eaton advantage contactors and starters td8e02te

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Technical Data Advantage FtfectIve- ~~~~~~~ 1999 Contactors and Starters

Non-combination

Cutler-Hammer

Design Characteristics and Optional Features

Design Characteristics

Configurations -

Open Types:

- W201: FVNA Contactor

- W211: FVR Contactor

- WZOO: FVNR, Non-combmatlon starter

- W210: FVR. Non-combination starter

Enclosed Types:

- ECAOl: Full Voltage Non- reversing (FVNR) Contactor

- ECAOP: Full Voltage Reversing fFVRI Contactor

- ECAOI: FVNR, Non-combination starter

- ECAOG: FVA. Non-combination starter

- ECA07: FVNR, Non-combination Starter with Control Power Transformer (CPT)

Addlhonal configurations are available and described in other publications and Technical Data publications.

Cantactors - Available in NEMA Swes 1 - 6, three-pole, non-reversing and reversing.

Starters- Available in NEMA Sizes 1 6. three-phase, non-reversing and reversing, and non-reversing with control power transformers as standard.

Open Devices-Three-point maunt- ing up to and including Size 4. reversing and non-reversing contactors and starters.

Enclosures - Contactors and starters are available in NEMA Type 1,3R, 4/4X and 12 enclosures. Ample wiring space meeting or exceeding the National Electrical Code (NE0 requirements is provided at the top and bottom for easy installation.

- The NEMA Type 1,3R, 4/4X and 12 enclosures have external reset buttons as standard and there are four (41 holes plugged for cover controls. The doors can be pad- locked to prevent unauthorized entry. The door is easily remov- ableforwirina orformaintenance purposes. -

- NEMA Type 3R enclosures are for outdoor aoolications and are rated for rain; sleet and external ice buildup. They have knockouts in the bottom and provtsmns for a

F54u TD.tlE.02 T E

hub in the top. They are painted with a ooivester urethane powder co& paint meeting UL. reauirements. The color is ANSI 61 gray

- NEMAType 4/4X enclosures are for indoor or outdoor applications and provide protection from splashing water, hosedirected water and wind-blown dust. Watertight conduit hubs are provided in the top and bottom. NEMA Sires 1 - 5 are in Type 4X made of a stainless steel 304 mate- rial. NEMA Size 6 devices are in a Type 4. painted steel enclosure.

- NEMA Tvpe 12 is for indoor applications to protect from dripping liquids, falling dirt and dust. No knockouts or hubs are provided in NEMA Type 12 enclosures. They are painted with a polvester “re- thane powder coatpa/nt meeting UL reauirements. The color IS ANSI 61 gray.

Standards -

UL listed: Oven & Enclosed -File #E19224.

CSA certlfled: Guide #NLDX

Enclosed - File #LR28548,

Dwgned to meet or exceed NEMA standards.

Ambient Temperature 0” to 40°C

Overload Relay Standard Features -

- DIP switch selectable for Trip Class 10, Class 20 and Class 30

- DIP switch selectable for Manual or Automatic Reset.

- Remote Reset and other opera- tional reset options available.

- Ground current sensing.

- Phase loss protectIon.

- Phase unbalance protection.

Optional Features

Control Transformers -Available as either a field kit or factory optw~ in all size starters.

. Local Cover Control -

- Available as factory Installed on the enclosure or flange.

- Kits are available for field installation on NEMA Type 1, 3R. 414X or 12 enclosures.

- Advantage Control Modules (ACM) available in Status Only (with Reset) for monltorlng, or with pushbuttons and Reset for

various types of control functions ISTART/STOP. HAND/OFF/AUTO. etc.).

Auxiliary Contact Module -

- Each module provides four (4) separate contact sets.

- Contacts are single break, bifur- cated, and isolated for no polarity restrictions.

Bell Alarm Module - 1 NO-1 NC, isolated contacts with 5A continuous rating. Simply plugs into reset port.

Mechanical Interlock -

- Cam operation to insure positive actlo”.

- Electrical interlocking contacts included (2NC).

Remote Electrical Reset -

- Can be mounted anywhere on ellClOSUW.

- Optional lighted reset for trip indication.

Communications

- WPONI module for IMPACC

- WPONIDNA module for DeviceNet.

Description

These products are a full line of advanced design contactors and starters that are setting a new standard in motor control. Revolutionary in design, the Cutler-Hammer Advantage mot& starters employ state-of-the-art technol- ogy in solving motor control application problems. The Advantage motor starrers and contactors extend operat- fng life in a physical space requirement 20% to 80% of the size of conventional motor starters and contactors.

Cutler-Hammer Advantage controllers maintain constant coil power, regard- less of van/ing control circuit conditions, which eliminates coil burnout, contact chatter, and welding due to low voltage or fluctuating control signals.

Multi-function overload protection options prowde application flexibility while reducing inventory. Communica- tion capabilities allow the Advantage starters and contactors to be interac- twely linked to control systems for monitoring, troubleshooting and control. Technological advances such as pre-start diagnostics, Increased accuracy, and the ability to communicate with other svstems are benefits not realized in traditional motor starters and contactors.

Cutler-Hammer Advantage Contactors and Starters Non-combination

Technical Data Effectwe: January 1999

Some of the unique key features of this line are:

,. Long Life- due to significantly less contact bounce, regulated power to the coil eliminating coil burnout, and no contact “kiss” position or chatter

Smaller Physical Size - 20% to 80% smaller than conventional devices allows the use of smaller enclosures and control panel boxes.

Solid-State Overload Relay - completely heaterless. Standard protection features Include phase loss and unbalance, selectable trip class, automatic/manual reset and ground current sensing.

Communication Capability-offers low costcommunicationsof ON/OFF commands. status and motor data; can be linked to automated control systems.

Microprocessor based-the contactor will not close on low control voltage, and the armature closina SDSSd is controlled to reduce contact bounce. Optimized coil power provides high contact force in a minimned physical sire. This hiqh contact force contrib- utes to extended electrical life.

0 Reduced Heal Generation by using current sensors rather than heaters, temperature rise in the overload relay IS eliminated. Low coil holding power reduces heating in the magnet coil. High contact force results in less heat generated in the contact set.

Advantage Control Modules (ACM) - provide a cost-effective alternative to pushbuttons, selector switches, indicating lights, reset mechanisms, and panel meters. Simple plug-in wiring reduces installation labor.

The Advantage starters and contactors are microprocessor based. The pat- ented SURE Chip is the “brains” of these devices. The SURE Chip is an application specific microprocessor

designed specifically for the Cutler Hammer Advantage starters and cone tactors. The same magnet assembly components used in conventional starters are used in this product line- maanet, toll, movino armature, sta- tionary and moving contacts. The use of the SURE Chio. alono with current sensors, DIP switches, control wiring terminal and communications port, all on one circuit board, allows you to have significant benefits while staying smaller than the average contactor or starter. It gives you the full motor protection characteristics of a starter ~ from a contactor-sized unit. In addition, the SURE ChiD’s operation crow “ides extended mechanical and electrical life by lessening contact bounce and optlmwmg coil power and contact force.

When a start signal is received by the starter, control circuit checks are made before power is applied to the COII. These checks verify that the start signal is valid, and prevent closing when conditions exist that would damage or destroy the device.

The START signal is checked for three consecutive cycles to ensure that it IS not a false slgnal.

The control voltage IS monitored to ensure sufficient voltage for closing

The phase angle of the start signal is compared to the coil SIgnal. If phase angles are the same, the signal is considered valid.

If the unit passes those verification checks, a power pulse to the coil IS sup plied. The coil cu.rrent is then read a&l if current is sufficient, a *r&De” of optimum power is applied to’the coil.

The Advantage starters experience a reduced contact bounce of only 0 - 2 milliseconds because ofthe optimized power applied to the coil, and the low velocity at which the magnet faces meet.

Higher contact force lowers the resistance and subsequent heat given off

as a result of current passing through the contactor, which raises the current carrying capability of the device.

IncreasIng contact force in conventional starters can only be achieved by mcreaslng the sze of the magnet and coil, and consequently the size of the device. The SURE Chip optimizes the power to the coil, providing high contact force while maintaining smaller physical sire.

When a co11 IS energized or de-energized in a conventional starter, a voltage spike may occur. Some devices on the circuit such as PLCs or computers, may be affected by this spike. In the Advantage contactors and starters, the coil is isolated from the line bv its electronic cir- cultry. The voltage spike IS minimized, eliminating the need for costly surge suppressors.

Contact chatter or “kiss” occurs when the control voltaqe is insufficient to completely close-the starter, when the voltage signal is varying. or when there is a drop in control voltage. The Advan- tage microprocessor first decides that there is sufficient voltage present to completely pull in and seal the magnet and armature. After this, the regulation of power to the coil makes the &tacts hold together tightly until the microprocessor determines that the voltage is no longer sufficient. At this point, the starter opens cleanly, never reaching the kiss oosition. It has the abilitv to ride through momentary loss or’vari- ante in control power.

Another feature of the Advantage controllers IS known as “Distributed Open- ing.” The starter stores the order in which the phases were opened in the previous “stop.” Then, the opening sequence is rotated between the phases to enaure even contact wear. This distributed opening is disabled if the starter is wired with two-wire control, where the control power applied to iE) terminal is interrupted.

TO.BE02TE F5.N

Technical Data Advantage ~~~~~~~~~~~~~~~~ 1999 Contactors and Starters

Cutler-Hammer Page4

Non-combination

Mechanical Characteristics ! Table 1 - Mechanical Characteristics

siz. I Cinsnsions in lncher

Height Width Depth

Panel Area I” Square Inches Weightin Pounds

Mechanical Interlock

Combinations Available

6M 6.50 8.00 B.llO 10.08 1008 250 2.50 3.68 3.68 IO7 7 07 4% 4.96 5.54 5.54 7.64 7 64

16.25 16.25 29.44 2944 7127 7, 27 2.00 2.w 8 00 BOO 30.00 30.00

“en., Hor12. Ven.. Horn Vert. Hariz Vert. How vw., “or,2 “w-t, tlonz

Maximum Cable Size/Phase

Copper IAWGIMCM) 8 AWG 4 AWG 250 MCM 250 MCM 1 -MOMCM 2-5gOMCM Auxiliary Electrical Circuits AvaIlable 8 8 8 8 8 8 Mau. Wire Size for Aux. Elec. Circuit IAWGI 12 12 12 12 12 12 MIX. Wire Size for Control Circuit IAWGWG) Two-14 Two-14 TWO_14 Two-14 Two 14 Two 14

Table 2 -Circuit Board Characteristics

Conformal Coating of Board

DIP Switches

HumisealtlB31,Ac~lic Type

Grayhill Sews 15. Gold-Platad Spring and GalI Contacts IO m,cro,nches of gold plating

Contactor and Starter Sizes

The Size 1 contactors can operate over a 2 to 10 hp range.

There are two Size 1 starters lcontac- tar with overload relay) that cover the l/4 to 10 hp range and the .47 to 27 Full Load Amp range.

600V AC. The contacts are rated at 10 NOTE: Unless a table is otherwise hp. so if the unit is sat on the “No Pro- footnoted in this document, “Size 1” tection” mode of the overload relay, it refers to Size 1 contactors, Size 1 can be used as a contactor at 10 hp at lower current range. and Size 1 upper f,nnv nc current ranae starters. ( _ _ _ _

The Sire 1 Upper current range starter orotects over an FLA range of

e TheSize 1 Lower current range starter protects over an FL4 range of .47 to 3.81Aat a 1.15to 1.25 service factor. It can operate over a l/4 to 2 hp range at

3.15to’27Aata1.15to1.25SF.lican operate over a 2 to 10 hp range at 600V AC.

FAra TDSEOZTE


Technical Data Effective: January 1999

( Operating Characteristics

Table 3 -Operating Characteristics

I I Slla 1 I

t

TD.8E.OZ.T.E F:T*N

Technical Data Advantage Page 5 Effective: January1999 Contactors and Starters Cutler-Hammer

Non-combination

Electrical Characteristics

Table 4 -Electrical Characteristics

FATeN TD.8E.OZ.T E


Technical Data Effectwe: January 1999 Page 1

f Short-Circuit Ratings \

These motor controllers are suitable symmetrical amperes) shown, in cir- protected by the SCPD shown for use on circuits capable of deliver- cults rated not more than the voltage

ing not more than the current (RMS shown in Tables 5 through 10, when

‘able 5 -Size 1 Short-Circuit Ratings rable 7 -Size 3 Short-Circuit Ratings

able 6 - Size 2 Short-Circuit Ratings

hlsgnetlc OnlyO 5OA Marked GMCP 42,OOOA 2NJV GMCP T”ae CE 0 25,OOOA 4mlv

Marked HMCP 100,OOOA 48oV HMCP

-able 8 -Size 4 Short-Circuit Ratings

TOGEOZTE F:T*N

Technical Data Advantage Effective’~~~~~~ 1999 Contactors and Starters

Non-combination

Cutler-Hammer

1 ‘able 9 -Size 5 Short-Circuit Ratinss Table 10 - Size 6 Short-Circuit Ratinas

Coil Characteristics

Table 11 -Coil Characteristics

sim 1 sire * Sk. 3 Sk. 4 Size 5 Sire 5 Control PDWW Nommal Control Voltage 12OVl60 Hz or 12OVffiO Hz or 12OV/60 Hz or 12OVI60 Hz or 120”,60 HZ or 120”,60 Hz or

llOVl50 Hz llOV150 Hz llOVl50 Hz llOV/50Hz llO",50HZ llWi50 Hz operaung lxnas -v 54t0 145v 54fO l45V 54to t45v 5410 145v 54to 145v 54to 145v

- Freq. -2% to +2% per utility -2% to t2% per utility -2% to +2% per utility -2% tu 12% per utility 2% to t2% per utility -2% to t2% per utility

Control Power Transtormer Recommended (65% P&Up WI 100 VA lOOVA 15OVA 15OVA 300 VA 300 VA

AC Coil sS#

Burden (Open VA PF= 501 250 VA 250 VA 500 VA 500 VA 2600 VA 2600 VA (ClosedVA~PF=.28) 25VA 25 VA 50 VA 5OVA 50 VA 50 VA (Closed Waftsi 5W 5W low low low low

P,ck-“p Volts @ 78V 78V 78V 78V 78V 78V Droo-OutVoltsa 54V 54” 54” 54V 54V 54V


Technical Data Effective January 1999 Page 5

Overload Relay Operation

The Advantage starters use a unique current sensor which outputs a voltage proportional to the change in current. The SURE Chip squares and integrates the value to achieve a true measure of motor heating. This approach allows for a linea@ motor protection curve which can protect to within a 2% accuracy level. No thermal elements in the Cutler-Hammer advanced design overload relay means no time lost for heat transfer from the element as in conventional starters. This device also has a nonvolatile operating memory, which allows it to remember that the motor is hot after control power is removed.

Advantage’s unique current sensors offer a higher degree of accuracy than thermal overload relays. These sen- sow., combined with reliable solid-state circuitn/. allow multiple selectable prom tection options built right into the con- tactorframe. This allows the starterto be the same size as the contactor, and therefore, much smaller than conventional starters.

To select the trip class and trip range of the overload relay, it is not necessary to replace any portion of the device. The usersimplyflipsfiveswitchesto setthe trip current rating and trip class. There are no heater coils to order. inventon/ or install. A DIP switch (Dual In-line Package) takes the place of all that.

Select classes as follows:

lil Class lo-To protect a hermetic motor (refrigeration compressor1 a submersible pump motor, or any quick starting motor such es an IEC design. Also use with Design E motors.

L Class 30 - For long motor accelera- tion time.

ii Class 20 For all other applications.

s No Protection -Selecting this setting effectively transforms the starter into a contactor.

TD.8E.0Z.T.E 6:T*N

Technical Data Advantage ~~~~~~~~ ~~~~~~ ,999 Contactors and Starters

Non-combination

Cutler-Hammer

Further flexibility is provided by the two reset methods inherent in these devices,

b Automatic Reset - Reset is auto- matIc on thermal overload trips only, and the time to reset is propor tional to the overload relay class.

e Manual Reset -The starter will NOT reset automatically if it tripped on a thermal overload condition. A RESET button must be pressed manually.

Protection is provided bye required cooling period before the overload relay C&I be reset. After an overload trip, once the cooling period has passed, the starter may also be reset by removing and then restoring control power.

After a ground fault. phase loss, or phase unbalance trip, the starter can only be manually reset with control power ON.

Short-Circuit Withstandability

The current sensors and related CIT. cuitry in the Cutler-Hammer Advan- tage starters are immune to damage by high currents and so are not the limiting factors in establishing short- circuit withstand ratings. Heaters in conventional starters rated less than 1OOA have a maximum amount of current that they can withstand without losing calibratto”. The current sensor in the Advantage starter simply satu- rates under high current conditions, and limits the voltage signal transmit- ted to the SURE Chip.

Ground Current Sensing Protection

Cutler-Hammer Advantage starters with ground current sensing protection feature provide equipment pro&c- tion against ground currents between a facrory-set low level and a lockout current. It is designed to open the circuit when it senses the low-level and arcing ground currents often occurring in motor branch circuits. This feature is standard with the CutlwHammer Advantage starters. As an option. it can be omitted.

NOTE: These devices are NOT Ground Fault Interrupters IGFlsl designed to protect people. Additionally, branch circuit short-circuit protective devices are to be used to clear faults that exceed the interrupting rating of the starter.

The table below gives trip amperes and lockout amperes for each size of the starter. Lockout current is the sum of the phase current and ground current.

Table 13 -Ground Current Sensing

siza Trip Lockout Trip curr.Rt EYrrell nme

Phase Unbalance

If the unbalance of any two phases is greater than 30% of the DIP switch selected trip rating of the starter, a phase unbalance is declared and a trip occurs. No time delav is rewired for reset. This feature IS &and&d in the Cutler-Hammer Advantaae starter. To customize your protecti&, phase unbalance can be omitted by disabling the protection using a” Advantage Programming Module (WAPM).

Phase Loss

The Advantage starter will trip on phase loss, after two seconds. if the current in any one phase is lower than the currents listed in Table 17. No time delay is required for reset. Phase loss protection IS standard on the Cutler- Hammer Advantage starter. As a” option, this feature can be omitted by disabling the protection using a” Advantage Programming Module (WAPM).

F5.N TD.8E.02.T.E


Technical Data Effective January 1999

Overload Relay Characteristics

Table 14 - Overload Relay Characteristics

sin 1 size 2 size 3 size4 sin !! size I

Overload Accuracy

XrnetoTq RepeatabIlIty 5% 5% 3% .5% .5% Or,h Due to Temperature 25%llO~C 25%/lO~C :&WC 2596110°C 25%/lO”C 25%/10”c

Ground Fault Trip

Trip Range Stan D&y

SeeTab,e 13,Page,G SeeTablel3.Page18 SeeTable 13,PagelD ;;~~ble13,Page18 SeeTable13,PagelO SeeTablel3,Pqs,O 17 see I7 set 17 set 17 xc 17 set

Trip O&y .4 sec. 4 set 4sec .4 sec. 4 set 4 set

Tvsical Rerellimer

I3 Phase at 600% Tr,p Rat~ngsl Class IO 2 25 ml” 2 25 mtn. 2 25 mm 2.25 m,n 2.25 min. 2 25 ml” Class 20 45 min 45 ml,“. 45 ml”. 4.5 mm. 4.5 ml”. 4.5 ml”. Class 38 5.75 mm 5.75 mm 8 75 min 8.75 mm 6.75 min. 6.75 ml”. Ground Fault Manual Only/ Manual Only/ Manual Only/ Manual Only/ Manual Only/ Manual Only/

lmmed,ate lmmedlale lmmed,ate Immediate Immediate ,mmed,ate

Phase Loss or Unbalance Manual Only/ Manual Only/ Manual Only/ Manual Only/ Manual Only/ Manual Only/ lmmed,are lmmed,ate lmmed~ate lmmedlate lmmed,ate Immediate

Trip/Cool Down on Loss of Power

Thermal-If power IS restored 2 25 ml” 2 25 m,n 2 25 min 2 25 m,n 2 25 min 2 25 min. aher this time expires. the unit w,, have automatically reset Phase Loss or Ground Fault 0 N0WOlatlle NO”~YOl~,lI~ N0WOlatlle N0n-VOlatlle NOll-“Ol~tIl~ Non-volatile

INo Battery) INa Battery) INo BatteryI iNo BattewO INa Batter/l INo BatteryI

Reset Methods

Auto Reset Thermal Only Thermal Only Thermal Only Tbemla, Only Thermal Only Thermal Only taca, Reset RI, Tr,ps All Trips AllTrips All Tnps A,, Trips All Tnps Remote Reset Optional -All Trips Optional- AI,Trlps Optional-AIlTrips Optional -AllTrips Optional -AllTr~ps Optional- A,, Trips IMPACC Reset Optional -AllTrips Opt~anal- All Trips Optional -AllTr~ps Optional -AIlTrips Optional -AIlTrips Optional-All Trips

Table 15 - Motor FLA Current Ranges

I NEH*Siza Irn 1 2 3 4 5 I

1.15to 1.25S.F. .47 - 3.81 3.15 - 27.00 3.15- 45.03 9.90 - 90.08 9.90 - 135.00 38.30 - 270.00 38.X - 54a co I 0 SF .51 4.14 3.43 27.00 3.43 455.Go 10.80 go 00 10.80 135.00 41 70 270 00 41.70 - 540.00

Table 16 - Data from Tables 430 - 147 through 150 of 1996 NEC Motor Amperes at Full Load @J, Three-Phase AC

iv Pinperer

zal “&a 2aB veiis 230 “Oltn WI Il,l 571 VOID

l/2 25 2.4 22 1 1 9 3/4 37 35 32 16 13

1 4.8 4.8 42 2.1 17

5 17.5 18.7 152 7.8 81 7-l/2 253 24 2 22 11 9

10 32.2 30.8 28 14 II

15 483 48 2 42 21 17

;: 82.1 78.2 594 74.8 ; 34 27 ::

30 92 88 80 40 32 40 120 114 lo4 52 41 50 150 143 130 85 52

60 177 169 154 77 82 76 221 211 192 96 77

100 285 273 248 124 99

125 359 343 312 156 125 150 414 398 360 180 144 2w 552 528 4BO 240 192

TD.SE.02.T.E I:T*N

Technical Data Advantage Effective. Januar( 1999 Contactors and Starters

Non-combination

Cutler-Hammer

Overload Relay Settings

Use the eight-position (pole) DIP switch visible behind the window I” the arc box cove, to select the method of reset (Manual or Automatic), the overload protection Class 110, 20. 30 or None), and the trip current rating appropriate for the motor full-load current in amperes IFLA).

Disconnect ALL Power Before Selecting Settings!

Remove the erc box cover to gain access. When a DIP switch handle is moved towards the position number (marked 8 through 1, left to right) that Dole is closed (represented bv “1”). hhen a switch handle is away from the position number, the pole is open (represented by “0”).

Reset Method (for thermal overload trips only) -Set the type of reset desired using DIP position 8.

L Manual-On thermal overload trips, reset time must elapse before press- ing RESET button, or starter will not reset.

L Automatic-Reset time is based on protection class.

Table 18 - Reset DIP Settinm

Overload Class

Use the Class 10 (Fast Trip) setting for hermetic refrigerant motor compres- sors, submersible pumps, and similar apolications, as well as for protecting g&ml-purpose motors where the load permits the motor to reach rated speed without the overload protection circuit tripping.

Use the Class 30 (Slow Trip) setting for special motors driving high inertia loads such as ball mills, reciprocating pumps, loaded conveyors, and the like.

Use the Class 20 (Standard Trip) setting for all other motor applications. Most NEMA-rated, general-purpose motors will be protected by a Class 20 setting.

If a properly selected trip current setting results in an overload trip, move to a higher CLASS setting rather than to a higher trip-current setting.

Select Class NONE when no overload, phase, or ground-fault protection is wanted. With NONE selected, the Class W200 Open Tvpe/ECA05 Enclosed Tvpe motor stane, will behave like a Class W201 Open Tvpe/ECAOl Enclosed Tvpe contactor.

Table 19 -Overload Class DIP Settings

susrlo~l I%** POllsO” I PDSIIID” r

10 6 0

20 II 1

Trip Current Setting

The overload trip current of an Advan- tage starter is determined by its DIP switch setting I” positions 5 through 1 as shown in Tables 20 throuah 26. Use only the table appropriate f& the starter and application involved.

For motors with a marked temperature rise of not over 40°C. or with a service factor of not less than 1.15. find in column A the range of motor FLA for the motor to be protected and use the set- tlng shown for DIP switch positions 5 through 1. For all other motors (ser. vice factor 1.0). select a range in Cal- umn B and use the setting shown for the DIP switches. Settings based on Column A give a trip rating of not more than 125% of motor FLA. Set- tings based on Column El give a trip rating of not more than 115% of motor FLA.

Table 20 - Size 1L Three-Phase Starters, Lower Current Range

1.47 ml.61 162 1.77 I 7s I 96 196G2.14 2 15 - 2.36 237 -260

3.26 / lW,Q 3.58 10011 394 1OlW 4Y 10101

ItTaN TO.SE.02.T.E


Technical Data Effectwe January 1999

3 I5 - 3.46 3 47 - 3.81 3.82- 4.19 4.20 4.61 4.62 5.0 5.1 55

175 -192 19.3 -21 1 21.2 -23.2 23.3 25.6 25.7 -27.0

able 22 - Siz

I Three-Phase Starters. Uppal

34s 375 3 93 QQQW 376m 413 4.33 00001 414- 455 4.77 OOOlQ

OQOl1 001m 00101

4 56 - 4.99 5.26 50 54 5.77 55 6.0 6.35

61 - 65 6.9 66 - 72 7.7 73 - 80 8.5 81 - 66 9.3 8.9 96 IQ.2 97 -106 11.2

107 -117 124 118 -129 13.6 130 -14.2 150 143 -15.7 16.5 156 172 18.1 173 -189 19.9

190 -209 21.9 !I0 -229 24.1 !3.0 25.2 26.5 Z5.3 27 8 29.1 179 -30.5 32.1 30.6 -337 35 3

338 -370 38.9 17.1 -40.7 42.8 10.8 mu.6 47.0 19.9 450 51 6

00110 OQlll 01000 01001 01010 01011

L

01100 01101 0,110 01111 10000 lOQQl

1OQlQ 10011 10100 1OlQl IOllQ 10111

Iloo llW1 11010 ,,Qll

QQQQQ QQQQI 00010 0001 I 00100 00101

00110 00111 01000 OlOOl 01010 QlOll

01100 01101 QlllQ Q,,ll 10000 10001

lOOlD 10011 lOlO 10101 10110

e

]

1 7

able 23 -Size 3 Three-Phas

e

9.9 - 10.6 10.8-11.7 109-11.9 118-12.9 ,20&13.’ 130-142 132-14.4 143-156 145-15.8 157-172 159-17.4 173-18.9

175-19.2 19.0 - 20.9 193-21.1 21 .o 22.9 21 2-23.2 23 0 - 25.2 233-256 25 3 - 27.6 257-281 27 9 30.6 282-30.9 30.7 33.6

31.0-341 33 7 - 37.0 34.2 37.5 37, -408 376-413 409-449 4, 4 -45.4 450-49.4 45 5 50.0 49 5 54.3 50 I 54.9 544-59.7

55 0 - 60.5 598-657 606-665 658-723 666 -73.2 72 4 - 79.6 733-80.7 79.7 - 87.7 808-88.7 87.8 90.0 888 900

9.9- 10.8 IQ.9 11.9 lZ.Q- 13.1 13.2 - 14.4 l4.G 158 15.9 - 174

21.2 23.2 23 3 25.6 25.7 - 28.1 28 2 - 30 9

31 Q 34.1 34.2 - 37.5 37.6 - 41 3 41.4 454 45.5 - 5c 0 501- 549

55 0 60.5 60.6 - 66.5 66.6 - 73.2 73.3 80.7 80 6 66 7 86 8 - 97 5

97.6 - 106 IO7 - 117 1,s - 129 130 135

itartern rip Rating hlpwes,

124 136 15.0 16.5 IS.1 19.9

21 9 24 I 26.5 29.1 32.1 35.3

36 8 427 47.0 51.7 56.9 62.6

66.6 15.1 63.3 91.6

101 111

I Three-Phase Starters

I H

IP Switch so %3*i,i0na.) iml,

QQQQQ 00401 QQQlQ 00011 00100 QQlQl

00110 00111 01000 01001 0,010 01011

01100 01101 Q,llQ Q,lll 10000 lOOQ1

10010 1OOll 10100 10101 10110 10111

NIP Switch sming ytim’

00000 00041 00010 00011 QQlw OOlOl

00110 00111 OlOW 01001 01010 01011

OllQQ QllQl 01110 Ollll lOoDD 10031

10010 10011 10100 10101 lOl10 10111

1lQQQ 11001 11010 11011

TD.8E.QZ.T.E F5.N

Technical Data Advantage ~~~~~~~~ ~~~~~~ IW Contactors and Starters

Non-combination

Cutler-Hammer

IMPACC Communications

The 9600 baud IMPACC Network 1s one communication networkavailablewith the Cutler-Hammer Advantage line of motor controls. This network ties toaether monitorina. protection and control devices. There are a variety of IQ and other IMPACC compatible devices

This important feature of the Advan- tage products allows for:

* Data COlleCtlOn

4 Troubleshooting

h Monitoring

Control from remote locations

NOTE: Other IMPACC devices can be intermixed with WZOO on the same twisted pair network i.e.: IQ, AEM, Addressable Relay, etc.

As maw as 1.000 comoatible devices. installed in vsr~ous assemblies, can communicate over an IMPACC Svs- tern. These devices may be moniiored and controlled by a computer in a remote location up to 7500 feet away.

Hardware

To utilize the IMPACC network, a simple plug-in, snap-on Product Network Interface (PONI) is reauired for each device with which co&nunication is desired.

The catalog designator for the device designed to work with the Cutler- Hammer Advantage starters and con- tsctors IS WPONI. It prowdes data and control functions as well as address wheels for addressing up to 1000 devices. Each WPONI is set to a different address and twisted pair wire is daisy-chained between the dewces. Advantage controllers and existing IQ or other IMPACC products can be intermixed on a single IMPACC network.

NOTE: The WPONI may not be used on any other IMPACC devices, and the standard IMPACC PONI will not work on an Advantage product.

The WPONI provides the following functions:

1_ ON, OFF, and RESET control

s Data-in the form of

- Current in three phases

- Phase unbalance

- Control voltage

- Status (ON. OFF, TRIPPED, or NO RESPONSE)

- Overload alert (YES or NO)

- Trip Cause and Trip Data

- DIP switch settings

- AUTO/MANUAL reset

Overload relay Class

Trip rating

SoftWsre

Several interface/software options are available which utilize IMPACC:

h SERIES Ill -a comprehensive Windows@ -based package with graphics capabilities and other control and monitoring functions. Series Ill uses the INCOM protocol.

a Other software packages which may be used with IMPACC or an IMPACC driver include:

- Indelec, Inc.: MultivlewB

- Intellution, Inc.: The Fix@ and DMACS@

- Iconics, Inc.: Genesis”

DeviceNet” Communication Module

Another communication network uti- lized by the Advantage line of motor control is DeviceNet. The DeviceNet communication module, catalog number WPONIDNA, has an attached cable and plug making it easy to plug into the Advantage line of controllers. The module can be snapped on to the top or bottom of the Advantage unit. It can also be mounted separatelv using the mounting plate a&mbly, cataloi number WPONIEIASE. The module provides DeviceNet users with the ability to control and monitor the functions of the Advantage system at 125K, 250K and 5MlK baud. A connector is provided so that a LOCAL/OFF/REMOTE

hard contact may be used to selectively enable or disable the output of the control functions from the module without affecting its ability to monitor. A “feed- back” input is provided so that the state of an auxiliary contact may be read over the DeviceNet network.

Three bicolor LEDs indicate:

i DeviceNet address

Network status (including connected, not connected, not powered)

i Module status (including normal operation, minor fault, needs commissioning)

The module gives Advantage communication capabilities of:

F 500K baud Master/Slave

= Polled I/O connection

Explicit Message connection

lil Adheres to ODVA (Open DeviceNet Vendor Association) motor starter profiles, with additional functionality

The communication features offered sre:

5 ON/OFF control

d Trip reset

jl Three-phase motor current

+ Average motor current

L Starter status (OFF, POWER ON, RUNNING, TRIPPED)

i Percent phase unbalance and thermal capacity

I Cause of trip indication

I Data at time of trip (phase currents, percent motor thermal capacity, trip cause)

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Technical Data Effective-January 1999

Wiring Options

Control Power and Terminals

Cutler~Hammer Advantage motor controllers require a constant source of control power to operate and indicate a tripped condition. Loss of control power or a severe drop in control voltage WIII cause the motor controller to Open.

The location and function of each control terminal is:

kI 3 -Terminal to which START signal must be delivered. Signals may be momentary or maintained. AcceDt- able voltages are 5- 125V DC’ or 24 - 12OV AC. This inout is basicallv a dry contact. Input impedance IS 18K ohms.

Li P - Run permit-terminal must be energized constantly to permit opw ation. Acceptable voltages are 5 - 125V DC or 24 - 120V AC. This input is basically a dry contact. Input impedance is 18K ohms.

E - Ungrounded side of control power source. Must be either 120V AC, 60 Hz or 11OV AC, 50 Hz

C - Grounded (Common) side of control power source.

Trip Indicator/Reset Options

Wiring for the four trip indicators and/or

reset buttons are as follows:

Remote Reset and Trip Indicator

Local Trip lndwtor Only

Remote Reset Onlv

No Remote Reset or Trip Indication

For Local Reset only, no wiring required.

Communications Port

The communications and trip indica- tar/reset connections are shown below.

Communications devices must be plugged into the front SIX pins as shown. This connection is “keyed” to prevent improper connection.

Trip indication or reset devices must be plugged into the back two pins as shown. Only one such device may be used.

Control Options

A nonweversing motor controller may be used with 2-wire control or any one of three J-wire control schemes. The four point (3-P-E-C) terminal block shown in Figure 5 is attached to the shock-mounted circuit board and will give approximately l/l6 inch under screwdriver pressure.

In all cases, control power to terminals 3-P-E-C must be in phase. An interposing relay must be used whenever the controlling signal to 3 or P is a different ohase anale (reference to ground) t’han the voltage supplied to E and C. (See Two-Wire Control later in this publication.)

NOTE: Emergency stop should break the “E” connection. A maintsined NC

TD 8E.02.T.E F:T*N

Technical Data Advantage EtiectIvr ~~~~~~~~~~~~ Contactors and Starters

Non-combination

Cutler-Hammer

Recommended Method of Wiring Three-Wire Control Usinq Internal Electronic Holdinq

The recommended method of wiring the Advantage controllers is 3-wire control using internal electronic holding.

In this instance:

a The momentary start signal is wired to terminal 3.

* The maintained stop signal is wired to terminal P.

L No holding circuit interlock is required. The START/STOP signals may vary in voltage wlthin the specification listed earlier.

This is the recommended method of wiring because it provides the full range of communications and product features. All IMPACC functions are available.

The virtues of 3.wire control can also be obtained without an external auxiliary contact and jumper by using the internal holding circuit. Wire as shown in Figures 10 through 13 shown on Pages20 and 21. Attach and route wires to a remote reset/trip indicator module where provided.

NOTE: When wiring according to Fig we 11, you are breaking power to the board on drop-out. This will cause a momentary “no response” condition over the communications port.

l!S*N TD.8E.OZ.T.E


Technical Data Eileclive. January 1999

Attach a WPONI communications module and connect it to the IMPACC network daisv-chain fashion as shown in Figure 12.

When wired as shown in Figure 12, the motor can be reset, stopped and started via the IMPACC network. In order to start the motor “~a IMPACC. control circuit terminal P must be energized.

NOTE: Sizes 5 and 6 horizontal rwers- ing cc&actors have their Forward and Reverse contactor arrangement reversed. Reverse contactor is on left and Forward contactor is on the right.

Three-Wire Control with Conventional Holdinq Circuit

Wire as shown in Figure 13 with or without communications, using external auxilian/ contact IMal as the holding circuit interlock between control circut terminals 2 and 3. Add a jumper of 14. 16 or 18 AWG stranded wire between control terminals 3 and P. Attach and route wires to a remote RESETflRlP indicator module where provided.

With Communications

Attach a WPONI communications module and connect it to the IMPACC network daisv-chain fashion as shown in Figure 13.

TO Other IMPACC NetwOrk Devices

TD.BE.02 T E F:T*N

Technical Data Advantage E&e ~~~~~~ 1999 Contactors and Starters

Cutler-Hammer

Non-combination

Three-Wire Control with Joa Option

The contacts of a two-position NOR- MAL - JOG selector switch can be added to the control circuit between point 2 and 3 of Figure 15 where an external electrical interlock IS used as the holding circuit. Install a 14, 16 or 18 AWG stranded wwe iumoerfrom 3 to P. Where the internal iold/ng circuit is used. wire as shown in Figure 14. No jumper is needed. Attach and route wires to a remote RESETIKYIP indicator module where provided.

With Communications

Attach a WPONI communications module and connect it to the IMPACC network daisy-chain fashion as shown in Figure 14. Where IMPACC control is used, the selector switch must be a type that breaks one circuit before making the other when switching from NORMAL to JOG.

When wired as shown in Figure 14. the motor can be started and stopped via IMPACC, provided the selector switch is in the NORMAL position. When the selector switch is in the JOG position,

r I I I I I I I I I

IP I I I I

L

the motor cannot be started via IMPACC with the Selector switch in IMPACC, but it can be stopped vfa IMPACC. However, the motor will restart when the START button is pushed. The starter can be reset via

either mode. Ttle motOr can only be reset via IMPACC when wired as shown I” Figure 15.

c

F:T*N TD SE 02.T.E


Technical Data Effective January 19%

! Two-Wire Control

Wire as shown in Figure 16. Install 14, 16 or 18 AWG stranded wire jumper from 3 to P. Attach and route wires to a remote RESET/TRIP indicator module where provided.

NOTE: Automatic reset should not be used with Z-wire control circuits where automatic starting of the motor may be hazardous.

With Communications

Attach a WPONI communications module and connect it to the IMPACC network daisy-chain fashion as shown in Figure 16.

When wired as shown with two-wire control, the motor cannot be started or stopped via IMPACC The motor starter can be only reset and data obtained via IMPACC where two-wire control is used.

PLC Interface

With the addition of the 3 and P terminals, a number of PLC wiring options exist. Various~pesofPLCoutputdevices may be used to control an Advantage starter. The following three output types are addressed in this section:

I Relay Output at 12OV AC.

1 Solid-State (Triac) Output at 120VAC.

I Transistor Output at 24V DC.

Benefits of Discrete Interface

The benefits of the discrete interface (3 and PI include:

Low power interface - 18K ohms

)* Universal interface-same for all sizes due to low power required. No interposing relays are needed for Sizes 1 - 6.

lb Dry contact compatible.

* Phase detection for noise immunity, during SURE-Stan diagnostics.

Relay Output at 12OV AC

The relay output creates a 12OV AC dry contactsignaItothestarterterminals3 and/or P, channeling power to the control inputs. This p&ides relay output control for Sizes 1 through 6 without the use of interposing relays because co11 power IS not being switched.

NOTE: This is the recommended method of PLC control.

Figure 17 shows the wiring diagram for starter control by Relay Output.

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Technical Data Effective. January 1999

Solid-State (Triac) Output at 120V AC

Triac crutputs possess two unique characteristics:

ii Need for a sufficient load current in order to latch the device on

$c Leakage current in the OFF state

Outputs require sufficient load current in order to latch the triac device on. There are two methods of latching in the triac:

Loading Resrstor Method

The load current needed to latch in the triac output boards may require a resistor placed across the terminalLsl3 and/or P The high impedance of these input terminals may not support the minimum current required to maintain the ON state of the triac (Figure 181.

Typically. a 50 mA load will latch all triac output modules; however, It is recommended that You check the specificatrons of the board manufacturer. To find the resistor needed and minimum watts required, based on the manufacturer’s specrfications, use the formulae below.

RN=120/lL

where RN is the resistor needed, and IL is the Latch-In Current from PLC specs.

The minimum watts for the resistor should be:

The addition of a 2.4K ohm (7 watt1 resrstor in parallel with the Advantage inputs may be necessary. The resistor is wired across the P and/or 3 terminals and the C terminal per Figure 18. The use of a RELAY output card from a PLC will elrminate the need for loading resistors in the circuit

Jumper Method

An alternative to the loading resistor method is to jumper together 3, P and E and control the coil and input loads srmultaneously. This method does not require a loading resistor since coil power is praeent. Unfortunatelv, with this method, some functions of the starter are unavailable-such as elec- trrcel reset, anti-flutter protection, and manv of the IMPACC communication fur&ions (Figure 19).

Advantage Contactors and Starters Non-combination

Cutler-Hammer

F:T*N TD 8E.OZ.T.E


Technical Data Effectwe. January 1999

Leakaqe Current in OFF State

Triac outouts possess another unique characte;istic’-- they produce leakage current in the OFF state. If this leakage current is high enough, the Advantage controller may fail to drop out when a *top signal is given.

The Advantage contactor is designed to remain closed when AC voltages in the range of IZOV to 132V AC are applied to the P (run permit) terminal.

The Cutler-Hammer Advantage Starter has an input impedance of approxi- mat& 18K ohms. A leakage current highe; than 1.3 mA might irevent the unit from opening when it receives a stop signal.

To correct certain leakage problems in the field, a voltage divider can be added. The resistance values shown below will result in the application of 24V to the “P” and “3” terminals when IOOV is supphed by a triac output. This 24V is sufficient to close the Advantage controller. In the OFF state. with the leakage currents shown, the voltage at the “P” terminal will be 3V or less. This will ensure the dropout of the Advan- tage controller (Figure 20).

Transistor Outout at 24V DC

Transistor output module literature tvoicallv shows leakaoe currents rang- i&from .l to 3.5 mArThis OFF state- leakage could be misinterpreted as a true signal.

The Advantage starters were reliably controlled without an interposIng load to drain this leakage current. Ho&ver, Cutler-Hammer cannot guarantee tram sistor leakage in the field or that a particular application would not experience false turn-on due to output leakage currents.

A resistor load circuit could be added to drain this leakage current (Figure 21).

Table 37 indicates recommended vel- “es of Rl and R2 for typical maximum 24V transistor leakage CurrentS

--I 3

P

R,

12OV AC

C

R2

TD.8E.OZ.T.E F5.N

Technical Data Advantage Effective. January 1999 Contactors and Starters

Non-combination

Cutler-Hammer

Drive Applications

When using Advantage starters and contactors in drive apphcatlons, certain considerations must be made first.

Parallel Applications

Both the contactors and starters have filters to eliminate any response to the high frequency noise put on the power bus by solid-state drives. Therefore, applications involving Advantage con- t&tors and starters in parallel circuits (Figure 221 will not experience interfer- ence problems.

It is common practice to provide mechanical isolation of the drive by means of a bypass contactor. Using an Advantage contactor on the line side of the driveprovides both the electrical isolation and the inherent benefits of brownout protection and communi- catfonscapabilltv IFiaure 23). It is NOT RECOMMiNDEd that an Advantage m be used for this application. Because the current on the line side of the drive is only a representation of the motor current, and the drive WIII compensate and limit the current drawn, the starter will not be able to protect the motor.

Contactor After Drive Apphcatlons

Using an Advantage contactor on the load side of 8 drive also gives the same inherent benefits of brownout protectIon and communication capability. Again, the use of the w is NOT RECOMMENDED. The drive output will be of various frequencies. The starter uses a base frequency of either 50 Hz or 60 Hz for the timing required to make measurements.

Power Disconnecr

L

Motor

_


Technical Data Effecttue January1939 Page27

/ Approximate Dimensions in Inches and Shipping Weights

L

Clrcut Aux.

I E

1

Table 38 - Open Type: Non-reversing

NEW. sne Wids p1 High B

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Technical Data Advantage Effective: Januani 1999 COi'ItaCtOrS and Starters

Cutler-Hammer

Non-combination

Approximate Dimensions in Inches and Shipping Weights

NOTE: For Dimensions of Open Reversing Starter using ACM modules-Contact Cutler-Hammer.

Table 39 - OpenType: Reversing NEMI SIZ@ Widl A Hi#l B onp c MDuning D MO”“,i”~ E RI”,*

FZ*N TDX02.T.E


Technical Data Effective: January 1999

f Approximate Dimensions in Inches and Shipping Weights

TD.OE.02.T.E I5.N

Technical Data Advantage EMve January 1999 Contactors and Starters Cutler-Hammer

Page30

Non-combination

Approximate Dimensions in Inches and Shipping Weights

-l

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Technical Data Effective January 1999

Other Advantage Publications

Advantage Color Brochure -SA-412

Application Guide -TD.8.5.T.E 02

Copyright Cutler-Hammer Inc., 1999. All Rights Reserved

TD.BE.02.T.E

Technical Data Advantage Page.32 Effective: January 1999 Contactors and Starters

Non-combination

Cutler-Hammer

Cutler-Hammer Publication NO. T0.8E.02.T.E Primed I” U S.A , GG

eaton advantage contactors and starters td8e02te

Documents

dip switch selectable

holding circuit interlock

impacc network daisv

advantage programming module

advantage control modules

control power source

impacc network daisy

wponi communications module