Eaton S801+ Series User Manual Download Page 45

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Troubleshooting

S801+ Soft Starter

MN03900002E—November 2012

www.eaton.com

Local Control Troubleshooting Flow Chart

Start

End

Check protection
LEDs / fault code and
attempt to cleat

Fault
Condition
not Present

Consuit
Manual to
diagnose
Fault Code

VerifyFault
condition
does not
exist

Contact
Eaton
Support

Correct fault
condition

Check for
external
device
failures

Possible
Transient fault,
set Reset Mode
to Manual

Check basis
for STOP
Command

Is the

Fault LED

Lit?

Fault

Reset

Stop

Command

received

Is Reset

Mode set
to AUTO?

Unit trips

fault code

present

Fault

Code

repeats

Yes

Summary of Contents for S801+ Series

Page 1: ...S801 Soft Starter User Manual Effective November 2012 New Information...

Page 2: ...POSE OR MERCHANTABILITY OTHER THAN THOSE SPECIFICALLY SET OUT IN ANY EXISTING CONTRACT BETWEEN THE PARTIES ANY SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF EATON THE CONTENTS OF THIS DOCUMENT SHALL N...

Page 3: ...77 ETN CARE 386 2273 8 00 a m 6 00 p m EST FAX 800 752 8602 After Hours Emergency 800 543 7038 6 00 p m 8 00 a m EST If you are in the U S or Canada and have OI or PLC questions you can take advantage...

Page 4: ...ower Wiring 10 S801 V10 Installation Requirements 12 Lug Installation S801 N and S801 R 13 Lug Installation S801 T S801 U and S801 V Frames 13 Control Wiring Inputs 13 DIP Switch 13 Control Wiring Ter...

Page 5: ...u Begin to Troubleshoot 31 Fault Codes 31 Define the Problem 32 ACCESSORIES Lug Kits 35 Optional Accessory Kits 35 Replacement Parts 35 APPENDIX A PARAMETERS Parameters 36 APPENDIX B OVERLOAD PROTECTI...

Page 6: ...EML30 Lug Kit Installed on Load Side 13 Control Wiring Control Terminal Block 13 DIP Switch 13 120 Vac Control 15 24 Vdc Control 15 Basic Connection Diagram for 3 Wire Pushbutton 16 Basic Connection...

Page 7: ...d S801 R 10 Line and Load Power Wiring S801 T S801 U and S801 V 11 Terminal Block Wiring Capacity 14 Terminal Block Functions 14 Control Power Requirements 18 Eaton Recommended 24 Vdc Power Supplies 1...

Page 8: ...verload Protection Overload Adjustment Range Inline Connected 38 Motor FLA Potentiometer Values 38 Thermal Motor Overload Times 39 Appendix C Ratings Cooling and Power Losses Inline Standard Duty 15 S...

Page 9: ...e Be sure equipment is properly grounded Wear safety glasses whenever working on electronic controllers or rotating machinery Warnings and Cautions This manual contains clearly marked cautions and war...

Page 10: ...ARNING Make sure you read and understand the procedures in this manual before you attempt to set up or operate the equipment WARNING Do not work on energized equipment unless absolutely required If th...

Page 11: ...S801 Soft Starter x S801 Soft Starter MN03900002E November 2012 www eaton com...

Page 12: ...fter the motor reaches speed internal contacts are closed to bypass the SCRs The S801 Soft Starter utilizes a Control Interface Module CIM that allows the user to configure the device and evaluate fau...

Page 13: ...0 FLA of the measured load currents in the 111 to 132 MHz and 152 to 155 MHz frequency range Should this occur and affect the functions of the required motor protection settings refer to the troublesh...

Page 14: ...th Height S801 N37 5 8 2 6 7 37 187 2 2 66 67 6 6 45 163 9 S801 N66 5 8 2 6 7 37 187 2 2 66 67 6 6 45 163 9 S801 R10 10 5 4 8 7 92 201 2 4 38 111 3 6 64 168 6 S801 R13 10 5 4 8 7 92 201 2 4 38 111 3 6...

Page 15: ...rms symmetrical amperes 480 volts maximum when protected by a circuit breaker Frame Size Fuses Circuit Breaker Voltage SCCR Rating A S801 N J HFD 600 10 kA S801 R RK5 J HFD HKD 600 10 kA S801 T RK5 J...

Page 16: ...iew Verify that the unit s catalog number and options match those stated on the order purchase form CAUTION Unit may weigh up to 103 pounds Use suitable lifting device Storage It is recommended that t...

Page 17: ...ounting hardware may utilize either tapped holes in the panel or lock washers and nuts to secure the soft starter To mount the unit use all the hardware specified in the table below Required Mounting...

Page 18: ...on com 7 Dimensions Approximate Dimensions in inches mm S801 N S801 R 4X 0 22 5 5 6 87 174 5 1 97 50 0 7 37 187 2 6 45 163 9 5 35 135 9 5 89 149 7 3 32 84 4 2 66 67 6 4X 0 27 6 8 3 54 90 0 7 44 189 0...

Page 19: ...eaton com Approximate Dimensions in inches mm S801 T S801 U 11 77 299 0 12 71 322 9 6 47 164 4 7 65 194 4 5 40 137 3 5 95 151 1 5 91 150 0 0 28 7 1 6X 2 95 75 0 11 77 299 0 7 16 181 8 6X 12 72 323 1...

Page 20: ...Soft Starter MN03900002E November 2012 www eaton com 9 Approximate Dimensions in inches mm S801 V 4X 0 2650 6 731 6 50 165 1 7 39 187 8 11 05 280 6 16 57 420 8 2X 15 63 397 0 6 79 172 5 3 05 77 5 9 84...

Page 21: ...incoming power wiring If the motor turns in the incorrect direction upon energization exchange two phases at the motor terminal box or at the output terminals of the soft starter Changing the input w...

Page 22: ...ad side of the soft starter Catalog Number Conductor Size Number of Conductors Torque Lb in Nm Lug Kit Kits Required S801 T 4 1 0 MCM 2 250 28 3 EML22 2 4 0 500 MCM 1 250 28 3 EML23 4 0 500 MCM 2 2 25...

Page 23: ...kcmil cables for each phase between RD circuit breaker and soft starter OPTIONAL Two 2 3 in x 1 4 in bus with a 1 4 in spacer per terminal Note See the figure below for alternative layouts 5 Line and...

Page 24: ...iously removed S801 V Shown with Terminal Cover Removed and EML30 Lug Kit Installed on Load Side Control Wiring Inputs Control wiring is connected to the S801 by one 1 terminal block and one 1 RJ12 co...

Page 25: ...stop is selected the soft stop will begin and run to time out 1 START Control Input 24 Vdc only momentary input with 3 wire control maintained for 2 wire control Applying 24 Vdc to terminal 1 while P...

Page 26: ...ith an electronic control it is highly recommended that a noise suppressor be used across the relay coil In the case of an AC coil the noise suppressor is made up of a series connected resistor and ca...

Page 27: ...24 Vdc control power supply and the control terminal block 2 See Using an Auxiliary Relay section below if it is desired to use a relay instead of an indicating lamp for terminals 13 14 95 96 and 98...

Page 28: ...it is desired to use a relay instead of an indicating lamp for terminals 13 14 95 96 and 98 3 120 Vac may be applied to terminals 13 14 95 96 and 98 4 Add ferrite Fair Rite 0446176451 to DC Power Lead...

Page 29: ...Steady State for the power supply Sum of the Sealed In Power of all the Starters Outrush for the power supply Sum of the Inrush Power of all the Starters Formulas to calculate control power requiremen...

Page 30: ...losed prior to starting the soft starter and remain closed until the Soft Starter has been stopped to ensure proper soft starter and system operation If an electromagnetic contactor is used on the lin...

Page 31: ...ration Inline Connected Soft Starter For each start the length of time the SCRs are conducting current as well as the magnitude of that current determine how hot the SCRs will get Between successive s...

Page 32: ...uld be noted that a lightly loaded motor takes less torque and thus lower voltage and time to accelerate to full speed For this case the S801 will go into bypass before the ramp reaches full voltage I...

Page 33: ...nitial Torque or lower are not recommended as the motor may not develop adequate torque to accelerate properly Current Limit Soft Stop The Soft Stop feature is used for applications that require a con...

Page 34: ...arameter values Terminal 3 Overload on Start Momentary application of 24 Vdc to Terminal 3 prior to a start raises the overload fault trip point to 125 of the maximum rating of the frame size for the...

Page 35: ...is set to AUTO or MANUAL 24 Vdc power to the Start terminal is reapplied Start command momentary Edge sensing will allow a motor restart when Fault condition is cleared The Permissive terminal is supp...

Page 36: ...ult Fault codes Overload Hardware failure Protections Overload Jam Stall Phase loss Phase reversal Fault Reset Method Ramp Start Current Limit Selection Ramp Start or Current Limit Start Ramp Time and...

Page 37: ...ss contactor s close a sound similar to contactor chatter may be heard This sound is the result of multiple contactors in some models closing one after the other in a very short period It is normal op...

Page 38: ...st be set to motor nameplate FLA to achieve proper overload protection S801 N66 Amps 20 66 20 S801 R10 Amps 32 105 32 S801 R13 Amps 42 135 42 S801 T18 Amps 56 180 56 S801 T24 Amps 75 240 75 S801 T30 A...

Page 39: ...ore than one error condition caused a stop Once you see the same flash code repeated you have seen all the flash codes for the error conditions that caused the stop For example if you see three flashe...

Page 40: ...out hesitation Motor rotation should begin within 2 seconds If Stall Faults occur at the end of the ramp time increase Initial Torque Kick Start Torque and Time and or Soft Start Time to get into bypa...

Page 41: ...corresponding current reduction value base on the initial Torque setting of the soft starter Using the default Initial Torque value of 45 the expected current will be 67 of the above values or 132 26...

Page 42: ...T button located below the CIM down or apply 24 Vdc to terminal 4 and count the number of times all the LEDs on the CIM flash For example if you see three flashes and then two more flashes after a sho...

Page 43: ...in table above to aid in determining the appropriate corrective action Verify that the Permissive input terminal is at 24 Vdc Then start the S801 the Control Input terminal block If the S801 does not...

Page 44: ...g S801 Stopped or Faulted Condition Possible Problem Suggested Corrective Action Status LED is GREEN Stop command received Terminal block wiring not secure Loss of 24 Vdc control power Transient fault...

Page 45: ...anual to diagnose Fault Code VerifyFault condition does not exist Contact Eaton Support Contact Eaton Support Correct fault condition Check for external device failures Possible Transient fault set Re...

Page 46: ...3 Description S801 Frame Accessory Kit Part Number Panel Mounting Kit 3 ft cable S801 EMA69A Panel Mounting Kit 5 ft cable S801 EMA69B Panel Mounting Kit 8 ft cable S801 EMA69C Panel Mounting Kit 10 f...

Page 47: ...Amps 75 240 75 S801 T30 Amps 95 304 95 S801 U36 Amps 112 360 112 S801 U42 Amps 131 420 131 S801 U50 Amps 156 500 156 S801 V36 Amps 112 360 112 S801 V42 Amps 131 420 131 S801 V50 Amps 156 500 156 S801...

Page 48: ...then two flashes you are seeing the first code again This means you have seen all the flash codes for this stop You may now release the RESET button or remove 24 Vdc from Control terminal Block Termin...

Page 49: ...which inhibits a reset for three minutes After this timer expires the device may be reset and the thermal fault is cleared At this point another internal timer is started this timer is 26 x 3 or 48 m...

Page 50: ...hibit time are saved to the non volatile memory These values are reloaded when the device boots and the timer is restarted at the full reset time This means if the 3 minute inhibit timer has been runn...

Page 51: ...oft Starter MN03900002E November 2012 www eaton com Overload Trip Curves Time Seconds Percent FLA 10000 0 1000 0 100 0 10 0 1 0 0 Class 5 Class 20 Class 10 Class 30 100 200 300 400 500 600 700 800 900...

Page 52: ...30 55 59 30 25 40 30 75 60 100 75 S801 R10 135 40 63 80 40 30 50 40 100 75 125 100 S801 R13 Frame Size T 180 51 90 110 60 50 60 60 150 125 150 150 S801 T18 240 75 110 147 75 60 75 75 200 150 200 200 S...

Page 53: ...33 15 15 20 15 50 40 50 50 S801 R10 80 22 40 45 25 20 30 25 60 50 75 60 S801 R13 Frame Size T 115 33 59 63 30 30 40 30 75 75 100 100 S801 T18 150 45 80 90 50 40 50 50 100 100 150 125 S801 T24 192 55 1...

Page 54: ...to determine the enclosure size and any cooling requirements Maximum Power Loss Catalog Number FLA Current Range Inline Power Loss Watts S801 N37 11 37 amps 30 S801 N66 20 66 amps 33 S801 R10 32 105 a...

Page 55: ...the two windings in parallel The soft starter is then used to control the current applied to the motor An in sight disconnect means should be installed per code requirements Dual Voltage Motor A dual...

Page 56: ...tage Default 480V Start Method Voltage Ramp or Current Limit Default Voltage Ramp Start Time As required Default 20 seconds Initial Torque As required Default 45 Auto Reset Mode As Required Default Ma...

Page 57: ...ithout a signal at the P terminal Terminal 1 is energized momentary or maintained to issue a START command Signal duration must be a minimum of 500ms for the Soft Starter to recognize the START comman...

Page 58: ...ication Conditions RED Active fault is present cannot RESET GREEN Not responding to START command from field wiring LEVEL Sense Insufficient voltage at Terminal P Insufficient voltage at Terminal 1 ED...

Page 59: ...d tight and voltage is of the proper value Phase voltages and or currents have significant imbalance Verify continuity of fuses or breakers disconnects or isolation contactors Verify all connections a...

Page 60: ...econds if the motor is not at synchronous speed and the current is in excess of 2X FLA This feature is not user settable Verify that the motor is properly sized for the load 13 Jam Soft Starter in Byp...

Page 61: ...mal start parameters BUT the bypass contactors will not close Running continuously on the SCRs will generate more heat than can be dissipated by the internal fans resulting in an over temperature faul...

Page 62: ...ting load Excessive load Increase soft starter capacity be sure model ratings can handle current demands Notes During the Start Ramp Time the maximum RMS value of the 3 phase current s are monitored I...

Page 63: ...ust prior to the voltage loss at Terminal the soft starter will recognize this condition as a STOP command This condition would cause a shutdown of the soft starter without logging FC41 Suspect source...

Page 64: ...essed RESET button on the face of the soft starter is a sub miniature switch mounted on the PCB You will feel a slight detent when the switch closes Pressing the switch beyond this point does not incr...

Page 65: ...General Information 54 S801 Soft Starter MN03900002E November 2012 www eaton com...

Page 66: ...General Information S801 Soft Starter MN03900002E November 2012 www eaton com 55...

Page 67: ...General Information 56 S801 Soft Starter MN03900002E November 2012 www eaton com...

Page 68: ...olutions to solve our customers most critical challenges Our focus is on delivering the right solution for the application But decision makers demand more than just innovative products They turn to Ea...

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