75KW Bypass soft start

Overview

This soft start controller uses advanced microprocessors as its core, applies advanced software design methods and the latest hardware technology, and adopts thyristor phase-shifting technology to achieve soft start and soft stop functions for AC asynchronous motors. It also has multiple protection functions such as phase failure, overvoltage, undervoltage, overcurrent, overload, three-phase imbalance, and short circuit.

This soft starter covers 7.5KW~600KW, with reliable quality and good electromagnetic compatibility (EMC). It can be widely used in heavy-duty equipment such as fans, water pumps, ball mills, crushers, conveyors, and compressors. Before installing or operating this soft starter, please read and understand this manual. Only professionals can provide the ideal replacement product for pressure reducing starting equipment such as diagonal conversion, autotransformer pressure reduction, and magnetic control pressure reduction.

1. The soft starter has the following characteristics

• Adopting high-performance microcontrollers and digital logic control technology, it has strong anti-interference ability.

• The startup parameters can be flexibly set according to different loads to achieve the optimal current curve and torque control characteristics.

• It provides a smooth and gradual starting process for the electric motor, reduces the impact of starting current on the power grid, lowers equipment vibration and noise, prolongs the service life of the mechanical transmission system, and improves the working environment for workers. The starting current can be adjusted according to the load to reduce starting losses and generate optimal torque with minimal current.

• There is no phase sequence requirement for the input power supply.

• It can be set as free parking and soft parking, with adjustable soft parking time.

• Comes with standard RS485 interface and Modbus protocol (order declaration).

• Adopting a 4x8 LCD display, parameter modification and operation are simple and intuitive.

• The product has a novel structure, reliable performance, strong functionality, and easy installation and operation.

2. Structural characteristics

• Intelligent soft starter: naturally air-cooled, external AC contactor. Online soft starter, no need for external AC contactor.

• Intelligent starter cabinet: exquisite structure and simple installation.

3. Introduction to Typical Applications of the Product

• The product is widely used in various industries such as thermal power generation, hydropower, power transmission and distribution equipment, metallurgy, chemical industry, mining, and construction.

• The water pump utilizes the soft stop function to alleviate the water hammer phenomenon when stopped, saving the cost of system maintenance.

• The ball mill utilizes a voltage ramp to start, reducing gear torque wear and maintenance workload, saving both time and expenses.

• The fan reduces belt wear and mechanical impact, saving maintenance costs.

• The compressor utilizes current limiting to achieve smooth start-up, reduce motor heating, and extend service life. The belt conveyor achieves a smooth and gradual starting process through soft start, avoiding product movement and material spillage.

4. Usage and environmental conditions

• Applicable standard: GB14048.6-2008

• Usage category: AC-53A or AC-53B

• Rated voltage: 380V ± 15%, AC three-phase symmetrical power supply; Customizable soft starters with rated voltages of 220V, 480V, and 660V

• Frequency: 50Hz/60Hz ± 2%

• Startup frequency: 12 times/hour

• Cooling method: Natural air cooling for soft starter, fan cooling for intelligent soft starter cabinet.

• Installation method: wall mounted or cabinet vertical

• Protection level: IP00

• Operating altitude: 1000 meters without capacity reduction (for every 100 meters increase above 1000 meters, the current decreases by 0.5%)

• Environmental temperature: Storage: -25 ℃~+70 ℃

• Working temperature: -5 ℃~+55 ℃, above 40 ℃, with a 2% decrease in current per liter of 1 ℃

• Relative humidity: maximum 90% (at a temperature of 20 ℃)

• Pollution level: Shh level

5. Packaging Content

• a. Soft starter/cabinet

• b. User Manual

• c. Certificate of Conformity

6. Working principle

The principle block diagram of this soft starter is shown in Figure 2. The power part is composed of three pairs of anti parallel thyristors as shown in Figure 1. The core microprocessor of the control part collects the synchronization signal, voltage signal, current signal, and motor power factor angle of the power grid. The control software applies thyristor phase-shifting technology based on the changes of these four parameters to gradually increase the voltage applied to the motor to full voltage according to a certain law. By appropriately setting control parameters, the torque and current of the motor can be well matched with the load requirements.

7. Purchase inspection

• Before removing the soft starter from its packaging material, please confirm that the packaging cardboard box has not been damaged during transportation. The damage to packaging cartons is usually caused by improper transportation. If any damage is found, please notify the carrier and your distributor representative.

• Please confirm that the nameplate and label of the soft starter comply with the packaging list and corresponding purchase order. If the soft starter is not installed immediately, it should be stored in a clean and dry area with an ambient temperature of -25 ℃~+70 ℃.

Product Selection

1. Product nameplate

2. Model meaning

3. Selection precautions

Soft starters must provide a force greater than the load resistance torque to complete the start-up. For ordinary loads such as water pumps, fans, etc., it is recommended to configure soft starters with the same or higher gear specifications. For heavy loads such as ball mills, 6-stage fans, crushers, etc., it is recommended to configure soft starters with higher or second gear specifications.

install

1. External dimensions of soft starter

① 0.75KW heavy~75KW light (Figure 311)

② 75KW heavy~800KW light (Figure 312)

2. Installation requirements

Installation direction

① Be sure to install the soft starter in a vertical direction, do not invert it, and use screws to install it on a sturdy structure.

② When the soft starter operates, it generates heat. To ensure the flow of air, it should be as shown in Figure 3.2. Leave some space in the design. Generate heat and dissipate it upwards, so do not install it under heat-resistant equipment.

③ The main circuit adopts upper and lower outlets, and the wires should ensure sufficient current carrying capacity.

wiring

1. Application wiring diagram

Dimensions of online soft starter

Terminal configuration diagram

(1) Main circuit terminal diagram

(2) Terminal diagram of control circuit

(3) Control circuit terminal wiring

Online soft starter primary and secondary line diagram

Bypass type soft starter primary and secondary wiring diagram

Display keyboard interface

1. Display keyboard instructions

2. Buttons

3. Function parameter table

Fault Code Table and Solutions

Safety precautions

safety

• Before installing or operating this soft starter, please read and understand this manual. Only professionals can install/repair and maintain the soft starter.

• Installation and maintenance operations should strictly follow this manual, relevant national standards, and industry practices. Otherwise, the manufacturer shall not be responsible for any adverse consequences caused by failure to operate in accordance with the corresponding guidance specifications.

• Before maintaining the soft starter or motor, all power inputs must be disconnected.

• After installation, carefully inspect and verify that no parts (such as wire ends, screws, washers, etc.) have fallen into the live parts.

Warning

• The control part of this product (including the triggering unit and the central processing unit control part) is equipped with dangerous voltage. The triggering unit has the same high voltage as the main circuit. If it is illegally touched, it will be very dangerous and may cause electric shock accidents.

• After connecting this product to the main power supply, even if the control voltage is disconnected or the starter is stopped, a full voltage signal for sampling will still appear at the output terminal of the soft starter.

• The product must be well grounded to ensure safe normal operation and prevent accidental electric shock injuries. Do not connect power factor compensation capacitors to the output terminal of the soft starter.