Baldor MN894 manual

Multipurpose Soft Starter Sizes 8 to 840 AMP Installation & Operating Manual 9/06 MN894[...]

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T able of Contents T able of Contents i MN894 Section 1 General Information 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

ii T able of Contents MN894 Indicators 3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power On 3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

T able of Contents iii MN894 Section 6 Specifications and Product Data 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identification 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

iv T able of Contents MN894[...]

Section 1 General Information General Information 1-1 MN894 Introduction Three phase multipurpose soft starter control provides reduced voltage, three phase motor starting. Ramp up and extended ramp down features provide an effective means to start and stop material handling equipment and pumping equipment to minimize spillage and water hammer prob[...]

1-2 General Information MN894 Figure 1-1 Layout and Identification CB L1 L2 L3 T1 T2 T3 CT4 CT3 CT2 CT1 CPT MOV PC1 PC2 PC3 Fan Fan LCM F1 F2 F3 TB1 OL GND Overtemperature Switch R1 R2 Fan Snubber Capacitor Snubber Resistor Shunt T rip Legend : CB - Motor Circuit Protector or fusible disconnect CPT - Control transformer (control voltage) CT1, 2, 3,[...]

General Information 1-3 MN894 Figure 1-2 Logic Control Module Block Diagram 1 2 3 4 5 6 12345 6 O N OFF ON S2 RDD CM OC T ACH CL BP Ramp Mode Select Logic & Firing Control CM PF MIN MAX R U N RD TD S T O P CL PT RU TU S T A R T User Adjustment Control Power Overcurrent Trip Current Monitor Motor Power 400 300 200 100 0 %FLA M O T O R C U R R E [...]

1-4 General Information MN894 Major Components (Refer to Figures 1-1 and 1-2). Logic Control Module (LCM) The LCM (Logic Control Module) operates in the voltage ramp mode or current limit mode during ramp up and ramp down (if ramp down is selected). The LCM controls the amount of current that the power cells deliver to the motor during ramp up and [...]

General Information 1-5 MN894 Snubber Network 160 through 840 amp models only . A resistor and capacitor series circuit (snubber) is wired in parallel with each disk type SCR. The RC network enhances the electrical characteristics of the SCR and provides high voltage transient protection. Shorted SCR Detection: If a shorted SCR condition is detecte[...]

1-6 General Information MN894 Configurations Control Only: Soft start control, without motor overload protection or branch circuit protection circuit breaker or fusible disconnect switch. Suitable for installation with a series contactor or as a retrofit for an existing motor starter . Non-combination Starter: Soft start control with motor overload[...]

General Information 1-7 MN894 Limited Warranty For a period of two (2) years from the date of original purchase, BALDOR will repair or replace without charge controls and accessories which our examination proves to be defective in material or workmanship. This warranty is valid if the unit has not been tampered with by unauthorized persons, misused[...]

1-8 General Information MN894 Safety Notice This equipment contains voltages that may be as high as 600 volts! Electrical shock can cause serious or fatal injury . Only qualified personnel should attempt the start-up procedure or troubleshoot this equipment. This equipment may be connected to other machines that have rotating parts or parts that ar[...]

Section 2 Installation Installation 2-1 MN894 Receiving, Inspection and Storage When you receive your control, there are several things you should do immediately . 1. Observe the condition of the shipping container and report any damage immediately to the commercial carrier that delivered your control. 2. Remove the control from the carton. Inspect[...]

2-2 Installation MN894 T able 2-1 Three Phase Rating Fuse MCP (GE) R a ti ng (AMPS) Amps Class Short Circuit A RMS Amps T ype Short Circuit A RMS 8 100 J 5,000 20 5,000 16 100 J 5,000 20 5,000 30 200 J 5,000 50 5,000 100 RK1 5,000 50 SELA , 55 175 J 42,000 100 SELA SFLA 10,000 80 175 J 42,000 100 SFLA SGLA 10,000 160 400 RK5 100,000 300 SGLA SKLA 4[...]

Installation 2-3 MN894 Installation 1. Mount the panel or enclosure to the mounting surface. The panel or enclosure must be securely fastened to the mounting surface. Refer to the mounting dimensions in Section 6 of this manual. 2. Ground the panel and control per NEC article 250 as well as state and local codes. 3. Use copper wire rated for at lea[...]

2-4 Installation MN894 Non-Motor and Special Motor Applications Non-motor load: The multipurpose control is designed to provide reduced starting voltage for standard three phase induction motors. The control may also start non-motor loads for controlled inrush current applications with resistive or inductive loads. Consult Baldor if the control is [...]

Section 3 Operation Operation 3-1 MN894 T ypes of Starting V oltage Ramp % Line V oltage 25 50 75 100 RU TD CL RD TU Time 0 PT Current Limit % FLA 100 200 300 400 CL RD Time 0 PT T ach % Full Speed 25 50 75 100 RU RUN RD Time 0 V oltage Starting (S2-4 = OFF) During start the initial voltage (TU) is set to a level where the motor will begin to turn [...]

3-2 Operation MN894 Start Adjustments (Refer to Figure 3-1). Ramp Up Ramp up time (RU) is adjustable from 3 to 50 seconds. RU adjusts the voltage ramp or the tachometer starting ramp time. For voltage starting, RU adjusts the time it takes the motor to reach full voltage. Actual acceleration time to full speed depends upon the motor load and the se[...]

Operation 3-3 MN894 Run Adjustments (Refer to Figure 3-3). Current Monitor Current monitor set point (CM) is adjustable from 50 to 400% FLA to monitor the running current after the motor reaches the full run condition. With CM enabled (S2-2=ON), if the running current exceeds the CM set point, the control will shut down, the CUR MON contact will cl[...]

3-4 Operation MN894 S2-4 T achometer and V oltage Ramp Select (T ACH) “On” position: The control is in the tachometer ramp mode during start and stop. Starting and stopping times are independent of the load conditions. Ramp up (RU) is dependent on the ramp up and current limit (CL) settings. RD is dependent on the RD and CL settings. Note: Curr[...]

Operation 3-5 MN894 Control Connections (Refer to Figure 3-5). CLOSE TO RUN Close to Run terminals 12 and 13. Close to run contact must be closed to initiate ramp up and run. Close to Run contact must be opened to initiate ramp down to stop. Close to run contact must be dry and electrically isolated contact. If a voltage is applied to these termina[...]

3-6 Operation MN894 Indicators Power On The PWR light indicates that power is supplied to the internal power supply of the control. W ARNING: If the power light is not illuminated, it does not necessarily mean that the line voltage is off. Electrical shock hazard may exist. Measure the voltage at the line terminals before service. Over Current OC o[...]

Section 4 Start-up Start-up 4-1 MN894 Safety Notice Be sure to read and understand all notices, warning and caution statements in Section 1 of this manual. If you have any questions about the safe operation of this equipment, please contact your Baldor representative before you proceed. Start-up Checklist Recommended Equipment V olt meter (20k W pe[...]

4-2 Start-up MN894 Quick Set-Up 1. Check continuity of the motor wiring and check for phase to phase and phase to ground short circuits. 2. Connect the control wiring for your application. (Refer to section 2 for wire size and torque specifications). 3. For MB# − XXX models, verify the control transformer is set for the line voltage. For MA# − [...]

Start-up 4-3 MN894 T ach Feedback Starting 1 1. Set for ramp up with ramp down as follows: S2-1 = OFF Ramp down disable S2-2 = OFF Current monitor S2-3 = OFF Over current shut down S2-4 = ON T achometer enable S2-5 = OFF Current limit enable S2-6 = OFF Bypass contactor Set RU, TU, PT and PF fully CCW . Set RD and RT at mid point. 12. Set for ramp u[...]

4-4 Start-up MN894 Starting Instructions Choose one of the following examples that best matches your application. Read the procedure and set the control according to the procedure or use the steps to develop your own procedure. V ariable Load with V oltage Ramp (S2-2=OFF , S2 − 4=OFF) T ypically used for non-inertial loads, loads that increase wi[...]

Start-up 4-5 MN894 High Friction Load with V oltage Ramp (S2-2=OFF , S2-4=OFF) T ypically used for loads that require high breakaway torque and low acceleration torque; i.e., conveyors in icy environment, equipment that resists starting due to lack of use, traction loads, etc. 1. Set RU, TU, PT , RD, TD and PF fully counterclockwise (CCW). 2. Adjus[...]

4-6 Start-up MN894 Inertial Load (S2-1=ON, S2-4=OFF , S2-5=ON) T ypically used on coasting and/or flywheel loads; i.e., chippers, centrifuges, compressors, crushers, chillers, band saws, centrifugal fans and blowers. Note: Ramp down and pulse start are not normally used with inertial loads. 1. Set TU, PT , RD, TD and PF fully counterclockwise (CCW)[...]

Start-up 4-7 MN894 T achometer Mode (S2-4=ON, S2-5=OFF) T ypically used for changing loads that require consistent starting and stopping times, independent of load condition, and pumping applications with severe head pressure to reduce water hammer; i.e., pumps, conveyors, stackers and other material handling equipment. 1. Set RU, TU, PT , RD, TD a[...]

4-8 Start-up MN894 Start-up T roubleshooting The Multipurpose Control module has 7 LEDs to help diagnose problems. There is a summary of the functions and indications on pages 2-8 and 2-9. The Multipurpose starter was tested under load with all SCR and electronic functions checked before shipping. Note: T o test the output of a soft starter a motor[...]

Start-up 4-9 MN894 Circuit Breaker is T ripping − During Starting If the shunt trip light comes “ON” during starting it may detect a weak input phase. This is typical of grounded delta and open delta power systems. For proper operation, a four wire WYE system is recommended. If the shunt trip light is ON and it is determined that input power [...]

4-10 Start-up MN894[...]

Section 5 T roubleshooting T roubleshooting 5-1 MN894 Safety Notice Be sure to read and understand all notices, warning and caution statements in Section 1 of this manual. If you have any questions about the safe operation of this equipment, please contact your Baldor representative before you proceed. Preliminary Checks In the event of trouble, di[...]

5-2 T roubleshooting MN894 SCR T ests If the SCR devices are suspected of failure, these tests can be used to test the SCR’s. Inspection Be sure the physical condition of components is correct. Refer to Figure 5-1. 1. Be sure power is off. 2. Inspect power cell connections for tightness and signs of overheating. 3. Replace snubber capacitors if t[...]

T roubleshooting 5-3 MN894 Resistance T est Disconnect the power cell or SCR pack from all external wiring before you perform a resistance check. Use an ohmmeter with 20,000 ohms per volt or greater impedance for the resistance measurements. Refer to T able 5-1 and Figure 5-1. 1. Be sure power is OFF . 2. Remove all wiring from the power cell or SC[...]

5-4 T roubleshooting MN894 SCR Replacement SCR Polarity Figure 5-2 shows the polarity and wire colors for correct SCR installation. It also shows the locations of the tightening bars. Figure 5-2 SCR Polarity M160 / M250 M420 / M600 / M840 White wire to GT terminal, Red wire to T terminal White wire to GL terminal, Red wire to L terminal White wire [...]

T roubleshooting 5-5 MN894 With the SCR device installed with the tightening bar and bolts (Figure 5-2), tighten the bolts as follows: (see Figure 5-3) 1. T ighten the nuts evenly until finger tight. 2. T ighten bolts in 1/4 turn increments. 3. Use the SCR tightening pressure gauge and measure the deflection of the T ightening bar . The middle and [...]

5-6 T roubleshooting MN894 T able 5-3 T roubleshooting Chart Symptom Cause Corrective Action Motor is not connected. Connect motor to T1, T2 and T3 of control. MCP trips as it is ST contact on control is always closed. Repair or replace logic control module. MCP trips as it is closed (also see Improper input voltage. Obtain the correct source volta[...]

T roubleshooting 5-7 MN894 T able 5-3 T roubleshooting Chart Continued Symptom Cause Corrective Action Incorrect heater size or setting. Check overload relay heater table in Appendix A. Loose or burned heater . T ighten or replace heater . Overload relay trips when starting Long starting time. (high inertia loads may require slow trip overloads. Ev[...]

5-8 T roubleshooting MN894 The control panel is intended to provide years of trouble free service with appropriate cooling and protection from the elements. Should trouble occur , refer to the appropriate control manual for control and motor troubleshooting information. Reset the Circuit Breaker If the circuit breaker is tripped, it must be reset t[...]

T roubleshooting 5-9 MN894 Reset an Overload Relay If the Overload relay is tripped, the tripped indicator (Reset Button of Figure 5-6) will be in the “T ripped” position. 1. V erify that the overload condition has been cleared to allow restart. 2. V erify motor lead connections are tight. 3. Allow time for the overload to cool. 4. Press the ?[...]

5-10 T roubleshooting MN894[...]

Section 6 Specifications and Product Data Specifications and Product Data 6-1 MN894 Identification Three Phase Starters Control T ype M- Multipurpose M B Control Group A - Self powered logic control module B - Logic control modules that require 1 15 or 230V AC. Input V oltage Code 7- 208/230/460V AC (60Hz) 8- 230/460/575V AC (60Hz) MA9- 220/380/415[...]

6-2 Specifications and Product Data MN894 Multipurpose Control Specifications Three Phase Starters Input V oltage MA7-008 MA7-016 MA7-030 V oltage VA C MA8-008 MA8-016 MA8-030 VA C 3PH 60Hz HP I C HP I C HP I C 230 2 5 10 460 8 8 10 16 20 30 575 5 10 25 Input V oltage MB7-055 MB7-080 MB7-160 MB7-250 MB7-420 MB7-600 MB7-840 V oltage VA C MB8-055 MB8[...]

Specifications and Product Data 6-3 MN894 Control Specifications Control Method 6 SCR’s connected in inverse parallel for full-wave 3 phase control Peak Inverse V oltage 208/230 460 575 1200V AC minimum 1200V AC minimum 1600V AC Start T ime Adjustable range 3-50 seconds (current limit starting is not timed). Stop T ime Adjustable range 5-50 secon[...]

6-4 Specifications and Product Data MN894 Wire Size & T ightening T orque Specifications OR (A) (A) (C) (D) (D) (B) (B) (D) (D) GND GND 8, 16 Amp Control Only Combination Starter and Non-Combination Starter and Control Only Line Input Motor Output Load GND GND Control Connections Line Input Motor Output Load Control TB1 (C) Wire Size T orque Sp[...]

Specifications and Product Data 6-5 MN894 Mounting Dimensions Open Panel A Dia B w h d Open/Panel Dimensions Amp Rt i Control Only Non-Combination Starter Combination Starter p Rating A B h w d Dia A B h w d Dia A B h w d Dia 8 12.25 10.25 1 1.63 9.63 10.16 0.25 21.00 14.50 19.50 13.00 10.16 0.50 21.00 14.50 19.50 13.00 10.16 0.50 16 12.25 10.25 1 [...]

6-6 Specifications and Product Data MN894 Mounting Dimensions Continued NEMA 1, 3R and 12 A Dia B w h d NEMA 1 Dimensions Amp Rt i Control Only Non-Combination Starter Combination Starter p Rating A B h w d Dia A B h w d Dia A B h w d Dia 8 14.00 12.00 1 1.00 1 1.00 1 1.35 0.28 24.00 16.00 21.88 1 1.00 1 1.35 0.31 24.00 16.00 21.88 1 1.00 1 1.35 0.[...]

Specifications and Product Data 6-7 MN894 Connection Diagrams MA Style 8, 16 and 30 AMP Combination and Non-Combination Starter and Control only 13 12 11 10 9 8 7 6 5 4 3 2 1 16 17 14 15 19 20 Close T o Run Start / Run Shunt Tri p Ramp End T ach Input MTR PWR CUR MON CT Input   OL 97 98   R X 1 15VAC AB F3 A F1 A F2 B B 13 14 12 11 OL 9[...]

Section 1 General Information 6-8 Specifications and Product Data MN894 Connection Diagrams Continued MB Style 8, 16 and 30 AMP Combination and Non-Combination Starter and Control only 13 12 11 10 9 8 7 6 5 4 3 2 1 16 17 14 15 19 20 Close T o Run Start / Run Shunt Tri p Ramp End T ach Input MTR PWR CUR MON CT Input  OL 97 98   R X 1 15VAC [...]

Section 1 General Information Specifications and Product Data 6-9 MN894 Connection Diagrams Continued MA Style 55 and 80 AMP NEMA 1 and Panels Combination and Non-Combination Starter and Control only 13 12 11 10 9 8 7 6 5 4 3 2 1 16 17 14 15 L1 L2 L3 GL1 GL2 GL3 GT1 GT2 GT3 T1 T2 T3 19 20 Close T o Run Start / Run Shunt Tri p Ramp End T ach Input M[...]

Section 1 General Information 6-10 Specifications and Product Data MN894 Connection Diagrams Continued MB Style 55 and 80 AMP NEMA 1 and Panels Combination and Non-Combination Starter and Control only 13 12 11 10 9 8 7 6 5 4 3 2 1 16 17 14 15 L1 L2 L3 GL1 GL2 GL3 GT1 GT2 GT3 T1 T2 T3 19 20 Close T o Run Start / Run Shunt Tri p Ramp End T ach Input [...]

Section 1 General Information Specifications and Product Data 6-1 1 MN894 Connection Diagrams Continued NEMA 1 & Panel Mounted Size 160 − 840 AMP Control Only 13 12 11 10 9 8 7 6 5 4 3 2 1 16 17 14 15 L1 L2 L3 GL1 GL2 GL3 GT1 GT2 GT3 T1 T2 T3 19 20 Close T o Run Start / Run Shunt Tri p Ramp End T ach Input MTR PWR CUR MON CT Input   [...]

Section 1 General Information 6-12 Specifications and Product Data MN894 Connection Diagrams Continued NEMA 1 & Panel Mounted Size 160 − 840 AMP Combination & Noncombination 13 12 11 10 9 8 7 6 5 4 3 2 1 L1 L2 L3 GL1 GL2 GL3 GT1 GT2 GT3 T1 T2 T3 19 20 Close T o Run Start / Run Shunt Tri p Ramp End T ach Input MTR PWR CUR MON CT Input  [...]

Section 1 General Information Specifications and Product Data 6-13 MN894 Connection Diagrams Continued NEMA 12 Size 160 − 840 AMP Combination & Noncombination Bypass 13 12 11 10 9 8 7 6 5 4 3 2 1 L1 L2 L3 GL1 GL2 GL3 GT1 GT2 GT3 T1 T2 T3 19 20 Close T o Run Start / Run Shunt Tri p Ramp End T ach Input MTR PWR CUR MON CT Input   R1 12 8 [...]

Section 1 General Information 6-14 Specifications and Product Data MN894[...]

Appendix A Reference Information Appendix A-1 MN894 Glossary BP Bypass Contactor CC Current Calibrator CCW Counterclockwise CL Current Limit CM Current Monitor CS & RS Resistor & Capacitor series circuit CUR MON Current Monitor CT Current T ransformer CW Clockwise FLA Full Load Amperes (Motor) LCM Logic Control Module LED Light Emitting Dio[...]

A-2 Appendix MN894 Size 055 M t FLA S1 Switch Position and Setting Motor FLA 12345678 24 − 2 6 01000111 27 − 3 0 10100111 31 − 3 4 00010111 35 − 3 8 01010111 39 − 4 2 00110111 43 − 4 5 01110111 46 − 4 8 11110111 49 − 5 1 00001111 52 − 5 5 10001111 Size 080 M t FLA S1 Switch Position and Setting Motor FLA 12345678 44 − 4 6 011101[...]

Appendix A-3 MN894 Quick Reference Chart Ramp Up Time (3-50 sec.) T achometer: Time to reach full speed. V oltage: Time to reach full speed. T orque Up (40-75% voltage) T achometer: Disabled. V oltage: Initial starting voltage for ramp. Current Limit (75-400% FLA) T achometer or voltage: Enabled by S2-5=ON. Maximum current during ramp up and ramp d[...]

A-4 Appendix MN894 Overload Relay Adjustment A class 30 electonic relay is provided with combination and non-combination starters. Read the FLA from the motor nameplate and set the overload dial to the correct ampere setting. Refer to the table that represents the starter size. Caution: Select the table that matches you starter size only . Do not u[...]

Appendix B Circuit Breaker Adjustments Adjustments B-1 MN894 Circuit Breaker Adjustment (Inrush current estimation) Mechanical adjustment of the trip setting may be necessary if the circuit breaker is replaced. The first step of this adjustment procedure is to determine the motor inrush current (in amperes). Inrush current is also called “Locked [...]

Section 1 General Information B-2 Adjustments MN894 Example: 3 phase Motor rated at 50 HP at 460V AC, 65 amps (continuous), code letter J. I Inrush + ǒ 7.5 x 50 x 577 460 Ǔ + 470A mperes Circuit Breaker Adjustment The calculated Inrush Amps value is used to initially set the breaker . If the circuit breaker trips during use, the trip level is inc[...]

Baldor District Offices[...]

BALDOR ELECTRIC COMP ANY P .O. Box 2400 Ft. Smith, AR 7290 1 − 2400 (479) 646 − 471 1 Fax (479) 648 − 5792 © Baldor Electric Company MN894 Printed in USA 9/06[...]