Power Electronics Ltd.

Digital Soft Starter

PED-Start
Edition 10 Febuary 2000

Power Electronics Ltd. P.O.B 255 OR-YEHUDA 60200 ISRAEL Tl.972-3-5334855 Fax.972-3-5334783

Web : power-electronics-il.com email : hespek@netvision.net.il

 TABLE OF CONTENTS

Section 1. PED START GENERAL INFORMATION/BLOCK DIAGRAM

1.1 PED START description 2
1.2 Unpacking 3
1.3 Mounting Instructions 3

Section 2. PROGRAMMING AND OPERATION MODES

2.1 Functional Description 5
2.2 Programming 7-8
2.3 Protections and parameters 8

Section 3. FRONT PANEL DESCRIPTION

3.1 Keypad Operation 14

Section 4. WIRING AND CONNECTIONS 15

4.1 Electrical Connections warnings and guidelines 16
4.2 Power Connections 17
4.3 Control Connections

Section 5. SPECIAL CONFIGURATIONS

5.1 Bypassing the starter after start-up 18
5.2 Reversing Motor's Rotation 18

Section 6. TROUBLESHOOTING
19

1
1. GNERAL INFORMATION / Block Diagram

PED-Start
CT
U L1

M V L2 LINE
VOLTAGE
3
W L3

CT

Firing pulses

Current Voltage
Optocouplers Sampling Sampling

Temp. sampling

Memory Microcontroller

PED-START
3 phase digital aoft starter

ON

RUN

FAULT
PARA FAST

F CONTRAST
ENTER
Control Terminals
V T
3 Auxiliary
Strip Relays

Power Electronics Ltd.

Figure 1

2
1.1 PED START description

The PED-Start is a highly sophisticated unit

providing smooth stepless start-up and stop
for inductive motors.
The PED-Start is utilizing a unique method of
synchronization and firing of the power
devices enabling a great reduction in
electrical, mechanical and hydraulic shocks.
The PED-Start provides a complete solution
for the motor and load, controlling, monitoring
and protecting.
PED-Start incorporates a microprocessor aiming
for high precision, flexibility, simplicity and
reliability.
This section provides instructions for unpacking,
mounting and preparing the PED-Start for
operation.

1.2 UNPACKING

Unpack the PED START and inspect it for any

physical damage that might have occured in
shipment .
Check that the starter's rating comply with the
starter's nominal current with mains and control
voltage.
In the event of damage , please contact your
local distributor.

1.3 MOUNTING INSTRUCTIONS

The PED START should be mounted in an

electrical cabinet.
it is recommended to mount the PED START
directly on a metalic plate , to improve heat
dissipation.
In order to ensure sufficient heat dissipation ,
the PED START must be mounted vertically (fans
at the bottom) , leaving 10 cm of free space
around it.
Verify that the PED START surrounding
environment is free of liquids, dust, or corrosive
fumes.
Ambient operating temperature of the PED
START is 45° C, it is recommended to mount
the starter in a ventilated cabinet.

3
2. Programming and operation modes

This section provides instructions

and information required for
programming and operating the
PED-Start including functional
description.
- Description of the user's interface.
- Operation flowcharts.
- Adjustments before start-up.

2.1 FUNCTIONAL DESCRIPTION

Operation modes.

The PED-Start has the following modes:

STAND-BY MODE
The starter is ready to start upon pressing
the external start pushbutton (or activating
the ON/OFF switch) and the following
messages appear on the display:-

PED-START PRESS
PARA FOR SETTING

and the three phase voltages

L1 220v L2 220v
L3 220v

In this mode the two messages are displayed

in rotation every few seconds.

SETTING MODE PARA-

Pressing the pushbutton METER will replace
the last screen with the first parameter.

FACTORY ADJUSTED
XXX,X NOMINAL CUR

4
Re-pressing the "PARA" pushbutton will
replace the displayed parameter with the
next one.
Setting the pushbuttons to increase and
to decrease.
To load the adjusted parameters into
ENTER
permanent memory, press the pushbutton

I.T. MODE
While the motor is operating at initial torque,
the following screen appears on the display
(phase current and I.T. Mode).

UXXX.XA VXXX.XA
WXXX.XA I T MODE

ACCELERATION MODE
Following the Initial Torque Mode the starter
switches to the Acceleration Mode and the
motor accelerates according to the pre-
programmed start-up parameters and the
following screen appears on the display.

UXXX.XA VXXX.XA
WXXX.XA ACC MODE

This mode terminates when the motor reaches

its working current, the message ACC. MODE
will be replaced by CUR LIM if the current
limit function is activated.

UXXX.XA VXXX.XA
WXXX.XA RUNNING

If a warning condition occurs, the message

RUNNING will be replaced by a warning
message.
Three warning messages are possible:
OVERLOAD, ASYM CUR, UND LOAD.
F
In this mode, pressing the pushbutton V T
displays the motor current and the three
phase voltages in rotation every few seconds.

5
DECELERATION MODE
Upon pressing the external stop pushbutton (or
activating the ON switch) the starter decelerates
reducing the motor's voltage while stop is
controllable the following screen
appears on display:-

UXXX.XA VXXX.XA
WXXX.XA DEC MODE

At the end of this mode the PED-Start returns

to STAND-BY MODE.

2.2 PROGRAMMING

6 keypad pushbuttons are available to

program the parameters. The LCD consists of
two lines, 16 characters-per-line.

START-UP PARAMETERS

* Initial Torque Level -

Determines the starting torque of the motor
instantly after start command. Range 30/100%
of nominal voltage.

* Initial Torque Time -

Determines the period through which the motor
operates at initial torque. Range 0 / 10 second.

* Acceleration Time -
Determines the acceleration period if no current
limit occurs during acceleration.
Range 2/15 seconds.

* Current Limit -
Determines the current limit threshold during
the acceleration procedure.
Range: up to 5 x Inom (units Amper).

6
 2.3 PROTECTIONS AND PARAMETERS

* Overload -
Determines the level of current trip out.
Range: (0.7 - 1.2) x Inom.
60
40
* Overload time factor -
20
Determines the overload curve.
10
Range: 0 - 10 (10 is slow). The overload

MINUTES
protection response time can be extracted 6
4
graphically from the overload curves shown
2
in Figure 2. 1
40

* Underload - 20

SECONDS
Determines the threshold value of the 10 SLOW
6
underload current protection. 4 FAST
Range: (0 / 0.8) x Inom (units Amper). 2

1
* Underload Time - 1.5 3 6
Determines the period through which the (x NOMINAL CURRENT)
motor is allowed to run at current lower than Figure 2
the underload threshold.
Range: 5 / 10 seconds.

STOP PARAMETERS

*Decel Time -
Determines the deceleration time after a
STOP or OFF command is given.
Range: 2 / 45 seconds.

SPECIAL SETTING PARAMETERS

* Free Wheel Stop -

If yes, a STOP or OFF command will turn
off the motor. The motor will decelerate under
it's natural conditions depending on the load.

* Decel Pump Mode -

If yes, a unique algorithm will take care of
the relevant parameter to enable the motor
to decelerate smoothly avoiding water
hammering.

7
 Upon completion of the start-up create a stop in
order to decelerate, push and hold FAST button,
when the motor stalls, press button.

The current will drop to 0. This step is registered

and stored in the permanent memory and is
carried out only once. If a different setting is
required, follow the same procedure.

* Bypass Soft stop -

If yes, the delay relay will release immediately
after a STOP (or OFF) command is given, in
order to phase back and enable a safe soft stop.

* Shearpin Mode -
If yes, the starter will trip immediately when
the working current reaches the threshold
of the pre-set shearpin current. (This protection
is active only during RUNNING mode).

* Shearpin Current -
Determines the threshold value of the shearpin
current protection.
Range: (0.7 / 1.2) x Inom (units Amper).

* Nominal Current -
Determines the nominal current of the starter.
This parameter is factory adjusted, but can be
re-adjusted by the user.

PROTECTIONS

* ASYM CUR fault -

Current imbalance greater than 40% will cause
a trip out and a stop of the motor.
The following screen appears
ASYM CUR FAULT
AT REGISTERED MODE

Shorted SCR's or disconnected load -

A trip out occurs if any of the SCR's is shorted
or the load disconnected.
The following screen appears SHORTED SCRS OR
DISCONNECTED LOAD

8
PEAK CUR fault -
A trip out occurs upon a current surge greater
than 6 x In.
The following screen appears
PEAK CUR FAULT
AT REGISTERED MODE

OVER TEMP fault -

The PED-Start is protected against over
heating
via a thermal element located on the heatsink.
If temperature exceeds 85 C, a trip out occurs,
followed by a soft stop.
The following screen appears OVER
PEAK TEMP
CUR FAULT
FAULT
AT REGISTERED MODE

SHEARPIN fault -
At running mode, if current exceeds the set
shearpin level, a trip out followed by soft stop.
The following screen appears
PEAK
SHEARPIN
CUR FAULT
FAULT
AT
ATREGISTERED
RUNNING MODE
MODE

OVERLOAD fault -
Overload fault occurs if running current
exceeds the set overload current following
the protection curve. See figure 2.
The following screen appears
OVERLOAD
PEAK CUR FAULT
FAULT
AT
ATREGISTERED
REGISTERED MODE
MODE
UNDERLOAD fault -
At running Mode if current is below the underload
set current. The motor trips out followed by
soft stop.
The following screen appears
UNDERLOAD
PEAK CUR FAULT
FAULT
AT REGISTERED
RUNNING MODE
MODE

Instead of AT REGISTERED MODE we shall

see on the screen either AT RUNNING MODE,
AT ACCELERATION, AT DECELERATION,
depending on the event.

9
Motor overheating protection (via thermistor)-
This protection method tends to get more
popular recently. Undoubtfully this is the most
effective and reliable method to protect
electric motors. The PED-Start enables a direct
hook-up of the thermistor to the starter (no
extra circuits are required).
The PED-Start provides as well self-testing
against open or short circuit of the thermistor.

Phase missing -
The starter monitors the 3-phase input
voltage.
Upon any voltage failure, the motor trips out
followed by soft stop.

PEAK
PHASECUR
MISSING
FAULT
AT REGISTERED MODE

10
2.3

PED START PRESS

PARA FOR SETTING

FACTORY ADJUSTED
XXX.X NOMINAL CUR

INI TORQUE LEVEL

XX.X %
SOFT START
Parameters
INI TORQUE TIME
X.X SEC.

ACCEL LIMIT
XXX.X AMP

CURRENT LIMIT
XXX.X AMP

OVERLOAD
XXX.X AMP

O.L TIME FACTOR

X.X 10=SLOW
STARTER & MOTOR
Protections
UNDERLOAD
XXX.X AMP

UNDERLOAD TIME
X.X SEC

DECEL TIME
XX.X SEC.

SPECIAL SETTING
X 1=YES 0=NO

YES

11
 SPECIAL SETTING "YES"

FREEWHEEL STOP
X 1=YES 0=NO

DECEL PUMP MODE

X 1=YES 0=NO

BYPASS SOFTSTOP
X 1=YES 0=NO

SHEARPIN MODE
X 1=YES 0=NO

SHEARPIN CURRENT
XXX.X AMP

NOMINAL CURRENT
XXX.X AMP

HISTORY FAULT
3 LAST FAULT

SECOND FAULT
BEFORE LAST FAULT

FIRST FAULT BEFORE

LAST FAULT

STAND BY MODE

12
3.0 FRONT PANEL DESCRIPTION

Adjust working parameter via the keypad on

the front panel. Use contrast potenziometer
on the right side of the keypad to PED-START
dimnes/brightness the display. 3 phase digital aoft starter

ON
3.1 KEY PAD FUNCTION

PARA
Pressing the button will replace the RUN

METER displayed parameter with the next

one. FAULT
PARA
FAST
METER

While pressing this button , the value

CONTRAST
of the param will increase. F
ENTER
V T

While pressing this button , the value

of the parameter currently displayed
decreased.
Power Electronics Ltd.

Third button works in conjunction

FAST
with or This push-button
is active only for setting nominal
current parameter.

Pressing <enter> will load the

ENTER
adjusted parameters into permanent
memory.

F Pressing <F-I-V> displays the motor

V T currents and phase voltages in
rotation, every few seconds of running
mode . This button can be used to
reset.

LED ON Steady light when control voltage

is connected.

LED RUN Blinks during acceleration and

decceleration process, glowing
continuously at running mode.

LED FAULT Glows continuously in event of

any fault.

13
 4. WIRING AND CONNECTIONS

4.1 ELECTRICAL CONNECTIONS WARNINGS

AND GUIDELINES * Terminal 7 -NEUT -if the mains neutral is
available connect neutral to terminal 7.

Before connecting the PED-Start , familiarize

yourself with the following warnings and
guidlines :
*The PED-Start is not a switching device . When
the supply voltage is connected , the control is
OFF , and the load is disconnected the full line
voltage appears at the starter's output terminals
. INSTANTANEOUS RELAYS -Activated with
Disconnect the supply voltage to any
maintenance work on the starter or on the
motor.
*Switches connected to control terminals are
working under low isolated control voltage (24
VAC).
AUXILIARY RELAYS OPERATION
The PED-Start includes three auxiliary relays,
each activating change over contact (AC1 type
230VAC/5A).
The relays are designated :
start command and release after stop
command.
DELAY RELAY - Activated when the start-up
is completed and released at the end of the
decceleration if the bypass soft stop mode
selected is 0.

*Verify that an appropriate short-circuit FAULT RELAY - Activated at any fault condition.
protection or fuse ) is connected in series with
the PED -Start . (Pressing integral or external reset will release
the fault relay only if the reason for fault is
*Do not connect power-factor correction removed).
capacitors at the starter's output terminals , or
at the motor's terminals. If capacitors are
required , connect them at the starter's input
terminals.

*The internal printed circuit board carries high

(mains) voltage Take all necessary safety
precautions when approaching or working on
it.

4.2 POWER CONNECTION

Connect the power cables to the PED-Start as

shown in Figure 3.

4.3 CONTROL CONNECTIONS

Connect the control voltage leads to the

pertaining terminals shown in figure 3.

*Terminals 1,2 and 3 START/STOP push-button

or ON/OFF switch.

*Terminals 4 and 5 -External Reset.

*Terminals 6 -COMMON (generally not used)

14
 CONTROL PCB

PED-Start R1 R2 R3

J9 J1 N.C.
1 2 3 4 5 6 7 8 9 10 11 12 13 1415 1617 18 19 20 J10
JP11

Opt-Th
JP10

INSTANT DELAY FAULT

COMMON

STOP RESET
NEUT.

START
START
STOP

STOP
F
1
CONTROL
VOLTAGE
220V AC

ON/OFF

CONTROL VOLTAGE 220V AC

F1

U L1
PED-Start
M V L2 LINE
3~ VOLTAGE
W L3

POWER AND CONTROL CONNECTIONS

FIGURE 3

15
 Instant Delay Fault
Relay Relay Relay
R1 R2 R3

J9 J1 N.C.
J10
1 2 3 4 5 6 7 8 9 10 11 12 13 1415 1617 18 19 20
Control INSTANT DELAY FAULT
COMMON

NEUT.
JP11
JP10

Voltage Opt-Th
220V AC STOP RESET
START

CONTACTOR
SUPPLY
VOLTAGE
220 VAC

CT X
U L1

Y
M V L2

3~ Z
W L3
CT LINE
VOLTAGE
PED - Start

Bypassing the starter after start-up

FIGURE 4

16
 R1 R2 R3

J9 J1 N.C.
J10
1 2 3 4 5 6 7 8 9 10 11 12 13 1415 1617 18 19 20
Control INSTANT DELAY FAULT
COMMON

NEUT.
JP11
JP10

Voltage Opt-Th
220V AC

L CONTACTOR
SUPPLY
VOLTAGE
CT 220 VAC
U L1

M V L2

3~
W L3 R
CT LINE
VOLTAGE
PED - Start

FIGURE 5

17
 6 TROUBLESHOOTING

This section describes the procedure intended for use troubleshooting the PED Start .
Use the procedure when a problem malfunction is detected during operation.

SAFETY PRECAUTIONS
* The internal printed circuit board carries high (mains) voltage.

*Do not check the starter with a high voltage tester (such as a megger).

The troubleshooting guide consists of the following columns :

- Symptom/Message - describes problems and malfunctions which might be detected by the

operator

- Possible Cause - describes the most likely reason for malfunction symptoms.

- Corrective Action - details the operation/maintenance procedures required to repair the

malfunction.

Symptom/message Possible Cause Corrective Action

Starter remains in READY Control leads are disconnected Check control leads
mode and does not start up

SHORTED SCR'S OR Short circuit of one or two Check and repair

DISCONNECTED LOAD thyristors
Disconnect motor

OVERLOAD FAULT AT Low current limit set Increase current and set
ACCELERATION overload time

ASYM CUR FAULT AT ________ Loose connection in the power Check and repair
cables

PEAK CUR FAULT AT ________ Short circuit to ground or Check motor ,leads and repair.
between phases in power lines

OVER TEMP FAULT AT _______ Heatsink temperature exceeds Verify that the ambient
the permissible level temperature is within the
permissible range.
Check the fans

UNDERLOAD AT _______ Motor current is lower than the Check the mechanical load
preset level

18