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Softstarters Type PSE18...
PSE370 Installation and commissioning manual
This manual belongs to:
Softstarters Type PSE18...PSE370 Installation and commissioning manual 1SFC132057M0201
ABB Softstarters PSE18...PSE370
This is the Installation and Commissioning Manual for Softstarters Type PSE18 PSE370 based on software version 01.01.02. Document number: 1SFC132057M0201 Revision: D Issue date: 2011-10-03 Data subject to change without notice. We reserve all rights to this document, even in the event that a patent is issued and a different commercial proprietary right is registered. Improper use, in particular reproduction and dissemination to third parties, is not permitted. This document has been carefully checked. If the user nevertheless detects any errors, he is kindly asked to notify us as soon as possible. The data contained in this manual is intended solely for the product description and is not to be deemed to be a statement of guaranteed properties. In the interests of our customers, we constantly seek to ensure that our products are developed to the latest technological standards. As a result, there may be some differences between the softstarter and the information in this manual.
Authors address: ABB AB Cewe-Control SE-721 61 Vsters, Sweden Telephone: +46 (0) 21 32 07 00 Telefax: +46 (0)21 12 60 01
http://www.abb.com/lowvoltage
Copyright 2011. All rights reserved. Specification subject to changes without notice.
This chapter describes warning and information signs used in this manual, which the user should pay attention to. The softstarter shall be installed by authorized personnel only. This manual is a part of the PSE Softstarter and should always be accessible to personnel working with this product. The manual shall always be read through before performing any installation or commissioning tasks.
2.1 Use of signs caution, warning and information
Caution icon indicates the presence of a hazard which could result in personal injury.
Warning icon indicates the presence of a hazard which could result in damage to equipment or property.
Information sign alerts the reader to pertinent facts and conditions.
1 2 3 4 5 6 7 8 9 10 11 12 Introduction ............................................ Quickstart ............................................... Description ............................................. Mounting ................................................ Connection ............................................. Human-Machine Interface (HMI) .............. Functions and configuration .................... Fieldbus communication ......................... Maintenance ........................................... Troubleshooting ...................................... Wiring diagrams ...................................... Index ...................................................... 7 11 15 27 31 45 55 79 81 83 95 99
Customer feedback report ............................... 102
Documentation for PSE18...PSE370 softstarter .......................................... Installation and Commissioning................................................................... Intended audience ................................................................................. General ............................................................................................. Requirements .................................................................................... Revision notes and other documents ..................................................... Acronyms and abbreviations .................................................................. Explanation of concepts ......................................................................... 8 8 9 9 9 9 10 10
1.1 Documentation for PSE18...PSE370 softstarter
For the Softstarter Type PSE18...PSE370, the following manuals are available: 1SFC132059M9901 (User manual short form, printed) 1SFC132057M0201 (English version, PDF-file) In the future, the following documents will be available as PDF-files: 1SFC132057M3401 (Swedish) 1SFC132057M0101 (German) 1SFC132057M0301 (French) 1SFC132057M0901 (Italian) 1SFC132057M0701 (Spanish) 1SFC132057M1601 (Portuguese) 1SFC132057M3101 (Dutch) 1SFC132057M4001 (Polish) 1SFC132057M1101 (Russian) 1SFC132057M1801 (Finnish) 1SFC132057M1901 (Turkish) 1SFC132057M1301 (Arabic) 1SFC132057M2001 (Chinese) Please check: www.abb.com/lowvoltage/. On this site select the link Control Products and then continue to Softstarters.
1.2 Installation and Commissioning Manual
This manual contains instructions on how to install, commission and maintain the softstarter. The manual covers procedures for mechanical and electrical installation, and installation of communication devices. It also covers energizing, setting, and configuration and verifying settings. For brief information see Softstarters Type PSE18...PSE370 User Manual short form, containing the same languages as the Installation and Commissioning Manual. Softstarters Type PSE18...PSE370 User Manual short form has document ID 1SFC132059M9901. For quickest possible start, read Chapter 2 Quickstart or go to the short form manual (1SFC132059M9901). A complete compilation of ABBs softstarters can be found in Main catalogue Softstarters, document ID 1SFC132005C0201.
1.2.1 Intended audience
The installation and commissioning manual is intended for the installation, commissioning, and maintenance personnel responsible for getting the softstarter into normal service and out of service.
The installation personnel must have a basic knowledge in handling electric equipment. The commissioning and maintenance personnel must be well experienced in using this kind of equipment.
1.2.2 Revision notes and other documents
For latest information on revisions and other documents related to the PSE Softstarters, please check www.abb.com/lowvoltage/. On this site select the link Control Products and then continue to Softstarters.
1.2.3 Acronyms and abbreviations
The acronyms and abbreviations described in table 1.1 are used in this manual.
Acronym/ abbreviation BP DOL EOL FB FBP HMI Ie IT LCD LED PCB PLC PTC SC SCR TOR Uc Ue Us Description By-pass Direct-on-line Electronic overload protection for the Motor Fieldbus FieldBusPlug Human-Machine Interface Rated operational current Information Technology Liquid Crystal Display Light Emitting Diode Printed Circuit Board Programmable Logic Controller Positive Temperature Coefficient Short Circuit Silicon Controlled Rectifier (thyristor) Top of Ramp (full voltage/Full-On) Rated control circuit voltage * Rated operational voltage * Rated control supply voltage *
*) For definition see IEC 60947-1 edition 5.0
1.2.4 Explanation of concepts
The setting of current Ie is the setting for the rated operational current (main current) of the motor. Ue = Rated operational voltage on the motors operational current (three phase main voltage feeding the motor). Us = Rated control supply voltage, feeding the electronics in the softstarter. Uc = Rated control voltage, used for controlling the softstarter.
Quickstart ................................................................................................... 12
This chapter is a short guide on how to connect, configure and start the softstarter in the easiest way.
Ready Run Protection
This product has been carefully manufactured and tested but there is a risk that damage can occur from abnormal handling during transportation. Therefore, the procedure below should be followed during initial installation:
Mounting, electrical connection and settings of the softstarter shall be made in accordance with existing laws and regulations and be performed by authorized personnel.
1SFC132235F0001
Connecting Softstarters PSE18...PSE370 Inside Delta will cause damage to the equipment, and there is a risk of death or serious injury.
1SFC132265F0001
Figure 2.1: LED status indicators.
LCD display with backlight. Exit key for cancelling parameter edits and moving up one menu level. Select/Reset key for changing and storing parameter values, moving down one menu level, and to reset tripping events. Navigation keys for navigating the menu and changing parameter values. Flashing numbers or text shown in the display indicates that the menu/value can be changed or scrolled.
1SFC132263F0001
Before connecting the Softstarters PSE size 18...PSE170 to operational supply voltage for the first time, the control supply voltage must be turned on to ensure that the by-pass relays are in the open position. This is necessary to avoid unintentional starting of the equipment during the connection.
1. 2. Be aware of the ambient temperature. Derating is required above 40 C (104 F). See chapter 3.6. Mount the softstarter according to Chapter 4 Mounting.
L1 L2 L3 N L N
Hazardous voltage. Will cause death or serious injury. Turn off and lock out all power supplying this device before starting work on this equipment.
Connect the terminals 1L1, 3L2 and 5L3 to the operational voltage on the power supply line side. Connect the terminals 2T1, 4T2 and 6T3 to the motor.
1L1 3L2 5L3
Run TOR 2T1 4T2 6T3
1SFC132237F0001
Capacitors for power factor compensation are not allowed between the softstarter and the motor, since this can cause current peaks which can damage the thyristors in the softstarter. If such capacitors are to be used, they should be connected on the line side of the softstarter.
Figure 2.2: Example connection of PSE Softstarter
Connect control supply voltage to terminals 1 and 2 (100-250 V 50/60 Hz). Connect the functional earth to terminal 14, with an earthing point close to the softstarter.
The earthing is not a protective earth, it is a functional earth. The earthing cable should be as short as possible. Maximum length 0.5 m. The earthing cable should be connected to the mounting plate, which should also be earthed.
7. Connect the start, stop and other control circuits including the analog out to the terminals, 8, 9, 10, 11, 12, 13 if needed. This section is using an internal 24 V DC. Do not feed with any external voltage.
Do not connect an external voltage to the control terminals 8, 9, 10, 11, 12, 13 and 14. Failure to observe the above may damage the softstarter and the warranty may no longer be valid.
8. Connect terminals 3, 4, 5, 6 and 7 when using the signal output relays. These are potential free contacts for maximum 250 V AC, 1,5 A AC-15. Make sure you are using the same voltage level within this terminal section.
1SFC132268F0001
Figure 2.3: Configuration of the parameter Rated Current.
The same external voltage (maximum 24 V DC or maximum 250 V AC) must be connected to the output relay terminals 3, 4, 5, 6 and 7. Failure to observe the above may damage the softstarter and the warranty may no longer be valid.
9. Switch ON the control supply voltage Us, terminals 1 and 2.
If disabled, press any key to activate the light in the display. Enter the application setting by pressing the Select key a second time. Press select again to enable editing of the Ie parameter. This is indicated by a flashing value. Increase or decrease the value by pressing the Up or Down keys repeatedly. Holding the key down will speed up the change. Press the Exit key to abort change. When the rated current of the motor is reached, press the Select key again to save. If needed, continue to set other parameters according to the application following the same procedure. Press the Exit key to return to the top level.
10. Continue to configure parameter Ie as described in figure 2.3. Complete information about configuration is available in Chapter 6 Human-Machine Interface (HMI) and Chapter 7 Functions and configuration. 11. Switch ON the operational voltage Ue. The green Ready LED will turn solid. 12. Give start command to the softstarter.
Depending on the two phase control, a connected motor terminal always carries live hazardous voltage. Do not touch terminals when voltage is applied. Output terminals will have live voltage even when the device is OFF. This can cause death or serious injury.
Overview .................................................................................................... Markings and connections .......................................................................... Type designation......................................................................................... Documentation ........................................................................................... Environmental influence .............................................................................. Specifications ............................................................................................. Technical data ............................................................................................ General .................................................................................................. Weights.................................................................................................. PSE Softstarter types ............................................................................. IEC information ...................................................................................... information .............................................................................. Dimensions ............................................................................................ Drilling plan ............................................................................................ 16 17 18 18 18 18 19 19 19 20 21 22 23 25
This chapter describes the PSE Softstarter in general, specifications as well as available accessories and spare parts.
The PSE Softstarter is a microprocessor-based softstarter designed with the latest technology for soft starting and soft stopping of three-phase squirrel cage motors. The softstarter has several advanced features as standard.
1SFC132253F0001
Figure 3.1: Integrated By-pass. Controlled phases 1 and 3 (L1 and L3).
Integrated by-pass in phases L1 and L3, see figure 3.1. Thyristors are used on phases L1 and L3 for controlling the motor voltage. Phase L2 is directly connected to the motor, see figure 3.1. Select between voltage ramp or torque control during start and stop. Motor protection, as well as underload and locked rotor protection.
The keypad on the front is designed to be as user-friendly as possible, with a clear display showing icons. The PSE Softstarter can be controlled in two ways: Hardwire inputs control Fieldbus communication interface Only one type of control method can be enabled simultaneously. Default selection is hardwire inputs control. The integrated fans for cooling are operated only during ramping (start/stop) and when the temperature of the heat sink is high. The temperature is monitored by a thermistor mounted on the heat sink. Check that you have the correct product in regards to operational voltage, control supply voltage and rated motor data. See chapter 3.3 Type designation. The PSE18...PSE370 Softstarters operates over wide voltage ranges. Rated operational voltage 208 - 600 V AC Rated control supply voltage 100 - 250 V AC
Figure 3.2: Torque control is offered as standard with the PSE softstarter.
The product should only be used within the specified ratings. Be aware of the ambient temperature and altitude above sea level. Derating is required above 40 C (104 F) and above 1000 m (3281 ft).
3.2 Markings and connections
Line side connection
Terminal marking of control circuits
PSE 18-600-70
Green Green Yellow Red Display
Order code Technical data according to IEC 947-4-2 Technical data according to UL 508 and CSA-C22.2 No. 14-05 Fieldbus connection
Motor side connection
External Keypad connection
Figure 3.3: Markings and connections
Softstarters Type PSE18...PSE370 Installation and commissioning manual 1SFC132057M0201 Chapter 3 17
1SFC132238F0001
3.3 Type designation
Type designation to be found on the softstarters front. See figure 3.4.
PSE18 - 600 - 70
A Softstarter type: PSE B Current rating: 18 = 18 A C Operational voltage: 600 = 208 - 600 V 50/60 Hz D Control supply voltage: 70 = 100 - 250 V 50/60 Hz
Figure 3.4: Type designation
Documentation such as brochures, catalogs, certificates, and drawings included can be found at: www.abb.com/lowvoltage. Select the link Control Products and then continue to Softstarters.
3.5 Environmental influence
The product is designed to minimize the environmental effects during manufacturing and use of the product. Most of the materials used, are of recycle type, and shall be handled and recycled according to existing laws. Further information regarding used material and recycling of the product can be found at: www.abb.com/lowvoltage
3.6 Specifications
Degree of protection (Operational circuit) Operating position Ambient temperature IP 00 Vertical at 30o Storage. -40 oC to + 70 oC (-40 oF to 158 oF) Operation: -25 oC to + 40 oC (-13 oF to 104 oF) without derating. + 40 oC to + 60 oC (104 oF to 140 oF) with derating 0.6 % /1 oC (0.6% / 1,8 oF). Altitude 1000 m (3281 ft.) above sea level without derating. 1000-4000 m (3281 - 13123 ft.) above sea level with derating 0.007% / m. Pollution degree Relative humidity Standards 3 5-95% (non-condensing) IEC 60947-1 IEC 60947-4-2 EN 60947-1 EN 60947-4-2 UL 508, CSA C22.2 No 14-10
3.7 Technical data
General data Rated insulation voltage, Ui Rated operational voltage, Ue Rated control supply voltage, Us Voltage tolerance Frequency tolerance Rated impulse withstand voltage Number of controlled phases Inputs Analog out Cooling system Rated duty EMC Recommended fuse Supply circuit Communication protocols
600 V 208-600 V 50 / 60 Hz 100 - 250 V 50 / 60 Hz +10% to -15% 5% 6 kV operational circuit / 4 kV control supply circuit 2 Start, stop, reset 4-20 mA Fan Uninterrupted IEC 60947-4-2 Class A Lloyds Register (2002) 6A Delayed MCB use characteristics DeviceNet/Profibus/Modbus/CANopen
This product has been designed for class A equipment. Use of the product in domestic environments may cause radio interference, in which case the user may be required to employ additional mitigation methods.
3.7.2 Weights
Type PSE18...60 PSE72...105 PSE142...170 PSE210 PSE250...370 Weight in kg 2.4 2.5 4.2 12.4 13.9 Weight in lbs 5.3 5.5 9.2 27.3 30.6
3.7.3 PSE Softstarter types
Type Rated Current Ie (A) Motor size 380 - 415 V (kW) Motor size 480 V (hp) Motor size 600 V (hp) Power loss at Rated Current (W) Power supply requirements holding (VA) Power supply requirements pull-in value (VA) PSE 18 18 7.5 10 15 0.2 16 19,9 PSE 25 25 11 15 20 0.4 16 19,9 PSE 30 30 15 20 25 0.5 16 19,9 PSE 37 37 18.5 25 30 0.8 16 19,9
Type Rated Current Ie (A) Motor size 380 - 415 V (kW) Motor size 480 V (hp) Motor size 600 V (hp) Power loss at Rated Current (W) Power supply requirements holding (VA) Power supply requirements pull-in value (VA) PSE 45 45 22 30 40 1.2 16 19,9 PSE 60 60 30 40 50 2.2 16 19,9 PSE 72 72 37 50 60 3.1 16 19,9 PSE 85 85 45 60 75 4.3 16 19,9
Type Rated Current Ie (A) Motor size 380 - 415 V (kW) Motor size 480 V (hp) Motor size 600 V (hp) Power loss at Rated Current (W) Power supply requirements holding (VA) Power supply requirements pull-in value (VA) PSE 105 PSE 142 PSE 170 PSE 210 106 55 75 100 6.6 16 19,9 143 75 100 125 12.1 16 31 171 90 125 150 17.6 16 31 210 110 150 200 8.8 23 350
Type Rated Current Ie (A) Motor size 380 - 415 V (kW) Motor size 480 V (hp) Motor size 600 V (hp) Power loss at Rated Current (W) Power supply requirements holding (VA) Power supply requirements pull-in value (VA) PSE 250 PSE 300 PSE 370 250 132 200 250 12.5 23 350 302 160 250 300 18 23 350 370 200 300 350 27.4 23 350
3.7.4 IEC information
Equipment suitable for use in a circuit with maximum available fault current as shown when protected by devices indicated in table 3.8. Examples of semiconductor fuses and MCCB according to IEC. For more information about fuses see: http://www.abbcontrol.fr/coordination_tables/coordtable.htm
Type 2 co-ordination Type 1 co-ordination
600V Iq 85kA Semicond. Bussmann DIN 43620 Softstarter Type PSE18-600-70 PSE25-600-70 PSE30-600-70 PSE37-600-70 PSE45-600-70 PSE60-600-70 PSE72-600-70 PSE85-600-70 PSE105-600-70 PSE142-600-70 PSE170-600-70 PSE210-600-70 PSE250-600-70 PSE300-600-70 PSE370-600-70 Type 170M1563 170M1564 170M1566 170M1567 170M1568 170M1569 170M1571 170M1572 170M3819 170M5809 170M5810 170M5812 170M5813 170M6812 170M6813 Rating 40A 50A 80A 100A 125A 160A 250A 315A 400A 450A 500A 630A 700A 800A 900A
400V Iq 35kA
400V Iq 50kA
Type T2N160 MA20 T2N160 MA32 T2N160 MA52 T2N160 MA52 T2N160 MA52 T2N160 MA80 T2N160 MA80 T2N160 MA100 T3N250 MA160 T3N250 MA200 T3N250 MA200 T4N320 PR221-I In320 T5N400 PR221-I In400 T5N400 PR221-I In400 T5N630 PR221-I In630
Type T2S160 MA20 T2S160 MA32 T2S160 MA52 T2S160 MA52 T2S160 MA52 T2S160 MA80 T2S160 MA80 T2S160 MA100 T3S250 MA160 T3S250 MA200 T3S250 MA200 T4S320 PR221-I In320 T5S400 PR221-I In400 T5S400 PR221-I In400 T5S630 PR221-I In630
Examples of equipment suitable for use in a circuit with maximum available fault current as shown when protected by devices indicated. See table 3.9. For more information see: http://www.abbcontrol.fr/coordination_tables/coordtable.htm
Normal breaker
550-600V High Fault Current 85kA 440-480V 550-600V
Standard breaker
440-480V 550-600V
Softstarter Type PSE18-600-70 PSE25-600-70 PSE30-600-70 PSE37-600-70 PSE45-600-70 PSE60-600-70 PSE72-600-70 PSE85-600-70 PSE105-600-70 PSE142-600-70 PSE170-600-70 PSE210-600-70 PSE250-600-70 PSE300-600-70 PSE370-600-70
Class J Fuses 40A 50A 60A 80A 100A 125A 150A 175A 225A 300A 350A 450A 500A 600A 600A
High Fault Current 25kA
High Fault Current 14kA
Normal breaker Ts3N070TW Ts3N100TW Ts3N100TW Ts3N125TW Ts3N150TW TsN150TW
High Fault Current 35kA
Standard breaker Ts3L070TW Ts3L100TW Ts3L100TW Ts3L125TW Ts3L150TW Ts3L150TW T4S250TW T5S300TW T5S300BW T5S400BW T5S400BW
T4N250TW T5N300TW T5N300TW T5N400BW T5N400BW
T6N600BW T6N600BW T6N800BW T6N800BW
T6S600BW T6S800BW T6S800BW T6S800BW
3.7.6 Dimensions Dimensions PSE 18...105
6,5 mm (0.256 in)
245 mm (9.645 in)
30 mm (1.181 in) 80 mm (3.150 in)
1SFC132259F0001
90 mm (3.543 in)
Dimensions PSE 142...170
37 mm (1.457 in) 7 mm (0.276 in)
PSE142-600-70
278 mm (10.947 in)
295 mm (11.614 in)
221 mm (8.701 in)
5 mm (0.197 in) 109,5 mm (4.311 in)
219,5 mm (8.642 in)
185,5 mm (7.303 in)
1SFC132260F0001
35 mm (1.378 in) 113,5 mm (4.468 in) 130 mm (5.118 in)
17,5 mm (0.689 in)
Dimensions PSE 210...370
9,2 mm (0.363 in)
470 mm (18.503 in)
40 mm (1.575 in) 550 mm (21.653 in)
532 mm (20.944 in)
5 mm (0.197 in) 43,75 mm (1.723 in) 163,5 mm (6.437 in) 19,6 mm (0.772 in) 190 mm (7.480 in) 125,5 mm (4.941 in)
236,5 mm (9.311 in)
1SFC132266F0001
3.7.7 Drilling plan Drilling plan PSE 18...105
mm 80 0 in) 5 (3.1
/4 6 (1
(9.0 mm
n) 55 i
Drilling plan PSE142...170
mm 113,5 in) 8 (4.46
M6 (
(1 8 mm
1SFC132272F0001
1SFC132271F0001
Drilling plan PSE210...370
mm 163,5 in) 7 (6.43
600210-
0.94 m (2
4 in)
1SFC132273F0001
Receiving, unpacking and checking ............................................................ Intermediate storage .............................................................................. Mounting .................................................................................................... Handling when mounting ....................................................................... Requirements......................................................................................... Minimum enclosure size ......................................................................... Minimum distance to wall and front ........................................................ 28 28 28 28 29 29 30
This chapter describes instructions on how to receive the softstarter and how to mount it in a proper way.
4.1 Receiving, unpacking and checking
Check that the package is turned with the correct side up, figures 4.1 and 4.2. Check for transport damages. Remove the transport casing. Visually inspect the softstarter. Check that the order code corresponds with the delivery documents. Check that all items are included, according to the delivery note. Check the softstarter as well as the package. If you find any damages, please contact the transport company or the supplier immediately.
Figure 4.1: Unpacking PSE18...PSE170
1SFC132239F0001
4.1.1 Intermediate storage
Until the softstarter is mounted it should be stored in its package.
4.2.1 Handling when mounting
The softstarter is available in three physical sizes. All models of PSE can be taken out of the packages and be mounted without lifting equipment. See chapter 3.7.2 for weights.
Figure 4.2: Unpacking PSE210...PSE370
Never lift the softstarter by the connection bars, since it may cause damage to the product.
4.2.2 Requirements
See Chapter 3 Description for environmental requirements. The PSE Softstarters exist in three different physical sizes which are designed to be mounted with M6 (1/4 in.) bolts as well as bolts of equivalent dimension and strength. Measures and drilling plans will be found in chapters 3.7.6 Dimensions and 3.7.7 Drilling plan.
4.2.3 Minimum enclosure size
In applications where the softstarter is installed in an enclosure, the following minimum enclosure sizes are recommended. Dimensions according to the sketch in figure 4.3.
Table 4.1 IEC
PSE18...105 PSE142...170 PSE210...370
W (mm) 400 400 600
H (mm) 500 600 1000
D (mm) 260 260 300
1SFC132269F0001
W (in) PSE18...105 PSE142...170 PSE210...370 20 30 36
H (in) 24 36 48
D (in) 12 12 16
min number of latches 1 2 1
Dimensions and drilling plan see Chapter 3 Description.
Figure 4.3: Dimensions minimum enclosure size
Using a too small enclosure and/or failure to follow the instructions in other ways may result in overheating of the PSE Softstarter and operational disturbances.
4.2.4 Minimum distance to wall and front
Check that a sufficient flow of air for cooling purposes can circulate from the bottom to the top of the softstarter, and has a free passage away. Figure 4.3.
Risk of damage to property. Ensure that no liquids, dust or conductive parts enter the softstarter.
1SFC132240F0001
Figure 4.4: Airways
Make sure that the distances to the surrounding walls are sufficient, and that the mounting angle is within specifications shown in figure 4.5. Follow the minimum distance to front and wall, as described in figure 4.4 and the table below.
The values in table 4.3 are minimum distances.
A (mm [inch]) PSE18...105 100 [3.94] 100 [3.94] 100 [3.94] B (mm [inch]) 10 [0.394] 10 [0.394] 10 [0.394] C (mm [inch]) 20 [0.788] 20 [0.788] 20 [0.788]
1SFC132243F000
PSE142...170 PSE210...370
Figure 4.5: Minimum distances to wall and front
1SFC132242F0001
Figure 4.6: Maximum mounting angle
1SFC132280F0001
Chapter 5 Connection
General....................................................................................................... Electrical connection................................................................................... Considerations when controlling two of three phases ............................. Before connecting softstarters PSE18...PSE170 .................................... Connection of the operational power circuit ........................................... Control supply and control circuit ........................................................... Control supply voltage, terminals 1 and 2 .......................................... Functional earth, terminal 14.............................................................. Start and Stop, terminals 8 and 9 in circuit with terminals 11 or 12. .. Reset event, terminal 10 .................................................................... Analog output, terminals 13 and 14 ................................................... Status output relays, terminals 3, 4, 5, 6, and 7 ................................. Connection of communication devices (optional) ........................................ External keypad ..................................................................................... Technical data for External Keypad .................................................... Transfer of parameters ....................................................................... Transfer of parameters from softstarter to external keypad ............ Transfer of parameters from external keypad to softstarter ............ Fieldbus communication ........................................................................ 32 32 32 33 34 35 35 36 37 38 39 40 41 41 41 42 42 42 43
This chapter describes the electrical connections as well as connections for communication devices that have to be made before you can use the softstarter.
Mounting and electrical connection of the softstarter shall be made in accordance with existing laws and regulations and be performed by authorized personnel.
For basic connection, see Chapter 2 Quickstart. For circuit diagrams for connection of the softstarter, see Chapter 11 Wiring diagrams.
5.2 Electrical connection
5.2.1 Considerations when controlling two of three phases
Even when stopped, there will be a voltage on the motor on phase 2. This will not start the motor and the motor will not be heated up (compare with inside delta connection). For more information about two phase control see Chapter 3 Description. Semiconductors do not replace air isolation and the recommended solution is to use a line contactor to break the current. See figure 5.1.
1L1 3L2 5L3 1 2 8 9 10 11 12 13 14 Run TOR 2T1 4T2 6T3 Fault
Depending on the two phase control a connected motor terminal always Figure 5.1: Connection of PSE Softstarter and con- carries live voltage. Touching terminals and other live parts can result in death or serious injury. nection in series with a line contactor.
Since Softstarters PSE18 PSE370 has control in two phases, the connection must be done In Line only, in accordance with the circuit diagrams in figure 5.2 and in Chapter 11.
Figure 5.2: ABB PSE Softstarter must be connected In Line only.
Softstarters PSE18...PSE370 must not be connected Inside Delta since this will cause damage to the equipment and there is a risk of death or serious injury. Figure 5.2.
5.2.2 Before connecting softstarters PSE18...PSE170
5.2.3 Connection of the operational power circuit
The softstarter is recommended to be connected with a line contactor as described in figure 5.1. Additional circuit diagrams will be found in Chapter 11 Wiring diagrams. Softstarters PSE18...PSE105 are provided with built-in cable clamps. The cables must be stripped before connection, and the length of the exposed wire should be 20 mm or 0.8 in. Connect according to figures 5.3 and 5.5. For Softstarters PSE142...PSE370 the cables must have lugs and be connected to the terminal bars, according to figure 5.4 and 5.5. Connect the line side to terminals 1L1, 3L2, 5L3. Connect the motor to terminals 2T1, 4T2, 6T3. The terminals marking are printed on the front of the softstarter.
3L2 5L3
2T1 4T2 6T3
Figure 5.3: PSE18...PSE105 connection of the connection module line side and motor side terminals
PSE18...105
Figure 5.4: PSE142...PSE370 connection of the line side and motor side terminals
Using connection module M8
AWG12 .. 6 2,5 .. 10 mm2 2x2,5 .. 2x10 mm2 AWG6 .. 2/0 10 .. 70 mm2 2x10 .. 2x70 mm2
Cu 75C only
4T2 6T3
6 Nm - 53 lb.in
(If connection module is removed)
Using connection bars
M6 9 Nm - 80 lb.in
8 Nm - 71 lb.in
max 22 mm (0.866 in)
max 20 mm (0.787 in) max 5 mm (0.197 in)
PSE142...170
11/6-16 UNF-2S
Using connection module
ATK185: AWG4 to 300kcmil Cu 75C only
Using connection bars M8 18 Nm - 160 lb.in
max 24 mm (0.945 in)
max 22 mm (0.866 in) max 8 mm (0.315 in)
275 lb.in
ATK300: AWG4 to 400kcmil ATK300/2: AWG4 to 500kcmil or 2xAWG4 to 2x500kcmil Cu 75C only
Using connection bars M10 28 Nm - 240 lb.in
max 30 mm (1.181 in)
max 30 mm (1.181 in) max 10 mm (0.394 in)
375 lb.in
Figure 5.5: Tightening torques and dimensions for terminal bars and lugs
Capacitors for power factor compensation are not allowed between the softstarter and the motor, since this can cause current peaks which can burn the thyristors in the softstarter. If such capacitors are to be used, they should be connected on the line side of the softstarter.
34 Chapter 5 Softstarters Type PSE18...PSE370 Installation and commissioning manual 1SFC132057M0201
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PSE210...370
5.2.4 Control supply and control circuit
Wires in industrial control applications are divided into three groups: main power supply, control supply and control.
5.2.4.1 Control supply voltage, terminals 1 and 2
Connect neutral and live to terminal 1 and 2, as shown in figures 5.6 and 5.7.
Check that you have the correct control supply voltage Us.
Figure 5.6: Terminals for control supply voltage
4 x 0,8 mm (0.157 x 0.031 in)
0,2 .. 4 mm2, AWG 24 ... 10 2x0,2 .. 1,5 mm2, 2 x AWG 24 ... 16 0,2 .. 4 mm2, AWG 24 ... 10 2x0,2 .. 1,5 mm2, 2 x AWG 24 ... 16
0,5 Nm - 4,3 lb.in
Figure 5.7: Tightening torques and wire area
5.2.4.2 Functional earth, terminal 14
Connect the cable to an earthing point close to the softstarter. The cable should be as short as possible. A suitable earthing point would be next to the softstarter on the mounting plate, as shown in figures 5.8 and 5.9. The mounting plate should also be earthed.
This is not a protective earth, it is a functional earth. The earthing cable should be as short as possible. Maximum length 0.5 m.
Figure 5.8: Terminal for functional earth
3,5 x 0,6 mm (0.138 x 0.24 in)
AWG 24 ... 12
0,2 .. 2,5 mm2 2x0,2 .. 1,5 mm2 0,2 .. 2,5 mm2 2x0,2 .. 1,5 mm2
Figure 5.9: Tightening torques and wire area
5.2.4.3 Start and Stop, terminals 8 and 9 in circuit with terminals 11 or 12.
The PSE Softstarter has a built-in holding circuit and does not require sustained signals on start input. Use internal control supply voltage from terminals 11 or 12. Connection of start and stop terminals using conventional circuit with push buttons, see figures 5.10 and 5.12. A conventional circuit with auxiliary relay is also possible, see figure 5.11 and 5.12.
Do not connect an external voltage to any of the control terminals 8, 9, 10, 11, 12 and 13. Failure to observe the above may damage the softstarter and the warranty may no longer be valid.
L Stop Start
Figure 5.10: Terminals for start and stop, conventional circuit with push button
Figure 5.11: Terminals for start and stop, conventional circuit with auxiliary relay
3,5 x 0,6 mm (0.138 x 0.024 in)
Figure 5.12: Tightening torques and wire area
5.2.4.4 Reset event, terminal 10
The reset control terminal 10 is in circuit with terminals 11 or 12 used for remote reset of trip events. See figures 5.13 and 5.14.
Figure 5.13: Terminal for reset event
Figure 5.14: Tightening torques and wire area
5.2.4.5 Analog output, terminals 13 and 14
Analog output can be used for the connection of analog instruments. If the analog output is used, the cables shall be connected to terminals 12 (+) and 13 (-). See figures 5.15 and 5.16. Analog out signal can vary in the range 4 - 20 mA, corresponding to 0 - 120 percent of set value for parameter Ie. 100 percent corresponds to 17.3 mA.
Figure 5.15: Terminals for analog output
Figure 5.16: Tightening torques and wire area
5.2.4.6 Status output relays, terminals 3, 4, 5, 6, and 7
By connection to terminals 3, 4, 5, 6, and 7, RUN, TOR and EVENT are available for a contactor, a PLC or a status indicator, which can use these signals as an input. The COM connection on terminal 3 is a shared neutral connection for terminals 4, 5, 6, and 7. Run signal is given from terminal 4 during start ramp, running, and stop ramp if used. It can be used to control the line contactor. Top of Ramp (TOR) signal is given from terminal 5 when full voltage to the motor is applied. The event relay is available as normal closed outlet on terminal 6 and normal open outlet on terminal 7. It is indicating a present fault or protection. The event signal can be used as input for a status indicating lamp or a LED. For connection see figures 5.17 and 5.18.
The same external voltage (24 V DC or 110-250 V AC) must be connected to the output relay terminals 3, 4, 5, 6 and 7. Failure to observe the above may damage the softstarter and the warranty may no longer be valid.
Figure 5.17: Terminals for status output signals
0,2 .. 4 mm2 2x0,2 .. 1,5 mm2 0,2 .. 4 mm2 2x0,2 .. 1,5 mm2
Figure 5.18: Tightening torques and wire area
40 Chapter 5 Softstarters Type PSE18...PSE370 Installation and commissioning manual 1SFC132057M0201
5.3 Connection of communication devices (optional)
5.3.1 External keypad
An external keypad for door mounting can be connected to the softstarter. A 3-meter cable including both the communication and the power supply to the keypad makes the connection. The cable shall be connected to the external keypad connection at the bottom of the softstarter. See Figures 5.19 and 5.20. The external keypad can also be used for transferring parameters from one softstarter to another. Note that IP66 cannot be achieved when the keypad is not mounted. When the external keypad is used, both keypads will work in parallel, but the softstarter built-in keypad always has the highest priority if the keys on both units are pressed simultaneously.
5.3.1.1 Technical data for External Keypad
General data Display LCD type Ready: Green Run: Green Proction: Yellow Fault: Red Storage: -40 oC to +70 oC (-40 oF to 158 o CF). Operation: -25 oC to +60 oC (-13 oF to +140 oF). Standards IEC/EN 60947-4-2 UL508 CSA C22.2 No 14 IP66 UL Type 1, 4X Indoor, 12 Status indicating LEDs
Figure 5.19: External keypad
Figure 5.20: Connection of external keypad
Softstarters Type PSE18...PSE370 Installation and commissioning manual 1SFC132057M0201 Chapter 5 41
5.3.1.2 Transfer of parameters
To transfer (copy) parameters from one PSE Softstarter to another, connect the External keypad to the chosen softstarter and follow the sequence below. For more information about navigating, see Chapter 6 in this manual. The Transfer Parameter menu is hidden and only possible to reach when the external keypad is connected to the softstarter. Start in Settings Level with cursor on Ie icon. Press Arrow Up to enter Transfer Parameter menu, and the text tP will be displayed on the LCD.
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5.3.1.2.1 Transfer of parameters from softstarter to external keypad Transfer of parameters from softstarter to external keypad is possible in all states, except during ramping. During ramping it is not possible to enter the TP menu.
When you are in the Transfer Parameter menu confirm and continue by pressing Select. A text toSS will now be present on the LCD display. Scroll to FrSS and Figure 5.21: Transfer of parameters from softstarter confirm selection by pressing Select key, and the text FrSS will now be flashing. to external keypad Continue and transfer by pressing Select. If the transfer was successful, the text donE will be displayed on the LCD, otherwise a fault code will be displayed. Press Exit or select to return to Transfer Parameter menu. Press then exit for returning to a higher menu level.
5.3.1.2.2 Transfer of parameters from external keypad to softstarter Transfer of parameters from external keypad to softstarter is possible only in standby state. During ramping, it is not possible to enter the TP menu. If transfer of parameters is done during TOR, a fault code will be displayed. When you are in the Transfer Parameter menu confirm and continue by pressing Select. A text toSS will now be present on the LCD display. Confirm selection of toSS by pressing Select key and the text toSS will now be flashing. Continue by pressing select. If valid parameters will be accepted, a value for parameter Rated Motor Current Ie will be displayed, otherwise a fault code will be displayed. Scroll and select a setting for Ie, see chapter 7.5.1. Confirm selection and save by pressing Select. If transfer is performed, the text donE will be displayed, otherwise a fault code will be displayed. Press Exit or Select to return to Transfer Parameter menu. Press Exit for returning to a higher menu level. A list showing all parameters which will be transferred is available in chapter 7.3 List of available parameters.
Figure 5.22: Transfer of parameters from external keypad to softstarter
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The parameters Rated Current of the motor and PSE will not be transferred.
Display Description Transfer Parameter Transfer of parameters from external keypad to softstarter Transfer of parameters from softstarter to external keypad Confirmation of successful transfer
How to operate the External keypad, see Chapter 6 Human-Machine Interface (HMI).
5.3.2 Fieldbus communication
See Chapter 8 Fieldbus communication.
Chapter 6 Human-Machine Interface (HMI)
Overview .................................................................................................... Application ............................................................................................. Design ................................................................................................... LED status indicators......................................................................... LCD display and keypad.................................................................... Locking/unlocking the keypad................................................................ Reset of all settings ................................................................................ Reset of tripping events ......................................................................... Menu structure....................................................................................... Information Level ............................................................................... Settings Level and settings menu ...................................................... Navigating the menu ................................................................................... 46 46 46 47 48 49 49 49 50 50 50 52
Chapter 6 Human-Machine Interface
This chapter describes how the Human-Machine Interface (keypad, LED status indicators and LCD display) works.
The Human-Machine Interface is used for several purposes such as setting up the PSE Softstarter parameters, including protection functions and fieldbus communication. The HMI is also providing status information by LED status indicators and the LCD display. The PSE Softstarter monitors and displays different values. When switching on the supply voltage the LCD will first display the Information Level, which is showing motor current, input voltage on the line side, power factor, and voltage to the motor. The Information Level also displays information on whether the keypad is locked or unlocked.
6.1.2 Design
The appearance of the HMI is showed in figure 6.1. The HMI consists of: LED status indicators LCD display with backlight Selection and navigation keys On start-up all LCD segments and LEDs will be briefly illuminated. The LCD backlight will automatically turn off after some time of inactivity. Turn it on by pressing any key. When switching on the supply voltage the LCD will first illuminate all available segments, LEDs and the backlight. Thereafter the Information Level is displayed. See figure 7.1.
Figure 6.1: LED status indicators.
LCD display with backlight. Exit key for cancelling parameter edits and exiting one menu level. Select/Reset key for changing and storing parameter values, entering one menu level, and to reset tripping events. Navigation keys for navigating the menu and changing parameter values. Flashing numbers or text shown in the display indicates that the menu/value can be changed or scrolled.
6.1.2.1 LED status indicators
The LED status indicators work as in table 6.1: Table 6.1 LED Ready Color Green Description Run Green Protection Yellow Fault Red Off: when control supply voltage Us is off or unconnected. Flashing light when control supply voltage Us is On and operational voltage Ue is Off. Steady light when control supply voltage Us is On, and operational voltage Ue is On. Off when the motor not is running. Flashing light when softstarter is controlling operational voltage Ue during start or stop ramp. Steady light when full operational voltage Ue is on at Top of Ramp. Off: when the softstarter has not tripped on any protection Steady light on protection when reset is not possible. Flashing light on protection when reset is possible. Off: when the softstarter has not tripped on any fault Steady light on fault when reset is not possible. Flashing light on fault when reset is possible.
When fault or protection LED is activated, the LCD display will show the actual fault or protection as an event code. See table 10.1.
Ready Run Protection Fault
6.1.2.2 LCD display and keypad
The keypad is based on the same user concept as common on mobile phones. See figure 6.1. The LCD display contains three rows. The top row has 8 parameter icons. The middle row has a lock symbol, 4 digits and units. The bottom row has 4 parameter icons. On the middle row various information is presented. A cursor A indicates which parameter value is possible to change at each position, as shown in figure 6.2.
The Exit key for cancelling parameter edits and for exiting one menu level. The Select/Reset key normally has more than one function, such as selecting, changing, storing, and manual reset of tripping events, depending on present view. The navigation keys are used for navigating in the menu and changing parameter values. Flashing numbers or text shown in the display indicates that the parameter value can be changed or scrolled. If key is held down, scrolling will be faster. When selecting from a list, the scrolling is done in a closed loop. You will find a description of all settings in Chapter 7 Functions and configuration and configuration. The menu structure of the keypad is illustrated in figure 6.7.
Figure 6.2: Cursor indicating parameter accessible for configuration
6.1.3 Locking/unlocking the keypad
1. Press the Exit key to exit to the Information Level. 2. The keypad is unlocked if the middle row is not indicating the lock icon to the right. 3. Press both Navigation keys 4 seconds to lock the keypad, and protect all parameter settings from unintentional change from the keypad. See figure 6.3. 4. The keypad is locked if the a padlock is present on the middle row. 5. Press both Navigation keys 2 seconds to unlock the keypad, and allow changes of the parameter settings.
Figure 6.3: Locking/unlocking the keypad
6.1.4 Reset of all settings
How to reset all the changed parameters back to user default settings is described in chapter 7.7.1.
6.1.5 Reset of tripping events
The Select/Reset key can be used to reset tripping events via the keypad, see figure 6.4. For details about resetting of tripping events, see chapter 7.6.
Figure 6.4: Reset of tripping events
6.1.6 Menu structure
The structure of the menu is described in figure 6.8. All different parameters and levels of the menu, and how they can be reached by scrolling, are also described.
Figure 6.5: Information Level
6.1.6.1 Information Level
By pressing a key the backlight will be switched on, and the Information Level will be displayed. The Information Level contains general operational information described in chapter 7.1. Use navigation keys to present all selections. The selections are presented one by one on the middle row. See figure 6.5 and menu structure in figure 6.8.
Select 6.1.6.2 Settings Level and settings menu Reset
The Settings Level is reached from the Information Level by pressing the Select key. See figure 6.6. and menu structure in figure 6.8.
Figure 6.6: Enter Settings Level pressing the Select key.
The settings menu is used to set up the PSE Softstarter with parameters for the current application. Available settings are presented one by one on the top and bottom of the display. Use navigation keys to move the cursor to present all selections. In figure 6.7 the cursor is currently marking the parameter Rated Select Ie, which by pressing Current Exit Select key a second time will be accessible for tuning.
Reset eset
Figure 6.7: Settings Level
A % Cos j V
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Lock/Unlock Settings Level Reset all parameter settings to user default values PSE Ie (Rated current of motor) Individual OFF, 1...30 s OFF, 1...30 s 30...70 % 1.5...7 x Ie OFF On OFF Torque Control during stop ramp On OFF
Start Ramp time Stop Ramp time Initial/End Voltage Current Limit Torque Control during start ramp
Setting of time must be performed in Start Ramp time
Setting of time must be performed in Stop Ramp time
Set Initial Voltage
Normal ramp Ramp with Kick Start
30...100 OFF
HAnd 10A/10/20/30 Auto OFF
Underload Protection 0.2...1 x Ie
OFF Locked Rotor Protection 0.5...7 x Ie Auto dPoF OFF 0...255 (readable) dPon FieldBus Control On 0...255 dPon LocC dPoF trIP Auto HAnd Hand
Figure 6.8: Menu structure PSE Softstarter
Softstarters Type PSE18...PSE370 Installation and commissioning manual 1SFC132057M0201 Chapter 6 51
6.2 Navigating the menu
The menu is navigated by the keypad. The Navigation keys are used to scroll up or down. The Select key is used to select a setting and save. The Exit key is used to cancel without selecting or saving a setting, and to go to a higher level of the menu, as illustrated in figure 6.9. 1. 2. 3. 4. Turn on the backlight by pressing any key. On the Information level use the Navigation keys for scrolling the different operational information. Press the Select key to Enter the Settings level. See A in figure 6.10. A cursor is marking the accessible parameter, in this case Rated Current Ie. Press Select key again to enable editing of the parameter Rated Current. See B in figure 6.10. A flashing value on the middle row indicates that the parameter is available for scrolling and for selection. Increase or decrease the value by pressing Navigation key repeatedly. Holding the key down will speed up the scrolling. See C in figure 6.10. When the rated current of the motor is reached, press the Select key again to save. See D in figure 6.10. It is possible to select and adjust the other parameters by following the same procedure. At any point, press Exit to cancel a setting, and return to the information level.
Figure 6.9: Press Exit key to cancel and to go to a higher level of the menu.
Figure 6.10: Navigating the menu
Chapter 7 Functions and configuration
Softstarter operational data ........................................................................ Parameter settings ..................................................................................... List of available parameters ........................................................................ Basic settings principal ............................................................................... Functions ................................................................................................... Rated Current Ie of motor ...................................................................... Start Ramp Time .................................................................................... Stop Ramp Time .................................................................................... Initial/End Voltage................................................................................... Current Limit .......................................................................................... Torque Control during start ramp............................................................ Torque Control during stop ramp............................................................ Kick Start ............................................................................................... Electronic Motor Overload Protection E.O.L. .......................................... Underload Protection ............................................................................. Locked Rotor Protection ........................................................................ FieldBus Control (optional hardware required)......................................... Fieldbus Address ............................................................................... Download Parameter ......................................................................... Fieldbus Operation When Fault .......................................................... Type of Operation for Reset of Fieldbus Fault ..................................... Reset of tripping events .............................................................................. Special functions ........................................................................................ Reset all parameter settings to user default values ................................. PSE parameter ...................................................................................... Representation of signals in time domain .................................................... Application settings .................................................................................... 56 56 57 59 60 60 60 61 62 63 64 65 66 67 68 69 70 71 71 72 73 73 74 74 75 76 77
How to navigate the menu, see Chapter 6 Human-Machine Interface (HMI), especially chapter 6.2 Navigating the menu.
7.1 Softstarter operational data
The information level is the top level of the user menu. Information about output current, line voltage, power factor, and voltage to the motor is displayed.
On the information level the softstarter displays current values for: 1 Motor current (A) 2 Voltage to the motor (%) 3 Power factor /Cos j 4 Input voltage on the line side (V)
The motor current is calculated as the maximum RMS value of the three phases. Using the motor current displayed on Information level as input for setting of Current Limit, may result in too low Current Limit. This may cause a longer starting time and unnecessary heating of the motor.
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7.2 Parameter settings
Settings can be done in four different ways: Keypad Fieldbus communication (option) External keypad (option) With the keypad or external keypad, settings can be done as individual parameter setting of all essential parameters. When the fieldbus communication (option) is enabled, most parameters can also be modified from this interface. User default parameter set is stored in the unit for a possible reset to default values. See chapter 7.7.1 about resetting parameters to user default values.
Figure 7.1: Information Level, displayed information
The motor may start unexpectedly if there is a start signal present, when doing any of the actions listed below. Switching from one type of control to another (fieldbus control / hardwire control). Resetting events. Using automatic event reset.
7.3 List of available parameters
A list of the available parameters for PSE18...PSE370 is visible in table 7.1.
Parameter transfer with External Keypad Description Display symbol Setting range Default value Access from Fieldbus Actual setting
Rated Current of motor Ie
Start Ramp time
Individual Individual See tables in chapter 3.7.3 PSE Softstarter types. Setting range is 30-100 percent of Ie 1...30 s 10 s
HMI W W
Stop Ramp time
OFF, 1...30 s
Initial/End Voltage
30...70 %
1.5 x 7 Ie
4.0 x Ie
Torque Control during start ramp
Torque Control during stop ramp
OFF, 30...70 %
Electronic Motor Overload Protection (EOL) Tripping Class (EOL) Type of operation (EOL) 10 A, 10, 20, 30 HAnd/Auto
R = Readable W = Writeable T = Will be transferred (uploaded/downloaded)
Softstarters Type PSE18...PSE370 Installation and commissioning manual 1SFC132057M0201 Chapter 7 57
Level Type of operation Locked Rotor Protection Level Type of operation Fieldbus Control
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Fieldbus address Download Parameter Fieldbus Operation When Fault Type of Operation
255 dPoF/dPon LocC/trIP HAnd/Auto
dPon LocC HAnd
HAnd = Manual reset of the protection or fault. Auto = Automatic reset of the protection or fault. 2 OFF = Fieldbus is not allowed to control the motor. On = Fieldbus is allowed to control the motor. 3 255 = Address of the FieldBusPlug will be used. 4 dPon = Download of parameters from PLC enabled. dPoF = Download of parameters from PLC blocked.
5 Accessible only if On is previously selected.
trIP = Trip on fault. LocC = Local control on fault - hardwire control is possible 6 Accessible only if trIP is previously selected. HAnd = Manual reset of the protection or fault. Auto = Automatic reset of the protection or fault.
Parameter transfer with External Keypad
Access from Fieldbus
7.4 Basic settings principal
The Settings level (menu) consists of predefined parameters for the selected application which should be used if an easy and quick setup is required. At any point, press Exit to cancel a setting and return to the information level. 1. 2.
Stop ramp p
Illuminate the display by pressing any of the keys. From Information Level, enter Settings Level by pressing Select key. See figure 7.2. Enter the setting for the Rated Current Ie by pressing Select key. Set Ie using the navigation keys. Since the motor must be connected In Line, use the motor current on the rating plate. Press Exit to Cancel, or Select to save. Continue to the Start Ramp time setting, or press Exit key to return to the Information Level. Go to the Start Ramp time setting using the lower navigation key. Press Select and adjust the time using the navigation keys. Press Select to save and continue, or press Exit to cancel and return to the Information Level.
Initial / end voltage nd
Setting Rated current curre
Current limit rent
10. Go to Stop Ramp time setting using the lower navigation key. 11. Press Select. Choose OFF or adjust the time using the navigation keys. 12. Press Select to Save and continue to the next parameter, or Exit to Cancel and return to the Information level. 13. Go to the setting Initial/End Voltage using the lower navigation key. 14. Press Select, and adjust the value using navigation keys. 15. Press Exit to Cancel, or Select to save and continue. 16. Go to Current Limit by pressing the lower navigation key. 17. Press Select, and set the Current Limit factor On or OFF using the navigation keys. 18. Press Exit to Cancel or Select to save and continue.
Start ramp rt
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19. Press upper lower navigation key to continue to EOL class. 20. Press Select, and scroll with the navigation keys to choose the required Tripping Class, or OFF. 21. Press Exit to Cancel or Select to save and continue. 22. Press Select to set User or Auto. 23. Scroll using the navigation keys. 24. Press Select to save and continue. 25. Press Exit to return to the information level.
Figure 7.2: Basic configuration of frequently used parameters
7.5 Functions
This chapter describes all settings and functions possible in the PSE Softstarter, as well as the easiest way of finding them. Respective default values, setting ranges and parameter strings shown in the display are also stated.
7.5.1 Rated Current Ie of motor
This parameter allows for configuring of the current that the softstarter will be exposed to. Since the motor must be connected In Line, set the rated motor current, which can be found on the motor rating plate.
Figure 7.3: Rated Current parameter displayed
Default value Individual (depending on size)
Individual Rated motor current (depending on size) Ie See tables in chapter 3.7.3 PSE Softstarter types. Setting range is 30100 percent of Ie
7.5.2 Start Ramp Time
Figure 7.4: Start Ramp Time parameter displayed
The Start Ramp Time parameter allows for tuning of the time for the start ramp to reach full voltage (Top of Ramp, TOR). This parameter is controlling both voltage controlled and torque controlled start ramps. When a start signal is given the PSE Softstarter performs a start ramp by controlling the output voltage to the motor so that the voltage is increased linearly from the initial voltage level to full voltage. Since the torque depends on both the voltage and the current, the torque curve does not always follow the voltage curve. This has the effect that the torque curve will not increase linearly. If parameter Torque Control Start is set to OFF, a voltage ramp will be performed during the start ramp. The voltage and RPM of the motor will follow the graph in figure 7.5. If a torque curve with linear increase is preferred, choose Torque Control during start ramp described in chapter 7.5.6. Display Default value 10 s Setting range 0-30 s Description Setting time for voltage controlled, and torque controlled, start ramps
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The time set in Start Ramp Time is also the setting for the time in Torque Control Start, if this parameter is enabled.
Figure 7.5: The function of Start Ramp Time
60 Chapter 7 Softstarters Type PSE18...PSE370 Installation and commissioning manual 1SFC132057M0201
7.5.3 Stop Ramp Time
The Stop Ramp Time parameter allows for tuning of the time for the stop ramp to reach the End Voltage from Top of Ramp (TOR). When a stop signal is given the PSE Softstarter performs a stop ramp by controlling the output voltage to the motor so that the voltage is decreased linearly from full voltage to the end voltage level. Since the torque depends on both the voltage and the current, the torque curve does not always follow the voltage curve. This has the effect that the torque curve will not decrease linearly. If parameter Torque Control during stop is set to OFF, will a voltage ramp be performed during the stop ramp. The voltage and RPM of the motor will follow the graph in figure 7.7. If a torque curve with linear decrease is preferred, set Torque Control during stop to On. See chapter 7.5.7.
Figure 7.6: Stop Ramp Time parameter displayed
This parameter shall be set to OFF for applications with a big flywheel mass involved.
Display Default value Setting range OFF 0-30 s Description Setting time for voltage controlled and torque controlled, stop ramps
The time set in Stop Ramp Time is also the setting for the time in Torque Control Stop, if this parameter is enabled.
Figure 7.7: The function of Stop Ramp Time
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7.5.4 Initial/End Voltage
This parameter makes it possible to set the initial voltage level where the start ramp begins. The value for end voltage where the stop ramp ends, will automatically be 10 percent lower than the initial voltage. During start ramp will then the voltage increase from the initial voltage level, to full voltage. During stop ramp will the voltage decrease from full voltage to the end voltage level and then cut the power to the motor. Figure 7.9.
Figure 7.8: Initial/End voltage parameter displayed
If the initial voltage is set too low, it will cause longer starting time and unnecessary heating of the motor. The motor might not reach full speed (TOR).
Default value 30 %
Setting range initial voltage 30-70 %
Description Initial and end voltage for start ramp and stop ramp
Figure 7.9: The function of Initial/End Voltage
7.5.5 Current Limit
It is possible to limit the starting current by using this function. The limit can not be exceeded during start and stop ramp. When the Current Limit is reached, the output voltage stays stable until the current level falls below the limit, then the ramping continues. The relation between Current Limit, the current I to the motor and the output voltage is described in figure 7.13.
Figure 7.12: Current Limit parameter displayed
The starting current must be high enough to make it possible for the motor to reach the rated speed. The lowest possible current depends on the performance of the motor and the characteristics of the load. If the Current Limit is set too low, it will cause longer starting time and unnecessary heating of the motor.
Display Default value 4 x Ie Setting range 7...1.5 x Ie Description Level of Current Limit in relation to output voltage.
t1 5 I
Current limmit 2
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Figure 7.13: The relation between the Current Limit , the current I to the motor, and the output voltage U
7.5.6 Torque Control during start ramp
It is possible to use the torque control during the start by activating this parameter. Torque control results in a more linear accelerating of the speed in a majority of applications. When using the torque control the output voltage to the motor is controlled so that the motor torque will follow a predefined optimal curve from the initial voltage level to full voltage during start. This has the benefit that the mechanical starting behavior of the equipment driven by the motor will be much softer compared to the use of voltage ramp. During the torque controlled start the motors voltage and RPM will follow the graph in figure 7.15.
Figure 7.14: Torque Control during start ramp parameter displayed
During start ramp, the output voltage to the motor is controlled so that the torque will follow a predefined optimal curve from the initial voltage level to full, voltage during start. This has the benefit that the mechanical starting behavior of the equipment driven by the motor will be much softer compared to the use of voltage ramp. During the torque controlled start the voltage U and RPM of the motor will appear as the graphs in figure 7.15. Display Default value OFF Setting range On/OFF Description Torque Control during start
The time for the Torque Control during start ramp is set in the parameter Start Ramp time.
Figure 7.15: The function of Torque Control during start
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7.5.7 Torque Control during stop ramp
When activating this parameter (On) makes it possible to control the motor torque during stop. Using torque control will result in a more suitable decelerating of the speed mainly requested when stopping pumps. When using torque control the output voltage to the motor is controlled so that the motor torque will follow a predefined optimal curve for best possible stop. This has the benefit that the mechanical stopping behavior of the equipment driven by the motor will be much softer compared to using voltage ramp. This can be especially useful in pump applications where a sudden stop can cause water hammering and pressure surges. During the torque controlled stop the motors voltage and RPM will follow the graphs in figure 7.17.
Figure 7.16: Torque Control during stop ramp parameter displayed
Setting range On/OFF
Description Torque Control during stop ramp
The time for the Torque Control during stop ramp is set in the parameter Stop Ramp time.
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Figure 7.17: The function of Torque Control during stop ramp
7.5.8 Kick Start
This parameter makes it possible to tune the kick start voltage level which is applied for a short time duration, before a normal start ramp is performed. Kick Start provides enough torque during start, but still ensuring a soft start. It can be set on any of the predefined voltage levels. For each voltage level there is a fixed time duration relation (t), which is increasing with the different kick voltage levels. This function can be useful for applications with high initial friction or having a need of extra power in the first part of the start, as jammed pumps or conveyor belts. See table 7.2 and graph in figure 7.19.
Table 7.2 Kick Start settings Kick start setting Kick start voltage Ue (percent) 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 Kick start time t (s) 0.30 0.35 0.40 0.45 0.50 0.55 0.60 0.65 0.70 0.75 0.80 0.85 0.90 0.95 1.00
Figure 7.18: Kick Start parameter displayed
Note that the Current Limit function is not working during Kick Start.
Operational time Normal ramp Ramp with Kick Start
OFF, 30...100 % Level of Kick Start
Figure 7.19: The function of Kick Start
7.5.9 Electronic Motor Overload Protection E.O.L.
This parameter makes it possible to set the required class of motor overload protection. Four different classes are available. See figure 7.21. Class 10A Class 10 Class 20 Class 30 There is an option for type of reset after tripping. Hand or automatic is available. Hand is default value for reset of Electronic Motor Overload Protection after tripping. Reset of this protection is not possible before measuring a lower temperature, which must be reached by the motor. Display Default value 10 HAnd Setting range OFF, 10A, 10, 20, 30 HAnd/Auto Description Tripping class for Electronic Motor Overload Protection (E.O.L) Type of operation for reset of Electronic Overload Protection (E.O.L) 1
Figure 7.20: Electronic Motor Overload Protection EOL parameter displayed
1SFC132102F0001
HAnd = Manual reset:
_	When tripping will stop the motor, a manual reset is required before restart can be done. Auto = Automatic reset: _	When tripping will stop the motor, an automatic reset is performed before the unit is ready for restart.
Figure 7.21: Tripping curves for the Electronic Motor Overload Protection (E.O.L.)
A B C D Class 30 Class 20 Class 10 Class 10A
Figure 7.22: Type of operation for reset of Electronic Motor Overload Protection fault parameter displayed
7.5.10 Underload Protection
When active the Underload Protection trip if the current (Ie) will fall to a lower level than the set value for 30 seconds or more.
This protection could be used to avoid for example a pump running dry, detect a broken belt or similar.
There is an option for type of reset after tripping, hand or automatic. HAnd is default value for reset of Locked Rotor Protection after tripping.
Figure 7.23: Underload Protection parameter displayed
OFF, 0.2...1 Level of Underload Protection x Ie HAnd/Auto Type of operation for reset of Underload Protection 1
Figure 7.24: Type of operation for reset of Underload Protection fault parameter displayed
7.5.11 Locked Rotor Protection
This protection will when activated trip if the motor current exceeds the set level when the motor is running at full voltage. The Locked Rotor Protection parameter will be activated when the motor has been running at full voltage (Top of Ramp) for 30 seconds. The reaction time for tripping is 1 second.
OFF, 0.5 - 7 Level of protection for locked x Ie rotor HAnd/Auto Type of operation for reset of Locked Rotor Protection 1
Figure 7.25: Locked Rotor Protection parameter displayed
1. HAnd = Manual reset: _	When tripping will stop the motor, a manual reset is required before restart can be done. Auto = Automatic reset: _	When tripping will stop the motor, an automatic reset is performed before the unit is ready for restart.
Figure 7.26: Type of operation for reset of Locked Rotor Protection fault parameter displayed
7.5.12 FieldBus Control (optional hardware required)
This parameter is used for configuration of the fieldbus communication. Connecting the PSE Softstarter to the FieldBusPlug automatically enables fieldbus communication. To enable control of the softstarter using fieldbus, this parameter must be set to On. If FieldBus Control is set to OFF, fieldbus can only be used for monitoring softstarter data. If this parameter is set to On, the softstarter might trip on fieldbus fault if no fieldbus communication is available. If the intention is to run without fieldbus control, this parameter should be set to OFF.
The motor may start unexpectedly if there is a start signal present when doing any of the actions listed below. Switching from one type of control to another (fieldbus control / hardFigure 7.27 Fieldbus Control parameter wire control). Remember that when parameter Fieldbus Fault Reaction displayed Fault Ready Run Protection is set to LocC, this switch can happen automatically. Resetting of events. If using automatic event reset.
Fieldbus Control parameters and settings Display Default value OFF Setting range OFF/On Description Control of the softstarter with fieldbus. Fieldbus Address 1 Possible to block parameter download from PLC 2.
255 dPoF
0...255 dPoF/dPon
1SFC132264F0001
LocC/trIP
Operation When Fault 2
HAnd/Auto 4 Type of operation for reset of Fieldbus Fault 3
255 =	Address of FieldBus Control will be used. Accessible only if Fieldbus Control previously is set to On. Accessible only if trIP is previously selected. HAnd = Manual reset: _	When tripping will stop the motor, a manual reset is required before restart can be done. Auto = Automatic reset: _	When tripping will stop the motor, an automatic reset is performed before the unit is ready for restart.
More information about Fieldbus communication and optional accessories is available in Chapter 8 Fieldbus communication.
7.5.12.1 Fieldbus Address
The parameter Fieldbus Address allows setting of address for the fieldbus communication. The setting range for the fieldbus address is 0...255. If the address is set to 255, the address stored in internal memory of the fieldbus plug will be used. See documentation for the fieldbus plug for more details on address setting. It is possible to read and set this parameter via the keypad when Fieldbus Control is set to On or OFF. Changing this parameter will automatically reset the fieldbus interface and the new address will be active. If PLC was communicating with the old address, the PLC needs to be re-configured.
Figure 7.28: Fieldbus Address parameter displayed
Setting range 0...255
Description Fieldbus Address
7.5.12.2 Download Parameter
This parameter allows for blocking parameter download from the fieldbus. Note that download of parameters works differently for different fieldbus protocols. See documentation for the protocol used. It is possible to read and set this parameter via the keypad when Fieldbus Control is set to On or OFF.
Figure 7.29: Download Parameter displayed
Default value dPon
Setting range dPoF/dPon
Description Download Parameter enabled. Download Parameter blocked.
7.5.12.3 Fieldbus Operation When Fault
This parameter is accessible only if Fieldbus Control is previously set to On. In case of fieldbus malfunction, for instance due to power loss or a broken cable, this parameter allows for different (operations in case of a fault) reactions to the fault. Setting Fieldbus fault reaction to trIP will make the softstarter trip on a fieldbus fault. Selecting trIP makes reset of the fault necessary, in case of a tripping event.
Figure 7.30: Fieldbus Operation When Fault parameter displayed
When LocC is selected, the control of the softstarter will automatically switch from fieldbus control to local control. The switch to local control will make hard-wire control possible. When the Fieldbus starts working again the control is automatically switched back to the Fieldbus. There is a 10 second delay before controlling the motor is possible.
Default value LocC
Setting range LocC,/trIP
Description Operation When Fault 1
trIP LocC
Trip on fieldbus fault. Automatically move to local control on fieldbus fault.
7.5.12.4 Type of Operation for Reset of Fieldbus Fault
Select what operation shall be asserted if a fieldbus communication fault occurs. Manual or automatic options are available. HAnd is the default value for reset of Fieldbus Fault: If HAnd is selected - The motor will stop and manual reset is required. If Auto is selected - The motor will stop and automatic reset is performed.
Figure 7.31: Type of operation for reset of Fieldbus fault parameter displayed
This parameter is accessible only if trIP is previously selected for the parameter fieldbus Operation When Fault.
Default value HAnd
Setting range HAnd/Auto
Description Type of operation for reset of Fieldbus Fault. 1
7.6 Reset of tripping events
In case of tripping event the PSE Softstarter can be reset via hardwire, keypad, external keypad, or Fieldbus. If the setting HAnd is chosen as an action in case of an tripping event for a parameter with this option, manual resetting of the softstarter is required.
If the setting Auto is chosen as an action in case of an tripping event for a parameter with this option, resetting of the softstarter will be performed automatically.
Figure 7.32: Reset of tripping events
7.7 Special functions
7.7.1 Reset all parameter settings to user default values
Start from Information Level and press in sequence the keys Exit and Select for a few seconds, as described in figure 7.29. The text string rES will be displayed on the LCD as in figure 7.34. Press Select to enter Reset All Settings, and the text string rES on the LCD starts flashing. Press Exit key to cancel, or press Select to reset all settings.
After reset it is necessary to press Exit for returning to Information Level.
Figure 7.33: Entering menu Reset all settings to user default values
The motor may start unexpectedly if there is a start signal present when doing any of the actions listed below. Switching from one type of control to another (fieldbus control / hardwire control) Resetting all parameters Resetting events If using automatic event reset
Figure 7.34: Reset All Settings to user default values parameter displayed
7.7.2 PSE parameter
This parameter contains information about the type of PSE Softstarter which is available. The PSE parameter must be configured after replacing the PCB. This parameter must not be changed if the PCB has not been replaced. Read chapter 3.3 Type designation to get information about how to find out the size of the softstarter. Start from Information Level and press in sequence the keys Exit, Select and Arrow Up for a few seconds, see figure 7.31. The text string Id will be displayed on the LCD as in figure 7.36. Press Select to enter parameter PSE, and the text string Id the LCD starts flashing. Press Exit to return to Information level or Scroll to configure according to the softstarters size. Press Select to confirm.
Figure 7.35: Entering PSE parameter
Configure parameter PSE only if the printed circuit board has been replaced.
Figure 7.36: PSE parameter displayed
7.8 Representation of signals in time domain
Timing diagram for the basic functions of the softstarter, with a representation of a set of signals in the time domain is found in table 7.3.
Table 7.3: Timing diagram
Operational voltage on the line side Control circuit - Start input
Control circuit - Stop input
Operational voltage on the motor side
Signal output relay - Run signal
Signal output relay - TOR signal
Signal output relay - Tripping event NC signal Signal output relay - Tripping event NO signal Status signal - Ready LED
Status signal - Fault LED
1SFC132254F0001
Status signal - Run LED
7.9 Application settings
In table 7.4 the recommended parameter settings for different applications are described.
Table 7.4: Application settings
Recommended basic setting
Centrifugal fan Axial fan Centrifugal pump High pressure pump Compressor Grinder Mixer Bow thruster Hydraulic pump Crusher Conveyor belt Escalator Lift/Elevator Cutter Band saw Circular saw
10 s 10 s 10 s 10 s 5s 10 s 10 s 10 s 10 s 10 s 10 s 10 s 10 s 10 s 10 s 10 s
OFF OFF 10 s 10 s OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF
40 % 40 % 40 % 50 % 40 % 40 % 40 % 40 % 40 % 40 % 50 % 40 % 40 % 40 % 40 % 40 %
5.0 x Ie 5.0 x Ie 5.0 x Ie 5.5 x Ie 4.5 x Ie 5.0 x Ie 5.0 x Ie 4.5 x Ie 4.5 x Ie 5.0 x Ie 5.0 x Ie 4.5 x Ie 4.5 x Ie 5.0 x Ie 5.0 x Ie 5.0 x Ie
OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF
OFF OFF On On OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF
Please note that the parameter values above are to be used as a guide only. Variations in load conditions may require additional tuning.
For Heavy Duty applications the Initial/End Voltage might need to be increased.
as well as the Current Limit
Chapter 8 Fieldbus communication (option)
Overview .................................................................................................... Required accessories ............................................................................. Instructions ............................................................................................ 80 80 80
Chapter 8 Fieldbus communication
The PSE Softstarter has an interface on the front for connecting the ABB FieldBusPlug used for fieldbus communication. Through this interface it is possible to control the softstarter, retreive status information, as well as upload and download of parameters. The interface between the softstarter and the FieldBusPlug is independent of the fieldbus protocol used. Independent of softstarter size or delivery date it is possible to connect any of the available Fieldbus protocols later on, since this is defined in the FieldBusPlug itself. The following Fieldbus protocols are available: DeviceNet CANopen Profibus Modbus More information about the installation of fieldbus communication is available in chapter 7.5.12 FieldBus Control (optional hardware required).
8.1.1 Required accessories
To connect the PSE Softstarter to a fieldbus system, the following accessories are required: ABB FieldBusPlug Accessory FBPA ABB FieldBusPlug for present fieldbus protocol (check that the cable length is sufficient). Connectors for bus connection. End plug (some protocols). Software for PLC set-up.
Figure 8.1: Principle of a fieldbus network with PSE Softstarters connected
To do the set-up of input and output telegrams, parameter settings, instructions, etc. are available at: www.abb.com/lowvoltage: DeviceNet Profibus DP Modbus CANopen 1SFC132066M0201 1SFC132067M0201 1SFC132068M0201 1SFC132069M0201
Chapter 9 Maintenance
Regular maintenance .................................................................................. Service and repair ....................................................................................... 82 82
This chapter describes the maintenance required for the PSE Softstarter. This product needs very little maintenance, but some components should be checked regularly.
Do not open the softstarter or touch any live parts when the operational voltage and control supply voltage are connected. Due to the two phase control, a connected motor terminal always carries live hazardous voltage. Do not touch terminals when voltage is applied. Output terminals will have live voltage even when the device is OFF. This can cause death or serious injury.
9.1 Regular maintenance
Check that all mounting bolts/screws are fastened. Tighten if necessary. Check that all connections of main, control- and supply circuits are fastened. Tighten the terminal screws and bolts on the connection bars, if necessary. Check that the cooling airways are free from dirt and dust. If required, use pressurized air to clean. Check external filters. Clean, if necessary. Check that the fan is working and rotating freely The blades shall rotate without any resistance. This can be checked at voltage free state. Check the Real Time Clock and adjust if necessary. In case of a fault, or if a fault can not be reset, see Chapter 10. Refer to the timing diagram for the basic functions of the softstarter.
9.2 Service and repair
In case the PSE Softstarter has to be repaired, a spare parts list and necessary instructions are available at: www.abb.com/lowvoltage. Select the link Control Products and then continue to Softstarters. Spare part list: Changing of HMI-module: Changing of Thyristor and By-pass relay/contactor: Changing of fans: 1SFC132062M0201 1SFC132063M0201 1SFC132064M0201 1SFC132065M0201
Service and repair should be performed by authorized personnel only. Note that unauthorized repair may affect the warranty.
In the event of a short circuit on the load side of a softstarter the device could be completely destroyed and possibly cause danger to personnel. By using a correctly rated short circuit protection device, i.e. a fuse or a circuit breaker, the damage will be limited to one of the following two categories, defined IEC 60947-4-2 and EN 60947-4-2: Type 1: The softstarter might be damaged and some or all parts might need to be replaced. The case or enclosure must not be damaged or become live during the short circuit. Type 2: The device should be operable after the event of a short circuit.
General....................................................................................................... Overview of indications ............................................................................... Tripping events ........................................................................................... Start up problems and faults....................................................................... General problems and faults ....................................................................... Fault indications.......................................................................................... Protection indications ................................................................................. Failure indications ....................................................................................... 84 84 85 86 87 89 92 93
This chapter is a guide that can be used in case problems should arise with the PSE Softstarter or the application. The PSE Softstarter normally indicates a fault with LED Fault status indicator, and the LCD displays type of fault. When a protection is activated, it will be indicated with the LED protection status indicator, and the LCD displays what type of protection is active. More information about LEDs and LCD display is available in chapters 6.1.2.1 and 6.1.2.2. Faults not displayed on the PSE Softstarter Human Machine Interface can also be found in this chapter.
10.2 Overview of indications
This table shows in which state the different indications for protections, faults, and failures may show up.
Table 10.1 Overview of indications for protections, faults and failures
Motor control states
At completed stop ramp X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
At start command
At stop command
At start ramp
At completed start ramp
Electronic Motor Overload Protection Underload Protection Locked Rotor Protection Software faults
P1 P2 P3 SF20 SF3x SF4x
Shunt fault By-pass open Softstarter thermal overload
SF50 EF1x
Phase loss Bad Network quality External Current lost Fieldbus fault Low supply voltage High current
EF20 EF3x
EF40 EF50 EF6x Fy
At stop ramp X X X X X X X X X
External keypad failures
Displayed as Current lost x = phase number, 4 indicates multiple or unknown phase y = failure number 1-8 Activated after 30 s.
Chapter 10 Softstarters Type PSE18...PSE370 Installation and commissioning manual 1SFC132057M0201
10.3 Tripping events
Depending on PSE Softstarter configuration, different events may be signalled on the LCD. All event codes are found in table 10.2: Event list.
Table 10.2: Event list
Event code SF20 SF3x SF4x SF50 EF1x EF20 EF3x EF40 EF50 EF6x P1
Event description Software fault Shunt fault By-pass open Softstarter thermal overload Phase loss fault Bad network quality Current lost fault Fieldbus fault Low supply voltage High current fault Motor overload protection
Cause Fault in software By-pass relay/contactor does not open or thyristor short circuit By-pass relay or by-pass contactor does not close or opens Thyristors overheated Power loss on operational current on one or several phases Excessive disturbances in the operational supply network Operational current on one or several phases lost Fault on Fieldbus communication Voltage too low or briefly interrupted in control supply network for softstarter Operational current higher than 8 x Ie Load on motor higher than motor rating and corresponding selected EOL Class. Current limit parameter is set on a too low value. Load on motor too low Load on motor too high for a short time
Underload protection Locked rotor protection
SF = Softstarter fault EF = External fault P = Protection
x = phase number, 4 indicates multiple or unknown phase
10.4 Start up problems and faults
Status LEDs not lighting and LCD is blank.
Possible cause Control supply voltage Us is not connected.
Solution Connect according to a circuit diagram. See Chapter 5 Connection and Chapter 11 Wiring diagrams.
Green Ready LED steady lighting or flashing, and LCD faint.
1SFC132297F0001
LCD display backlight auto shut off.
Touch any key on the keypad.
1SFC132298F0001
10.5 General problems and faults
Status Motor humming/starts without given start signal. Possible cause By-pass relay closed, due to abnormal handling. (PSE18...PSE170 only). Solution Switch off operational voltage and control supply voltage. Switch on voltage in correct succession. 1. Control supply voltage on terminals 1 and 2. See chapter 5.2.4. 2. Wait 4 seconds, and then switching on operational voltage on terminals L1, L2 and L3. See chapter 5.2.3. If same fault remains, contact your ABB Sales Office. Check and replace relay or contactor. If same fault remains, contact your ABB Sales Office. Check and replace thyristor. Contact your ABB Sales Office. Check and correct the wiring. Connect the control supply voltage according to a circuit diagram. See Chapter 5 and Chapter 11. Connecting Inside Delta not allowed.
By-pass contactor/relay stuck in closed position. Shorted thyristor. The motor connection is not correct. (Must be connected In Line).
Bad motor sound during start and operation.
The motor connection is not correct. (Must be connected In Line).
Check and correct the wiring. Connect the control supply voltage according to a circuit diagram. See Chapter 5 and Chapter 11. Connecting Inside Delta not allowed.
Incorrect ramp time for start.
Try different ramp times (some adjustments can be necessary for best result). See chapter 7.5.2. Try different settings for the parameter Initial /End Voltage. See chapter 7.5.4, or contact your ABB Sales Office. Try different settings for the parameter Current Limit. See chapter 7.5.5, or contact your ABB Sales Office. Check that the softstarter corresponds to the motor size. Try different ramp times for stop (some adjustments can be necessary for best result). See chapter 7.5.3. Try different settings for the parameter Initial /End Voltage. See chapter 7.5.4, or contact your ABB Sales Office. Check that start and stop command is not given at the same time. Check connection for start and stop. See chapter 5.2.4.3. Check that start and stop command is not given at the same time.
Incorrect Initial/End Voltage.
Incorrect current limit.
The motor is too small. (current is out of measuring range). Bad motor sound during stop. Incorrect ramp time for stop.
Start and stop command given at the same time. Motor does not start when giving start command using hardwire inputs. Control wiring not correct. Start and stop command given at the same time.
Status Displayed current in LCD is not stable. Motor does not start with fieldbus
Possible cause The motor is too small. (current is out of measuring range). Softstarter has tripped on fault or protection. Softstarter is in Local Mode.
Solution Check that the softstarter corresponds to the motor size. Perform a reset on any active event. See chapter 6.1.5 Reset of tripping events. Check that the Auto Mode bit of the binary output telegram setting is 1. Check that the Local Mode digital input on the FieldBusPlug accessory is set to Remote. If the parameter Fieldbus Operation When Fault is set to LocC, there will be a 10 second delay before it is possible to re-start after communication is reestablished. Check PLC configuration. Verify that parameters are matching between the PLC and the softstarter fieldbus documentation for the fieldbus protocol used. Verify that fieldbus Download Parameter is set to dPon. Ensure that block-parameters are enabled.
Fieldbus Operation When Fault parameter is set to LocC.
Digital or binary signals incorrect. Loading of parameters with fieldbus does not work properly.
PLC configuration incorrect. Fieldbus settings
10.6 Fault indications
Status Software fault Red Fault LED steady lighting or flashing, and LCD event code SF20. See chapter 6.1.2.1 about LED status indicators activation for faults and protections.
Possible cause Fault in software.
Solution Disconnect and reconnect the control supply voltage (Us) and make a restart. See chapter 5.2.4. If same fault remains, contact your ABB Sales Office. Check parameter PSE and select correct setting corresponding to the type of PSE Softstarter. See chapter 7.7.2.
PSE parameter fault.
1SFC132300F0001
Shunt fault Red Fault LED steady lighting, and LCD event code SF3x 1 . See chapter 6.1.2.1 about LED status indicators activation for faults and protections.
By-pass relays closed after transport, (PSE18...PSE170 only).
Switch off operational voltage and control supply voltage. Switch on voltage in correct succession. 1. Control supply voltage on terminals 1 and 2. See chapter 5.2.4. 2. Wait 4 seconds, and then switching on operational voltage on terminals L1, L2 and L3. See chapter 5.2.3. Check and replace relay. Contact your ABB Sales Office for replacement kit. Check and replace thyristor. Contact your ABB Sales Office for replacement kit. Check control supply voltage Check and replace by-pass relay/contactor. Contact your ABB Sales Office for replacement kit.
The by-pass contactors/relays are not opening.
1SFC132317F0001
Thyristors short circuit.
By-pass open Red Fault LED steady lighting, and LCD event code SF4x 1 . See chapter 6.1.2.1 about LED status indicators activation for faults and protections.
Power loss on control supply circuit. By-pass relays/contactors open or bypass relays/contactors do not close.
1SFC132302F0001
Softstarter thermal overload Red Fault LED steady lighting, and LCD event code SF50. See chapter 6.1.2.1 about LED status indicators activation for faults and protections.
Thyristors overheated. If the fault remains after reset, the heat sink temperature is too high.
Softstarters Type PSE18...PSE370 Installation and commissioning manual 1SFC132057M0201 Chapter 10 89
1SFC132303F0001
Check that the fans are working in a proper way. See chapter 9.1. Check that the cooling airways are free from dirt and dust. See chapter 9.1. Check that the ambient temperature is not too high. Derating is required above 40oC (104 oF). See chapter 3.6. Check that the mounting angle is not more than 30 o. See chapter 4.2.4. Check that PSE Softstarter not is too small for the number of starts and stops performed each hour.
Status Phase loss fault Red Fault LED steady lighting, and LCD event code EF1x 1 . See chapter 6.1.2.1 about LED status indicators activation for faults and protections.
Possible cause Fuse blown.
Solution Check and replace fuses in all three phases.
Power loss on operational current on one or several phases. The main contactor or circuit breaker is open.
Check and correct supplying operational network. Check and close contactor/breaker or any external switching device. Control main contactor with Run signal relay on terminal 4. See chapter 5.2.4.6. Add a time relay before contactor opening. If Stop Ramp not is needed, set Stop Ramp Time to 0. Check and correct supplying operational network.
1SFC132318F0001
Main contactor opens too quickly at stop.
Bad network quality Red Fault LED steady lighting, and LCD event code EF20. See chapter 6.1.2.1 about LED status indicators activation for faults and protections.
Excessive disturbances in the operational supplying network.
Short power loss on all three phases in the operational network.
1SFC132311F0001
Check and correct supplying operational network.
Current lost fault Red Fault LED steady lighting, and LCD event code EF3x 1 . See chapter 6.1.2.1 about LED status indicators activation for faults and protections.
Operational current too low or lost on one or several phases.
Check and correct supplying network
Phase loss on line side or motor side.
Check and correct supplying network See Phase loss EF14. Check and replace PCB/thyristor. Contact your ABB Sales Office for replacement kit.
1SFC132310F0001
Thyristors not able to conduct
The motor is too small. (current is out of measuring range).
Check that the softstarter corresponds to the motor size.
Status Fieldbus fault Red Fault LED steady lighting, and LCD event code EF40. See chapter 6.1.2.1 about LED status indicators activation for faults and protections.
Possible cause Fault on fieldbus connection or FieldBusPlug Accessory.
Solution Check that the correct type of FieldBusPlug accessory is used. See Chapter 8 or contact your ABB Sales Office. Check that the connection of the FieldBusPlug is correct. See chapter 3.2. Check the connection of the fieldbus accessory. Perform a reset on any active event. See chapter 6.1.5 Reset of tripping events. Check that the correct type of FieldBusPlug accessory is used. See Chapter 8 or contact your ABB Sales Office. Check that the connection of the FieldBusPlug is correct. See chapter 3.2. Check the connection of the fieldbus accessory. Check PLC configuration. Possible Fieldbus fault. Put PLC in run mode. Check PLC configuration. Set Fieldbus Control parameter to OFF. Check and correct control supply voltage. Check control supply network for short interruptions.
1SFC132313F0001
Fieldbus communication is not working.
PLC is not running. Fieldbus Control is enabled on a non-fieldbus application. Low supply voltage Red Fault LED steady lighting, and LCD event code EF50. See chapter 6.1.2.1 about LED status indicators activation for faults and protections.
The control supply voltage is too low on terminals 1 and 2. Short power loss on the control supply network.
1SFC132314F0001
High current fault Red Fault LED steady lighting, and LCD event code EF6x 1 . See chapter 6.1.2.1 about LED status indicators activation for faults and protections.
Operational current higher than 8 x Ie.
Check if the motor is locked or running stiff. Check the bearings in the motor and connected equipment. Check if the load on the motor is too heavy. Check isolation on the motor windings. Replace the motor.
1SFC132315F0001
10.7 Protection indications
Status Motor Overload Protection (EOL) Red Fault LED steady lighting, and LCD event code P1. See chapter 6.1.2.1 about LED status indicators activation for faults and protections. Remark that time delay for reset can be long depending on temperature.
Possible cause Load on motor higher than motor rating and corresponding selected EOL Class.
Solution At start Check and correct the reason for the overload. Increase Initial/End Voltage. Check the motor rating plate for Ie. Increase Current Limit. Make Start Ramp Time shorter. At start Chose a motor with more power, and a softstarter rated for higher current. Check and correct the reason for the overload. Check that the ramp time for start not is too long. Check that correct EOL Class is used. Continuous run Check the rating of the plate for Ie. Check operational voltage. Chose a motor with more power, and a softstarter rated for higher current. Check and correct the reason for the overload. Check that correct EOL Class is used. Check and correct the reason for the underload. Check that the setting Ie are according to the operation conditions. See chapter 7.5.1. Check that the Underload Protection parameter is set according to operational conditions. Se chapter 7.5.10.
Too many starts and stops during a short time.
1SFC132320F0001
The motor has been exposed to an overload condition because the current over a certain time is too high. (The load on the motor shaft is too high).
Underload Protection Red Fault LED steady lighting, and LCD event code P2. See chapter 6.1.2.1 about LED status indicators activation for faults and protections.
The motor current is below set level and time.
1SFC132316F0001
Locked Rotor Protection Red Fault LED steady lighting, and LCD event code P3. See chapter 6.1.2.1 about LED status indicators activation for faults and protections.
The motor is running stiff for some reason. A damaged bearing or a stuck load could be possible causes. Decrease in operational voltage can give a higher operational current.
Check the bearings of the motor and load.
1SFC132322F0001
10.8 Failure indications
Status Transfer of parameters failed Only showing on external keypad. Can occur for transfer both from the PSE and to the PSE. Same failure for F1, F2, F3, F4 and F6.
Solution Try again. If the same failure remains, contact your local ABB Sales Office.
Transfer of parameters failed Only showing on external keypad. Can occur for transfer to the PSE.
No parameters stored in the PSEEK.
Load the parameters that you want to transfer from selected PSE. If the same failure remains, contact your local ABB Sales Office.
All parameters was not transferred Only showing on external keypad. Can occur for transfer both from the PSE and to the PSE.
Fault in software.
Try again. If the same failure remains, contact your local ABB Sales Office.
Not possible to transfer parameters to PSE when it is in TOR.
Return the PSE to idle state and try again If the same failure remains, contact your local ABB Sales Office.
Chapter 11 Wiring diagrams
Circuit diagram PSE18...PSE370 (Fuse and contactor version) .................. Circuit diagram PSE18...PSE370 (MCCB version)....................................... 96 97
Circuit diagram PSE18...PSE370 (Fuse and contactor version)
L1 L2 L3 N MCCB L N
Circuit diagram PSE18...PSE370 (MCCB version)
1SFC132274F0001
A Abbreviations 10 Acronyms 10 Active 68, 71, 84, 88, 91 Airways 30, 82, 89 All settings 48, 49, 51, 60, 74 Altitude 16, 18 Analog out 13, 19, 39 Range 39 Analog output 39 Application setting 13, 77 Axial fan 77 B Bad network quality 84, 85, 90 Basic settings 59 By-pass 10, 12, 16, 33, 82, 84, 85, 87, 89 By-pass doesnt close 85, 87 By-pass open 84, 85, 89 By-pass relays 12, 33, 89 C Centrifugal Fan 77 Centrifugal Pump 77 Circuit diagram 32, 33, 34, 86, 87, 96, 97 Communication devices 8, 32, 41, 46, 56 Connection 32, 41 Fieldbus 16, 17, 46, 51, 56, 70, 71, 72, 73, 74, 80, 85, 91 Communication protocols 19 Compressor 77 Configuration 12, 13, 48, 56, 59, 70, 85, 88, 91 Connection 12, 17, 28, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 80, 82, 86, 87, 91 Control circuit 10, 13, 17, 35, 76 Connection 17, 35, 37 Earthing 36 Start and Stop 37 Control supply voltage 10, 12, 13, 16, 18, 19, 33, 35, 37, 47, 76, 82, 86, 87, 89 Conventional circuit 37 Conveyor (belt) 66, 77 Cooling 16, 19, 30, 82, 89 Cooling system 16, 19, 30, 82, 89 CosPhi 51, 56 Current 10, 12, 13, 18, 20, 21, 22, 32, 34, 42, 46, 50, 52, 56, 57, 59, 60, 61, 63, 66, 68, 69, 77, 87, 88, 92 Current Limit 22, 51, 56, 57, 59, 63, 66, 77, 85, 87, 92 D Default values 51, 56, 58, 60, 74 DeviceNet 19, 80 Dimensions 23, 24, 25, 26, 29, 34 Display at start up 46, 84 Document ID 8 Document number 3 Download of parameters 58, 71, 80 Download Parameter 58, 71, 88 Drilling plan 25, 26 E Earthing 36 Connection 36 Electrical connection 36 Start and stop terminals 37 Supply voltage and control circuit 35
Electronic Motor Overload Protection 51, 57, 67, 84, 85, 92 Class 51, 57, 59, 67, 85, 92 Type of operation 57, 67 EMC Class 19 Enclosure sizes 29 Environmental influence 18 EOL 10, 51, 57, 59, 67, 84, 85, 92 Event 12, 38, 40, 46, 47, 48, 49, 56, 70, 72, 73, 74, 76, 82, 84, 85, 88, 89, 90, 91, 92 Event relay 40 External keypad 17, 41, 42, 56, 57, 58, 73 Download of parameters 41, 42, 57, 58, 70, 71, 80, 88 Fault indication 93 Transfer of parameters 41, 42, 57, 58 Upload of parameters 41, 42, 57, 58, 80 57, 58, 71, 73, 86 Locking 49 Status 46, 47 Status indicators 46, 47 Unlocking 49 Kick Start 51, 57, 66 Level 66
F Fans 16, 19, 77, 82, 89 Fault 21, 22, 40, 41, 42, 47, 58, 70, 72, 73, 82, 84, 87, 88, 89, 90, 91, 92 Fault indication 46, 47, 84, 89, 93 Faults 84, 86, 87, 89, 90, 91, 92 Fieldbus 10, 16, 17, 46, 51, 56, 58, 70, 71, 72, 73, 74, 80, 84, 85, 88, 91 Address 58, 70, 71 Communication 16, 46, 56, 70, 71, 73, 80, 85, 88, 91 Connection 17, 80, 91 Control 51, 56, 58, 70, 71, 72, 74, 80, 91 Fault 70, 72, 73, 84, 85, 91 Plug 10, 58, 70, 71, 80, 88, 91 Type 80 Type of operation 58, 70, 73 Frequency 18, 19 Full-On 10 Full voltage 10, 40, 60, 61, 62, 64, 69 Functional earth 13, 36, 96, 97 Functions 46, 56, 60, 74, 76, 82 Fuse 19, 21, 22, 82, 90, 96 H Hardwire 16, 56, 58, 70, 72, 73, 74, 87 Hardwire inputs control 16, 87 High current 84, 85, 91 HMI 10, 46, 47, 48, 49, 50, 51, 52, 57, 58, 82 Holding circuit 37 Human-Machine Interface 10, 46, 47, 48, 49, 50, 51, 52 Humidity 18 I Ie 10, 13, 20, 39, 42, 50, 51, 52, 57, 59, 60, 63, 68, 69, 77, 85, 91, 92 IEC 10, 17, 18, 19, 21, 29, 41, 82 Information level 46, 49, 50, 51, 52, 56, 59, 74, 75 Initial/End voltage 51, 57, 59, 62, 77, 87, 92 In Line 12, 33, 59, 60, 87 Inputs 16, 19, 87 Internal control supply voltage 37 K Keypad 16, 17, 41, 42, 46, 48, 49, 52, 56,
L LCD 10, 12, 41, 42, 46, 47, 48, 74, 75, 84, 85, 86, 88, 89, 90, 91, 92 LCD backlight 12, 46, 50, 52, 86 LCD display automatic switch off 46 LED 10, 12, 13, 41, 46, 47, 76, 84, 86, 89, 90, 91, 92 Level 12, 51, 59, 69 Altitude 16, 18 Current level 63 Information level 46, 49, 50, 51, 52, 56, 59, 74, 75 Kick Start 66 Locked Rotor Protection 58, 69 Menu level 12, 42, 46, 48, 50, 52 Settings level 42, 50, 51, 52, 59 Underload Protection 51, 58, 68 Voltage level 13, 60, 61, 62, 64, 66 Locked Rotor Protection 16, 51, 58, 68, 69, 84, 85, 92 Level 51, 58, 69 Type of operation 58 M Maintenance 9, 82 Markings 17 MCCB 21, 22, 97 Menu, description 46, 47, 48, 49, 50, 51, 52, 53 Menu tree 51 Minimum distance to wall/front 30 Minimum enclosure size 29 Mixer 77 Modbus 19, 80 Motor overload protection 51, 57, 67, 84, 85 Tripping class 51, 57, 59, 67 Type of operation 51, 57, 67 Motor side terminals 17, 34 Motor sound 87 Motor underload protection 51, 58, 68, 84, 85, 92 Level 58, 68 Type of operation 58, 68 Mounting 12, 13, 28, 29, 30, 32, 36, 41, 82, 89, 96, 97 N Navigation keys 12, 46, 48, 49, 50, 52, 59 Non closing by-pass contactor 12, 85, 87 By-pass open 12, 84, 85, 89 Non opening by-pass contactor 85, 89 O Operational circuit 18, 19 Connection 34 Operational supply voltage 12, 33 Output relays 13, 40 Overview 16, 46, 80, 84 P
Parameter 12, 13, 39, 46, 48, 49, 50, 52, 56, 57, 60, 61, 62, 64, 65, 66, 67, 69, 70, 71, 72, 73, 74, 75, 80 Basic settings 59 Download of parameters 42, 58, 71, 80 List of available parameters 57, 58 Reset 12, 46, 49, 51, 56, 70, 71, 74 Reset of all settings 49, 51 Settings 49, 51, 56, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 77 Transfer of parameters 41, 42, 57, 58, 80 Upload of parameters 41, 42, 57, 58, 80 Phase L1 12, 16, 32, 34, 87, 89, 96, 97 Phase L2 12, 16, 32, 34, 87, 89, 96, 97 Phase L3 12, 16, 32, 34, 87, 89, 96, 97 Phase loss 84, 85, 90 P hp 20 P kW 20 PLC 10, 40, 58, 70, 71, 80, 88, 91 Pollution degree 18 Profibus DP 80 Protection 10, 12, 16, 18, 36, 40, 41, 46, 47, 48, 49, 51, 57, 58, 67, 68, 69, 74, 75, 82, 84, 85, 86, 88, 89, 90, 91, 92 Type of operation 57, 58, 67, 68, 69, 70, 73 PSE parameter 75, 89
S Selection key 13, 42, 50, 52, 59 Semiconductor fuse 21 Setting current Ie 10, 50, 52, 59 Settings 12, 42, 48, 49, 50, 51, 52, 56, 60, 66, 70, 74, 77, 80, 87 Settings level 50, 51, 52 Settings menu 50 Shorted SCR 87 Shunt fault 84, 85, 89 Softstarter Thermal Overload 84, 85, 89 Softstarter types 20 Specifications 16, 18, 30 Start 16, 32 Start and Stop 8, 12, 13, 16, 19, 37, 40, 47, 51, 57, 59, 60, 62, 63, 64, 67, 68, 69, 70, 73, 74, 75, 76, 84, 86, 87, 88, 92 Connection 12, 17, 28, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 80, 82, 86, 87, 91 Start Ramp Time 51, 57, 59, 60, 64, 92 Start up faults 86 Circuits, connection 12, 13, 17, 31, 80, 82, 96, 97 Status information 46, 80 Stop Ramp Time 51, 57, 59, 61, 65, 90 Storage 18, 28, 41 T Technical data 17, 19, 41 Temperature 10, 12, 16, 18, 41, 67, 89, 92 Thermistor 16 Thyristor 10, 12, 16, 34, 82, 85, 87, 89, 90 Timing diagram 76 Shunt fault TOR 10, 12, 32, 40, 60, 61, 62, 96, 97 Torque 16, 34, 35, 36, 37, 38, 39, 40, 51, 60, 61, 64, 65, 66
Torque Control 16, 51, 57, 60, 61, 64, 65 Transfer of parameters 41, 42, 57, 58, 80 Tripping event 12, 48, 49, 72, 73, 76, 85 Troubleshooting 84 Two phase control 32, 37, 40, 46, 47, 56, 57, 59, 60, 62, 63, 64, 66, 70, 75, 82 Type designation 16, 18 Type of operation 57, 58, 67, 68, 69, 70, 73
U Uc 10 Ue 10 Underload 16, 51, 58, 68, 84, 85, 92 Protection 58, 68, 84, 85, 92 Type of operation 58, 68 Unlocking the keypad 49 Unpacking 28 Upload of parameters 41, 42, 57, 58, 80 Us 10 W Warning 4, 12, 13, 16, 28, 29, 30, 32, 33, 34, 37, 38, 39, 40, 84 Warning high current 84, 85, 91 Warning (tripping events) 85 Weights 19 Wire diagrams 96, 97
Q Quickstart 8, 12, 13 R Real time clock 82 Relay 12, 13, 33, 37, 40, 76, 82, 85, 87, 89, 90 Requirements 9, 20, 29 Reset all settings 49, 74
ABB would appreciate your comments on this product. Please grade the following questions by selecting one alternative per category. Your answer will enables us to improve our products.
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Please send this report to: ABB AB Cewe-Control SE-721 61 Vsters Sweden
Manual 1SFC132057M0201 rev D, October 2011
ABB AB Cewe-Control SE-721 61 Vsters, Sweden Telephone: +46 (0) 21 32 07 00 Telefax: + 46 (0) 21 12 60 01
Copyright 2011 ABB. All rights reserved. Specifications subject to changes without notice.
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