable from 1 to 40 seconds. The maximum setting is at the full clockwise position. In the voltage-ramp mode, this function ramps the motor voltage up from an initial step to full line voltage. The motor may come up to speed before the voltage ramp is finished; this depends on the application and the type of load on the motor. The voltage ramp will continue until full motor voltage is reached. This is called END OF RAMP.
Operation SECTION 3 DIP Switch Settings 7. Current Trip - The current trip is adjustable from 100 to 120% of the DIP switch current setting. It is active all the time; during start and run. The maximum setting is at the full clockwise position. This adjustment is used to accommodate the service factor rating of the motor. For example, for a service factor of 115%, the control should be set to 3/4 clockwise. The current trip adjustment will affect the entire overload trip-time curve. (See Figure 3-1.
Operation SECTION 3 DIP Switch Settings The MIN VOLTS and MAX VOLTS adjustments enable the Easy-Start ES to automatically follow the motor load and adjust the motor voltage to the value necessary to maintain normal operation at the most efficient energy usage. C. Stability Adjust - Every system has its own unique inertial response. It is the job of the Easy-Start ES starter control circuit to regulate over a very broad range of systems.
Operation SECTION 3 10000 8000 6000 5000 4000 3000 2000 ENCLOSURE AMBIENT TEMPERATURE 40° C 1000 800 CURRENT TRIP POT 600 500 CW 400 TRIP TIME IN SECONDS (COLD START) 300 CCW 200 100 80 60 50 40 ENCLOSURE AMBIENT TEMPERATURE 25° C 30 20 CURRENT TRIP POT 10 8 CW 6 5 CCW 4 3 2 1 0.6 0.
SECTION 4 Options About This Section This section of your Easy-Start ES Instruction Manual identifies options which are available factory installed for enclosed models only. After reviewing this section you will understand: ¥ Easy Start ES options that are available. ¥ Application notes for available options.
Options SECTION 4 Available Options All Easy-Start ES options are available as factory installed for enclosed models only and must be ordered with Easy-Start ES. By checking the nameplate or by visual inspection it can be determined what options are supplied with a unit. Operator Devices: Following is a list of available options. Cat. No. Suffix Description A Start (Green), Stop (Red), Reset (Gray) pushbuttons. B Hand-Off-Auto Selector Switch (Gray), Reset (Gray) pushbutton.
Options SECTION 4 Available Options Control Devices: Cat. No. Suffix Description Cutler-Hammer Transformer Connections T2 300VA control power transformer. Other details Cat. No. Suffix T4 500VA control transformer. Other details same as T. Y2 Time delay relay, (type TR) delay on make. T 150VA control power transformer with 2 primary fuses. Easy-Start ES models have multi-voltage ratings.
Options SECTION 4 Circuit Breakers Available Options Available Plug-In Option Kits Description Catalog Number Extended Start Time KITESE The circuit breakers offered with Easy-Start ES are listed in Tables 4-1 and 4-2. The interrupting rating and terminal sizes are listed in Table 4-3. Caution Notice - May require oversized Easy-Start ES and may require changing thermal magnetic molded case circuit breaker (if optionally ordered) to magnetic trip only.
Options SECTION 4 Available Options Circuit Breakers Option No. Thermal Magnetic With Shunt Trip Easy-Start ES Model Frame Size Breaker Type Amps Mag. Trip Adj.
Options SECTION 4 Available Options Circuit Breakers Option No. Thermal Magnetic With Shunt Trip Easy-Start ES Model Frame Size Breaker Type C14 C43 ES045(1) F HMCP 30 C15 C44 ES070(1) F HMCP C16 C45 ES120 J C17 C46 ES180(2) C18 C18 C47 C47 C19 C19 C19 Amps Mag. Trip Adj. Nominal HP 208 230V 460 575V 3X-10X 5 15 100 3X-10X 25 50 HMCP 250 3X-6X 50 100 K HMCP 400 2.5X-5X 75 150 ES250(2) ES260(2) K K HMCP HMCP 400 400 3.75X-7.5X 3.75X-7.
Options SECTION 4 Available Options Circuit Breakers Circuit Breaker Type UL489 Interrupting Capacity Rating Max Breaker Amps Wire Range Terminals 240V 480V 600V HFD 100 100,000 65,000 25,000 #14 -1/0 HFD 150 100,000 65,000 25,000 #4 - 4/0 HJD 250 100,000 65,000 25,000 #4 - 350 MCM HKD 200 100,000 65,000 25,000 #3 - 350 MCM HKD 250 100,000 65,000 35,000 250-500 MCM HKD 300 100,000 65,000 35,000 250-500 MCM HKD 400 100,000 65,000 35,000 3/0-250 MCM (2) HMC 800
Options SECTION 4 Available Options Notice - IQ Data Plus II Ampere Display Special Functions Range: Minimum: 2% of CT used with IQ Maximum: 500% of Easy-Start ES Maximum Ampere Rating Cutler-Hammer ÒIQ Data Plus IIÓ Monitoring Device, catalog suffix ÒQ8Ó, provides the following readings: AC Ampere Phase A Phase B Phase C If local codes or customer preference prohibit line voltage on the door, do not use this option.
Options SECTION 4 Available Options Special Function (Option Boards) Special function option boards E, S and J plug into main logic board.
Options SECTION 4 Available Options Special Function The third function, Extended Time-Current, is activated by connecting a wire between the option board (TB37-1) and the main logic board (TB1-8). This connection activates DS2 on the logic board at the end of ramp-up.
Options SECTION 4 There are 5 LED indicators on the Printed Circuit Board: Available Options Special Functions: Option ÒJÓ POWER ON The board is factory set with both functions deactivated. The table below gives instructions on how to activate the two functions: Jam Trip DS411 Open Ò0Ó Closed Ò1Ó PHASE A GREEN OFF ON PHASE B GREEN PHASE C GREEN Function DS431 OFF ON JAM: Extra Form-C contacts, rated 1 amp, 120V ac available at TB41.
Options SECTION 4 Available Options Daughter Board Option ÒDÓ The Option Daughter Board is used whenever two or more Special Option Boards are supplied with the Easy-Start ES. These option boards must be the plug-in type. The Daughter Board will accommodate any two of the following boards: E Option - Extended Start Time S Option - Smooth-Stop ● J Option - Jam/Underload ● ● Whenever there are two or more plug-in option boards needed, one of the boards is plugged into the Mother Board (Main Logic board).
Options SECTION 4 Application Notes Extended Start Time Option This option is used to extend the starting time. It inhibits the Inverse Time Trip function output, on the Easy-Start ES Logic Board during this time period. The total time, for which the Inverse Time Trip function is inhibited, is adjustable from 2 to 12 minutes in discrete intervals, by using a DIP switch on the option board.
Options SECTION 4 Some typical applications for this option are: Application Notes The table below shows the DIP SW DS21 settings along with the user determined start time, cool down time, and the total time in minutes: DIP Switch DS21 Code Ò1Ó = Closed Ò0Ó = Open DS21 1234 USER DETERMINED START TIME COOL DOWN TIME TOTAL TIME MINUTES 1111 0111 1011 0011 1101 0101 1001 0001 1110 0110 1010 0010 1100 0100 1000 0000 0.5 0.6 0.7 0.8 1.0 1.2 1.4 1.5 2.5 2.8 3.6 4.2 5.0 6.0 8.5 10.5 1.5 1.5 1.5 1.5 1.5 1.
Options SECTION 4 Notice - When using the Extended Time- Application Notes Current option, do not make a connection between TB1-2 and TB1-8 on the main logic board. Extended Time-Current Option This option would enable the Easy-Start ES to be used on NEMA A, B, C, D, or any three-phase induction motor with locked rotor codes up to 8.0 KVA per horsepower.
Options SECTION 4 Application Notes Example-1 Continued: How to Select Settings for DIP Switches DS1 and DS2 on Logic Board: (Refer to Instruction Manual, Table 3-1). Select DS1 by looking in first column (DS2=000). Use a rating that is equal or slightly higher than 236.8 amps. Since we must satisfy both starting and running current, we must look at the same row, reading across, to find a setting equal or slightly less than the FLA (180 amps). We select 242.8 from the 1st column and 176.
Options SECTION 4 Application Notes Example-2: This is an application where a motor may require starting current of less than 500%, but for a longer period of time. Below is a table showing trip time in seconds vs. percent current limit: points were taken from Figure 3-1 of the Instruction Manual. Data was taken from the 40¡C ambient curves. Curr Trip 1.00 Curr Trip 1.15 Curr Trip 1.
Options SECTION 4 Application Notes Smooth-Stop Option The input-output functions and relays are brought out to the seven terminal blocks on the printed circuit ÒSÓ option board: The Smooth-Stop option is available with the following variations: (See Figure 4-16 for component layout.) Option ÒSÓ TB31-1, TB31-2 Input: Momentary N.O. pushbutton for smooth-stop.
Options SECTION 4 Smooth-Stop Option When Used With ÒBÓ Option (HOA Switch) Application Notes Smooth-Stop Function DS31-1 Open Ò0Ó Closed Ò1Ó OFF ON 1.1 Start motor by moving HOA switch from off to ÒHÓ position. End of Ramp-Up Relay DS31-2 Open Ò0Ó Closed Ò1Ó 1.0 Operating with HOA switch in ÒHÓ position. OFF ON The end of ramp-up relay can be used to control a by-pass contactor; see Figure 4-5. The interface relays K12 and K13 supply the proper 120V ac control logic to the by-pass contactor coil.
Options SECTION 4 Application Notes Smooth-Stop Option With Remote Maintained 2-Wire Contact Figure 4-7 shows how a 2-wire remote contact is used to SOFT-START and SMOOTH-STOP the motor. JAM Option (Close DIP switch DS41-1 to activate the JAM Trip option.) The JAM option is used to provide an immediate trip if there is an overload on the motor during the run mode. The JAM trip is de-activated during the START and STOP modes of the solid state motor starter operation.
Drawings This part of the Options section of this Instruction Manual presents the following series of drawings: ¥ Current vs. time ratings. ¥ Option schematics. ¥ Trip point settings and trip time curves. ¥ Connection diagrams. ¥ Component layouts. ¥ Dimension of option boards.
4-22 1 Easy-Start ES Instruction Manual NEMA-1 Current Vs. Time Ratings Figure 4-1 100 1 0.1 2 3 4 8 7 6 5 1,000 19 2 3 4 8 7 6 5 10,000 9 1 2 3 4 8 7 6 5 100,000 19 A.C. AMPS (COLD START) 2 3 4 1.0 5 6 7 8 91 2 3 10 5 6 7 8 91 2 3 4 100 5 6 7 8 91 TIME (SECONDS) (COLD START) 4 NEMA-1 CURRENT VS.
10 1,000 10,000 A.C. AMPS (COLD START) 1 0.1 1 2 3 4 1 9 8 7 6 5 2 3 4 1 9 8 7 6 5 2 3 4 1 9 8 7 6 5 2 3 4 1.0 5 6 7 8 91 2 3 4 2 3 4 100 5 6 7 8 91 TIME (SECONDS) (COLD START) 10 5 6 7 8 91 NEMA-12 CURRENT VS. TIME RATINGS 2 3 4 1,000 5 6 7 8 91 2 3 4 ES45 ES70 ES120 ES250 ES360 ES500 Easy ES-028 10,000 5 6 7 8 91 Drawings SECTION 4 NEMA-12 Current Vs.
Drawings SECTION 4 Easy ES-029 Extended Start Time with By-Pass Contactor Figure 4-3 Easy-Start ES Instruction Manual 4-24
Drawings SECTION 4 Easy ES-030 Option E1 - Extended Start Time with Ramp-Up Door Light Figure 4-4 Easy-Start ES Instruction Manual 4-25
Drawings Easy ES-031 SECTION 4 Smooth-Stop with By-Pass Contactor Figure 4-5 Easy-Start ES Instruction Manual 4-26
Drawings Easy ES-32 SECTION 4 Smooth-Stop ÒS-1Ó Option Figure 4-6 Easy-Start ES Instruction Manual 4-27
Drawings SECTION 4 120 VAC 120 VAC FAULT TRIP RELAY K1 K2 16 TB1-17 1 12 11 2 1 13 2 4 K2 K13A 14 K34 1 2 TB34-1 TB34-2 SMOOTH STOP BOARD TB31-1 TB31-2 21 K13C 22 (USER SUPPLIED) REMOVE CONTACT START/SMOOTH-STOP 1 1 2 2 OSL4-22A AUX RELAY RESET 1 K13 3 T2 2 K13B 43 44 NOTES: 3 1. INDICATES TB1-3 ON MAIN LOGIC BOARD. 2. FOR SAFTEY REASONS. THE REMOTE STARTING CONTACT MUST BE OPENED BEFORE THE STARTER CAN BE RESET, AFTER A FAULT TRIP OCCURS. 3.
Drawings SECTION 4 JAM TRIP SET AT 150% 10 DS412 3 0 0 0 1 1 0 1 1 DIP SWITCH CODE: “0” = OPEN “1” = CLOSED TRIP TIME IN SECONDS 5 2 1 0.5 11 10 01 00 0.2 0.1 Easy ES-034 1 1.
Drawings SECTION 4 UNDERLOAD TRIP SET AT 50% 10 DS432 3 0 0 0 1 1 0 1 1 DIP SWITCH CODE: “0” = OPEN “1” = CLOSED TRIP TIME IN SECONDS 5 2 1 11 0.5 10 01 0.2 0.1 00 0.1 0.2 0.3 0.4 0.5 1.
Drawings SECTION 4 NOTES: 1. Option ÒJ1Ó Jam Light 2.
Drawings SECTION 4 Easy ES-039 Daughter Board Connections Figure 4-13 Easy-Start ES Instruction Manual 4-32
Drawings SECTION 4 Easy ES-040 Printed Circuit Logic Board Component Layout Figure 4-14 Easy-Start ES Instruction Manual 4-33
Drawings SECTION 4 Easy ES-041 Option E - Printed Circuit Board Component Layout - Extended Start Time Figure 4-15 Easy-Start ES Instruction Manual 4-34
Drawings SECTION 4 Easy ES-042 Option S - Printed Circuit Board Component Layout - Smooth-Stop Figure 4-16 Easy-Start ES Instruction Manual 4-35
Drawings SECTION 4 Easy ES-043 Option J - Printed Circuit Board Component Layout - Jam-Underload Figure 4-17 Easy-Start ES Instruction Manual 4-36
Drawings SECTION 4 Easy ES-044 Option U - Printed Circuit Board Component Layout - Shorted SCR Detector Figure 4-18 Easy-Start ES Instruction Manual 4-37
Drawings SECTION 4 Easy ES-045 Option D - Printed Circuit Board Component Layout - Daughter Board Figure 4-19 Easy-Start ES Instruction Manual 4-38
Drawings SECTION 4 45, 70 & 120 AMPS 180 AMPS AND UP Easy ES-046 Dimensions for Logic Board, Daughter Board, Cover Board Assembly Figure 4-20 Easy-Start ES Instruction Manual 4-39
SECTION 5 Troubleshooting This section of your Instruction Manual describes what to do if your drive indicates there is a problem. After you review this section, you will understand: ¥ Troubleshooting Guide. ¥ SCR Diagnostic Tests. ¥ Renewal Parts List. Caution Make sure you read, understand and follow all of the Safety Statements in the Safety section of this manual before you troubleshoot your Motor Starter. If further assistance is needed please feel free to contact CutlerHammer.
Troubleshooting SECTION 5 Troubleshooting Guide A. Equipment Required 1. Multimeter Simpson 260 or Equivalent. 2. Clamp-On Ammeter. Danger High Voltage When making any measurements other than voltage or current readings, be sure that the line power is disconnected. Never use a grounded voltmeter or oscilloscope to make measurements. 5. Check the diagnostic LEDÕs.
Troubleshooting SECTION 5 Troubleshooting Guide If the RUN LED comes on and the motor does not rotate; check the following: UNDER VOLT LED - Measure the voltage at test point TP-6 on the logic board; it should be greater than 5 VDC. - Check DIP switch DS1 and DS2 settings against motor FLA. Remember, DS2 is only activated if there is a connection made between TB1-2 and TB1-8 on the logic board. - Curr Lim LED - The motor may be in a current limit; check the Curr Lim adjustment.
Troubleshooting SECTION 5 Troubleshooting Guide D. SCR Diagnostic Tests C. Problem: The motor rotates but does not reach full speed. The RUN LED is on; but the END OF RAMP LED does not come on. Check: 1. DIP switch DS1 and DS2 settings against motor FLA. 2. Current limit adjustment may be set too low and will not provide enough starting torque; turn Curr Lim adjustment CW to increasing starting current. Measure the motor current with a clamp-on ammeter. 3.
Troubleshooting SECTION 5 SCR Diagnostic Tests E. Logic Board Digital Trigger Output: 7. Measure the 6 digital trigger SCR gate pulse outputs using a multimeter on the DC voltage range. These points are available on the connectors on the logic board. Pin Number Pin Number Cathode (-) Gate (+) Caution Voltage is applied to the starter during this test. Exercise safe operation procedures. Procedure: J101 J101 J201 J201 J301 J301 1 3 1 3 1 3 4 6 4 6 4 6 1. Turn off all power to the Easy-Start ES. 2.
Troubleshooting SECTION 5 SCR Diagnostic Tests SCR Service Procedures: (Hockey-Puk Type) When changing SCRÕs in the field, it is best to remove the entire heat sink and lay it in a horizontal position. However, if this is not convenient, the following procedure can be used: 1. Remove the printed circuit logic board. 2. Remove the line power cable. 3. Remove the power strap between the two short heat sinks. 7.
Troubleshooting SECTION 5 SCR Diagnostic Tests 500 kg. (1,100 lb.) 1/4" - 20 1-1/4 - turn 1000 kg. (2,200 lb.) 1/4" - 20 2-1/4 - turns S + 50.80 (S + 2") ”S“s Heatsink •Scr. Nut Holder Bolt 69.85 90.40 (2.75") (3.56") Washers (2) Bolt Length S + 40 mm (1.5") 19.05 (0.75") Spring Insulator Easy ES-046 Typical SCR Clamp Used In ES180, ES260 Figure 5-1 SPRING BOTTOM EDGE OF LEAF USED AS INDICATING REFERENCE POINT NUMERALS 1, 2 & 3 INDICATE 1000 LB.
Troubleshooting SECTION 5 SCR Diagnostic Tests Pre-Start - Review Cutler-Hammer recommended procedures for mounting ÒdiscÓ power semiconductors (refer to W SCD Mounting Kit instructions). - CAUTION: Deficient heat sink materials may creep or cold flow, relax, deflect with time and temperature under these high load forces. Stack assemblies must be thoroughly checked at design ratings. - Spring load bar epoxy insulation coating is rated at 130¡C NEMA B, 5000V RMS.
Troubleshooting SECTION 5 SCR Diagnostic Tests Easy ES-S048 Assembly Sink-Device Clamp Figure 5-3 Easy-Start ES Instruction Manual 5-9
Troubleshooting SECTION 5 SCR Diagnostic Tests Easy ES-S049 Stack Loading Figure 5-4 Easy-Start ES Instruction Manual 5-10
Troubleshooting SECTION 5 SCR Diagnostic Tests Notice - Use sparingly - Apply only a thin coat of compound. Changing Isolated Block SCRÕs: The following procedure can be used for changing isolated block SCRÕs. 1. Remove the printed circuit logic board. 2. Remove the power and control connections from the SCR and identify the wires. 3. Remove the SCR block. 4. Before installing the new SCR block, the old thermal compound and any foreign matter should be removed from the heat sink mating surface.
Troubleshooting SECTION 5 SCR Diagnostic Tests J4 PIN # FUNCTION LOCATION CONDITION TEST VOLTAGE 1 +10VDC VR1-2 3-PH VOLTAGE ON 10V +.5 2 CURRENT SIG CURRENT SIG TP1 TP1 START RUN/AT FULL LOAD 0 TO 4.5 VDC 0.90V + .04 VDC 3 TRIGGER VOLTS TP6 RUN FULL LOAD RUN NO LOAD 6 TO 8 VDC 3 TO 3.5 VDC 4 CURR SIG CURR SIG 03 COLL 03 COLL START RUN 0 0.1 TO .
Troubleshooting SECTION 5 Renewal Parts List Here is a recommended spare parts list for a typical Easy-Start ES installation: The renewal parts are listed by an abbreviated Easy-Start ES model number, showing the current and voltage rating. The parts listed apply to both open panel and enclosed models. One Logic Board. One Stack Assembly, or Two SCRÕs. One set of MOVÕs.
Troubleshooting SECTION 5 Renewal Parts List Fuses for Fan Control Power Transformers (2 Required per Model): 208/230/460 and 380/415V Models up to 560 Amps: BUSS FNQ-2, 2 Amp 460/500/575V Models up to 560 Amps: BUSS KTK-1-1/2, 1-1/2 Amp 208/230/460 and 380/415V Models 500 and 750 Amps and above: BUSS FNQ5, 5 Amp Option Boards: Extended Start Time: Jam/Underload: Smooth Stop/End of Ramp: Shorted SCR Detector: The following is a list of MOVÕs and their ratings: MOV Number AC Volts Joules 0088219B 00882
Troubleshooting SECTION 5 Renewal Parts List The following is a list of Easy-Start ES models, their SCR stack assemblies or back-to-back SCRÕs. The list indicates whether the DV/DT snubber or MOV components are included when the stack or back-to-back SCRÕs are ordered. MODEL NO.
Troubleshooting SECTION 5 Renewal Parts List MODEL # LOGIC BOARD 2D66806 SCR 9029- SCR STACK ASSY BACK-TO-BACK SCRÕs C.T.
Troubleshooting SECTION 5 Renewal Parts List Voltage Plugs: Line Voltage Plug Part Number Voltage Stamped On Plug 208/230/460V Models: 208/230V 460V Plug 9028-460A Plug 9028-460C 230 460 380/415V Models: 380V 415V Plug 9028-460G Plug 9028-460H 380 415 460/500/575V Models: 460/500V 575V Plug 9028-460J Plug 9028-460K 500 575 Easy-Start ES Instruction Manual 5-17
Cutler-Hammer Solid State Reduced Voltage Motor Starter Aftermarket Services • • • • • • Technical/telephone support. Resident service engineers in major trading centers. Factory repair services. Warranty administration. Equipment modification and upgrading services. Training seminars.
