Installation and

maintenance manual

Softstarters
PS S 18/30…300/515

1SFC 388002-en ed.4 2003-04-08

PS S18/30-500…44/76-500 PS S50/85-500…72/124-500
PS S18/30-690…72/124-690

PS S85/147-500…142/245-500 PS S175/300-500…300/515-500
PS S85/147-690…142/245-690 PS S175/300-690…300/515-690
Contents

1. Softstarter marking 3

2. Mounting 4
2.1 Drilling plan 4
2.2 Minimum distance to wall/front 4

3. Connection 5
3.1 Main circuit Bar 1L1, 3L2, 5L3 5
as well as 2T1, 4T2 och 6T3
3.2 Control voltage and control circuit 6

4. Setting 9
4.1 Start ramp 9
4.2 Stop ramp 9
4.3 Initial voltage (UINI) / Current limit 9
function (ILIM)
4.4 Switch for selection of connection 10
type, Line/Delta switch S1
4.5 Basic settings for different 11
applications

5. Maintenance 12

6. Trouble shooting 12

7. Technical data 15
7.1 Dimensions 15
7.2 Circuit diagram 16

WARNING
More than one live circuit
- see diagram
Do not operate machine with the grounding wire disconnected

WARNING
The operation, installation and servicing of this product must
be carried out by a qualified electrician, following installation
standards and safety regulations. Check that you have the
correct softstarter unit in regards to net voltage, rated motor
data and type of connection.

2
 1. Softstarter marking

These softstarters fulfil the

! demands according to 89/336/EEC

and EN 60947-4-2 / IEC 947-4-2,
Equipment class A.

Terminal marking of
Supply voltage Us
control circuit

Softstarter Type

Status indication
Green
Green
Red
Red

Terminal marking of
main circuit

Order code 72: Ie = 72A

AC-53a : without
by-pass
8-1.6: 8*Ie in 1,6 sec
Technical data acc. 80-6: 80% in operation
to IEC 947-4-2 and 6 starts/h

Technical data
acc. to UL 508
Picture 1.1

Serial number

3
 2. Mounting

To have a suitable cooling, the softstarter has to be

mounted vertically, see picture 2.1.
The softstarter should not be mounted in a way that
the airways are blocked. Follow recommended
distances acc. to section 2.2.

!
All technical data for the softstarter are
valid for an ambient temperature of 40ºC.
For temperatures above of 40ºC, up to Picture 2.1
max. 60ºC, the rated current has to be
derated with 0,8% per ºC.

2.1 Drilling plan

K L M
PS S18/30-500...44/76-500 105 184 M6
PS S50/85-500...72/124-500
125 234 M6
PS S18/30-690...72/124-690
PS S85/147-500...142/245-500
158 320 M6
PS S85/147-690...142/245-690
Picture 2.2
PS S175/300-500…300/515-500
333 320 M6
PSS175/300-6900…300/515-690

2.2 Minimum distance to wall/front

The following distances give enough clearance for
airflow around the softstarter for suitable cooling.
Please note that the values are minimum distances.

Picture 2.3 Picture 2.4

Air gap Outer dimensions of the softstarter

A B C E F H
PS S18/30-500...44/76-500 20 10 100 120 200 163
PS S50/85-500...72/124-500
20 10 100 140 250 163
PS S18/30-690...72/124-690
PS S85/147-500...142/245-500
20 10 100 181 340 265
PS S85/147-690...142/245-690
PS S175/300-500…300/515-500
20 10 100 356 340 265
PS S175/300-690…300/515-690

4
 3. Connection

3.1 Main circuit, Terminal / Bar 1L1, 3L2, 5L3 as

well as 2T1, 4T2, 6T3 Picture 3.1
All softstarters, PS S 18/30 to PS S 300/515, can be
connected both ”In Line” (see picture 3.1) and ”Inside Alt 1 Alt 2
Delta” (see picture 3.2, alt. 1 and 2) with the motor.

!
Remember to set the Line/Delta
switch S1 in the right position.
See further on page 10

Picture 3.2

For mounting of a current Line side

!
transformer for the current limit
function, see further
instructions section 3.2.6
on page 8.

Connect the line side to terminals / bars 1L1,

3L2, 5L3 and motor side to terminals / bars 2T1,
4T2 and 6T3. The terminal marking is printed on
the softstarter front label.

! The softstarter unit is not

phase sequence sensitive Picture 3.3

Motor side

PS S18/30-500...44/76-500
ø 6,5 Pozidriv N° 2
2 x 2,5... 16 mm 2

M5 AWG 4...8 5,6

5,6
2 x 2,5... 10 mm2
10
2,3 Nm - 20 Ib.in

PS S50/85-500...72/124-500
PS S18/30-690...72/124-690
ø 6,5 2
1 x 6 ... 50 mm2
2 x 6 ... 25 mm
M8 AWG 1...8
13

1 x 6 ... 36 mm22
2 x 6 ... 16 mm
10
4 Nm - 35 lb.in

PS S85/147-500...142/245-500
PS S85/147-690...142/245-690

Max. 22mm
M8 Max. 24mm

Max. 8mm
9 Nm - 80 lb.in

PS S175/300-500...300/515-500
PS S175/300-690...300/515-690

Max. 30mm
M10 Max. 32mm

Max. 10mm
18 Nm - 160 lb.in

5
 3. Connection

3.2 Control voltage and control circuit

3.2.1 Supply voltage, terminals 1 and 2

Connect neutral and phase to terminal
1 and 2. See picture 3.4

! Check that you have the

correct supply voltage Us.

Picture 3.4

3.2.2 Earthing of the unit, terminal 3

Suitable cable: grey or black 1,5-2,5 mm2
AWG12…16

The cable should be as short as possible and shall

be connected to an earthing point close to the
softstarter. A suitable earthing point would be next to
the softstarter on the mounting plate. See picture 3.6.
The mounting plate should also be earthed.

This is not a protective earth,

it is a function earth.

!
Picture 3.5
The earthing cable should be
as short as possible and shall
be connected to an earthing
point close to the softstarter.

Picture 3.6

M3 3,5 x 0,6
2
0,14 ... 2,5 mm
1.............................12 AWG 12...22
2
0,14 ... 2,5 mm

0,5 Nm - 4,3 Ib.in

6
 3. Connection

3.2.3 Control circuit for Start and Stop, Terminals

4, 5 and 6
The softstarter has a built in holding circuit, which
enables an easy circuit. See picture 3.8

A conventional circuit with aux. relay is also possible.

See picture 3.9

Picture 3.7

Picture 3.8 Picture 3.9

3.2.4 Signal relay for fault. Terminals 7 and 8 :

Fault
The built in contact gives signal at fault
(normally open or normally closed contact).
Technical data: max 250V / 1,5A, AC-15.

3.2.5 Signal relay for indication of completed start

ramp. Terminals 9 and 10 : By-pass

The built in contact is closed when the start ramp is

completed, and opened when a stop signal is given
(closed only during continuous operation).

Picture 3.10

7
3. Connection

3.2.6 Connection of current transformer T2

(accessory), Terminal 11 and 12 T2
The function Current Limit requires a current trans-
former to be connected to terminals 11 and 12. The
current transformer is an accessory, which can be
purchased separately (see techn. catalogue)

Check that you have the

! correct current transformer

(correct ratio).
See table 3.1
Picture 3.11

Mounting T2
Mount the current transformer close to the softstarter,
see pictures 3.11 and 3.12.

Connection

The current transformer can be connected to a phase

of your choice. Picture 3.13 and 3.14 shows
alternative position when connected in phase L1.

Check in table 3.1 how many turns you need for the
primary side of the transformer. Connect the trans- Picture 3.12
former acc. to picture 3.12 for one turn, or acc. to
picture 3.11 for two turns.

Smallest cable size which can be used is 1,5mm²

AWG 16

A different current transformer from a local supplier

can also be used – technical data : min 1VA

Picture 3.13 Picture 3.14

Tab 3.1

For softstarter Ratio Turns Order code Connection

see picture
PS S 18/30 60/1 2 1SFA 89 9001 R1060 3.11
PS S 30/52 40/1 1 1SFA 89 9001 R1040 3.12
PS S 37/64 50/1 1 1SFA 89 9001 R1050 3.12
PS S 44/76 60/1 1 1SFA 89 9001 R1060 3.12
PS S 50/85 75/1 1 1SFA 89 9001 R1075 3.12
PS S 60/105 75/1 1 1SFA 89 9001 R1075 3.12
PS S 72/124 100/1 1 1SFA 89 9001 R1100 3.12
PS S 85/147 125/1 1 1SFA 89 9001 R1125 3.12
PS S 105/181 150/1 1 1SFA 89 9001 R1150 3.12
PS S 142/245 200/1 1 1SFA 89 9001 R1200 3.12
PS S 175/300 250/1 1 1SFA 89 9001 R1250 3.12
PS S 250/430 400/1 1 1SFA 89 9001 R1400 3.12
PS S300/515 400/1 1 1SFA 89 9001 R1400 3.12

8
 4. Setting

The softstarter has three rotating switches as well as

one 2-position switch. Basic settings for different
applications are listed in the tables on page 11.

Picture 4.1

4.1 Start ramp

Sets the time for how fast the voltage shall be
increased during start. Adjustable in 16 steps between
1 and 30 seconds. See picture 4.2.

Picture 4.2

4.2 Stop ramp

Sets the time for how fast the voltage shall be
decreased during stop. Adjustable in 16 steps
between 0 and 30 seconds. See picture 4.3.

Picture 4.3

4.3 Initial voltage (UINI) / Current limit function

(ILIM)
4.3.1 Initial voltage (UINI)
WHITE scale
Sets the starting voltage level for the start ramp, as
well as the end voltage of the stop ramp.
Adjustable in 5 steps between 30% and 70% of full
voltage.

4.3.2 Current limit function (ILIM)

A softstarter always reduces starting current.
The current limit function allows you to pre-set a
Picture 4.4
maximum starting current which will never be
exceeded.

BLUE scale
The same rotating switch as for initial voltage (UINI).
Sets the current limit, if a current transformer T2 is
connected to terminals 11 and 12.
Adjustable in 11 steps between 1,5 and 4 times the
current transformers ratio. When setting the
parameter (ILIM) on the blue scale, the initial voltage
(UINI) will always be a fixed value of 40%.

9
 4. Setting

4.4 Switch for selection of connection type, Line/ S1

Delta switch S1

The softstarter can be connected to the main circuit in

several different ways. ”In Line” with the motor (see
picture 4.6) or ”Inside Delta” with the motor (see
picture 4.7). Set this switch in the position
corresponding to the chosen connection type.

Picture 4.5

In Line with motor Inside Delta with motor

Alt 1 Alt 2

Picture 4.6 Picture 4.7

10
 4. Setting

4.5 Basic settings for different applications

4.5.1 Without current transformer T2 connected

Type of load Ramp time Ramp time Initial voltage

for start for stop UINI
(sec) (sec)
Bow thruster 10 0 30%
Centrifugal fan 10 0 30%
Centrifugal pump 10 20 30%
Piston compressor 10 0 30%
Lifting equipment 10 10 60%
Rotary converter 10 0 30%
Stirrer, Mixer 10 0 60%
Scraper 10 10 40%
Screw compressor 10 0 40%
Screw conveyor 10 10 40%
Unloaded motor 10 0 30%
Conveyor belt 10 10 40%
Heat pump 10 20 30%
Escalator 10 0 30%
Hydraulic pump 10 0 30%

4.5.2 With current transformer T2 connected

Tab 4.2

Type of load Ramp time Ramp time Initial voltage Current limit
for start for stop UINI ILIM (xle)
(sec) (sec) (Fixed value) (start)
Bow thruster 10 0 (40%) 2,5
Centrifugal fan 10 0 (40%) 3,5
Centrifugal pump 10 20 (40%) 3
Piston compressor 10 0 (40%) 3
Lifting equipment 10 10 (40%) 3,5
Rotary converter 10 0 (40%) 2,5
Stirrer, Mixer 10 0 (40%) 3,5
Scraper 10 10 (40%) 3,5
Screw compressor 10 0 (40%) 3,5
Screw conveyor 10 10 (40%) 3,5
Unloaded motor 10 0 (40%) 2,5
Conveyor belt 10 10 (40%) 3,5
Heat pump 10 20 (40%) 3
Escalator 10 0 (40%) 3
Hydraulic pump 10 0 (40%) 2,5

11
5. Maintenance
Check that the cooling airways of the softstarter
unit are free from dirt and dust. Check also that
the fan is working and rotating freely. The fan can
be checked at voltage free state, so that rotation
of blades is possible without resistance. They shall
not rotate heavily.

6. Trouble shooting
Motor humming / starts without given start signal
Status / Indication Check

•One or several thyristors can be shorted / broken

•Is the by-pass contactor stuck in closed opsition

Motor does not start

Status / Indication Check

•Is supply voltage connected to terminal 1 and 2?

•Is start signal given (closed circuit between terminals 5 and 6)?
•Is the circuit closed between terminals 6 and 4?
•Verify that start and stop signals are not given at the same time.
•Is the Line/Delta switch S1 in the right position?

•Is the correct frequency connected?

•Is the Line/Delta switch S1 in the right position?
•Is the Inside Delta connection done in the right way?
•Is main voltage connected to terminals 1L1, 3L2 and 5L3?
•Has the thermal overload relay tripped and opened the main
contactor?
•Check all connections
RESET:Give stop signal or disconnect voltage from terminals 1 and 2.

•Is the Line/Delta switch S1 in the right position?

•Is there an overtemperature in the softstarter? The same fault will
occur again after RESET, if the softstarter is still too warm. Check
that the fans are working in a proper way. Also check that cooling
airways are free from dirt and dust.
•If it is not possible to RESET the fault, then the processor is faulty.
•If fault occurs approx. 60-70 sec after start signal is given, then the
softstarter tries to ramp up but is not succeeding. Check all
connections. If current transformer is used: Is the current limit
settings high enough? Is the ratio of the current transformer right?
•If inside delta connection is used: Is the motor circuit closed and
are the connections carried out correctly.
RESET:Give stop signal or disconnect voltage from terminals 1 and 2.

12
6. Trouble shooting
Motor stops during start / continuous operation
Status / Indication Check

•Phase loss in the main circuit? Has the thermal overload relay
tripped and opened the main contactor? Has a fuse blown?
•Check all connections.
RESET:Give stop signal or disconnect voltage from terminals 1 and 2.

•Is there an overtemperature in the softstarter? The same fault will

occur again after RESET, if the softstarter is still too warm. Check
that the fans are working in a proper way. Also check that cooling
airways are free from dirt and dust.
•If it is not possible to RESET the fault, then the processor is faulty.
•If fault occurs approx. 60-70 sec after start signal is given, then
the softstarter is trying to ramp up but is not succeeding. Check
all connections.
•Phase loss between softstarter and motor? Check connections.
•One or more thyristor pairs are shorted / broken.
•Is the Line/Delta switch S1 in position ”In Line”, even though the
softstarter is connected ”Inside Delta”?
•If inside delta connectionis used: Is the motor circuit closed and
are the connections carried out correctly?
RESET:Give stop signal or disconnect voltage from terminals 1 and 2.

Fault at stop

•Phase loss main circuit? Has main contactor opened before stop
ramp has finished? Has a fuse blow?
•Is the by-pass contactor stuck in closed position
RESET: Give both start and stop signal or disconnect voltage from
terminals 1 and 2.

•Phase loss on load side? Check connections

RESET: First give start signal, then stop signal or disconnect voltage
from terminals 1 and 2.

13
6. Trouble shooting

Bad motor sound during start and operation

Status / Indication Check

•Is the motor too small?

•Is the Line/Delta switch S1 in the right position?
•Is the ”Inside Delta” connection done in the right way?
•Phase loss on line or load side? Check connections.

Bad motor sound during stop or stop ramp finish too early
Status / Indication Check

•Try different ramp time for stop (some adjustment can be

necessary for best result).
•Phase loss on line or load side? Check connections.
•Is the Line/Delta switch S1 in the right position?

Soft stop can only be used for applications

! were the motor stops too quickly with direct

stop. See further regarding settings in tables
on page 11.

Current limit function not adjustable (only valid for start)

Status / Indication Check

•Is a current transformer connected to terminals 11 and 12?

•Is the rotating switch for parameter ILIM turned to the blue scale?
•Is the correct current transformer used?
•Is the current transformer correctly connected?
•Is the motor suitable for the softstarter (too small motor)?

Other combination of LED:s than above:

•View LED:s straight from the front, othervise the neighbouring

LED seems to be lit.
•The printed circuitboard in the softstarter is faulty

!
In some cases the actual ramp time can differ
from the set value. If motor starts/stops softly,
then everything is OK.

14
 7. Technical data
7.1 Dimensions

PS S18/30-500…44/76-500 PS S50/85-500…72/124-500
PS S18/30-690...72/124-690

163

163
10

10
120 140

105 7,5 125 7,5

6,5(4x)
6,5(4x)
200
184

250
234
2

9
PS S85/147-500…142/245-500 PS S175/300-500…300/515-500
PS S85/147-690…142/245-690 PS S175/300-690…300/515-690
265

265
1.5
1,5

181 3,1

158
356 3.1
333
320

340

320

340

7(4x)
7(4x)
10
10

15
 7. Technical data

7.2 Circuit diagram

16