Mitsubishi Electric MEsoftstart/I00 Users, Installation & Instruction Manual Download Page 100

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100 Protective functions

PROTECTIVE FUNCTIONS & TROUBLESHOOTING (PRO)

This chapter explains the protection functions that are implemented in the PRO variants of the soft starter. For
troubleshooting on the Core variant refer to paragraph 5.4.

This chapter explains the operation and use of this product. Always read the instructions before using the equipment.

PROTECTIVE FUNCTIONS & TROUBLESHOOTING (PRO) ................................................................................................. 100

OFT STARTER FAULT AND ALARM INDICATIONS

........................................................................................................................100

OW TO RESET THE SOFT STARTER AFTER A FAULT HAS OCCURRED

................................................................................................101

ROUBLESHOOTING USING THE FAULT DISPLAY ON THE SOFT STARTER

...........................................................................................102

ENERAL

ROUBLESHOOTING

...............................................................................................................................................105

Summary of Contents for MEsoftstart/I00

Page 1: ...ATION CORE MODELS 49 BASIC OPERATION PRO MODELS 62 MESOFTSTART COMMUNICATION INTERFACE 82 PROTECTIVE FUNCTIONS TROUBLESHOOTING PRO 100 MAINTENANCE AND INSPECTION 106 SPECIFICATIONS 110 APPENDICES 117 Thank you for choosing this Mitsubishi Electric Europe B V softstarter This Instruction Manual provides installation instructions and guidelines for advanced use of the MEsoftstart series soft starter...

Page 2: ...o be used in equipment or systems in situations that can affect or endanger human life When considering this product for operation in special applications such as machinery or systems in passenger transportation medical aerospace atomic power or submarine applications please contact your nearest Mitsubishi Electric sales representative Although this product was manufactured under conditions of str...

Page 3: ...DES OF THE SOFT STARTER 63 POWER UP THE SOFT STARTER 64 METHOD OF VIEWING AND CHANGING CONFIGURATION PARAMETERS 64 PARAMETERS 65 PARAMETER INTER DEPENDENCIES 75 BASIC OPERATION PROCEDURE OPERATION FROM TFT DISPLAY PANEL 76 BASIC OPERATION PROCEDURE OPERATION FROM A REMOTE CONTROLLER 79 USING THE AUTO MAINTENANCE FEATURE 81 MESOFTSTART COMMUNICATION INTERFACE 82 MESOFTSTART PC APP 83 MESOFTSTART MO...

Page 4: ...th levels They are important for personnel safety Electric Shock Prevention WARNING Do not open the soft starter enclosure while there is power on the soft starter power terminals Ensure that the power is OFF MCCB open before working on the motor or any load connected to the motor Do not assume that the power at the motor is OFF while the power to the soft starter is still ON NOTE When wired for i...

Page 5: ...Halogen based materials are often included in fumigant which is used to sterilize or disinfest wooden packages When packaging prevent residual fumigant components from being infiltrated into Mitsubishi Electric products or use an alternative sterilization or disinfection method heat disinfection etc for packaging Sterilization or disinfection of wooden package should also be performed before packa...

Page 6: ... MFS Motor Frame Size in kW MODBUS Communication Protocol originally published by Modicon now Schneider Electric in 1979 MOLC Motor Overload Current MSC Maximum Starting Current MULC Motor Underload Current OC Open Circuit PC Personal Computer PF Power Factor PLC Programmable Logic Controller PTC Positive Temperature Coefficient thermistor RJ45 Connector standard used for Modbus RTU and TCP commun...

Page 7: ...entiometers each for start and stop ramp definition and a few slider switches to fully configure the soft starter Monitoring and control with PC Application on Modbus RTU Pro Used for complex applications where more advanced control options are required Setting up Monitoring and Control with full function local colour touch TFT screen as shown and or PC Application on Modbus RTU or TCP This manual...

Page 8: ...heavy duty c Bypass contactor installed if the soft starter is used with an internal or external bypass contactor the on time of the soft starter is only during starting and stopping this reduces thermal loading and a smaller soft starter model may be appropriate A bypass contactor is recommended for applications where the motor is started and then runs for a long time before it is stopped For app...

Page 9: ... current 125A Heavy Duty Table 1 MEsoftstart I00 guideline for motor sizes1 Model MEsoftstart I01 is rated at 200A continuous current and can be used at 480A starting current for normal duty and at 250A starting current for heavy duty applications MEsoftstart I01 can be ordered for voltage ranges from 400Vac to 690Vac and can be ordered with a built in bypass contactor or can be installed with an ...

Page 10: ...02 Continuous rated current 390A Max starting current 730A Normal duty Max starting current 390A Heavy Duty Table 3 MEsoftstart I02 guideline for motor sizes1 Model MEsoftstart I03 is rated at 600A continuous current and can be used at 1440A starting current for normal duty and at 750A starting current for heavy duty applications MEsoftstart I03 can be ordered for voltage ranges from 400Vac to 690...

Page 11: ... applications MEsoftstart I04 can be ordered for voltage ranges from 400Vac to 690Vac and can be used with an external bypass contactor or without a bypass contactor Model MEsoftstart I04 Continuous rated current 900A Max starting current 1600A Normal duty Max starting current 900A Heavy Duty Note a built in bypass contactor option is not available with model MEsoftstart I04 Table 5 MEsoftstart I0...

Page 12: ...start I01 model soft starter can provide a maximum starting current of 184 or 250A if operated below 50 C These values should be de rated for operation at 60 C i e 60 C 50 C 1 4 14 thus 184 14 170 or 231A If this is insufficient for the application then more robust selection for this application may be MEsoftstart I02 with a de rated starting current of 287 14 273 or 371A see Table 3 Soft starter ...

Page 13: ...0s duration and approximately 400 of the motor s running current during start up a Calculations Here starting current needed 400 162 4 649 6A b Conclusion our starting current 250A allowed for heavy duty with MEsoftstart I01 Looking at MEsoftstart I02 its heavy duty starting current of 390A is also too low i e MEsoftstart I03 with a heavy duty starting current of 900A would suffice Use soft starte...

Page 14: ...14 Introduction Figure 2 Product marking Component and Terminal identification Component and terminals are identified in Figure 3 and Table 6 below Comparable markings are used on all other models ...

Page 15: ...15 Introduction Figure 3 Soft starter terminal and component identification ...

Page 16: ...o motor T2 l Busbar 12 BT3 Bypass contactor supply L3 to motor T3 m RJ 45 x 2 Two RS485 to MEsoftstart PC App Modbus RTU interface Two ports of the same Modbus port for easy daisy chaining 7 n 10 Pin Wiring terminal connector x2 Green Wiring terminals on top side 3 2 4 3 2 5 o 10 Pin Wiring terminal connector X2 Green Wiring terminals on bottom side Only on Pro variants 3 2 4 p TFT touchscreen TFT...

Page 17: ...tarter in a cabinet or enclosure where the terminals will not pose a hazard to personnel This section shows how to safely install the soft starter and provides guidelines for the selection or design of a suitable motor control centre cabinet enclosure Always read the instructions before installing connecting and using the equipment INSTALLATION INSTRUCTIONS 17 PREPARING FOR SOFT STARTER INSTALLATI...

Page 18: ...elta 3 wire connection The diagram below shows the connection diagram for the soft starter with and without built in bypass contactor for normal 3 wire connection With this method of connecting the motor the full motor starting current flows through the soft starter switching elements during start up After start up and if a built in or external bypass contactor is used the full running current of ...

Page 19: ... in or external bypass contactor is used 58 of the running current of the motor flows through the bypass contactor If no bypass contactor is used 58 of the motor s continuous running current flows through the soft starter switching elements Figure 5 Soft starter circuit diagram for 6 wire inside delta motor Ensure to connect the grid side terminals of the inside delta motor to the soft starter L1 ...

Page 20: ...e of the wiring of an inside delta motor when the grid connection on the soft starter is clockwise or anti clockwise Refer to Figure 6 to understand the difference Figure 6 6 wire Inside delta wiring for clockwise and anti clockwise grid rotation ...

Page 21: ... information on your motor before designing the peripheral devices Figure 7 shows the MEsoftstart I01 Core model soft starter and the associated peripheral devices The installation for the other MEsoftstart models will be the same Figure 7 Soft starter circuit diagram with peripheral devices ...

Page 22: ... run the motor when at full speed The BYPASS CONTACTOR discrete output signal refer Table 13 from the soft starter should be used to control the bypass contactor Select the bypass contactor according to the maximum running current of the motor as indicated on the motor manufacturer s label If the motor is wired in an inside delta circuit the bypass contactor may be selected to be 58 of the motor r...

Page 23: ...required around the soft starter refer par 2 3 3 Soft starter installation environment The following table lists the standard specifications of the soft starter installation environment Table 8 Soft starter environmental specification Environmental parameter Model Specification Notes Surrounding Air temperature MEsoftstart I00 MEsoftstart I01 MEsoftstart I02 MEsoftstart I03 MEsoftstart I04 10 C to...

Page 24: ...ect an installation place where temperature does not change suddenly o Avoid installing the soft starter near the air outlet of an air conditioner o If temperature changes are caused by opening closing of a door install the soft starter away from the door Humidity Operate the soft starter within the specified ambient air humidity Too high humidity will pose problems of reduced insulation and metal...

Page 25: ... explosion proof and it will have to be contained in a certified explosion proof cabinet If possible avoid installation in such environments and install the soft starter in a non hazardous place High altitude The soft starter may be used at its recommended current rating at altitudes lower than 1400m above sea level For the installation at an altitude above 1400 m de rate the rated current of the ...

Page 26: ...ilation type d Cooling by heat exchanger or cooler e g heat pipe cooler Table 9 Cooling systems for soft starter cabinet Cooling system Cabinet layout Comment Natural cooling Natural ventilation enclosed open type This system is low in cost and generally used but the cabinet size increases as the soft starter capacity increases This system is for relatively small capacities Natural ventilation tot...

Page 27: ...t sunlight high temperature and high humidity refer paragraph 2 2 2 e Install the soft starter on a non flammable wall surface f When encasing multiple soft starters install them in parallel as a cooling measure refer paragraph 2 3 4 g For heat dissipation and maintenance keep clearance between the soft starter and the other devices or cabinet surface Installation orientation of the soft starter T...

Page 28: ...rters in the same cabinet generally arrange them horizontally as shown in the right Figure 10 a When it is inevitable to arrange them vertically to minimize space take such measures as to provide guides since heat from the bottom soft starters can increase the temperatures in the top soft starters causing soft starter overheating Figure 10 Arrangement of multiple soft starters in a single cabinet ...

Page 29: ...generated in the soft starter is blown up from the bottom of the unit as warm air by the cooling fan When installing a ventilation fan for that heat determine the place of ventilation fan installation after fully considering air flow Air passes through areas of low resistance Make an airway and airflow plates to expose the soft starter to cool air ...

Page 30: ...or mounting the MEsoftstart soft starter in a cabinet or against a wall MEsoftstart I00 and MEsoftstart I01 Drilling plan Figure 12 Drilling plan MEsoftstart I00 with and without bypass contactor and MEsoftstart I01 without bypass contactor Figure 13 Drilling plan MEsoftstart I01 with bypass contactor MEsoftstart I02 Drilling plan Figure 14 Drilling plan MEsoftstart I02 without bypass contactor Fi...

Page 31: ...t I03 Drilling plan Figure 16 Drilling plan MEsoftstart I03 without bypass contactor Figure 17 Drilling plan MEsoftstart I03 with bypass contactor MEsoftstart I04 Drilling plan Figure 18 Drilling plan MEsoftstart I03 without bypass contactor ...

Page 32: ...the terminals and explains the wiring of the MEsoftstart I01 and MEsoftstart I02 models soft starter Always read the instructions before installing connecting and using the equipment WIRING 32 TERMINAL IDENTIFICATION 33 WIRING INSTRUCTIONS 35 ...

Page 33: ...The terminals are clearly marked on all MEsoftstart models Terminal identification Pro variants All Pro MEsoftstart variants have a Modbus TCP RJ45 terminal grid input side and additional signal terminals on green wiring terminal blocks Figure 19 shows the terminals connectors for Pro variant models MEsoftstart I01 and MEsoftstart I02 without built in bypass contactor Figure 19 Soft starter Pro va...

Page 34: ...nal identification Core variants Figure 20 shows the terminals for Core variant models MEsoftstart I00 and MEsoftstart I01 without built in bypass contactor Figure 20 Soft starter Core variant terminal identification ...

Page 35: ...put Connect these terminals via fuses and MCCB to the three phase supply lines Refer Figure 7 Ensure to connect the supply power to the correct terminals as shown in Figure 21 and Figure 19 or Figure 20 T1 T2 T3 Soft starter power output to motor and for models without built in bypass contactor Motor side bypass contactor Connect these terminals straight to a three phase squirrel cage motor No pow...

Page 36: ...ing channels of the soft starter require a system earthing to work correctly A lack of proper earthing connection may cause the soft starter to behave erratically The Earthing wire should be as short as possible preferably less than 0 5 m The earthing stud is an M8 bolt on all MEsoftstart models Use the same cable cross section as selected for power wiring in Table 11 Figure 22 Earthing wiring on ...

Page 37: ...37 Wiring Figure 23 Fitting protective guards over terminals ...

Page 38: ...ing the soft starter and while the motor is starting running stopping or the delay between starts is implemented X1 2 Ready_Relay return X1 3 Run Relay This output signal from the soft starter will be active when the soft starter is busy starting running or stopping the motor It may be used to monitor the operation of the soft starter X1 4 Run_Relay return X1 5 Shunt Trip Relay This output signal ...

Page 39: ...ft starter will read the sensor and be able to limit current to the motor when the temperature rises above the pre configured maximum for the motor Refer Figure 7 Note MEsoftstart soft starters are not delivered with a temperature sensor as standard Please include the optional compatible temperature sensor when ordering the soft starter X2 5 LM35 Signal X2 6 LM35 24V X2 7 Reversing Contactor Note ...

Page 40: ...s RESET on the TFT or via the PC interface or remotereset X3 7 Fault Incoming Alarm Return X3 8 Auto Maintenance Input Auto Maintenance When this signal is active the Soft starter is in Auto and control will be possible from any remote location via RTU TCP PLC discrete inputs AND the TFT or Pot HMI on the box When this signal is not active the Soft starter is in Maintenance and the control will be...

Page 41: ...set the soft starter from e g a PLC controller NOTE that the system must be configured for REMOTE operation refer paragraph 6 7 1 Close this contactor to reset the soft starter open it to allow the soft starter to continue X4 2 External reset in return X4 3 Temperature Fault Output This output is set active when the soft starter trips due to a high temperature on internal heatsinks or on the motor...

Page 42: ...n configuring the soft starter and while the motor is starting running stopping or the delay between starts is implemented X1 2 Ready_Relay return X1 3 Run Bypass Relay This output signal from the soft starter will be active when the start ramp is completed and the motor is running It may be used to switch power to the motor using a bypass contactor once the motor is running and to again open the ...

Page 43: ...he Ready Relay output refer Table 12 X1 1 and X1 2 to be able to detect when the soft starter is ready to start the motor NOTE that the if the system is started with this signal and then stopped from the HMI push button or Modbus controller this switch will first have to be opened and then again closed before the motor will again start from a remote signal X2 4 Remote Start Stop Return and Auto Ma...

Page 44: ... or J3 RJ45 connectors on the soft starter refer Figure 19 and connects to a USB port on the PC Note that drivers for the RS485 to USB converter may need to be installed For the MEsoftstart dedicated cable the drivers will be provided with the cable Refer par 7 1 for instructions to install the drivers and the application The soft starters may be daisy chained on the RS485 line to enable the PC to...

Page 45: ...UTIONS FOR USE OF THE SOFT STARTER This chapter explains the precautions for use of this product Always read the instructions before using the equipment PRECAUTIONS FOR USE OF THE SOFT STARTER 45 CHECKLIST BEFORE APPLYING POWER 46 ...

Page 46: ...w is restricted the soft starter will overheat and trip Paragraph 2 3 3 Terminals are insulated Use terminals with insulation sleeves to wire the power supply and the motor Figure 21 The main circuit cable gauge is adequate Use an appropriate cable gauge to suppress the voltage drop to 2 or less If the wiring distance is long between the soft starter and motor the voltage drop in the main circuit ...

Page 47: ... and should be hard wired to the main circuit breaker to ensure that the operator can reliably stop the motor in case of an emergency Figure 7 Countermeasures are taken against EMI The input output main circuit of the soft starter includes high frequency components which may interfere with the communication devices such as AM radios used near the soft starter In such case install a noise filter On...

Page 48: ... installation with an existing or old motor or use in a hostile atmosphere to make sure to check the motor insulation resistance The voltage applied to the soft starter I O signal circuits is within the specifications Application of a voltage higher than the permissible voltage to the soft starter I O signal circuits or opposite polarity may damage the I O devices Paragraph 3 2 ...

Page 49: ...of MEsoftstart Industrial soft starter This chapter explains the operation and use of this product Always read the instructions before using the equipment BASIC OPERATION CORE MODELS 49 POWER UP THE SOFT STARTER 50 CONFIGURE THE SOFT STARTER FOR THE APPLICATION 51 CONTROLLING THE SOFT STARTER 53 TROUBLESHOOTING THE MESOFTSTART I CORE VARIANT 56 ...

Page 50: ...rol Use the Modbus commands to start and stop the motor Phase LED This LED indicates the detected phase of the applied 3 phase power The configured phase orientation must be Clockwise The interpretation of the Phase LED state is described in the table below LED state Detected phase Description LED off Unknown phase This occurs before AC power is applied and during phase synchronisation immediately...

Page 51: ...he LED flashes LED on Running mode Ramp up has been completed and if present bypass contactor has been engaged The motor should be running 1 Hz flashing Delay mode After stop or ramp down is completed the Soft starter is implementing the restart delay time 0 5 Hz flashing Error mode An error condition was detected All switching elements are off The soft starter awaits further operator intervention...

Page 52: ...ximum Number of starts per hour reverts to 60 This may be changed using the Modbus interface or PC Application to any number of starts per hour up to 60 JOG The soft starter provides the capability to JOG the motor This functionality may be used to e g align a conveyor belt with a loading bay The JOG functionality will allow the user to slowly turn the motor while the START button is being pressed...

Page 53: ...ith 135A full load current at power factor of 0 8 at 67 Configure a 110kW motor with 199A full load current at power factor of 0 8 at 100 Additional configuration parameters In addition to these parameters the soft starter may be configured via the Modbus RTU interface for Motor protection class between 5 and 30 default is 10 PT 100 motor temperature sensor to cause a trip on motor temperature mor...

Page 54: ... The Auto Maintenance feature must never be used in place of a proper safety procedure to ensure the safety of personnel working on the soft starter or the motor Start Stop or Reset The user may START STOP or RESET the motor via the MEsoftstart I soft starter as shown in Figure 34 Figure 32 MEsoftstart I Core Start Stop and Reset control options from the HMI panel Figure 33 MEsoftstart I Core Star...

Page 55: ... opened and then closed again If work needs to be done on the motor or the load ensure that the Main supply is switched off to prevent inadvertent starting from a remote switch or Modbus Master If an error occurs the motor will be stopped and the ERROR LED will be flashing to indicate the cause of the fault refer paragraph 5 4 Once the cause of the fault is understood and removed the soft starter ...

Page 56: ...ing checks should be done i Measure the incoming three phase supply power on the Grid side terminals of the soft starter If there is not supply power on all three terminals check the Main Circuit Breaker and contact the installer to find the problem ii If the supply voltage is present on all three phases measured on all three terminals and the soft starter is not showing any LEDs please contact yo...

Page 57: ...motor protection curve for the configured protection class was violated 8 Over current running Current exceeds the set current for the motor or soft start limit 9 Supply voltage unbalanced Voltage levels on input lines differ from each other with more than 20 10 Switching element Current flow detected in a line where the switching element is switched off or no current flow when the switching eleme...

Page 58: ... rating as well as the maximum starting current for the MEsoftstart soft starter ii Confirm that the maximum starting current of the MEsoftstart soft starter for the duty required by the installation is at least three times the motor full load current refer paragraph 1 1 1 iii If possible connect the PC Application to the Modbus RTU connector on the soft starter and read back the configuration ref...

Page 59: ...balance percentage to 25 if the motor specification permits that If more than 20 contact your plant electrician to check and try to balance phase loading for the plant ii The default phase current imbalance is 10 refer paragraph 5 2 1 This can be set to 20 maximum using the MEsoftstart PC application if the motor specification permits it Switching element This error indicates a hardware fault insi...

Page 60: ...or is not being activated when the start ramp is completed Refer to Figure 28 iii Confirm that the soft starter output is functioning correctly First configure for no bypass contactor and start the motor Measure the Bypass output on the green connector X1 This contactor should be closed when the start ramp is completed Note that this switching of the relay happens in any case whether configured fo...

Page 61: ...h the default communication settings and address of 1 iv If the Modbus Master is not the MEsoftstart PC application test the communication first with the MEsoftstart I Core variant PC application refer paragraph 7 1 v Replace the cable with a supplied Modbus RTU cable Install the provided drivers refer paragraph 7 1 1 1 and test again with the MEsoftstart I Core variant PC application vi If the in...

Page 62: ...product Always read the instructions before using the equipment BASIC OPERATION PRO MODELS 62 OPERATIONAL MODES OF THE SOFT STARTER 63 POWER UP THE SOFT STARTER 64 METHOD OF VIEWING AND CHANGING CONFIGURATION PARAMETERS 64 PARAMETERS 65 PARAMETER INTER DEPENDENCIES 75 BASIC OPERATION PROCEDURE OPERATION FROM TFT DISPLAY PANEL 76 BASIC OPERATION PROCEDURE OPERATION FROM A REMOTE CONTROLLER 79 USING...

Page 63: ...Refer to par 7 1 for an overview on using the PC Interface If the user selects to configure the soft starter the user is presented with options to select a Factory Default Configuration refer Table 18 or to create a User Configuration In the case of a User Configuration changes will be saved to the local non volatile memory on the soft starter as the CUSTOM configuration The saved configuration or...

Page 64: ...Figure 38 Viewing and changing parameters Enter the Parameter screen from the CONFIGURE screen as shown in Figure 37 Scroll through the parameters by pressing buttons to go to the next parameter or to go to the previous parameter button goes to the START screen refer Figure 37 and saves the configuration changes button goes to the EDIT screen where the parameter options can be viewed and changed T...

Page 65: ...s of the soft starter Reference Parameter group Parameters Factory Default where applicable 6 4 1 Basic Setup Motor Hardware Inside Delta No Workload Norm Heavy Normal Bypass Contactor Absent Motor Size kW depends on frame size Motor Application Default Phase Rotation Clockwise Protection Class 10 RPM Sensor Presence No 6 4 2 Basic Setup Start Setup Start Type Ramp Ramp Type Linear Time Ramp Up Ti...

Page 66: ...0 Maximum Starts Hour 10 Ramp Start Angle 0 Alpha Skip Start 36 Alpha Skip Stop 36 Note that same value for Skip Start and Stop implies that the Skip is disabled 6 4 5 Temperature Setup Heatsink Fan Control No Maximum Motor Temp 120 C Heatsink Restart Temp 40 C Motor Restart Temp 45 C Heatsink Fan Start 40 C Motor Temp Selection PT100 Note TMotor indicates that the LM35 sensor is selected 6 4 6 Jo...

Page 67: ...their coils updated to the same voltage level or damage to the coils will ensue 6 4 8 General Setup User Language English Motor Name Motor1 Local Remote Mode Local Password Edit 0 disabled Fault Incoming CB Fault 6 4 9 Communication Setup RS485 Baudrate 115200 RS485 Parity Even Modbus Slave Address 1 TCP IP Parameters Own IP address 192 168 0 15 IP subnet mask 255 255 255 0 Client IP address 192 1...

Page 68: ...art model soft starter is dependent on the following parameters Supply voltage Inside Delta or Normal 3 wire connection Load Duty Normal or Heavy Bypass contactor present or not present Depending on this configuration motor sizes may be selected as specified in the tables for each MEsoftstart model in paragraph 1 1 1 The TFT display guides the user by presenting only the applicable list of motor s...

Page 69: ...ifferent starting types that may be configured for the motor They are Ramp up Pedestal Kickstart Constant Current These parameters can be configured in the Advanced Setup refer paragraph 6 4 4 Ramp Type Lin RMS S Note that this parameter is not used when Start Type is Constant Current This parameter specifies the Ramp type that will be used during motor start and stop Options are Linear Time Linea...

Page 70: ...r Heavy Duty This time represents the maximum possible time that the motor could start in which includes current limited delays incurred during the motor starting phase If the motor has not achieved a Running status by the end of this time the soft starter shall trip and display a fault Note This parameter cannot be set to a value less than the Ramp up time above Ensure to allow enough time to sof...

Page 71: ...ge Kickstart Voltage In this mode the Firing angle of the SCRs has a brief step function that lasts for a defined period before returning to zero and then resuming a linear increase to the maximum value with respect to the Ramp up time This parameter determines the voltage amplitude of the kick start voltage as a percentage of the nominal voltage The parameter is selectable between 5 60 Kickstart ...

Page 72: ...d is subsequently drastically reduced MOLC Motor Over Load Current MOLC is specified as a percentage of MFLC The parameter is adjustable between 100 and 600 or up to the maximum Frame size capacity which is measured as a percentage of Max Full Load Current MFLC for the selected motor as shown above e g For a 45kW motor on a MEsoftstart I01 normal connection no bypass contactor the MOLC parameter r...

Page 73: ...perature before the soft starter is ready for operation again This parameter may be set between 30 C 60 C The default value is 40 C Motor Restart Temp This parameter is applicable when the motor has tripped due to exceeding the Motor Maximum Temperature The parameter defines the temperature below which a restart may safely be attempted again This parameter may be set between 35 C 80 C The default ...

Page 74: ...haracters that may be used to identify the soft starter station Default is Motor1 Local Remote Mode This parameter determines if the soft starter is controlled locally either from the TFT display or a Modbus master such as the MEsoftstart PC Interface or remotely via external digital control inputs e g a physical switch or a PLC When Remote operation is selected the TFT display will not activate t...

Page 75: ... S Curve X X X X Ramp Up Time Limited by Maximum Motor Start Time MMST Yes MMST Equal to MMST Fixed at 2s Max Motor Start Time MMST Yes Yes Yes Yes 2 Secs Kickstart Voltage X X Yes X X Kickstart Period X X Yes X X Constant Current X Yes X Pedestal RampUp X Yes X X X Pedestal RampDown X Yes X X X MSC Yes MULC Yes MOLC Yes Maximum Starts Hour SPH NORMAL Duty Starts per Hour 10 Ramp Up Time 30Sec and...

Page 76: ...s Refer to Figure 39 below to understand the usage and interpretation of the Parameter display area Figure 39 Understanding the display areas After power up the Parameter display area cycles between parameter sets The parameters sets are i Default parameter display ii General parameter display iii Temperature display iv Supply Status display v Voltage and Current measurement display vi Modbus and ...

Page 77: ...77 Basic operation Pro models Figure 40 Understanding the data display ...

Page 78: ...re 41 Power up the soft starter Start the Motor When the START MOTOR button is pressed the soft starter will start the motor applying the configuration parameters During the start of the motor the voltage as a function of time is displayed on a start progress screen Note that the screen in Figure 41 shows a Ramp start type This will depend on the selection as described in paragraph 6 4 2 ...

Page 79: ...onds Pushing the JOG MOTOR button again will cause the motor to coast to a stop If while using the JOG MOTOR button the motor starts to exceed a comfortable speed JOG MOTOR can be pushed again and then pushed again when it is back at a comfortable speed All motor tripping conditions are monitored during Jog and excessive running under Jog may sooner or later result in a trip Basic operation proced...

Page 80: ...ter may be wired for remote operation and operation may then be controlled by closing the START contactor wired on X3 9 and X3 10 as shown in Table 14 The soft starter will commence to do the start ramp up as configured refer paragraph 6 6 2 When the START contactor is opened the stop ramp will commence After completing the ramp down a delay will be implemented before starting is allowed again The...

Page 81: ... that the Auto Maintenance input on the soft starter must be normally closed for the soft starter to be in Auto control to enable control from remote PLC or any Modbus master or the TFT panel The Maintenance switch must open the Auto Maintenance input on the soft starter to prevent remote control of the soft starter When the Auto Maintenance input is open the soft starter will only accept control ...

Page 82: ...for the MEsoftstart I PRO variants and MEsoftstart I Core variants and explains how to install and use the software This chapter explains the operation and use of this product Always read the instructions before using the equipment MESOFTSTART COMMUNICATION INTERFACE 82 MESOFTSTART PC APP 83 MESOFTSTART MODBUS INTERFACES 98 ...

Page 83: ...ation for the Pro variants provides real time monitoring while the motor is idle starting running and stopping The PC Application for the Core variants provides monitoring while the motor is stopped or running but not while starting and stopping Control The Modbus link PC Application PLC or SCADA allows Start Stop and Reset control Interface The MEsoftstart PC application for Pro variants can be u...

Page 84: ... be used for the MEsoftstart configuration and monitoring For the Core variant and if Modbus RTU is to be used for the Pro variant as well a cable with RS485 to USB converter will be used The drivers for the Modbus interface cable also need to be downloaded If Modbus TCP will be used the drivers are not required Open the folder where the files are copied The folder should look like Figure 44 Figur...

Page 85: ...uld be visible refer Figure 46 Figure 46 Home screen with Modbus RTU setup selected Once the MEsoftstart PC App is running the Information screen can be accessed by clicking the _icon The Information screen shows the software version and the supported MEsoftstart models Figure 47 Information screen ...

Page 86: ...ity is a problem ensure to use a terminating resistor on the other connector on the last soft starter in line if they are daisy chained refer paragraph 0 Note If the computer is connected to the internet and offers to find a driver for the new hardware wait for it to complete the procedure You may also point the computer to the driver in the MEsoftstart Installation files Driver for Modbus interfa...

Page 87: ...should be set for a static IP address Connect the computer to the MEsoftstart soft starter using a normal Ethernet cable Ensure to connect to J1 on top of grid side of the MEsoftstart enclosure Figure 49 MEsoftstart PC Application setup for Modbus TCP connection Connecting to the soft starter When the MEsoftstart I PC Interface Application is running and the Ethernet cable or Modbus USB cable is c...

Page 88: ...Pro variants Refer paragraph 6 4 9 for information on how to check the TCP and RTU Modbus communication parameters and RTU address on the soft starter using the TFT display For the Core variants Refer paragraph 5 4 16 Once the communication parameters and RTU address on the soft starter and the MEsoftstart PC App are the same try connecting to the soft starter again When first connected to the sof...

Page 89: ...hould commence Modbus communication and the Start screen Figure 51 should be visible On the Core variants Once connected the MEsoftstart I Core variant Mode LED will flash faster 1Hz to indicate that Modbus monitoring and Control is possible Limited configuration is also possible refer paragraph 5 2 1 Do not attempt to immediately start the motor first view the configuration and confirm that the s...

Page 90: ...iguration is selected to again upload from the soft starter overwriting changes that were made on the Configure screen Note that all the parameters that are available on the configuration screen are the same as those that are listed for the TFT display configuration refer Table 18 In addition the MEsoftstart PC App shows the model of the connected soft starter and a theoretical representation of w...

Page 91: ...ould select Download to save the configuration to the soft starter followed by Back to return to the Start screen There is an optional password when downloading a new configuration to the soft starter This is to prevent unauthorised changes to the soft starter If the password is not in use the value 0 will allow the ...

Page 92: ...en buttons Note that the default File Path where the configuration files are saved can be changed from the Home screen refer Figure 46 Configuring limits and tolerances using the MEsoftstart PC App On the Core and the Pro variants The soft starter implements protection against over temperature on the motor and on the soft starter heat sinks as well as supply voltage and current unbalance These par...

Page 93: ...n limits and tolerances Configuring general parameters and communication settings On the Core and the Pro variants Just like on the TFT display the MEsoftstart PC App may be used to configure general parameters and communication settings for the Modbus interface Refer Figure 56 for an overview of what can be changed on these screens Figure 56 Configure screen general parameters and communication s...

Page 94: ...PC application If JOG mode is no longer needed set the JOG Motor Voltage Percentage back to zero again The JOG buttons on the PC application and the TFT display will be removed Figure 57 Configure screen JOG mode Change the password and view the firmware revisions On the Pro variant If required a password can be set to protect against accidental or unauthorised changing of the configuration Note t...

Page 95: ... paragraph 5 3 2 On the Core and the Pro variants The MEsoftstart PC App may be used to control the soft starter From the Start screen use the START button to start the motor View the progress of the start ramp on the Start screen or the TFT display Press the Stop button and watch the stop ramp if configured and the implementation of the delay before start is again allowed ...

Page 96: ...MEsoftstart PC Application On the Core variant refer paragraph 5 3 2 On the Core and the Pro variants Whenever a fault is detected by the soft starter the soft starter will require a RESET before operation is possible again Investigate the cause of the fault fix the issue and Reset the soft starter using the button on the screen ...

Page 97: ...97 MEsoftstart PC Interface Application Figure 60 MEsoftstart PC Application Fault screen ...

Page 98: ...w configuration the soft starter checks the password and then performs a validity check on the received parameters and responds either with errors or with a positive response A single configuration parameter compliance failure will result in the whole configuration will be discarded refer paragraph 6 5 The Modbus Master may send regular status request messages beginning when the soft starter is in...

Page 99: ...from 1 to 247 Any write action either to Configuration registers or the Control Command register that receives a positive response back from the soft starter may be interpreted by the Modbus Master as confirmation that the configuration data is correct and will be saved in the soft starter or that the command will be put into effect An error response must be interpreted as the opposite Updates to ...

Page 100: ...the Core variant refer to paragraph 5 4 This chapter explains the operation and use of this product Always read the instructions before using the equipment PROTECTIVE FUNCTIONS TROUBLESHOOTING PRO 100 SOFT STARTER FAULT AND ALARM INDICATIONS 100 HOW TO RESET THE SOFT STARTER AFTER A FAULT HAS OCCURRED 101 TROUBLESHOOTING USING THE FAULT DISPLAY ON THE SOFT STARTER 102 GENERAL TROUBLESHOOTING 105 ...

Page 101: ...troller or PC application On the Fault screen press the RESET button to reset the fault on the soft starter or If the soft starter is under external control of the Modbus controller or the PC application refer Figure 60 Use the button on the PC application or the Modbus command to reset the soft starter If the soft starter is configured for Remote operation the remote reset may be used to reset th...

Page 102: ...bleshooting using the fault display on the soft starter If the displayed message does not correspond to any of the following or if you have any other problem please contact your sales representative The possible fault messages that the soft starter may display are listed in the table below together with a detailed description of the fault and corrective actions If you need assistance with troubles...

Page 103: ...rature on the motor caused the soft starter to trip in order to protect the motor This limit is defined by parameter Motor Maximum Temperature as described in paragraph 6 4 5 This error will auto correct once the motor temperature drops below the configured Motor re start temperature Refer paragraph 6 4 5 Inspect the motor and the load High motor temperature may be caused by a too heavy load or by...

Page 104: ...e soft starter will tolerate 16 Remote control from wired buttons or Modbus controller is not working The system may be in Maintenance so that ONLY control from the local HMI panel is allowed Ensure that the Auto Maintenance switch is on Auto to allow for any remote control Refer par 6 8 17 Maintenance was activated This is just an information message that the Maintenance input is active The condi...

Page 105: ... your local distributor Motor generates abnormal heat Description Corrective action The motor temperature is higher than expected Check the motor rating plate for supply voltage specification Inspect the motor rotation wiring fan and environment Check that the load is appropriate for the motor Measure for imbalance on voltage and current Reduce the start ramp up time a slow ramp may cause more hea...

Page 106: ...Precautions for Maintenance and Inspection MAINTENANCE AND INSPECTION This chapter explains the precautions for maintenance and inspection for this product MAINTENANCE AND INSPECTION 106 INSPECTION ITEM 107 ...

Page 107: ...during operation Motor operation alarm Improper installation environment Cooling system fault Abnormal vibration abnormal noise bearing noises in motor Abnormal overheat and discoloration of terminals Protective covers on terminals Periodic inspection Check the following when the unit is not operational Check that there is no voltage on the input terminals Check all areas inaccessible during opera...

Page 108: ...ective circuit Operation check Check that the output voltages across phases are balanced while operating the soft starter Contact the manufacturer Check that no fault is found in protection and display circuits during operation Contact the manufacturer Overall Check for unusual odor and discoloration Check for serious rust development Stop the equipment and contact the manufacturer Contact the man...

Page 109: ...e MEsoftstart I01 Core and all Pro variants Part name Estimated lifespan Description Cooling fan part number to be supplied 5 Operational years but greatly affected by the operational environment such as dust and humidity Replace as required Refer Advanced Maintenance Before starting the fan replacement switch power OFF wait for at least 10 minutes and then check the voltage with a Multi Meter or ...

Page 110: ...tions SPECIFICATIONS This chapter explains the specifications of this product Always read the instructions before using the equipment SPECIFICATIONS 110 SOFT STARTER SPECIFICATION 111 OUTLINE DIMENSION DRAWINGS 112 ...

Page 111: ...ture measurement channels sensors purchasable separately Fault indication Displayed on the TFT touch screen on Pro variants flashing LED sequences on Core variants Mounting Chassis mounted see dimensions Module physical data with finger guards Size WxHxD mm no bypass with internal bypass Weight no bypass with internal bypass Approximate heat loss without bypass at maximum rated current MEsoftstart...

Page 112: ...112 Specifications Outline dimension drawings MEsoftstart I00 100A model Figure 62 MEsoftstart I00 without internal bypass contactor Figure 63 MEsoftstart I00 with internal bypass contactor ...

Page 113: ...113 Specifications MEsoftstart I01 200A model Figure 64 MEsoftstart I01 without bypass contactor Figure 65 MEsoftstart I01 with internal bypass contactor ...

Page 114: ...114 Specifications MEsoftstart I02 390A model Figure 66 MEsoftstart I02 without bypass contactor Figure 67 MEsoftstart I02 with internal bypass contactor ...

Page 115: ...115 Specifications MEsoftstart I03 600A model Figure 68 MEsoftstart I03 without bypass contactor Figure 69 MEsoftstart I03 with internal bypass contactor ...

Page 116: ...116 Specifications MEsoftstart I04 900A model Figure 70 MEsoftstart I04 without bypass contactor Note No internal bypass contactor option is available for the MEsoftstart I04 model ...

Page 117: ...117 Instruction Manual Supplement APPENDICES This APPENDIX provides the additional maintenance information for this product APPENDIX 117 ADVANCED MAINTENANCE REPLACEMENT OF THE FAN 118 ...

Page 118: ...r as this will void the installer s warranty The installer may however need to open the soft starter to replace the fan or fans on the MEsoftstart I03 and MEsoftstart I04 Instructions are provided in this section Removing the bottom cover gives access to the fan Pictures show the MEsoftstart I01 Figure 71 Replacement of the fan ...

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Mitsubishi Electric MEsoftstart/I00, Users, Installation & Instruction Manual

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