Eaton Cutler-Hammer Easy-Start ES Series Instruction Manual
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Eaton Cutler-Hammer Easy-Start ES Series Instruction Manual

Eaton Cutler-Hammer Easy-Start ES Series Instruction Manual

Solid state reduced voltage motor starter
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Instruction Manual
For Model Easy-Start ES Solid State Reduced Voltage Motor Starter
Cutler-Hammer

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Summary of Contents for Eaton Cutler-Hammer Easy-Start ES Series

  • Page 1 Instruction Manual For Model Easy-Start ES Solid State Reduced Voltage Motor Starter Cutler-Hammer...
  • Page 2 This product discussed in this literature is subject to terms and conditions outlined in appropriate Cutler-Hammer selling policies. The sole source governing the rights and remedies of any purchaser of this equipment is the relevant Cutler- Hammer selling policy. NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OR WAR- RANTIES ARISING FROM COURSE OF DEALING OR USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS AND...

  • Page 3: Table Of Contents

    Table of Contents Page Safety ..........S-1 The Meaning of Safety Statements .
  • Page 4 List of Illustrations Figure Description Page Block Diagram ..........2-20 System Schematic (Hevi-Duty Co.
  • Page 5 List of Illustrations Figure Description Page 2-18 Dimension and Installation NEMA-1 Regular Enclosure ES180-_NR, ES260-_NR, ES560-_NR ......2-37 2-19 Dimension and Installation NEMA-1 Large Enclosure, ES180-_NL, ES260-_NL, ES560-_NL .
  • Page 6 List of Tables Table Description Page Starts-Per-Hour ES045 ........2-10 Starts-Per-Hour ES070 .

  • Page 7: Safety

    Safety Cutler-Hammer has made every effort to provide you with the safest motor starters on the market but wishes to point out how to safely operate and troubleshoot your starter. After you review this section you will: ¥ Understand the meaning of the Safety Alert Symbol, Danger, Warning, Caution, and Notice safety statements.

  • Page 8: The Meaning Of Safety Statements

    Safety The Meaning of Safety Statements Easy-Start ES Safety Statements You will find various types of safety information The following safety statements relate to the on the following pages and on the labels installation, operation and troubleshooting of attached to the equipment. This section explains Cutler-Hammer Motor Starters.
  • Page 9 Safety Caution Danger Do not connect any additional control circuits, Isolated heat sink frames must be grounded with such as lamps and relays, across K2 coil (TB1-4 the grounding lugs provided. and TB1-12 on the logic board). All electrical codes must be followed which may require additional conduit and enclosure grounding.

  • Page 10: Introduction

    SECTION 1 Introduction About This Manual Congratulations! You have purchased one of the most sophisticated Solid State Reduced Voltage Starters in the industry. Models are available from 45 to 950 Amp applications. This manual provides a check list, drawings, specifications and pre-installation information, and the various available options to help you select the right equipment and properly install your Easy- Start ES Reduced Voltage Starter.
  • Page 11 About This Manual SECTION 1 Note that throughout the manual, titles of sections and specific bold italics italics . Items in parameters are shown in are important. If you have any questions or comments, please feel free to contact us. We at Cutler-Hammer are proud to have you as a customer and can assure you that you will have many productive years from your new Easy-Start ES Solid State Reduced Voltage Starter.

  • Page 12: Installation

    SECTION 2 Installation About This Section This section of the Easy-Start ES Instruction manual provides pre- installation information, drawings and specifications to help you properly install your Easy-Start ES Solid State Reduced Voltage Starter. To ensure successful installation, thoroughly read and understand the material presented in this section before you attempt to install the Starter.

  • Page 13: Pre-Installation

    Pre-Installation This part of the Installation section of this Instruction Manual before you install your drive provides guidelines to consider ¥ Description. ¥ Easy-Start ES Model Designation. ¥ Application Considerations. ¥ Considerations for Field Wiring. Easy-Start ES Instruction Manual...
  • Page 14 Pre-Installation INSTALLATION Description A built in energy saving circuit reduces the motor voltage and current at light loads, and saves power. The Easy-Start ES solid state unit is a complete reduced voltage 3-phase AC motor starter with Block Diagram Description (Figure 2-1) motor protection.
  • Page 15 Pre-Installation INSTALLATION Description The amplifier also has a stability adjustment which can be used to handle difficult motor load applications. It is marked STAB and is factory Sensing the line voltage provides important set to approximately midpoint. information for diagnostics and motor protection. The features include the following: A digital trigger is used on the SCR gates.
  • Page 16 Pre-Installation INSTALLATION Model Designation E S 1 2 0 - 4 E L - - - - Options Easy-Start 120- Type Enclosure/Panel: Ampere Rating: ER Regular NEMA-12 NR Regular NEMA-1 EL Large NEMA-12 NL Large NEMA-1 EP Open Panel Isolated Heat Sink * NP Open Panel Non-Isolated Heat Sink Line Volts: EC Open Panel Isolated Heat Sink 14.0"...
  • Page 17 Pre-Installation INSTALLATION Application Considerations Ambient Temperature Easy-Start ES is rated for 40¡C (104¡F) ambient Installation temperature. For above 40¡C derate by 5% for every 5¡C rise over 40¡C up to 50¡C (122¡F) 1. Ventilated NEMA 1 enclosures should be max. mounted so that enough clearance is available for air to enter and exit the EXAMPLE: ES180-4N is rated 180 Amps @...
  • Page 18 Pre-Installation INSTALLATION Application Considerations The percent off-time is therefore 12/60 X 100 = 20%. We next look at the starts per hour Table Frequent Starting/Stopping 2-2 for a 70 amp starter (ES070). We can see that the model ES070 can do only 40 starts per The number of starts and stops depends upon hour at 350 amps with a start time of 5 seconds many factors.
  • Page 19 Pre-Installation INSTALLATION Application Considerations Going directly from low speed to high speed or high speed to low speed would not give smooth transition and may cause a current surge. It is NEMA Design C and D Motors, Wound recommended that enough time delay be built Rotor Motors into the 2-speed 2-winding starter circuit (by others) to prevent changing speeds without...
  • Page 20 Pre-Installation INSTALLATION Application Considerations amps. From Figure 4-1, Model ES180 will supply 900 amps but only for 40 seconds; therefore a larger unit such as ES260 is required. Using Starting Time Figure 4-1, we see that ES260 will handle 900 amps for almost 200 seconds.
  • Page 21 Pre-Installation INSTALLATION Application Considerations Model Number ES120 Starts-Per-Hour Model Number ES180 Starts-Per-Hour Curr. Starting Start Percent Off-Time Curr. Starting Start Percent Off-Time Limit Current Time Limit Current Time AC Amps Sec. AC Amps Sec. 250% 250% 300% 300% 400% 400% 500% 500% Starts-Per-Hour ES120...
  • Page 22 Pre-Installation INSTALLATION Application Considerations Model Number ES250 Starts-Per-Hour Model Number ES260 Starts-Per-Hour Curr. Starting Start Percent Off-Time Curr. Starting Start Percent Off-Time Limit Current Time Limit Current Time AC Amps Sec. AC Amps Sec. 250% 250% 300% 300% 400% 1000 400% 500% 1250...
  • Page 23 Pre-Installation INSTALLATION Application Considerations Model Number ES360 Starts-Per-Hour Model Number ES500 Starts-Per-Hour Curr. Starting Start Percent Off-Time Curr. Starting Start Percent Off-Time Limit Current Time Limit Current Time AC Amps Sec. AC Amps Sec. 250% 250% 1250 300% 1080 300% 1500 400% 1440...
  • Page 24 Pre-Installation INSTALLATION Application Considerations Model Number ES560 Starts-Per-Hour Model Number ES750 Starts-Per-Hour Curr. Starting Start Percent Off-Time Curr. Starting Start Percent Off-Time Limit Current Time Limit Current Time AC Amps Sec. AC Amps Sec. 250% 1400 250% 1875 300% 1680 300% 2250 400%...
  • Page 25 Pre-Installation INSTALLATION Application Considerations Model Number ES950 Starts-Per-Hour Curr. Starting Start Percent Off-Time Limit Current Time AC Amps Sec. 250% 2375 300% 2850 400% 3800 500% 4750 Starts-Per-Hour ES950 Table 2-11 Easy-Start ES Instruction Manual 2-15...
  • Page 26 Pre-Installation INSTALLATION Considerations For Field After a trip, the Easy-Start ES must be reset by momentarily opening the 120 VAC on the logic Wiring board transformer T2. This is done by using a normally closed RESET pushbutton between TB1 3 and TB1-17 on the logic board. Should The Easy-Start ES requires the following basic incoming power to the Easy-Start ES be lost for a electrical connections: (Refer to Section 2 for...
  • Page 27 Pre-Installation INSTALLATION Considerations For Field The primary to FU-1 is factory connected to H1. One secondary lead is factory connected to X1. Wiring The X1 and H1 connections remain the same for all line voltages. Hevi-Duty Company - Multi Volt Wiring Practices Transformer Connections Care should be taken to see that all...
  • Page 28 Pre-Installation INSTALLATION Considerations For Field Wiring Cutler-Hammer Transformer Connections The fan CPT is factory connected as follows: Voltage Rating Easy-Start ES Used For Voltage Rating Transformer Connections 208/230/460 460V 380/415 380V If the incoming line voltage is different than the factory connected rated voltage shown in previous paragraph, reconnect the multi-voltage transformer primary and secondary as follows for...

  • Page 29: Drawings

    Drawings This part of the Installation section of this Instruction Manual presents the following series of drawings: ¥ Overload Characteristics. ¥ Control Connection and Schematic Diagrams. ¥ Outline dimensions and options for mounting each chassis. Easy-Start ES Instruction Manual 2-19...

  • Page 30: Block Diagram

    Drawings INSTALLATION Easy ES-001 Block Diagram Figure 2-1 Easy-Start ES Instruction Manual 2-20...

  • Page 31: System Schematic

    Drawings INSTALLATION System Schematic (Hevi-Duty Co. Multi Volt Transformer Connections) Figure 2-2 Easy-Start ES Instruction Manual 2-21...

  • Page 32: System Schematic (Cutler-Hammer Transformer Connections)

    Drawings INSTALLATION System Schematic (Cutler-Hammer Transformer Connections) Figure 2-3 Easy-Start ES Instruction Manual 2-22...

  • Page 33: Logic Board Terminal Block Tb1 Functions

    Drawings INSTALLATION Logic Board Terminal Block TB1 Functions Figure 2-4 Easy-Start ES Instruction Manual 2-23...

  • Page 34: Derate Curve For Altitude

    Drawings INSTALLATION Conversion factor—multiply altitude in feet by 0.3048 to obtain altitude in meters 1500 2500 3500 Altitude (Meters) Easy ES-005 Derate Curve for Altitude Figure 2-5 Easy-Start ES Instruction Manual 2-24...

  • Page 35: Momentary Contact Start/Stop Pushbuttons

    Drawings INSTALLATION Momentary Contact Start/Stop Pushbuttons Figure 2-6 Easy-Start ES Instruction Manual 2-25...

  • Page 36: Hand-Off-Auto Selector Switch

    Drawings INSTALLATION Hand-Off-Auto Selector Switch Figure 2-7 Easy-Start ES Instruction Manual 2-26...

  • Page 37: Start-Stop Pushbuttons With Hand-Off-Auto Selector Switch

    Drawings INSTALLATION Start-Stop Pushbuttons With Hand-Off-Auto Selector Switch Figure 2-8 Easy-Start ES Instruction Manual 2-27...

  • Page 38: Power Connections With Options (Hevi-Duty Co. Multi Volt Transformer)

    Drawings INSTALLATION Power Connections with Options (Hevi-Duty Co. Multi Volt Transformer) Figure 2-9 Easy-Start ES Instruction Manual 2-28...

  • Page 39: Power Connections With Options (Cutler-Hammer Transformer)

    Drawings INSTALLATION Power Connections with Options (Cutler-Hammer Transformer) Figure 2-10 Easy-Start ES Instruction Manual 2-29...

  • Page 40: Dimension And Installation Open Panel Es045-_Ep, Es070-_Ep

    Drawings INSTALLATION Dimension and Installation Open Panel ES045-_EP, ES070-_EP, ES120-_EP Figure 2-11 Easy-Start ES Instruction Manual 2-30...

  • Page 41: Dimension And Installation Open Panel Slim Line Motor Control Center

    Drawings INSTALLATION NOTES 1. PANEL MATERIAL: 14 GA (.074) STEEL FIELD WIRING LUGS WEIGHT FINISH: ASA 61 LIGHT GRAY WIRE GAUGE RANGE MODEL 2. PANEL SHOULD BE MOUNTED IN A VERTICAL LINE / LOAD LUGS GROUND LUGS POSITION TO PROVIDE PROPER COOLING. ES070-_EC AWG 14-1 0 AWG 14-2...

  • Page 42: Dimension And Installation Nema-12 Regular Enclosure Es045-_Er, Es070-_Er

    Drawings INSTALLATION Dimension and Installation NEMA-12 Regular Enclosure ES045-_ER, ES070-_ER Figure 2-13 Easy-Start ES Instruction Manual 2-32...

  • Page 43: Dimension And Installation Nema-12 Large Enclosure Es045-_El, Es070-_El, Es120-_El

    Drawings INSTALLATION Dimension and Installation NEMA-12 Large Enclosure ES045-_EL, ES070-_EL, ES120-_EL Figure 2-14 Easy-Start ES Instruction Manual 2-33...

  • Page 44: Dimension And Installation Open Panel Es180-_Np, Es260-_Np, Es560-_Np, Es250-_Ep, Es360-_Ep, Es500-_Ep

    Drawings INSTALLATION Dimension and Installation Open Panel ES180-_NP, ES260-_NP, ES560-_NP, ES250-_EP, ES360-_EP, ES500-_EP Figure 2-15 Easy-Start ES Instruction Manual 2-34...

  • Page 45: Dimension And Installation Open Panel Slim Line Motor Control Center Es120-_Ec

    Drawings INSTALLATION NOTES 1. EACH INCOMING LINE CABLE MUST PASS FIELD WIRING LUGS WEIGHT THRU THE CORRESPONDING CURRENT WIRE GAUGE RANGE MODEL TRANSFORMER. LINE / LUGS GROUND LUGS 2. PANEL MATERIAL: 14 GA (.074) STEEL ES120-_EC AWG #6-250MCM AWG 14-2 FINISH: ASA 61 LIGHT GRAY 3.
  • Page 46 Drawings INSTALLATION Easy ES-017 Dimension and Installation Open Panel Slim Line Motor Control Center ES180-_NC, ES250-_NC Figure 2-17 Easy-Start ES Instruction Manual 2-36...
  • Page 47 Drawings INSTALLATION Easy ES-018 Dimension and Installation NEMA-1 Regular Enclosure ES180-_NR, ES260-_NR, ES560-_NR Figure 2-18 Easy-Start ES Instruction Manual 2-37...
  • Page 48 Drawings INSTALLATION Dimension and Installation NEMA-1 Large Enclosure ES180-_NL, ES260-_NL, ES560-_NL Figure 2-19 Easy-Start ES Instruction Manual 2-38...
  • Page 49 Drawings INSTALLATION Easy ES-020 Dimension and Installation Open Panel ES750-_NP Figure 2-20 Easy-Start ES Instruction Manual 2-39...
  • Page 50 Drawings INSTALLATION Dimension and Installation NEMA-1 Large Enclosure ES750-_NL Figure 2-21 Easy-Start ES Instruction Manual 2-40...
  • Page 51 Drawings INSTALLATION Dimension and Installation NEMA-12 Large Enclosure ES250, ES360-_EL Figure 2-22 Easy-Start ES Instruction Manual 2-41...
  • Page 52 Drawings INSTALLATION Dimension and Installation NEMA-12 Large Enclosure ES500-_EL Figure 2-23 Easy-Start ES Instruction Manual 2-42...
  • Page 53 Drawings INSTALLATION Dimension and Installation NEMA-1 ES950-_NL Figure 2-24 Easy-Start ES Instruction Manual 2-43...
  • Page 54 Drawings INSTALLATION Dimension and Installation Open Panel ES950-_NP Figure 2-25 Easy-Start ES Instruction Manual 2-44...

  • Page 55: Specifications

    Specifications This part of the Installation section of this Instruction Manual presents the following specifications: ¥ General Specifications. Easy-Start ES Instruction Manual 2-45...
  • Page 56 Specifications INSTALLATION EASY-START ES SPECIFICATIONS: Current Ratings: Isolated Sink Non-Isolated Sink Suitable for NEMA-12 Suitable for NEMA-1 45 Amps 180 Amps AC Supply Voltage: Three voltage combinations for each current rating: 208/230/460 +10% - 15% 50/60 Hz 3-PH 380/415 +10% - 15% 50/60 Hz 3-PH 460/500/575 +10% - 15%...
  • Page 57 Specifications INSTALLATION EASY-START ES SPECIFICATIONS: Starting Continuous 3-phase sensing, adjustable from 200 to 500%. Current Limit: Energy Saving: The Easy-Start ES senses the motor load and slip speed and adjusts the motor voltage to conserve power whenever the motor is lightly loaded.

  • Page 58: Operation

    SECTION 3 Operation About This Section This section of the Instruction Manual provides information about the operation of the Easy-Start ES solid state reduced voltage motor starter. After you review this section you will understand: ¥ Operation of the Easy-Start ES Motor Starter. ¥...

  • Page 59: Adjustments

    Operation SECTION 3 Operation logic board . If a relay is used, it should have dry contacts. If this connection is not made, DS2 reverts to Ò000Ó setting, and therefore There are primarily two basic modes of operation. we use only the DS1 settings and the 1st 1.

  • Page 60: Dip Switch Settings

    Operation SECTION 3 DIP Switch Settings POSITIONS 0.282 0.247 0.223 0.201 0.179 0.164 0.153 0.142 0.364 0.321 0.291 0.263 0.234 0.215 0.202 0.187 0.432 0.382 0.348 0.315 0.282 0.260 0.243 0.227 0.501 0.445 0.407 0.369 0.331 0.306 0.287 0.268 0.544 0.485 0.444 0.404...

  • Page 61: Dip Switch Ampere Settings Es045

    Operation SECTION 3 DIP Switch Settings For complete DIP switch calibration AC current tables of all Models, see the following tables (Tables 3-2 thru 3-12). POSITIONS 12.7 11.1 10.1 16.4 14.4 13.1 11.8 10.5 19.4 17.2 15.6 14.2 12.7 11.7 10.9 10.2 22.5...

  • Page 62: Dip Switch Ampere Settings Es070

    Operation SECTION 3 DIP Switch Settings POSITIONS 19.7 17.3 15.6 14.1 12.5 11.5 10.7 25.5 22.4 20.4 18.4 16.4 15.1 14.1 13.1 30.2 26.8 24.3 22.0 19.7 18.2 17.0 15.9 35.1 31.2 28.5 25.8 23.2 21.4 20.1 18.8 38.1 34.0 31.1 28.3 25.4...

  • Page 63: Dip Switch Ampere Settings Es180

    Operation SECTION 3 DIP Switch Settings POSITIONS 50.8 44.5 40.2 36.2 32.1 29.5 27.6 25.6 65.5 57.7 52.4 47.3 42.1 38.8 36.3 33.7 77.8 68.8 62.6 56.7 50.7 46.7 43.8 40.8 90.2 80.2 73.2 66.5 59.6 55.1 51.7 48.2 97.9 87.3 79.9 72.7...

  • Page 64: Dip Switch Ampere Settings Es260

    Operation SECTION 3 DIP Switch Settings POSITIONS 73.3 64.2 58.1 52.3 46.4 42.6 39.8 37.0 94.6 83.4 75.6 68.3 60.9 56.0 52.4 48.7 112.3 99.4 90.4 81.9 73.2 67.5 63.2 59.0 130.3 115.8 105.8 96.0 86.1 79.6 74.6 69.7 141.4 126.2 115.4 104.9...

  • Page 65: Dip Switch Ampere Settings Es500

    Operation SECTION 3 DIP Switch Settings POSITIONS 141.0 123.5 111.7 100.5 89.3 81.9 76.6 71.1 182.0 160.3 145.4 131.4 117.0 107.7 100.8 93.7 216.0 191.2 173.9 157.5 140.8 129.8 121.6 113.4 250.5 222.7 203.4 184.6 165.6 153.1 143.5 134.0 272.0 242.6 222.0 201.8...

  • Page 66: Dip Switch Ampere Settings Es750

    Operation SECTION 3 DIP Switch Settings POSITIONS 211.5 185.3 167.5 150.8 133.9 122.9 114.8 106.6 273.0 240.5 218.1 197.1 175.5 161.6 151.2 140.6 324.0 286.7 260.8 236.2 211.2 194.7 182.4 170.1 375.8 334.0 305.1 276.9 248.4 229.6 215.3 201.0 408.0 363.9 332.9 302.7...

  • Page 67: Voltage Plugs And Jumper Positions

    Operation SECTION 3 DIP Switch Settings The plugs are stamped with voltage ratings according to Table 3-13; and upon initial inspection. 2. DIP Switch 3 (DS3) Notice - A voltage plug selected from Table DS3-1 Set to OPEN position for voltage 3-13, must be installed into the socket (J5) on ramp mode.
  • Page 68 Operation SECTION 3 DIP Switch Settings This adjustment should be set in conjunction with the ÒTimeÓ adjustment. With the ÒTimeÓ adjustment set to mid-range, and the ÒInitial Time - The ramp time is adjustable from 1 to StepÓ set to minimum (CCW), start the motor 40 seconds.
  • Page 69 Operation SECTION 3 DIP Switch Settings The Easy-Start ES automatically adjusts the motor voltage to the value necessary to maintain normal operation at the most Current Trip - The current trip is adjustable efficient energy usage. If the motor from 100 to 120% of the DIP switch current voltage is not as low as it was expected to setting.
  • Page 70 Operation SECTION 3 DIP Switch Settings PROCEDURE: Connect a voltmeter between any two phases at the load terminals. If the voltage remains The MIN VOLTS and MAX VOLTS constant, or, if it varies proportional to adjustments enable the Easy-Start ES to load changes, the starter is regulating and automatically follow the motor load and no adjustment is required.
  • Page 71 Operation SECTION 3 10000 8000 6000 5000 4000 3000 2000 ENCLOSURE AMBIENT TEMPERATURE 40° C 1000 CURRENT TRIP POT ENCLOSURE AMBIENT TEMPERATURE 25° C CURRENT TRIP POT 0.6 0.8 1 8 10 MULIPLES OF CURRENT SET BY DIP SWITCHES Easy ES-026 Over-Load Time-Current Characteristics Figure 3-1 Easy-Start ES Instruction Manual...

  • Page 72: Options

    SECTION 4 Options About This Section This section of your Easy-Start ES Instruction Manual identifies options which are available factory installed for enclosed models only. After reviewing this section you will understand: ¥ Easy Start ES options that are available. ¥...

  • Page 73: Available Options

    Options SECTION 4 Available Options Control Devices: Cat. No. Suffix Description All Easy-Start ES options are available as Auxiliary run relay 2 N.O. 2 factory installed for enclosed models only and N.C. contacts, unwired. must be ordered with Easy-Start ES. By Coil rating 110/120 VAC checking the nameplate or by visual inspection it Contact Rating 10 Amps AC...
  • Page 74 Options SECTION 4 Control Devices: Available Options Cat. No. Suffix Description Cutler-Hammer Transformer Connections 300VA control power Cat. No. Suffix Description transformer. Other details 150VA control power 500VA control transformer. transformer with 2 primary Other details same as T. fuses. Time delay relay, (type TR) Easy-Start ES models have multi-voltage ratings.
  • Page 75 Options SECTION 4 Available Options Circuit Breakers Available Plug-In Option Kits The circuit breakers offered with Easy-Start ES are listed in Tables 4-1 and 4-2. The interrupting Description Catalog rating and terminal sizes are listed in Table 4-3. Number Extended Start Time KITESE Caution Notice...

  • Page 76: Thermal-Magnetic Breaker

    Options SECTION 4 Available Options Circuit Breakers Option No. With Mag. Nominal HP Thermal Shunt Easy-Start Frame Breaker Trip Magnetic Trip ES Model Size Type Amps Adj. 230V 575V ES045(1) (1)--- ES045(1) (1)--- ES070(1) (1)--- ES070(1) (1)--- ES120 5X-10X ES120 5X-10X ES120 5X-10X...

  • Page 77: Magnetic Breaker

    Options SECTION 4 Available Options Circuit Breakers Option No. With Mag. Nominal HP Thermal Shunt Easy-Start Frame Breaker Trip Magnetic Trip ES Model Size Type Amps Adj. 230V 575V ES045(1) HMCP 3X-10X ES070(1) HMCP 3X-10X ES120 HMCP 3X-6X ES180(2) HMCP 2.5X-5X ES250(2) HMCP...

  • Page 78: Circuit Breaker Interrupting Rating And Terminal Sizes

    Options SECTION 4 Available Options Circuit Breakers Circuit UL489 Interrupting Capacity Rating Breaker Type Max Breaker Wire Range Amps Terminals 240V 480V 600V 100,000 65,000 25,000 #14 -1/0 100,000 65,000 25,000 #4 - 4/0 100,000 65,000 25,000 #4 - 350 MCM 100,000 65,000 25,000...
  • Page 79 Options SECTION 4 Available Options Notice - IQ Data Plus II Ampere Display Range: Special Functions Minimum: 2% of CT used with IQ Maximum: 500% of Easy-Start ES Maximum Cutler-Hammer ÒIQ Data Plus IIÓ Monitoring Ampere Rating Device, catalog suffix ÒQ8Ó, provides the following readings: If local codes or customer preference prohibit line voltage on the door, do not use this option.
  • Page 80 Options SECTION 4 The Extended Time-Current feature is Available Options accomplished by calibrating the starting current Special Function (Option Boards) with main DIP switch DS1, and after the motor has accelerated to full speed, (end of ramp-up) Special function option boards E, S and J plug by calibrating the Easy-Start ES for the normal into main logic board.
  • Page 81 Options SECTION 4 Available Options Special Functions: Option ÒJÓ Special Function The printed circuit board contains two functions: JAM and UNDERLOAD TRIP The third function, Extended Time-Current, is activated by connecting a wire between the There are four DIP switches mounted on the option board (TB37-1) and the main logic board Option J Board: (TB1-8).
  • Page 82 Options SECTION 4 There are 5 LED indicators on the Printed Circuit Available Options Board: Special Functions: Option ÒJÓ POWER ON GREEN Ò120 Volts AC is applied to the The board is factory set with both functions de- board.Ó activated. The table below gives instructions on how to activate the two functions: SHORTED SCR RED Jam Trip...
  • Page 83 Options SECTION 4 Available Options Whenever there are two or more plug-in option boards needed, one of the boards is plugged into Daughter Board the Mother Board (Main Logic board). The second and third boards, if necessary, are Option ÒDÓ plugged into the Daughter Board.

  • Page 84: Application Notes

    Options SECTION 4 down.Ó This cool-down period of time can be as Application Notes long as 1.5 minutes. Therefore, it is necessary to set the extended start time for 1.5 minutes longer Extended Start Time Option than the anticipated starting time of the motor. This permits the Inverse-Time Current Trip Circuit This option is used to extend the starting time.
  • Page 85 Options SECTION 4 Application Notes Some typical applications for this option are: - By-Pass Contactor control signal. The table below shows the DIP SW DS21 (Figure 4-3.) settings along with the user determined start - Sequential Starting of other motors, or time, cool down time, and the total time in process functions.
  • Page 86 Options SECTION 4 Notice Application Notes - When using the Extended Time- Current option, do not make a connection between TB1-2 and TB1-8 on the main logic Extended Time-Current Option board. This option would enable the Easy-Start ES to be Example-1: used on NEMA A, B, C, D, or any three-phase induction motor with locked rotor codes up to 8.0...
  • Page 87 Options SECTION 4 Application Notes This setting of DS1 would permit starting under full locked rotor conditions because Example-1 Continued: when utilizing the Extended Time-Current option, only DIP switch DS1 is in effect during How to Select Settings for DIP Switches DS1 and start.
  • Page 88 Options SECTION 4 Application Notes Example-2: This is an application where a motor may require starting current of less than 500%, but for a longer period of time. Below is a table showing trip time in seconds vs. percent current limit: points were taken from Figure 3-1 of the Instruction Manual.
  • Page 89 Options SECTION 4 Application Notes The input-output functions and relays are brought out to the seven terminal blocks on the printed Smooth-Stop Option circuit ÒSÓ option board: The Smooth-Stop option is available with the (See Figure 4-16 for component layout.) following variations: TB31-1, TB31-2 Input: Momentary N.O.
  • Page 90 Options SECTION 4 Smooth-Stop Option When Used With ÒBÓ Application Notes Option (HOA Switch) Smooth-Stop Function 1.0 Operating with HOA switch in ÒHÓ position. DS31-1 Open Ò0Ó Closed Ò1Ó 1.1 Start motor by moving HOA switch from off to ÒHÓ position. End of Ramp-Up Relay 1.2 To stop motor using smooth-stop function, DS31-2 Open Ò0Ó...
  • Page 91 Options SECTION 4 Application Notes Also, the inverse time delay of the JAM trip can be adjusted; DS41-2 and DS41-3 are used to adjust the trip time delay. The trip time delay Smooth-Stop Option With Remote Maintained works on an inverse-time-trip mode; ie. the 2-Wire Contact greater the amount of overload, the faster the trip time.

  • Page 92: Drawings

    Drawings This part of the Options section of this Instruction Manual presents the following series of drawings: ¥ Current vs. time ratings. ¥ Option schematics. ¥ Trip point settings and trip time curves. ¥ Connection diagrams. ¥ Component layouts. ¥ Dimension of option boards. Easy-Start ES Instruction Manual 4-21...
  • Page 93 Drawings SECTION 4 NEMA-1 Current Vs. Time Ratings Figure 4-1 Easy-Start ES Instruction Manual 4-22...
  • Page 94 Drawings SECTION 4 NEMA-12 Current Vs. Time Ratings Figure 4-2 Easy-Start ES Instruction Manual 4-23...
  • Page 95 Drawings SECTION 4 Easy ES-029 Extended Start Time with By-Pass Contactor Figure 4-3 Easy-Start ES Instruction Manual 4-24...
  • Page 96 Drawings SECTION 4 Easy ES-030 Option E1 - Extended Start Time with Ramp-Up Door Light Figure 4-4 Easy-Start ES Instruction Manual 4-25...
  • Page 97 Drawings SECTION 4 Smooth-Stop with By-Pass Contactor Figure 4-5 Easy-Start ES Instruction Manual 4-26...
  • Page 98 Drawings SECTION 4 Smooth-Stop ÒS-1Ó Option Figure 4-6 Easy-Start ES Instruction Manual 4-27...
  • Page 99 Drawings SECTION 4 120 VAC 120 VAC FAULT TRIP RELAY TB1-17 K13A TB34-1 TB34-2 SMOOTH STOP BOARD TB31-1 TB31-2 K13C (USER SUPPLIED) REMOVE CONTACT START/SMOOTH-STOP OSL4-22A AUX RELAY RESET K13B NOTES: INDICATES TB1-3 ON MAIN LOGIC BOARD. 2. FOR SAFTEY REASONS. THE REMOTE STARTING CONTACT MUST BE OPENED BEFORE THE STARTER CAN BE RESET, AFTER A FAULT TRIP OCCURS.
  • Page 100 Drawings SECTION 4 JAM TRIP SET AT 150% DS41- DIP SWITCH CODE: “0” = OPEN “1” = CLOSED Multiples of Full Load Current Set by DIP Switches DS1 and DS2 Easy ES-034 Easy ES-035 Jam DIP Switch Trip Jam Trip Time Curves Point Settings Figure 4-9 Figure 4-8...
  • Page 101 Drawings SECTION 4 UNDERLOAD TRIP SET AT 50% DS43- DIP SWITCH CODE: “0” = OPEN “1” = CLOSED 0.2 0.3 0.4 0.5 1.0 Easy ES-037 Easy ES-036 Underload DIP Switch Underload Trip Time Curves Trip Point Settings Figure 4-11 Figure 4-10 Easy-Start ES Instruction Manual 4-30...
  • Page 102 Drawings SECTION 4 NOTES: 1. Option ÒJ1Ó Jam Light 2. Option ÒJ2Ó Underload Light Easy ES-038 Options J1, J2 Jam-Underload with Red Trip Lights Figure 4-12 Easy-Start ES Instruction Manual 4-31...
  • Page 103 Drawings SECTION 4 Easy ES-039 Daughter Board Connections Figure 4-13 Easy-Start ES Instruction Manual 4-32...
  • Page 104 Drawings SECTION 4 Easy ES-040 Printed Circuit Logic Board Component Layout Figure 4-14 Easy-Start ES Instruction Manual 4-33...
  • Page 105 Drawings SECTION 4 Easy ES-041 Option E - Printed Circuit Board Component Layout - Extended Start Time Figure 4-15 Easy-Start ES Instruction Manual 4-34...
  • Page 106 Drawings SECTION 4 Easy ES-042 Option S - Printed Circuit Board Component Layout - Smooth-Stop Figure 4-16 Easy-Start ES Instruction Manual 4-35...
  • Page 107 Drawings SECTION 4 Easy ES-043 Option J - Printed Circuit Board Component Layout - Jam-Underload Figure 4-17 Easy-Start ES Instruction Manual 4-36...
  • Page 108 Drawings SECTION 4 Easy ES-044 Option U - Printed Circuit Board Component Layout - Shorted SCR Detector Figure 4-18 Easy-Start ES Instruction Manual 4-37...
  • Page 109 Drawings SECTION 4 Easy ES-045 Option D - Printed Circuit Board Component Layout - Daughter Board Figure 4-19 Easy-Start ES Instruction Manual 4-38...
  • Page 110 Drawings SECTION 4 45, 70 & 120 AMPS 180 AMPS AND UP Easy ES-046 Dimensions for Logic Board, Daughter Board, Cover Board Assembly Figure 4-20 Easy-Start ES Instruction Manual 4-39...

  • Page 111: Troubleshooting

    SECTION 5 Troubleshooting This section of your Instruction Manual describes what to do if your drive indicates there is a problem. After you review this section, you will understand: ¥ Troubleshooting Guide. ¥ SCR Diagnostic Tests. ¥ Renewal Parts List. Caution Make sure you read, understand and follow all of the Safety Statements in the Safety section of...

  • Page 112: Troubleshooting Guide

    Troubleshooting SECTION 5 Troubleshooting Guide 5. Check the diagnostic LEDÕs. These are located on the main logic board and also A. Equipment Required on the front door on standard factory supplied enclosures: 1. Multimeter Simpson 260 or Equivalent. 2. Clamp-On Ammeter. Front Door Status Panel: Logic Board: End of Ramp...
  • Page 113 Troubleshooting SECTION 5 Troubleshooting Guide If the RUN LED comes on and the motor does not rotate; check the following: UNDER VOLT LED Measure the voltage at test point TP-6 on the logic board; it should be greater than 5 VDC. Check voltages at the line terminals.
  • Page 114 Troubleshooting SECTION 5 Troubleshooting Guide D. SCR Diagnostic Tests C. Problem: The motor rotates but does not Caution reach full speed. The RUN LED is on; but the END OF RAMP LED does not come on. All power should be turned OFF when making Check: ohmmeter measurements.

  • Page 115: Scr Diagnostics Tests

    Troubleshooting SECTION 5 SCR Diagnostic Tests 7. Measure the 6 digital trigger SCR gate pulse outputs using a multimeter on the DC voltage range. These points are E. Logic Board Digital Trigger Output: available on the connectors on the logic board.
  • Page 116 Troubleshooting SECTION 5 SCR Diagnostic Tests 7. Place the SCR against the side of the sink that has the locating pin and make sure it engages and is seated properly. Place the SCR Service Procedures: (Hockey-Puk other half of the heat sink against the SCR, Type) and holding the assembly together, tighten the nuts on the compression clamp equally...
  • Page 117 Troubleshooting SECTION 5 SCR Diagnostic Tests 500 kg. 1000 kg. (1,100 lb.) (2,200 lb.) 1/4" - 20 1/4" - 20 1-1/4 - turn 2-1/4 - turns S + 50.80 (S + 2") ”S“s Heatsink •Scr. Nut Holder Bolt 69.85 90.40 (2.75") (3.56") Washers (2)
  • Page 118 Troubleshooting SECTION 5 SCR Diagnostic Tests Step 3: Check to make sure that load bars and heat sinks are parallel; equal lengths to thread may not show through each nut Pre-Start because of bolt length tolerances. (If load bars/sinks are not parallel, redo Review Cutler-Hammer recommended Step 2).
  • Page 119 Troubleshooting SECTION 5 SCR Diagnostic Tests Easy ES-S048 Assembly Sink-Device Clamp Figure 5-3 Easy-Start ES Instruction Manual...
  • Page 120 Troubleshooting SECTION 5 SCR Diagnostic Tests Easy ES-S049 Stack Loading Figure 5-4 Easy-Start ES Instruction Manual 5-10...
  • Page 121 Troubleshooting SECTION 5 SCR Diagnostic Tests Notice - Use sparingly - Apply only a thin coat of compound. Changing Isolated Block SCRÕs: 5. Place the SCR block into position on the heat sink. Insert bolts and tighten them finger The following procedure can be used for tight, or use a wrench until all the bolts are changing isolated block SCRÕs.
  • Page 122 Troubleshooting SECTION 5 SCR Diagnostic Tests J4 PIN # FUNCTION LOCATION CONDITION TEST VOLTAGE +10VDC VR1-2 3-PH VOLTAGE ON 10V +.5 CURRENT SIG START 0 TO 4.5 VDC CURRENT SIG RUN/AT FULL LOAD 0.90V + .04 VDC TRIGGER VOLTS RUN FULL LOAD 6 TO 8 VDC RUN NO LOAD 3 TO 3.5 VDC...

  • Page 123: Renewal Parts List

    Troubleshooting SECTION 5 Renewal Parts List Here is a recommended spare parts list for a typical Easy-Start ES installation: The renewal parts are listed by an abbreviated One Logic Board. Easy-Start ES model number, showing the One Stack Assembly, or Two SCRÕs. current and voltage rating.
  • Page 124 Troubleshooting SECTION 5 Renewal Parts List Option Boards: Part Number: Extended Start Time: 7882C10G01 Jam/Underload: 7882C38G01 Fuses for Fan Control Power Transformers Smooth Stop/End of Ramp: 7882C15G01 (2 Required per Model): Shorted SCR Detector: 9032334A 208/230/460 and 380/415V Models up to 560 Amps: BUSS FNQ-2, 2 Amp The following is a list of MOVÕs and their ratings: 460/500/575V Models up to 560 Amps:...
  • Page 125 Troubleshooting SECTION 5 Renewal Parts List The following is a list of Easy-Start ES models, their SCR stack assemblies or back-to-back SCRÕs. The list indicates whether the DV/DT snubber or MOV components are included when the stack or back-to-back SCRÕs are ordered. MODEL NO.
  • Page 126 Troubleshooting SECTION 5 Renewal Parts List LOGIC SCR STACK C.T. DV/DT BOARD ASSY SNUBBER MODEL # 2D66806 9029- BACK-TO-BACK 9010- 0088- 9010- 0034- SCRÕs 9071A17 ES045-4E None 9029-194 457A 219B NONE NONE ES045-3E None 9029-194 457A 219B NONE NONE ES045-5E None 9029-194AA 457A...
  • Page 127 Troubleshooting SECTION 5 Renewal Parts List Voltage Plugs: Line Plug Voltage Voltage Part Number Stamped On Plug 208/230/460V Models: 208/230V Plug 9028-460A 460V Plug 9028-460C 380/415V Models: 380V Plug 9028-460G 415V Plug 9028-460H 460/500/575V Models: 460/500V Plug 9028-460J 575V Plug 9028-460K Easy-Start ES Instruction Manual 5-17...
  • Page 128 Cutler-Hammer Solid State Reduced Voltage Motor Starter Aftermarket Services • Technical/telephone support. • Resident service engineers in major trading centers. • Factory repair services. • Warranty administration. • Equipment modification and upgrading services. • Training seminars. For service or more information call 1-800-322-4986 A response network that gives new meaning to customer service •...

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