14-Motor-Soft-Starter.Pdf

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Soft Starters

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Book 2 (14.3) www.automationdirect.com/soft-starters Soft Starters eSS-1 For the latest prices, please check AutomationDirect.com. Stellar® Series Soft Starters

Fully Digital with Touchscreen, 3-Phase Soft Starters SR55 Series, 17A – 477A The Stellar SR55 soft starters are fully digital, and use thyristors in all three motor phases for Advantage controlled reduced voltage motor starting and stopping. SR55 series starters have an Automatic Application Setup that fully configures the starter for a specific application Our Stellar Series of soft starters with one entry. And the SR55 series has built-in internal bypass relays and patented are designed to help you iERS (intelligent Energy Recovery System) that reduces energy costs when used on lightly reduce mechanical wear and tear loaded and oversized motors. on startup, reduce energy costs and help you minimize loss of production hours from equipment breakdown. When to use a soft starter? General purpose soft start applications are suitable where traditional across-the-line starting or wye-delta starting would typically be appropriate. Stellar soft starters should not be used if the starting time will exceed 30 seconds.

Why purchase your soft starter from AutomationDirect?

• Our soft starters are IN-STOCK and ready to ship

• FREE 2-day delivery when you order Features $49 or more • Can be connected ‘in-the-delta’, • 17-477A @ 200-480VAC allowing use of a smaller Soft Starter • FREE 30-day money-back guarantee • 24VDC, 110VAC, or 230VAC selectable • Can be used for motor reversing (with control voltage external contactors) • Internally bypassed during run • FREE #1 voted • Touchscreen with easy-to-navigate tech support • Fully programmable, full three-phase menu structure and quick automatic motor control application set up • VALUE PRICING • Built-in SCR failure protection, full • Can be used with local or on everthing we sell - motor overload protection remote control you’ll always get our • Full data logging (fault records, motor • Integrated Modbus RTU, or optional best price whether you current, operational status, etc.) Modbus TCP or EtherNet/IP order 1 or 100 items • Easily and separately adjustable motor communication start and stop times • iERS (intelligent Energy Recovery System) saves energy on lightly-loaded motors

Book 2 (14.3) eSS-2 Soft Starters 1-800-633-0405 For the latest prices, please check AutomationDirect.com.

3-Phase Basic The SR33 series is an ideal substitute for a Star/Delta starter because it fits into a similar footprint, thus simplifying installation. The SR33 Soft Starters up to 400 hp! soft starters use thyristors for controlled reduced voltage motor starting SR33 Series, 22A – 482A and stopping, then switch to internal bypass contacts for efficient running at rated speed. This series is designed to fit in place of existing wye-delta starters. 3-potentiometer setup (Start Voltage, Start Time, and Stop Time) make installation and commissioning easy. Features • 22–482A @ 208-230/460 VAC • Suitable for a wide variety • 24 VDC or 115 VAC I/O of motor loads • 24 VDC control power required • Designed to replace wye-delta starters • Two-phase control • Fault indication of 4 or 7 fault types, depending upon model. • Internal bypass contacts for Run • IP20 (SR33-22 to SR33-97) • Easily and separately adjustable IP00 (SR33-132 to SR33-482) motor start voltage and start and panel mount stop times • Two-year warranty

Compact 3-Phase The SR22 series is a low-cost family perfect for use in applications where space is a concern. The SR22 soft starters use thyristors for controlled reduced Soft Starters at Direct Prices voltage motor starting and stopping, then switch to internal bypass contacts for efficient running at rated speed. 3-potentiometer setup (Start Voltage, SR22 Series, 5A – 40A Start Time, and Stop Time) make installation and commissioning easy. Features Why purchase your • 5–40A @ 208–460V • Six error/trip indications: • 24 VDC control voltage AC Supply, Control Supply, soft starter from Overheated, Bypass Failure, • Easily and separately adjustable Shear Pin, Overcurrent motor start and stop times AutomationDirect? • Two-year warranty • Two-phase control • Internal bypass contacts for run • Our soft starters are IN-STOCK and • DIN rail mounting ready to ship • Two standard-size widths: 45 & 55 mm • FREE 2-day delivery when you order $49 or more • FREE 30-day money-back guarantee • FREE #1 voted tech support • VALUE PRICING on everthing we sell - you’ll always get our best price whether you order 1 or 100 items

Book 2 (14.3) www.automationdirect.com/soft-starters Soft Starters eSS-3 For the latest prices, please check AutomationDirect.com. Stellar® SR22 Series Compact Soft Starters Overview Advantages Standards & Approvals SR22 semi-conductor soft starters Mechanical Advantages • CE • Smooth acceleration; reduced shock and • RoHS provide many advantages when starting stress used instead of electro-mechanical • UL listed* (E333109) • Extend lifespan of mechanical drive train contactors to control 3-phase AC *(optional fans are UL recognized: components E132139, E77551, E89936) induction motors. The SR22 soft • Fluid couplings and some clutches can starters use thyristors for controlled reduced be eliminated Optional accessories voltage motor starting and stopping, Electrical Advantages • Cooling fan (increases # of starts/hour) then switch to internal contacts for effi- • Reduced starting current cient running at rated speed. Applications • More motors or larger motors can be • General purpose applications where started from lower-capacity power traditional across-the-line starting or sources wye-delta starting would typically be Features appropriate. • 5–40A @ 208–460V • Allows motors to be started more frequently • 24 VDC control voltage • Internal mechanical contacts open and • Easily and separately adjustable motor close under reduced current, increasing start and stop times lifespan and reliability • Two-phase control Economic Advantages • Internal bypass contacts for run • Lower overall costs for new installations • DIN rail mounting • Reduced maintenance and replacement • Two standard-size widths: 45 & 55 mm of mechanical drive train components • Six error/trip indications: AC Supply, • Reduced starting current reduces Control Supply, Overheated, Bypass electrical power costs Failure, Shear Pin, Overcurrent

SR22 Series Compact Soft Starters * Model SR22-05 SR22-07 SR22-09 SR22-12 SR22-16 SR22-22 SR22-30 SR22-36 SR22-40 Price $119.00 $131.00 $140.00 $170.00 $190.00 $224.00 $302.00 $375.00 $453.00 * Rated Current [class 5 starting] (A) 5 7 9 12 16 22 30 36 40 Rated Operational Voltage 208–460 VAC (-15% +10%) @ 50–60 Hz (±2Hz); 3 phase (2 phases controlled) * Motor Rating Refer to selection table. Starters must be sized according to HP AND starting class. Impulse Withstand Voltage 2.5 kV Insulation Voltage Rating 500V Short Circuit Current Rating 5kA Type 1 when protected by recommended semiconductor fuses Control Power approx 4VA @ 24 VDC (external power supply required) (UL applications require max 4A UL listed fuse) Control Inputs galvanically isolated opto-coupled inputs; require sourcing +24 VDC (control) Auxiliary Relay Output 250 VAC: 2.5A resistive, 0.2A inductive / 30 VDC: 3.0A resistive, 0.7A inductive Start Time Setting Range 1–30 seconds Start Voltage Setting Range 30–100% Stop Time Setting Range 0–30 seconds Start Duty 3 x full load current for 5 seconds @ standard rating Starts / Hour (standard) [10 starts / hr] OR [(5 starts / hr) + (5 soft stops / hr)] Starts / Hour (with optional fan) [60 starts / hr] OR [(30 starts / hr) + (30 soft stops / hr)] internally bypassed 0–40 °C [32–104 °F] – Above 40 °C [104 °F] derate linearly by 2% of unit FLC per °C to a max derate of 40% @ 60 °C [140 °F] Ambient Operating Temperature *** NOT UL TESTED ABOVE 40 ºC *** Transportation & Storage Temperature -25–60 °C [-13–140 °F] Humidity max 85% non-condensing; not exceeding 50% @ 40 °C [104 °F] Altitude 1000m [3281 ft]; 1000–2000m [3281–6562 ft] derate 1% of unit FLC per 100–2000m [328–6562 ft] Environmental Rating IP20 Shipping Weight 400g [14 oz] 680g [24 oz] 725g [26 oz] Dimensions [HxWxD] 143 x 45 x 117.8 mm [5.63 x 1.77 x 4.64 in] 167.5 x 55 x 117.8 mm [6.59 x 2.17 x 4.64 in] Accessories Cooling Fan (temperature controlled)** SR22-FAN-45 SR22-FAN-55 Price $45.00 $45.00 Dimensions does not add to soft starter overall dimensions adds 10 mm [0.39 in] to soft starter H dimension * Refer to Selection Table for deratings by application and overload trip class. ** Cooling fans do not run continuously.

Book 2 (14.3) eSS-4 Soft Starters 1-800-633-0405 For the latest prices, please check AutomationDirect.com. Stellar® SR22 Series Compact Soft Starters SR22 Soft Starters – O/L Trip Classes 1 SR22 Soft Starter Selection Default 5 1 Determine the required trip class based on the motor load and required start time. Heavy 20 2 Select the applicable SR22 part number based on the required Trip Class and motor HP. Agitator 10 3 Check application duty rating. (Frequency of motor starts can be increased by installing an Air Compressor - Equalized 5 optional soft-starter cooling fan, SR22-FAN-xx.) Air Compressor - Loaded 20 The standard range for the SR22 is Trip Class 5, which means that it is capable of withstanding Ball Mill 20 three times Full Load Current for five-second starts. For applications where longer starts are Centrifuge n/a required, the SR22 has four additional ratings: Class 10B, Class 10, Class 20, and Class 30. Chiller 10B These ratings correspond to IEC thermal/electronic overload trip classes. Conveyor - Unloaded 5 A separate overload protection device with a rating corresponding to the applicable trip class * Conveyor - Loaded 20 must be used with the SR22 soft starter. Crusher 30 Escalator 10B SR22 Soft Starters – Selection Table 2 * * Fan - Low Inertia < 85A 10 Motor Horsepower Application Trip Class * Fan - High Inertia > 85A 30 HP @ HP @ HP @ Class 5** Class 10B Class 10 Class 20 Class 30*** Feeder - Screw 10 208V 230V 460V Grinder 20 1 1 3 SR22-05 SR22-07 SR22-09 SR22-12 SR22-16 Hammer Mill 20 1.5 2 – SR22-07 SR22-09 SR22-12 SR22-16 SR22-22 Lathe Machine 10B 2 – 5 SR22-09 SR22-12 SR22-16 SR22-22 SR22-30 Mills - Flour, etc. 20 – 3 7.5 SR22-12 SR22-22 SR22-30 SR22-36 SR22-40 Mixer - Unloaded 5 3 5 10 SR22-16 SR22-22 SR22-30 SR22-40 SR22-40 + fan Mixer - Loaded 20 5 7.5 15 SR22-22 SR22-30 SR22-40 SR22-40 + fan n/a Pelletizer 20 Plastic and Textile Machines 10B 7.5 10 20 SR22-30 SR22-40 SR22-40 + fan n/a n/a Press - Flywheel 20 10 – 25 SR22-36 SR22-40 + fan n/a n/a n/a * Pump - Centrifugal 10B – – 30 SR22-40 n/a n/a n/a n/a * Pump - Positive Displacement 10 * A separate overload protection device with a rating corresponding to the applicable trip class must be used with the SR22. - Unloaded ** Do not use the Class 5 rating when there is a possibility of the motor starting under a heavy load. Rolling Mill 20 *** The SR22 is not suitable for very high inertia loads such as centrifuges or loaded crushers with start times > 30s. Saw - Band 10 Saw - Circular 20 SR22 Soft Starters – Duty Rating 3 * Screen - Vibrating 20 Motor Start Frequency (starts/hr) Cooling Fan Transformer, Voltage Regulator 10B Class 5 Class 10B to Class 30 SR22 Internal Tumbler 10 without fan 10 / hr 5 / hr Overcurrent Trip Curve Wood Chipper 30 with SR22-FAN-xx 60 / hr 30 / hr The internal overcurrent trip of the * Commonly required applications * @ 40 ºC [104 ºF] ambient temperature soft starter does not replace the required external overcurrent device. SR22 Max UL Overcurrent Protection SR22 Overcurrent Trip Curve UL Maximum Overcurrent Protection Devices * 100 for 5kA @ 480V Short Circuit Rating Soft Starter Maximum Non-Time-Delay Trip Rating * Model Fuse * – Class J or T Circuit Breaker * Number (600V rated) (600V rated) SR22-05 15A 10 SR22-07 15A SR22-09 30A N/A SR22-12 40A

SR22-16 50A Overcurrent Level 1 SR22-22 80A 80A SR22-30 100A 100A SR22-36 125A 125A SR22-40 150A 150A * Maximum trip ratings are for non-time-delay overcurrent protection devices. 0.1 * Motor branch circuit protection must be based on MOTOR Full Load Current, 11.5 22.5 33.5 44.5 5 and must comply with applicable local electrical codes. The 2008 NEC sec- Time (s) tion 430.52 recommends a maximum of 175% (up to 225% absolute maxi- Hot Curve Standard Curve Cold Curve mum) of motor FLC for time-delay fuses. (Class CC time-delay fuses are permitted up to the non-time-delay fuse maximum rating.)

Book 2 (14.3) www.automationdirect.com/soft-starters Soft Starters eSS-5 For the latest prices, please check AutomationDirect.com. Stellar® SR22 Series Compact Soft Starters

SR22 Dimensions

SIDE VIEW 60. 4 [2.38]

5 143 130

[5.63] [0.20] [5.12] 82. 6 [3.25]

45 OPTIONAL 30 117.8 [1.77] FAN [1.18] [4.64] 45mm Stellar Compact Soft Starter FRONT VIEW REAR VIEW SR22 size 45 mm DIMENSIONS = mm [in] 55mm Stellar Compact Soft Starter 72. 8 [2.86]

5 155

[0.20] [6.10] Cooling Fan for 45mm Soft Starters Cooling Fan for 55mm Soft Starters 167. 5 [6.59] 94. 7 [3.73] SR22 Start/Stop Timing Diagram

20 10 [0.39] 30 V

55 117.8 40 1 t-Start (s) 10 [2.17] OPTIONAL [4.64] OPTIONAL FAN [1.57] 100 70 FAN FRONT VIEW SIDE VIEW REAR VIEW V- V-Start (%) 50 30 Start SR22 size 55 mm DIMENSIONS = mm [in] 20 30 t t-Startt-Stop t-Stop (s) 10 0 SR22 – PLC I/O Compatibility SR22 – PLC & I/O Compatibility SR22 Wiring Diagram Product Line Module Type Module Numbers overload C0-00AR-D, C0-00DD2-D, C0-00DR-D, C0-02DD2-D, protection SR22-xx PLC Q1 C0-02DR-D F1 1L1 2T1 <100m L1 M CLICK DC Output C0-08TD2, C0-16TD2 Q1 F1 3L2 4T2 3~ L2 M Relay Output C0-04TRS, C0-08TR Q1 F1 5L3 6T3 L3 DC Output P3-08ND3S, P3-16ND3, P3-32ND3, P3-64ND3 Productivity3000 external power supply Relay Output P3-08TAS, P3-16TA, P3-08TRS, P3-16TR, P3-08TRS-1 +24V required 0V fuse @ 4A max (24VDC) PLC D0-05AR, D0-05DR, D0-05DR-D +24 0V DL05 D0-06AR, D0-06DD2, D0-06DD2-D, D0-06DR, PLC DL06 D0-06DR-D E1 Q1 (enable) EN -A2 DC I/O D0-07CDR (common) DL05/DL06 DC Output D0-10TD2, D0-16TD2, D0-08TR, F0-04TRS S1 (start/stop) +A1 DL105 PLC F1-130-DR, F1-130-DR-D DC I/O D2-08CDR L1 (fault relay) 23 24 DL205 DC Output D2-08TD2, D2-16TD2-2, D2-32TD2, F2-16TD2P Q1 = Cable protection Relay Output D2-04TRS, D2-08TR, D2-12TR, F2-08TR, F2-08TRS F1 = Optional semiconductor fuse for Type 1 Coordination (in addition to Q1) A1-A2 = Start/Stop DC Output D3-08TD2, D3-16TD2 External Control Circuit Elements DL305 E1 = Optional switch to allow trip reset without opening main breaker Q1 Relay Output D3-08TR, D3-16TR Q1= Auxiliary contact of main breaker Q1 S1 = Start/Stop control switch DC Output D4-16TD2, D4-32TD2 L1 = Indicator: ON = Ready; OFF = Fault DL405 Relay Output D4-08TR, D4-16TR, F4-08TRS-1, F4-08TRS-2 DC Output T1K-08TD2-1, T1K-16TD2-1 Terminator I/O Relay Output T1K-08TR, T1K-08TRS, T1K-16TR

Book 2 (14.3) eSS-6 Soft Starters 1-800-633-0405 For the latest prices, please check AutomationDirect.com. Stellar® SR33 Series Basic Soft Starters Overview Advantages Standards & Approvals SR33 semi-conductor soft starters provide Mechanical Advantages • CE • Smooth acceleration; reduced mechanical many advantages when used instead of shock and starting stress • REACH electro-mechanical contactors to control • Extend lifespan of mechanical drive train • RoHS 3-phase AC induction motors. The SR33 components • UL listed* (E333109) soft starters use thyristors for controlled • Fluid couplings and some clutches can be * (soft starters SR33-350 to SR33-482 reduced voltage motor starting and stop- eliminated are not UL listed or recognized) ping, then switch to internal contacts for Electrical Advantages Accessories efficient running at rated speed. • Reduces starting currents and spikes • Heat-shrink insulation kit SR33-HS1 Designed to fit in place of existing wye- • Reduces high transient currents (required for soft starters SR33-132 to delta starters. • More motors or larger motors can be SR33-280 used in UL applications) started from lower-capacity power Features sources Applications • 22–482A @ 208-230/460 VAC • Allows motors to be started more • General purpose applications where frequently traditional across-the-line starting or • 24 VDC or 115 VAC I/O wye-delta starting would typically be • 24 VDC control power required • Internal mechanical contacts open and appropriate. close under reduced current, increasing • Two-phase control lifespan and reliability • Internal bypass contacts for Run Economic Advantages • Easily and separately adjustable motor • Lower overall costs for new installations start voltage and start and stop times • Reduced maintenance and replacement • Suitable for a wide variety of motor loads of mechanical drive train components • Can replace wye/delta starters • Reduced starting current reduces • Fault indication of 4 or 7 fault types, electrical power costs depending upon model: SCR or Power Supply, Overheat, Control Power Supply, Bypass Relay Failure, Shearpin, Overload, Overcurrent • IP20 (SR33-22 to SR33-97) IP00 (SR33-132 to SR33-482) panel mount • Two-year warranty

SR33-66 to SR33-97

SR33-22 to SR33-55

SR33-132 to SR33-195 SR33-241 to SR33-482

Book 2 (14.3) www.automationdirect.com/soft-starters Soft Starters eSS-7 For the latest prices, please check AutomationDirect.com. Stellar® SR33 Series Basic Soft Starters SR33 Soft Starter Technical Specifications SR33 Series Basic Soft Starters – 22A-482A * – Model-Specific Specifications and Features Model SR33-22 SR33-29 SR33-41 SR33-55 SR33-66 SR33-80 SR33-97 Price $419.00 $448.00 $508.00 $569.00 $643.00 $685.00 $729.00 * Rated Current [trip class 5] (A) 22 29 41 55 66 80 97 * Motor Rating Refer to selection table. Starters must be sized according to HP and starting class. ** Short Circuit Current Rating (Type 1) 5kA for SR33-22 to SR33-55; 10kA for SR33-66 to SR33-195; 18kA for SR33-241 to SR33-482 Steady State Power Loss (W) 6 10 12 15 17 20 24 Control Power Supply Required Output Capacity approx 4VA Overload Trip n/a Terminals: Power / Ground wire clamp terminals / M6 wire clamp terminals / M8 Design Standards UL508 Industrial Control Equipment; EN/IEC 60947-4-2 “AC Semiconductor Motor Controllers and Starters” Environmental Rating IP20 Product Weight ( kg [lb] ) 2.3 [5.1] 3.5 [7.75]

Model SR33-132 SR33-160 SR33-195 SR33-241 SR33-280 SR33-350 SR33-430 SR33-482 Price $919.00 $1,013.00 $1,118.00 $1,758.00 $1,853.00 $2,805.00 $3,065.00 $3,218.00 * Rated Current [class 10(B) trip] (A) 132 160 195 241 280 350 430 482 * Motor Rating Refer to selection table. Starters must be sized according to HP and starting class. ** Short Circuit Current Rating (type 1) 5kA for SR33-22 to SR33-55; 10kA for SR33-66 to SR33-195; 18kA for SR33-241 to SR33-482 Steady State Power Loss (W) 35 42 52 60 69 83 104 121 Control Power Supply Required approx 12VA, capable of 4A for 250ms Output Capacity Overload Trip n/a Single-phase sensing; Non-adjustable; (refer to O/L trip curve) Terminals: Power / Ground external busbars / M8 external busbars / M10 UL508 Industrial Control Equipment n/a Design Standards EN/IEC 60947-4-2 “AC Semiconductor Motor Controllers and Starters” Environmental Rating IP00 Product Weight ( kg [lb] ) 4.3 [9.5] 9.7 [21.4] 13.5 [29.8] * Refer to Selection Table for deratings by application and overload trip class. ** When protected by recommended semiconductor fuse.

SR33 Series Basic Soft Starters – General Specifications and Features All Models (SR33 -22, -29, -41, -55, -66, -80, -97, -132, -160, -195, -241, -280, -350, -430, Models -482) Rated Operational Voltage / Frequency 230–460VAC rms 3-phase (-15% +10%) / 50–60Hz +/- 2Hz; Form Designation = Form 1 Impulse Withstand Voltage 4kV Insulation Voltage Rating 500V (IEC standard insulation rating. Actual testing proves insulation withstand capacity beyond 460V+10%) Control Power Supply 24VDC supplied externally to terminals X1-X2; Residual Ripple: 100mV; Spikes/Switching Peaks: 240mV; General Requirements Turn On/Off Response: No overshoot of Vout; Output voltage must be clamped to < 30V 24V DC/110V AC galvanically isolated terminals A1-A2 Control Input (Start/Stop) (1mA @ 24V DC; 3mA @ 110V AC; not suitable for use with PLC triac output) Control Relay Outputs 230VAC, 3A, resistive; 230VAC, 1A, AC15; Run – 13/14; Ready – 23/24 Start Time Setting Range 0 to 30 seconds Start Voltage Setting Range 30 to 100 percent Stop Time Setting Range 0 to 30 seconds Start Duty S1 per IEC 34-1 & VDE0530 Part 1. 3 x FLC for 5 seconds @ standard rating (Class5, 40°C [104°F]). Starts / Hour 10 starts per hour, or 5 starts + 5 soft stops per hour Index Rating Class 5; AC53b: 3-5: 355; internally bypassed (10 starts/hr) Indication Multi function LED on front panel 0 to 40 °C [32 to 104 °F] – Above 40°C [104 °F] derate linearly by 2% of unit FLC per °C Ambient Operating Temperature to a max derate of 40% at 60°C [140 °F]. (Derating not UL. Refer to separate UL Ratings and Protection Requirements) Transportation & Storage Temperature -25 to 60 °C [-13 to 140 °F] Humidity max 85% non-condensing, not exceeding 50% at 40°C [104°F] Altitude 1000m [3281 ft]. Above 1000m de-rate linearly by 1% of unit FLC per 100m to a max altitude of 2000m [6562 ft]. Pollution Degree For use in a Pollution Degree 2 environment; No corrosive gases

Book 2 (14.3) eSS-8 Soft Starters 1-800-633-0405 For the latest prices, please check AutomationDirect.com. Stellar® SR33 Series Basic Soft Starters SR33 Soft Starter Accessory

SR33 Series Basic Soft Starters – Accessory Part Number Name Price Description SR33-HS1 Insulation Kit $8.00 Heat-shrink insulation required for soft starters SR33-132 to SR33-280 used in UL applications. Can also be used with SR33-350 to SR33-482.

SR33 Soft Starter Index Ratings Index Rating Example - Bypassed Operation (AC-53b Utilization Category per IEC 60947-4-2) AC-53b = controller semiconductors provide squirrel-cage motor Start control SR33 Index Ratings – AC-53b (Bypassed Operation) * only; bypassed for Run and Stop. Trip X-Tx; IEC Index Ratings are comprised of Rated Operational Current (I ), Utilization I (A) Model # e Class OFF-time e Category, Overload Current Profile (X-Tx), OFF-time. 5 3-5; 355 (10) 22 to 482 SR33-22 to SR33-482 22 to 482 3-5; 355 (10) 3.5-12; 708 (5) 29 to 241 SR33-29 to SR33-241 10B Cycles / hr 3.5-12; 1188 (3) 280 to 482 SR33-280 to SR33-482 Start/Stop cycles per hour 3-23; 697 (5) 29 to 280 SR33-29 to SR33-280 10 OFF-time 3-23; 1177 (3) 350 to 482 SR33-350 to SR33-482 355 = 355s minimum OFF-time 4-19; 701 (5) 29 to 350 SR33-29 to SR33-350 before restart 20 4-19; 1181 (3) 430 to 482 SR33-430 to SR33-482 Overload Current Profile (X-Tx) 3-5 = 3 times rated current (Ie) for 5s 4-29; 691 (5) 41 to 430 SR33-41 to SR33-430 30 Rated Operational Current (Ie) 4-29; 1171 (3) 482 SR33-482 22 to 482 = controllers with Rated Operational * Index rating AC-53b is specified by IEC standard # 60947-4-2 Currents from 22A to 482A

Book 2 (14.3) www.automationdirect.com/soft-starters Soft Starters eSS-9 For the latest prices, please check AutomationDirect.com. Stellar® SR33 Series Basic Soft Starters SR33 Soft Starter Selection SR33 Sizing Guide These ratings correspond to IEC thermal/electronic overload The SR33 is designed for general purpose applications and trip classes, and the SR33 must be used with an overload where a traditional Wye/Delta is currently used (or considered protection device that has a rating corresponding to the Trip appropriate). Generally the motor will start off-load, and the Class selected. time to accelerate to full speed will be in the range of a few When using the selection tables to select the most appropriate seconds. SR33 model, please note the following: The standard SR33 range is suitable for the majority of applica- • The SR33 is not suitable for very high inertia loads, such as tions, and conforms to Trip Class 5, which means it is capable of centrifuges or loaded crushers, with starts > 30 seconds. withstanding three times Full Load Current for 5-second starts. • Do not use the Class 5 rating when there is a possibility of the However, there are instances where a different start profile is motor starting with a significant load. required. To satisfy these applications, the SR33 has four other ratings; Class 10B, Class 10, Class 20, and Class 30. • 2-pole motors may take longer to start, so use a minimum of Trip Class 10B.

SR33 Soft Starters – O/L Trip Class 1 Trip Start SR33 Selection Steps Application Class Time (s) Notes 1 Determine the required trip class based on the motor load and Suitable for Wye/Delta required start time. applications with < 5s 5 5 Standard start time, 2 Select the applicable SR33 part number based on the required Trip motor starts off-load Class and motor HP. Suitable for Wye/Delta Heavy 20 12–19 with applications > 12s start time Requires more starting 20 12 SR33 SELECTION – Selection Table 2 High Torque torque than a Wye/Delta Motor Soft Starter Application Trip Class Generally easy to start Centrifugal 10B 10–15 Pump when pumping water I (A) HP @ HP @ Class 5 Class 10B Class 10 Class 20 Class 30 230V 460V Positive 10 starts/hr 5 starts/hr 22 7.5 15 SR33-22 SR33-29 SR33-29 SR33-29 SR33-41 Displacement 10 5–10 Can be difficult to start Pump 29 10 20 SR33-29 SR33-41 SR33-41 SR33-41 SR33-55 (unloaded) 41 10 30 SR33-41 SR33-55 SR33-55 SR33-66 SR33-97 Off-Load 5 5 Unloaded at start 55 20 40 SR33-55 SR33-66 SR33-66 SR33-97 SR33-132 Conveyor 66 20 50 SR33-66 SR33-80 SR33-80 SR33-132 SR33-132 Heavy 20 5–10 Loaded at start conveyor 80 30 60 SR33-80 SR33-132 SR33-132 SR33-132 SR33-160 Generally fans less than 97 30 75 SR33-97 SR33-132 SR33-132 SR33-160 SR33-195 Low-Inertia Fan 10 10–20 or equal to 45kW (60hp) 132 50 100 SR33-132 SR33-195 SR33-195 SR33-241 SR33-280 Generally fans greater 160 60 125 SR33-160 SR33-241 SR33-241 SR33-280 SR33-350 High-Inertia 30 30 than or equal to 45kW Fan (60hp) 195 75 150 SR33-195 SR33-241 SR33-280 SR33-350 SR33-430 Special circuits ensure Off-Load 5 5–10 – – – – 3 starts/hr Compressor motor starts off-load 241 75 200 SR33-241 SR33-280 SR33-350 SR33-430 SR33-482 Some compressor Loaded 20 10–15 systems can be difficult 280 100 200 SR33-280 SR33-350 SR33-430 SR33-482 – Compressor to start 350 125 250 SR33-350 SR33-482 SR33-482 – – No material in basin; 5 5 Off-Load Mixer off-load 430 150 350 SR33-430 – – – – Heavy Mixer 20 10–15 Material in basin 482 200 400 SR33-482 – – – –

For Motor Overload Protection, the SR33 must be used with a separate customer-supplied Overload Protection Device that has a rating corresponding to the applicable Trip Class.

Book 2 (14.3) eSS-10 Soft Starters 1-800-633-0405 For the latest prices, please check AutomationDirect.com. Stellar® SR33 Series Basic Soft Starters SR33 Soft Starter Circuit Protection

100 90 80 70 60 UL Short Circuit Protection ** 50 Class J High-Speed SR33 Short Circuit 40 or RK5 Time-Delay Breaker Model Circuit Current-Limiting Rated 30 Number * Rating Fuse *** 40°C [104°F] Rated 600VAC 600VAC 3 starts/hr 20 SR33-22 5kA 35A – SR33-29 5kA 45A – SR33-41 5kA 60A – 10 9 SR33-55 5kA 80A – 8 7 SR33-66 10kA 125A –

Seconds to Trip 6 SR33-80 10kA 175A – 5 SR33-97 10kA 200A – 4 SR33-132 10kA 250A 350A 3 SR33-160 10kA 350A 450A 10kA 400A 500A 2 SR33-195 SR33-241 18kA 450A – SR33-280 18kA 450A – 1 * Soft starters SR33-350 to SR33-482 are NOT UL listed or recognized. Rated 1.1 1.52 2.543 3.54 .5 xIe Current ** Suitable for use on a circuit capable of delivering not more than the RMS symmetrical Amperes as indi- 241A 265 361 482 602 723 843 964 1084 cated at 480VAC maximum, when protected by fuses 280A 308 420 560 700 840 980 1120 1260 or inverse-time circuit breakers with rated maximum 350A 385 525 700 875 1050 1225 1400 1575 Amperes as indicated. *** Fuse comparable to Edison type JHL (class J) or ECSR 430A 473 645 860 1075 1290 1505 1720 1935 (class RK5). 482A 530 723 964 1205 1446 1687 1928 2169 Trip Level Current (Amps)

The SR33 can be used at ratings other than those RECOMMENDED FUSING stated. Use the above trip curves to determine the for IEC Type 1 Coordination Short Circuit Protection required unit for the duty. Rated Class J High-Speed or RK5 Time- SR33 SIBA Delay Current-Limiting Fuse* As an example, the SR33-280 will run a 200hp Short Model Circuit Semiconductor Rated 600VAC motor (280 Amp) at the maximum continuous Number Current Fuse running current and will allow an overload of 3 x Amp Edison JHL Part # 280 Amp (840A) for 12 seconds, 3 times per hour. SR33-22 2018920.50A 35A JHL35 The unit would also allow a 3.5 x overload (980A) SR33-29 45A JHL45 5kA 2018920.100A for approximately 5½ seconds, 3 times per hour. SR33-41 60A JHL60 Following an overload trip, subsequent restarts can SR33-55 80A JHL80 2018920.125A be restricted due to a cooling time. The severity of SR33-66 125A JHL125 overload determines the cooling time, which has a SR33-80 175A JHL175 maximum value of 10 minutes. 2061032.200A SR33-97 200A JHL200 10kA The Soft Starter Overload Trip curve SR33-132 2061032.250A 250A JHL250 shown on this page applies only to SR33-160 350A JHL350 model numbers SR33-241 through 2061032.400A SR33-195 400A JHL400 SR33-482, and it provides protection SR33-241 only for the Soft Starter. 2062032.630 450A JHL450 For Motor Overload Protection, a SR33-280 separate customer-supplied Overload SR33-350 18kA Protection Device must be provided. SR33-430 2063032.1000 – SR33-482 * Fuse comparable to Edison type JHL (class J) or ECSR (class RK5). Book 2 (14.3) www.automationdirect.com/soft-starters Soft Starters eSS-11 For the latest prices, please check AutomationDirect.com. Stellar® SR33 Series Basic Soft Starters

UL Maximum Surrounding Air Temperatures SR33 Maximum 40°C [104°F] Maximum 50°C [122°F] SR33 Maximum 40°C [104°F] Maximum 50°C [122°F] Model Model Number * I (A) HP @ 480V I (A) HP @ 480V Number * I (A) HP @ 480V I (A) HP @ 480V SR33-22 22 15 20 10 SR33-97 97 75 78 60 SR33-29 29 20 27 20 SR33-132 132 100 119 75 SR33-41 41 30 37 25 SR33-160 160 125 144 100 SR33-55 55 40 45 30 SR33-195 195 150 176 125 SR33-66 66 50 60 40 SR33-241 241 200 193 150 SR33-80 80 60 72 50 SR33-280 280 200 224 150 * Soft starters SR33-350 to SR33-482 are NOT UL listed or recognized. SR33 Soft Starter Timing Diagram

With Circuit Breaker With Contactor

V L1, L2, L3 Line Power

X1, X2 24VDC Control Power

23, 24 Ready Status

A1, A2 Start Input

13, 14 Run Status

~½ second V T1, T2, T3 Output Power

SR33 Soft Starter Standard Wiring Diagram For complete wiring instructions, refer to the “SR33 Digital Soft Starters Quick-start Guide: Installation and Operation” included with the SR33 soft starter and available online at www.AutomationDirect.com. Mains Supply + or L0Control Supply V or N L1 24VDC or 115VAC L2 L3 E-STOP STOP START Feeder cables OL CR Isolation and Protection Power Factor Switch-gear Correction CR Start/Stop control relay (provided by the customer) (optional by customer)

C Circuit Power Factor correction, SR33 Control Terminals Contactor if required, should NOT SR33 be installed in the SR33 Run C 1L1 3L2 5L3 13 14 PE branch circuit.

Ready/Fault PL Electrical 23 24 Ground 2T14T2 6T3 CR Start/Stop optional A1 A2 pilot light OL +24VDC X2 X1 0V Cable distance from SR33 to motor +24VDC DO NOT CONNECT AC control < 100m [328ft] POWER TO X2 & X1 power Induction Motor

Book 2 (14.3) eSS-12 Soft Starters 1-800-633-0405 For the latest prices, please check AutomationDirect.com. Stellar® SR33 Series Basic Soft Starters SR33 Soft Starter Dimensions ( mm [in] )

SR33-22 to SR33-55 – 15hp to 40hp @ 460V SR33-66 to SR33-97 – 50hp to 75hp @ 460V 62.0 134.9 157.5 [2.44] [5.31] [6.20] 73.7 203.0 [2.90] [7.99] 139.9 [5.51] 125.0 165.0 [4.92] [6.50] 145.0 Ø6.5 [5.71] 132.5 [0.26] 90.0 [5.22] [3.54] Ø8.5 [0.33] 160.0 [6.30] SR33-132 to SR33-195 – 100hp to 150hp @ 460V 157.5 203.0 [6.20] [7.99] 76.1 160.0 [3.00] [6.30]

165.0 [6.50]

145.0 [5.71] SR33-241 to SR33-482 – 200hp to 400hp @ 460V 204.0 Ø8.5 [8.03] [0.33] 48.0 48.0 160.0 [1.89] [1.89] M8 CLEARANCE [6.30] M10 EARTH

320.0 [12.60]

300.0 [11.81] 296.5 [11.67]

55.0 55.0 [2.17] [2.17]

198.6 [7.82]

104.0 [4.10]

Book 2 (14.3) www.automationdirect.com/soft-starters Soft Starters eSS-13 For the latest prices, please check AutomationDirect.com. Stellar® SR44 Full-Featured Soft Starters

Overview Advantages Standards & Approvals SR44 full-featured solid-state soft starters Mechanical Advantages • CE provide many advantages when used • Smooth acceleration; reduced mechanical • REACH instead of electromechanical contactors to shock and starting stress • RoHS control 3-phase AC induction motors. • Extend lifespan of mechanical drive train • UL listed* (E333109) The SR44 series soft starters are fully components * Options SR44-KPD & SR44-RS485 are digital, and use thyristors in all three • Fluid couplings and some clutches can be not UL approved motor phases for controlled reduced eliminated Optional accessories voltage motor starting and stop- Electrical Advantages • Communication/Modbus card SR44- ping. SR44s have an Automatic • Reduced starting currents and spikes RS485 Application Setup that fully configures the • More motors or larger motors can be • Remote keypad SR44-KPD* starter for a specific application with one started from lower-capacity power sources *(requires SR44-RS485) entry. SR44s also have a built-in • Allows motors to be started more “Optimizing” mode that reduces energy frequently Applications Economic Advantages costs when used on lightly loaded and • General purpose applications where • Lower overall costs for new installations oversized motors, and external bypass traditional across-the-line starting or • Reduced maintenance and replacement of capability for efficient running at rated wye-delta starting would typically be mechanical drive train components speed. appropriate. • Reduced starting current lowers demand Features charges • 9–242A @ 230–460VAC • Energy Optimizing mode reduces • 115 or 230 VAC selectable control voltage electrical power costs • Full three-phase motor control • Automatic Application setup feature • Fully programmable speeds installation by configuring the • Easily and separately adjustable motor SR44 for a specific application with one start and stop times setting. • External bypass capability for run • Advanced energy-saving Optimizing Mode SR44-KPD Remote Keypad improves motor efficiency and power factor while delivering demanded torque at low rpm (as compared to across-the-line control); and prolongs motor life • Can be connected ‘in-the-delta’, allowing use of a smaller Soft Starter • Can be used for motor reversing (with external contactors) • Suitable for a wide variety of motor loads • Keypad: 6 buttons with 2-line, 32-character display • Can be used with local or remote control SR44 Size 2 Soft Starter • Optional Modbus or Remote Keypad control • Programmable I/O for remote control: 1 digital input; 2 relay outputs SR44 Size 1 Soft Starter • Fault record history of last 5 trips • IP20, panel mount • Two-year warranty

SR44-RS485 Communication Card

Book 2 (14.3) eSS-14 Soft Starters 1-800-633-0405 For the latest prices, please check AutomationDirect.com. Stellar® SR44 Full-Featured Soft Starters SR44 Soft Starter Technical Specifications

SR44 Series Full-Featured Soft Starters – Size 1 – 9A-146A* Model SR44-9 SR44-16 SR44-23 SR44-30 SR44-44 SR44-59 SR44-72 SR44-85 SR44-105 SR44-146 Price $499.00 $499.00 $499.00 $499.00 No Match! $699.00 No Match! $799.00 $799.00 No Match! * Rated Current [class 10(B) trip] (A) 9 16 23 30 44 59 72 85 105 146 Rated Operational Voltage 230–460 VAC (-15% +10%) @ 50–60 Hz (±2Hz); 3 phase; (usable on 208V systems down to 196V) * Motor Rating Refer to selection table. Starters must be sized according to HP and starting class. Impulse Withstand Voltage 4kV Insulation Voltage Rating 690 VAC Short Circuit Current Rating (type 1) 5 kA 10 kA Control Power Consumption 8VA 10 VA 12 VA Control Voltage Range 115 VAC (-15% +10%) or 230 VAC (-15% +10%); 1 phase Control Fuse (external) 125 mA @ 115V; 63 mA @ 230V 200 mA @ 115V; 100 mA @ 230V Control Input 12/24 VDC or 115/230 VAC Control Relay Outputs (2) SPDT; 3A @ 230 VAC; AC11 (electro-magnet control) Start Time Setting Range 1–255 seconds Start Voltage Setting Range 10–60% [% of main power voltage] Stop Time Setting Range 0–255 seconds Ambient Operating Temperature 0–40 °C [32–104 °F] – Above 40 °C [104 °F] derate linearly by 2% of unit FLC per °C to a max derate of 40% @ 60 °C [140 °F] Transportation & Storage Temperature -25–60 °C [-13–140 °F] continuous ; -25–75 °C [-13–167 °F] NOT exceeding 24 hours Humidity max 85% non-condensing; not exceeding 50% @ 40 °C [104 °F] Altitude 1000m [3281 ft]; Above 1000m [3281 ft] derate linearly by 1% of unit FLC per 100m to MAX 2000m [6562 ft] Environmental Rating IP20 Shipping Weight 16 lb [7.3 kg] 18 lb [8.2 kg] Dimensions (HxWxD) 415 x 222 x 195 mm [16.3 x 8.74 x 7.68 in] * Refer to Selection Table for deratings by application and overload trip class.

SR44 Series Full-Featured Soft Starters – Size 2 – 174A-242A* Model SR44-174 SR44-242 Price No Match! $1,499.00 * Rated Current [class 5 starting] (A) 174 242 Rated Operational Voltage 230–460 VAC (-15% +10%) @ 50–60 Hz (±2Hz); 3 phase; (usable on 208V systems down to 196V) * Motor Rating Refer to selection table. Starters must be sized according to HP and starting class. Impulse Withstand Voltage 4kV Insulation Voltage Rating 690VAC Short Circuit Current Rating (type 1) 10 kA Control Power Consumption 18 VA Control Voltage Range 115 VAC (-15% +10%) or 230 VAC (-15% +10%); 1 phase Control Fuse (external) 200 mA @ 115V; 100 mA @ 230V Control Input 12/24 VDC or 115/230 VAC Control Relay Outputs (2) SPDT; 3A @ 230 VAC; AC11 (electro-magnet control) Start Time Setting Range 1–255 seconds Start Voltage Setting Range 10–60% [% of main power voltage] Stop Time Setting Range 0–255 seconds 0–40 °C [32–104 °F] – Above 40 °C [104 °F] derate linearly by 2% of unit FLC per °C Ambient Operating Temperature to a MAX derate of 40% @ 60 °C [140 °F] Transportation & Storage Temperature -25–60 °C [-13–140 °F] continuous ; -25–75 °C [-13–167 °F] NOT exceeding 24 hours Humidity max 85% non-condensing; not exceeding 50% @ 40 °C [104 °F] Altitude 1000m [3281 ft]; Above 1000m [3281 ft] derate linearly by 1% of unit FLC per 100m to MAX 2000m [6562 ft] Environmental Rating IP20 Shipping Weight 40 lb [18 kg] 50 lb [23 kg] Dimensions (HxWxD) 520 x 340 x 265 mm [20.5 x 13.4 x 10.4 in] * Refer to Selection Table for deratings by application and overload trip class.

Book 2 (14.3) www.automationdirect.com/soft-starters Soft Starters eSS-15 For the latest prices, please check AutomationDirect.com. Stellar® SR44 Full-Featured Soft Starters SR44 Soft Starter Optional Accessories

SR44 Series Full-Featured Soft Starters – Optional Accessories Part Number Name Price Description Can be used to remotely monitor and/or program SR44 Soft Starters. Rated NEMA 4/4X. No external power wiring required. Works with all SR44 Soft Starters. Includes: Keypad, Cable (3m). SR44-KPD Remote Keypad No Match! NOTE: Optional SR44-RS485 communication card must be installed to use the SR44-KPD remote keypad. SR44-KPD can control multiple SR44 Soft Starters, but only one at a time. Can be used to establish RS-485 communication between an SR44 Soft Starter and most Modbus masters. A PLC or PC is required to demux the data returned from the SR44. (See the User Manual for details and PLC sample ladder programs.) Plugs directly onto the control board of an SR44. No external power needed. Has both RJ45 connections and screw-type terminal strip connections; can be used with CAT5 RJ45-terminated Ethernet cable, or with twisted pair shielded wiring. SR44-RS485* Communication Card * $95.00 Max # of networked SR44s: 8. Max network length: 25m [82 ft] for RJ45 connections; 1200m [3937 ft] for RS-485 screw-terminal connections. Can be used with an SR44-KPD to create an internal RS-485 network between SR44 Soft Starters (one remote keypad to control multiple SR44s, one at a time). Works with all SR44 Soft Starters. Includes: Circuit card, Remote/Local selector switch. Communication cables for use with the SR44-RS485 communication card are available in our ZIPLink Wiring Solutions section: SR44-485HD15-CBL-2 for connection to certain PLCs; SR44-485RJ45-CBL-2 for connection to certain RS485 networks

SR44 Index Ratings (per IEC 60947-4-2)

SR44 Index Ratings * Standard Operation Bypassed Operation Model # Ie (A) AC-53a; X-Tx; F-S AC-53b; X-Tx; OFF-time AC-53a: 5-4; 99-10 AC-53b: 5-4; 120 SR44-9 to SR44-105 9 to 105 AC-53a: 3-35; 99-10 AC-53b: 3-35; 120 AC-53a: 4-6; 99-10 AC-53b: 4-6; 120 SR44-146 to SR44-174 146 to 174 AC-53a: 3-35; 99-10 AC-53b: 3-35; 120 AC-53a: 4-6; 60-3 AC-53b: 4-6; 420 SR44-242 242 AC-53a: 3-35; 60-3 AC-53b: 3-35; 420 * Index ratings AC-53a and AC-53b are specified by IEC standard # 60947-4-2

In line with the stated IEC starting duties, starters of 242 Amps and above have an enforced off period of seven minutes set as standard. During this period the display indicates “Stopped. Cooling”, and the starter will not respond to a start signal. IEC Index Ratings are comprised of Rated Operational Current (Ie), Utilization Category, Overload Current Profile (X-Tx), and Duty Cycle (F-S) or OFF-time. Index Rating Example - Standard Operation (AC-53a Utilization Category per IEC 60947-4-2) 9 to 105 - AC-53a: 3-35; 99-10 Duty Cycle (F-S) 99-10 = 99% duty cycle - 10 cycles/hr Overload Current Profile (X-Tx) 3-35 = 3 times rated current (Ie) for 35s Utilization Category AC-53a = controller semiconductors provide squirrel-cage motor Start, Run, and Stop control Rated Operational Current (Ie) 9 to 105 = controllers with Rated Operational Currents from 9A to 105A

Index Rating Example - Bypassed Operation (AC-53b Utilization Category per IEC 60947-4-2) 9 to 105 - AC-53b: 5-4; 120 OFF-time 120 = 120s minimum OFF-time before restart Overload Current Profile (X-Tx) 5-4 = 5 times rated current (Ie) for 4s Utilization Category AC-53b = controller semiconductors provide squirrel-cage motor Start control only; bypassed for Run and Stop Rated Operational Current (Ie) 9 to 105 = controllers with Rated Operational Currents from 9A to 105A

Book 2 (14.3) eSS-16 Soft Starters 1-800-633-0405 For the latest prices, please check AutomationDirect.com. Stellar® SR44 Full-Featured Soft Starters SR44 Soft Starter Selection

SR44 Soft Starters – O/L Trip Classes 1 Default 10 Heavy 20 SR44 Soft Starter Selection Steps Agitator 10 1 Determine the required trip class based on the motor load and required start time. Air Compressor - Equalized 10B Air Compressor - Loaded 20 2 Select the applicable SR44 part number based on the required Trip Class, Ball Mill 20 motor HP, and connection type. Centrifuge - extended start needed for sizing Chiller 10B Conveyor - Unloaded 10B SR44 Soft Starters – Selection Table 2 * Conveyor - Loaded 20 Motor Size Soft Starter Size Crusher 30 In-Line Connection In-Delta Connection ** Application Trip Class Escalator 10B HP @ HP @ HP @ HP @ HP @ HP @ Class Class I (A) I (A) Class 20 Class 30 * Fan - Low Inertia < 85A 10 208V* 230V 460V 208V* 230V 460V 10B 10 * Fan - High Inertia > 85A 30 9 2 3 5 15 2 3 7.5 SR44-9 SR44-16 SR44-23 Feeder - Screw 10 16 3 5 10 27 3 5 15 SR44-16 SR44-23 SR44-30 Grinder 20 23 5 7.5 15 39 5 7.5 25 SR44-23 SR44-30 SR44-44 Hammer Mill 20 30 7.5 10 20 51 7.5 10 30 SR44-30 SR44-44 SR44-59 Lathe Machine 10B 44 10 15 30 76 10 15 50 SR44-44 SR44-59 SR44-72 Mills - Flour, etc. 20 59 15 20 40 102 15 20 60 SR44-59 SR44-72 SR44-85 Mixer - Unloaded 10B 72 20 25 50 124 20 25 75 SR44-72 SR44-85 SR44-105 Mixer - Loaded 20 85 25 30 60 147 25 30 100 SR44-85 SR44-105 SR44-146 Pelletizer 20 105 30 40 75 181 30 40 125 Plastic and Textile Machines 10B SR44-105 SR44-146 SR44-174 146 50 60 100 252 50 60 150 SR44-146 SR44-174 Press - Flywheel 20 SR44-242 174 60 75 150 301 60 75 250 SR44-174 * Pump - Centrifugal 10B SR44-242 * Pump - Positive Displacement 202 60 75 150 349 60 75 300 n/a*** 10 - Unloaded SR44-242 242 75 100 200 419 75 100 300 n/a*** n/a*** Rolling Mill 20 * 208V applications are UL listed only as low as 196V. Saw - Band 10 ** For In-Delta connections, all six motor wires must be available for connection, and it is critical to exactly follow the Saw - Circular 20 In-Delta wiring diagram in the SR44 User Manual or Quick-start Guide. (Nine-lead motors CANNOT be connected in the delta.) The Soft Starter will only sense the Phase Current, which is about 58% of the Line Current. Screen - Vibrating 20 *** Please consider SR55 series soft starters for higher-current applications. Transformer, Voltage Regulator 10B Tumbler 10 Wood Chipper 30 * Commonly required applications

Book 2 (14.3) www.automationdirect.com/soft-starters Soft Starters eSS-17 For the latest prices, please check AutomationDirect.com. Stellar® SR44 Full-Featured Soft Starters

SR44 Max Overcurrent Protection

UL requires Recognized special Semiconductor Fuse Types for SR44 Soft Starters purpose fuses (JFHR2) for the UL JFHR2 Fuses for UL Applications * Non-UL ** S.C. protection of semi-conductor Model I Mersen Bussmann Edison e With- Bussman devices (rated 700 VAC, as indi- Name (A) (formerly Ferraz) Amps Model Model Amps stand Model # * cated in the Semiconductor Fuse Model # * # ** # ** Table) be used to obtain the short SR44-9 9 circuit ratings required by UL. 170M3110 6.9 URD 30 D08A 0063 63 FWP-50B E70S50 50 SR44-16 16 Suitable for use on a circuit capable SR44-23 23 of delivering not more than the indi- 5kA 170M3112 6.9 URD 30 D08A 0100 100 FWP-80B E70S80 80 SR44-30 30 cated RMS Symmetrical Amperes at SR44-44 44 170M3114 6.9 URD 30 D08A 0160 160 maximum rated operational voltage, FWP-125A E70S125 125 when protected by Semiconductor SR44-59 59 170M3115 6.9 URD 30 D08A 0200 200 SR44-72 72 Fuse type manufactured by 170M3116 6.9 URD 30 D08A 0250 250 FWP-200A E70S200 200 Company and Model Number indi- SR44-85 85 cated in the table. SR44-105 105 10 kA 170M3119 6.9 URD 30 D08A 0400 400 FWP-300A E70S300 300 These fuses are for short circuit SR44-146 146 protection of the semiconductors and SR44-174 174 170M3121 6.9 URD 30 D08A 0500 500 FWP-400A E70S400 400 must be mounted externally by the SR44-242 242 170M4114 6.9 URD 31 D08A 0500 500 FWP-500A E70S500 500 user between the unit and the * Use these fuses with SR44 soft starters in UL applications. incoming main power source; not ** Use these fuses with SR44 soft starters only in NON-UL applications. between the unit and the motor.

SR44 Internal Overload Trip ‘Current limit’, ‘Overload level’ and ‘Overload delay’ settings may be adjusted to limit overload currents in Overload start point accordance with the trip curves shown here. 1000 (See Menu Structure in User Manual or Seconds Quick-start Guide for default settings.) to trip

100 » For motors with FLCs lower than the rated current of the SR44, the ‘Overload level’ may be adjusted using the following formula: 10 Overload Level = Motor FLC x 1.1(A) Note: The overload monitors only one of the phases, and 1 the ‘Current Limit’ level is active only during motor starting. Delay = 140 (default) IMPORTANT: Delay = 80 We recommend that the control supply is maintained between starts to ensure the integrity 0.1 Delay = 30 of the overload, which will reset on control power removal. Delay = 10 7.2 x FLC shearpin cutoff 0.01 1 2 3 4 5 6 7 8 9 10 Fault current (Motor Current x N)

Book 2 (14.3) eSS-18 Soft Starters 1-800-633-0405 For the latest prices, please check AutomationDirect.com. Stellar® SR44 Full-Featured Soft Starters SR44 Dimensions Size 2: SR44-174 to SR44-242 250.0 Size 1: SR44-9 to SR44-146 [9.84] 500. 0 520. 0 [19.69] [20.47] 400.0 [15.75] 415.0 [16.34] 380.0 [14.96] 362.0 [14.25]

195.0 [7.68] 125.0 [4.92] 150.0 [5.91] All dimensions in mm [in] 222.0 [8.74] 340.0 Mounting holes & slots suitable for Mounting Holes/Slots M6 or 1/4” fittings [13.39] Unit weights: All dimensions in mm [in] SR44-9 to -44: 7.3 kg [16 lb] Mounting centers 250 x 500 [9.8 x 19.7] suitable for M6 fittings SR44-59 to -146: 8.3 kg [18 lb] Two “keyholes” at top; two open slots at the bottom Allow clearances: Unit weights: SR44-174: 16 kg [35 lb] 15 mm [0.59 in] each side 75 mm [3.0 in] top & bottom SR44-242: 22 kg [49 lb] 25 mm [0.98 in] front Allow clearances: 15 mm [0.59 in] each side 265. 0 [10.43] 75 mm [3.0 in] top & bottom SR44 size 1: SR44-9 to SR44-146 25 mm [0.98 in] front

SR44 size 2: SR44-174 to SR44-242 Ventilation for Enclosures When fitting an SR44 into an electrical enclosure, ventilation must be provided if the heat output of the unit is greater than the enclosure will dissipate. If the enclosure cannot dissipate enough heat, use the following formula SR44-KPD Mounting Dimensions to determine the fan requirement. An allowance has been incorporated 4 in (approximate) into the formula so that the figure for “Q” is the air delivery quoted in the 2.500 in [63.5 mm] fan supplier’s data.

Q = (4 x Wt) / (tmax – tamb) (A) (A) • Q = required volume of air (cubic meters per hour; m3/h) • Wt = total heat produced by the unit and all other heat sources within the

enclosure (Watts) Four Places • t max = maximum permissible temperature within the enclosure (40 °C for a Ta pped mounting holes; use #29 drill and 8-32 tap (Clearance mounting holes; use #19 or 0.166 in drill) fully rated SR44) (Use RTV sealant if NEMA 4X rating is required) • t amb = temperature of the air entering the enclosure (°C) (If you prefer to work in CFM, substitute °F for °C. Q will then be in CFM, 5.5 in (approximate) SR44-KPD Remote Keypad Mounting Dimensions 4.810 in [122.2 mm] instead of m3/h.) An approximation of the heat produced by the SR44 (in Watts) can be 1-11/16 in diameter hole; made by multiplying the Full Load Line Current by three. Exact figures use 1.25 in conduit knockout for unit Full Load Current are available in the SR44 user manual.

(B) 1.340 in [34.0 mm]

(A) (A)

1.250 in [31.75 mm]

Book 2 (14.3) www.automationdirect.com/soft-starters Soft Starters eSS-19 For the latest prices, please check AutomationDirect.com. Stellar® SR55 Full-Featured Soft Starters Overview Advantages Optional Accessories SR55 full-featured solid-state Soft Mechanical Advantages • EtherNet/IP communication module • Smaller physical size than equivalent Starters provide many advantages SR44 models (even with the built-in • Modbus TCP communication module when used instead of electromechan- bypass contactors) • Modbus serial communication splitter ical contactors to control 3-phase • Smooth acceleration; reduced • RJ12 to RJ45 adapter AC induction motors. The SR55 mechanical shock and starting stress • Power terminal IP20 finger guards Soft Starters are fully digital, and use • Extend lifespan of mechanical drive- • Remote touchscreen thyristors in all three motor phases for train components • Replacement touchscreen controlled reduced voltage motor starting • Fluid couplings and some clutches can and stopping. SR55s have an Automatic be eliminated • Replacement cooling fans Application Setup that fully configures the Electrical Advantages starter for a specific application with one • Reduced starting currents and spikes Applications entry. SR55s also have a built-in internal • More motors or larger motors can be • General purpose applications where traditional across-the-line starting or bypass and patented iERS (intelligent started from lower-capacity power sources wye-delta starting would typically be Energy Recovery System) that reduces appropriate energy costs when used on lightly loaded • Allows motors to be started more frequently • Applications with oversized or lightly and oversized motors. loaded motors (iERS reduces energy Economic Advantages usage) • Lower overall costs for new installations • Applications requiring lower inrush Features • Bypass relays built in currents • 17–477A @ 200–480VAC • Reduced maintenance and replacement • 24VDC, 110VAC, or 230VAC selectable of mechanical drive-train components control voltage • Reduced starting current lowers demand • Internally bypassed during run charges • Full three-phase motor control • iERS (intelligent Energy Recovery • Built-in SCR failure protection System) reduces electrical power costs • Full motor overload protection • Automatic Application setup feature speeds installation by configuring the • Full data logging (fault records, motor SR55 for a specific application with one current, operational status, etc.) setting • Fully programmable • Easily and separately adjustable motor start and stop times • iERS (intelligent Energy Recovery System) saves energy on lightly-loaded motors • Can be connected ‘in-the-delta’, allowing use of a smaller Soft Starter (no iERS optimizing with in-delta connections) • Can be used for motor reversing (with external contactors) • Suitable for a wide variety of motor loads • Touchscreen with easy-to-navigate menu structure and quick automatic application set up • Can be used with local or remote control • Integrated Modbus RTU, or optional Modbus TCP or EtherNet/IP communication • Optional remote touchscreen available • Programmable analog I/O, digital inputs, and relay outputs for remote control • Fault record history of last 10 trips (using the download fault log will give faults and running data for the life of the SR55) • IP20, panel mount with optional finger guards for frame sizes 1 and 2 soft starters • Two-year warranty • CE, ETL (CSA C22.2 No.14 and UL 508), REACH, RoHS

Book 2 (14.3) eSS-20 Soft Starters 1-800-633-0405 For the latest prices, please check AutomationDirect.com. Stellar® SR55 Full-Featured Soft Starters SR55 Soft Starter Technical Specifications SR55 Series Full-Featured Soft Starters – 17A–96A * SR55 SR55 SR55 SR55 SR55 SR55 SR55 SR55 SR55 Model -017 -021 -027 -034 -040 -052 -065 -077 -096 Frame Size 1 Price $843.00 $865.00 $875.00 $905.00 $975.00 $1,055.00 $1,125.00 $1,258.00 $1,288.00

* Rated Current Ie (A) 17 21 27 34 40 52 65 77 96 Rated Operational Voltage 200VAC to 480VAC * Motor Rating @ 200V (hp) 3 5 7.5 10 10 15 20 20 30 * Motor Rating @ 208V (hp) 5 5 7.5 10 10 15 20 25 30 * Motor Rating @ 230V (hp) 5 5 7.5 10 10 15 20 25 30 * Motor Rating @ 460V (hp) 10 15 20 25 30 40 50 60 75 Trip Class programmable 10 to 30

Index Rating [per IEC 60947-4-2] Ie: AC-53a: 3.5–17: 90–5 Impulse Withstand Voltage 4kV Insulation Voltage Rating 480V Short Circuit Current Rating (type 1) (kA) 5 10 Control Power Consumption 60W inrush to latch internal bypass relays; 4W steady state Control Voltage Range 24VDC +10%-15% or 110–230VAC +10%-15% Control Fuse (external) 4A Control Inputs (3) DI @ 24VDC, 110VAC, or 230VAC; (1) PTC Thermistor; (1) AI @ 0–10VDC 10mA max or 4–20mA Control Outputs (3) N/O relay and (1) N/C relay @ 30VDC 0.5A / 230VAC 1A resistive; (1) AO @ 0–10VDC 10mA max or 4–20mA ** Start Time Setting Range (s) 1 to 300 Start Voltage Setting Range (%) 10 to 100 ** Stop Time Setting Range (s) 0 to 300

Ambient Operating Temperature -20°C [-4°F] to 50°C [122°F] ; above 50°C derate linearly by 4% of SR55 Ie per °C to a maximum of 60°C (140°F) Transportation & Storage Temperature -20°C to 60°C [-4°F to 140°F] continuous Humidity max 85% non-condensing, not exceeding 50% @ 40°C [104°F]

Maximum Altitude 1,000m [3,281ft] ; above 1000m derate by 1% of SR55 Ie per 100m (328ft) to a maximum altitude of 2000m (6562ft) Main Circuit: IP00 (IP20 with optional finger guards for sizes 1&2 only); Control Circuit: IP20 Environmental Rating No corrosive gases permitted Weight (lb [kg]) 6.6 [3.0] 7.7 [3.5] *** Agency Approvals CE, CSA C22.2 No.14 (ETL tested), ETL 4004274, REACH, RoHS, UL508 (ETL tested) * Refer to Selection Table for deratings by application and overload trip class. ** Start Time and Stop Time define the length of time the soft starter varies the voltage to the motor. While a Variable Frequency Drive (AC Drive) can define motor speed throughout the acceleration and deceleration ramps by varying its output frequency, a soft starter only controls average voltage to the motor and cannot accurately control motor speed. Therefore, motor speed during acceleration and deceleration can vary with load. Example: a conveyor soft starter could have a Start Time of 10s. If the conveyor is empty, the motor may actually reach top speed in 8s. If the conveyor is heavily loaded, the motor may not reach full speed until 10s. For more information, please see the SR55 User Manual - “Appendix B: Soft Starter Application Considerations.” *** To obtain the most current agency approval information, see the Agency Approval Checklist section on the specific part number’s web page.

Book 2 (14.3) www.automationdirect.com/soft-starters Soft Starters eSS-21 For the latest prices, please check AutomationDirect.com. Stellar® SR55 Full-Featured Soft Starters SR55 Soft Starter Technical Specifications SR55 Series Full-Featured Soft Starters – 124A–477A * Model SR55-124 SR55-156 SR55-180 SR55-242 SR55-302 SR55-361 SR55-414 SR55-477 Frame Size 2 3 Price $1,413.00 $1,995.00 $2,180.00 $2,215.00 $2,375.00 $2,785.00 $3,495.00 $3,995.00

* Rated Current Ie (A) 124 156 180 242 302 361 414 477 Rated Operational Voltage 200VAC to 480VAC * Motor Rating @ 200V (hp) 40 50 60 75 100 125 150 150 * Motor Rating @ 208V (hp) 40 50 60 75 100 125 150 150 * Motor Rating @ 230V (hp) 40 60 60 75 100 150 150 150 * Motor Rating @ 460V (hp) 100 125 150 200 250 300 350 400 Trip Class programmable 10 to 30

Index Rating [per IEC 60947-4-2] Ie: AC-53a: 3.5–17: 90–5 Ie: AC-53a: 3.5–17: 90–3 Impulse Withstand Voltage 4kV Insulation Voltage Rating 480V Short Circuit Current Rating (type 1)(kA) 10kA 18kA Control Power Consumption 60W inrush to latch internal bypass relays; 4W steady state 120W inrush; 4W steady state Control Voltage Range 24VDC +10%-15% or 110–230VAC +10%-15% 110VAC +10%-15% Control Fuse (external) 4A Control Inputs (3) DI @ 24VDC, 110VAC, or 230VAC; (1) PTC Thermistor; (1) AI @ 0–10VDC 10mA max or 4–20mA Control Outputs (3) N/O relay and (1) N/C relay @ 30VDC 0.5A / 230VAC 1A resistive; (1) AO @ 0–10VDC 10mA max or 4–20mA ** Start Time Setting Range (s) 1 to 300 Start Voltage Setting Range (%) 10 to 100 ** Stop Time Setting Range (s) 0 to 300

Maximum Altitude 1,000m [3,281ft] ; above 1000m derate by 1% of SR55 Ie per 100m (328ft) to a maximum altitude of 2000m (6562ft) Environmental Rating Main Circuit: IP00 (IP20 with optional finger guards for sizes 1&2 only); Control Circuit: IP20 Weight (lb [kg]) 12.1 [5.5] 14.3 [6.5] 35.3 [16.0] 46.7 [21.2] *** Agency Approvals CE, CSA C22.2 No.14 (ETL tested), ETL 4004274, REACH, RoHS, UL508 (ETL tested) CE, REACH, RoHS * Refer to Selection Table for deratings by application and overload trip class. ** Start Time and Stop Time define the length of time the soft starter varies the voltage to the motor. While a Variable Frequency Drive (AC Drive) can define motor speed throughout the acceleration and deceleration ramps by varying its output frequency, a soft starter only controls average voltage to the motor and cannot accurately control motor speed. Therefore, motor speed during acceleration and deceleration can vary with load. Example: a conveyor soft starter could have a Start Time of 10s. If the conveyor is empty, the motor may actually reach top speed in 8s. If the conveyor is heavily loaded, the motor may not reach full speed until 10s. For more information, please see the SR55 User Manual - “Appendix B: Soft Starter Application Considerations.” *** To obtain the most current agency approval information, see the Agency Approval Checklist section on the specific part number’s web page.

Book 2 (14.3) eSS-22 Soft Starters 1-800-633-0405 For the latest prices, please check AutomationDirect.com. Stellar® SR55 Full-Featured Soft Starters SR55 Energy-Saving iERS Feature Intelligent Energy Recovery System How Much Will iERS Save? iERS is an advanced SR55 feature that can reduce the The savings realized by using iERS will vary by application, how energy consumed by lightly-loaded (or oversized) motors. heavily the motor is loaded, and the losses internal to the motor. iERS matches the power consumption to the load by moni- While these factors can be difficult to quantify, the following esti- toring and regulating voltage, current, and power factor mating tools and examples may help predict your potential savings: during the motor starting and running stages. iERS auto- Estimating Energy Savings matically bypasses itself when it is not needed (as the motor Basis for estimations: approaches full load torque/current), and continues moni- • 3-phase squirrel cage induction motor, standard type. toring to re-engage itself as needed (as the required motor • Supply: 380 to 440V, 50Hz. torque/current decreases). • Supply voltage > minimum working voltage on motor rating plate. In its most basic function, iERS reduces the voltage being • Operation 30% rated nameplate full load. fed to the motor when the motor does not need it. While Energy Savings Estimations – Table 1 the torque (and therefore current) required by the load stays 4-Pole Motor Size kW HP Estimated Savings (% rated kW) the same, reducing the voltage to the motor reduces excess 5 7.5 10 magnetizing current inside the motor. For a more detailed 22.5 30 6.5 Less than explanation of how iERS reduces magnetizing current and 55 75 3.5 saves energy, please see “Chapter 4: Principles of IERS” in 110 150 2.5 the SR55 User Manual. More than 110 150 1.5 Many, if not most, AC motor applications are oversized when the motor FLA is compared to actual running current. Energy Savings Modifying Factors – Table 2 Oversizing can be due to non-optimal design, but can also Motor Poles Motor Slip occur intentionally: many applications need a larger motor Number of Poles Add (% kW) % Slip Add (% kW) for starting reasons, for available headroom, for future 2 -0.5 0.5 -0.5 expansion, etc. Other applications may have different 4 0 2 0 motor demands based on loading; think of an “up” esca- 6 0.5 3.3 0.5 lator. A fully-loaded escalator requires a lot of torque 8 1 5 1 (current), while an empty escalator requires significantly less Examples of estimated savings: torque (current) to maintain speed. When the escalator is 1) 37.5 kW 4-pole motor empty, the motor will not draw as much current as its FLA. From Table 1, use the estimated savings figure for the next higher When the SR55 senses this reduced torque load, the starter rating, i.e. 55 kW = 3.5% of full rated kW. will reduce the voltage to the motor. This reduced voltage The savings would be approximately 3.5% x 37.5 kW = 1.3125 kW. results in reduced magnetizing current in the motor (and Savings % = kW saved / (30% loaded motor kW) thereby saves energy). Note that the current required by the = 1.3125 kW / (30% x 37.5 kW) = 12%. load stays the same; only magnetizing current is reduced. 2) 37.5 kW 2-pole motor From Table 1, use the estimated savings figure for the next higher rating, i.e. 55 kW = 3.5% of full rated kW. From Table 2, apply the pole-number factor of -0.5 %. The savings would be approximately (3.5 % - 0.5 %) x 37.5 kW = 1.125 kW. Savings % = kW saved / (30% loaded motor kW) = 1.125 kW / (30% x 37.5 kW) = 10%. Real-world applications: iERS has been installed in many pump-jack applications (for oil drilling, etc.). The cycle of a pump jack is extreme; for part of the cycle the pump requires near-full torque. In the other part of the cycle, the pump jack is very lightly loaded. In this extreme application, iERS reduced average power consumed by the pump jack (over 30-minute intervals) from 23.99kW down to 19.85kW. This is a 17% reduction in consumed power. Again, this is an extreme example and is not indicative of what a typical application may save. iERS has been installed on metal grinding equipment. A machine that was retrofitted with an iERS starter had a 75hp motor on a spindle that typically ran at about 20–30% of full load. iERS was able to reduce the energy consumed by this motor by 13–15%.

Book 2 (14.3) www.automationdirect.com/soft-starters Soft Starters eSS-23 For the latest prices, please check AutomationDirect.com. Stellar® SR55 Full-Featured Soft Starters SR55 Soft Starter Overcurrent Protection

Customer-supplied external power-circuit isolation devices (contactors, disconnect switches, fusible disconnects, shunt-trip circuit breakers, etc.) and short-circuit protection devices (circuit breakers, fuses, etc.) are required for use with SR55 soft starters. External Short-Circuit Protection Required for SR55 SR55 SR55 SR55 SR55 SR55 SR55 SR55 SR55 SR55 SR55 Model Number -017 -021 -027 -034 -040 -052 -065 -077 -096

Rated Operational Current Ie (A) 17 21 27 34 40 52 65 77 96 Mersen 6,9 URD 30xx Bussmann 170M30xx Semiconductor Fuse Type Bussmann 170M31xx #1 Bussmann 170M32xx (class aR) SIBA 20 61xx Rating (A) 100 100 160 160 160 200 200 250 315 #2 Class J High-Speed Current-Limiting Fuse Rating Z1 (A) 30 45 60 70 90 110 125 150 175 #3 Class J Time-Delay Fuse Rating Z2 (A) 30 40 50 60 70 100 125 150 175 #3 UL Listed Inverse Time-Delay Circuit Breaker Rating Z3 (A) 60 60 60 60 60 150 150 250 300

Rated Conditional Short-Circuit Current Iq (kA) 5 10 SR55 SR55 SR55 SR55 SR55 SR55 SR55 SR55 SR55 Model Number -124 -156 -180 -242 -302 -361 -414 -477 –

Rated Operational Current Ie (A) 124 156 180 242 302 361 414 477 Mersen 6,9 URD 31xx Mersen 6,9 URD 33xx Bussmann 170M40xx Bussmann 170M60xx Semiconductor Fuse Type Bussmann 170M41xx Bussmann 170M61xx #1 Bussmann 170M42xx Bussmann 170M62xx (class aR) SIBA 20 61xx SIBA 20 63xx Rating (A) 400 550 550 700 800 900 1000 1100 – #2 Class J High-Speed Current-Limiting Fuse Rating Z1 250 350 400 500 600 600 n/a #3 Class J Time-Delay Fuse Rating Z2 (A) 225 300 350 450 500 500 600 600 #3 UL Listed Inverse Time-Delay Circuit Breaker Rating Z3 (A) 350 450 500 700 800 1000 1000 1000

Rated Conditional Short-Circuit Current Iq (kA) 10 18 #1 Correctly selected semiconductor fuses can provide additional protection against damage to the SR55 unit (this is sometimes referred to as type 2 coordination). These semiconductor fuses are recommended to provide this increased protection.

#2 Suitable for use in a circuit capable of delivering not more than Iq rms Symmetrical Amperes, when protected by Class J high-speed current-limiting 600V-rated fuses with a maximum trip rating of Z1 (IEC Type 1 coordination short-circuit protection). #3 Suitable for use in a circuit capable of delivering not more than Iq rms Symmetrical Amperes, 480 Volts maximum, when protected by Class J time delay fuses with a maximum rating of Z2, or by a circuit breaker with an interrupting rating not less than Z3 rms Symmetrical Amperes, 480 Volts maximum as in table.

Motor overload 'cold' trip curves SR55 Soft Starter Overload Trip (20°C ambient) The SR55 soft starter provides motor overload protection, which can be configured through the touchscreen. Overload trip settings are determined by the Motor Current setting and the Trip Class setting. Trip class choices are class 10, class 20, and class 30. The SR55 soft starters are protected using full I2T motor overload with memory. rip time ( seconds ) rip time T

Multiple of Motor FLA

Book 2 (14.3) eSS-24 Soft Starters 1-800-633-0405 For the latest prices, please check AutomationDirect.com. Stellar® SR55 Full-Featured Soft Starters SR55 Soft Starter Selection

SR55 Soft Starters – SR55 Soft Starter Selection Steps O/L Trip Classes 1 1 Determine the required trip class based on the motor load and required start time. See examples Default 10 to the left (refer to the definitions of Class 10, 20, and 30 Trip Curves on page 24). Heavy 20 2 Below, select the row with the correct motor full load amps. Then select the correct SR55 soft starter Agitator 10 to the right based on Trip Class (longer start times require a larger starter). Notice that there are Compressor - Centrifugal 20 different Motor Amps columns for starters wired In-Line (most common) and In-Delta. Select the Compressor - Reciprocating 20 applicable SR55 part number based on the required Trip Class, motor HP, and connection type. Compressor - Rotary Screw 20 Derating is necessary if your application requires multiple starts per hour. Compressor - Rotary Vane 10 Refer to page 27, “SR55 Increased Starts per Hour – Derating.” Compressor - Scroll 10 Ball mill 20 SR55 Soft Starters – Selection Table 2 Centrifuge* 30 (per IEC 60947-4-1:2009 Table G.1) Bow Thruster - Zero Pitch 10 Motor Size Soft Starter Size Bow Thruster - Loaded 20 In-Line Connection In-Delta Connection * Application Trip Class Conveyor - Unloaded 10 HP @ HP @ I (A) I (A) Class 10 Class 20 Class 30 Conveyor - Loaded 20 200V 208V 230V 460V 200V 208V 230V 460V Crusher 30 17 3 5 5 10 29 7.5 7.5 10 20 SR55-017 SR55-021 SR55-027 Fan - Low Inertia < 85A 10 21 5 5 5 15 36 10 10 10 25 SR55-021 SR55-027 SR55-034 Fan - High Inertia > 85A 30 27 7.5 7.5 7.5 20 47 10 15 15 30 SR55-027 SR55-034 SR55-040 Feeder - screw 10 34 10 10 10 25 59 15 15 20 40 SR55-034 SR55-040 SR55-052 Grinder 20 40 10 10 10 30 69 20 20 25 50 SR55-040 SR55-052 SR55-065 Hammer mill 20 52 15 15 15 40 90 25 30 30 60 SR55-052 SR55-065 SR55-077 Lathe machines 10 65 20 20 20 50 113 30 30 40 75 SR55-065 SR55-077 SR55-096 Mills - Flour, etc. 20 77 20 25 25 60 133 40 40 50 100 Mixer - Unloaded 10 SR55-077 SR55-096 SR55-124 Mixer - Loaded 20 96 30 30 30 75 166 50 50 60 125 SR55-096 SR55-124 SR55-156 Molding Machine 10 124 40 40 40 100 215 60 75 75 150 SR55-124 SR55-156 SR55-180 Pelletizers 20 156 50 50 60 125 270 75 75 100 200 SR55-156 SR55-180 SR55-242 Plastic and textile machines 10 180 60 60 60 150 312 100 100 125 250 SR55-180 SR55-242 SR55-302 Press, flywheel 20 242 75 75 75 200 419 150 150 150 300 SR55-242 SR55-302 SR55-361 Pump - Submersible 10 302 100 100 100 250 523 150 150 200 450 SR55-302 SR55-361 SR55-414 Centrifugal Pump - Submersible 361 125 125 150 300 625 200 200 250 500 SR55-361 SR55-414 SR55-477 10 Rotodynamic 414 150 150 150 350 717 250 250 250 500 SR55-414 SR55-477 n/a Pump - Positive displacement 20 477 150 150 150 400 826 250 300 300 600 SR55-477 n/a n/a Reciprocating * For In-Delta connections, all six motor wires must be available for connection, and it is critical to exactly follow the In-Delta Pump - Positive 20 wiring diagram in the SR55 User Manual or Quick-start Guide. Nine-lead motors CANNOT be connected in the delta. The Soft displacement Rotary Starter will only sense the Phase Current, which is about 58% of the Line Current. Pump Jack 20 * For In-Delta connections, a main contactor that is controlled by the Run relay of the SR55 must be used in the incoming power Rolling mill 20 circuit for isolation. Circuit breaker isolation alone is not sufficient. * iERS energy optimizing feature is not available for In-Delta connections. Roots Blower 20 Saw - Band 10 Saw - Circular 20 Screen - Vibrating 20 Shredder 30 Transformers, voltage 10 regulators Tumblers 20 Wood chipper 30 * Size centrifuge starter at I(A) = (motor FLA x 2.3). Trip Class 30.

Book 2 (14.3) www.automationdirect.com/soft-starters Soft Starters eSS-25 For the latest prices, please check AutomationDirect.com. Stellar® SR55 Full-Featured Soft Starters SR55 Index Ratings (per IEC 60947-4-2) SR55 Index Ratings *

Model Number Ie (A) Standard Operation AC-53a; X-Tx; F-S SR55-017 to SR55-180 17 to 195 AC-53a: 3.5-17; 90-5 SR55-242 to SR55-477 242 to 500 AC-53a: 3.5-17; 90-3 * Index ratings AC-53a and AC-53b are specified by IEC standard # 60947-4-2. IEC Index Ratings are comprised of Rated Operational Current (Ie), Utilization Category, Overload Current Profile (X-Tx), and Duty Cycle (F-S) or OFF-time. Index Rating Example – Standard Operation (AC-53a Utilization Category per IEC 60947-4-2) 17 to 195 - AC-53a: 3.5-17; 90-5 Duty Cycle (F-S) 90-5 = 90% duty cycle - 5 cycles/hr [if multiple starts/hr are required, 90% D.C. requires off time ≥ 10% of previous run time] Overload Current Profile (X-Tx) 3.5-17 = 3.5 times rated current (Ie) for 17s Utilization Category AC-53a = controller semiconductors provide squirrel-cage motor Start, Run, and Stop control Rated Operational Current (Ie) 17 to 195 = controllers with Rated Operational Currents from 17A to 195A

Standard Overload Current Profile and Duty Cycle The SR55 has been designed for a specific Overload Current Figure 1: Standard Overload Current Profiles and Profile and Duty Cycle as shown above in the SR55 Index Duty Cycles Ratings. The Overload Current Profile is expressed by two symbols, X and Tx. Model X denotes the overload current as a multiple of Ie and repre- sents the maximum value of operating current due to starting,

operating, or maneuvering under overload conditions. Rated Current (A) Class 10 O/L Multiple (X) Class 10 O/L Time (Tx) Starts / Hour (S) Duty (F) For example, X = 3.5 means that the maximum overload start SR55-017 017 current allowed is 3.5 times FLC. SR55-021 021 Tx denotes the duration of the controlled overload currents SR55-027 027 during starting, stopping, operating, or maneuvering. SR55-034 034 For example, Tx = 17 means that the maximum allowed over- SR55-040 040 load current is permitted for up to 17 seconds only. SR55-052 052 The Duty Cycle is expressed by two symbols, F and S which 5 describe the duty and also set the time that must be allowed SR55-065 065 for cooling. SR55-077 077 F is the ratio of the on-load period to the total period expressed SR55-096 096 3.5 17 90% as a percentage. SR55-124 124 For example, F= 90 means that the soft starter is ON for 90% SR55-156 156 of the time and then OFF for 10% of the time between each SR55-180 180 start. SR55-242 242 If there are not multiple starts per hour, then the Duty Cycle is continuous. SR55-302 302 S is the number of starts or operating cycles per hour. SR55-361 361 3 For example, S = 5 means that the soft starter is capable of 5 SR55-414 414 equally spaced starts per hour. SR55-477 477 These characteristics are summarized in Figure 1.

Book 2 (14.3) eSS-26 Soft Starters 1-800-633-0405 For the latest prices, please check AutomationDirect.com. Stellar® SR55 Full-Featured Soft Starters SR55 Increased Starts per Hour – Derating If more than the standard number of starts/hour is required, the SR55 must be derated. To derate for more starts/hour, the motor full load current must be less than the SR55 current. The relationship between the SR55 deration and the starts/hour is given below in Figure 2 and the two examples that follow. This assumes that the SR55 is still operating at the same duty (F) as given in Figure 1. Figure 2: SR55 Starts/Hour Deration Deration Curve Starts/Hour Deration Factor 0.85 10 0.83 15 0.73 ]

20 0.66 n t 0.8 25 0.61

u r e 30 0.56 C 0.75 35 0.53 40 0.50 SR55

o r / t

n t 0.7 F a o n u r e i t C 0.65 r a d e D L o a

l 0.6 F u l o r

o t 0.55 M

[ 0.5 10 15 20 25 30 35 40 Starts / Hour Deration Factor = (138 - (24·ln(starts/hr))) / 100 [where ln(starts/hr) is the natural log of the # of starts/hour] Example: Deration Factor for 10 starts/hr = (138 - (24·ln(10))) / 100 = 0.83

Example 1: SR55 Selection and Configuration Example 2: SR55 Selection and Configuration Step SR55 Selection Step SR55 Selection 1 Application Loaded Conveyor 1 Application Agitator 2 Trip Class 20 2 Trip Class 10 3 Duty 90% 3 Duty 90% 4 In-Line or In-Delta In-Line 4 In-Line or In-Delta In-Line 5 Ambient Temperature 40°C 5 Ambient Temperature 40°C 6 Altitude 1000m 6 Altitude 1000m 7 Full Motor Load Current 80A 7 Full Motor Load Current 66A 8 Current Limit 4 x 80A = 320A 8 Current Limit 3.5 x 66A = 231A 9 Number of Starts/Hour 10 9 Number of Starts/Hour 20 10 Deration Factor (from Fig.2) 0.83 10 Deration Factor (from Fig.2) 0.66 11 SR55 (A) = Motor FLC / Deration Factor 96A 11 SR55 (A) = Motor FLC / Deration Factor 100A 12 Determine SR55 from Sizing Guide SR55-096 12 Determine SR55 from Sizing Guide SR55-124 Step SR55 Configuration Step SR55 Configuration 1 Select Application (Auto Setup) 1 Select Application (Auto Setup) 2 Leave Motor Current 100A (maximum) (Auto Setup) 2 Leave Motor Current 100A (maximum) (Auto Setup) Set Start Current Limit to 320A Set Start Current Limit to 231A 3 (Start Current Limit) 3 (Start Current Limit) (400% of motor FLC) (350% of motor FLC) Set Overload Level to 88A Set Overload Level to 72A 4 (Overload Settings) 4 (Overload Settings) (110% of motor FLC) (110% of motor FLC) Step SR55 Alternative Configuration Step SR55 Alternative Configuration 1 Set Application (Auto Setup) 1 Set Application (Auto Setup) 2 Set Motor Current to 80A (Auto Setup) 2 Set Motor Current to 66A (Auto Setup) 3 Warm Trip Time will be reduced to Trip Class 10 value (320A for 13s) 3 Set Trip Class to 30 (Overload Settings) 4 Warm Trip Time will be reduced to Trip Class 10 value (231A for 17s)

Book 2 (14.3) www.automationdirect.com/soft-starters Soft Starters eSS-27 For the latest prices, please check AutomationDirect.com. Stellar® SR55 Full-Featured Soft Starters SR55 Soft Starter Dimensions Dimensions = in [mm]

The addition of optional finger guards to size 1 and size 2 SR55 soft starters adds approximately 14mm [0.5in] to the soft starter vertical dimension, but does NOT change the clearance distance.

Frame Size 1: SR55-017 to SR55-027 Mount soft starter within 30° of vertical

Frame Size 1: SR55-034 to SR55-096 Mount soft starter within 30° of vertical

Book 2 (14.3) eSS-28 Soft Starters 1-800-633-0405 For the latest prices, please check AutomationDirect.com. Stellar® SR55 Full-Featured Soft Starters SR55 Soft Starter Dimensions Dimensions = in [mm]

The addition of optional finger guards to size 1 and size 2 SR55 soft starters adds approximately 14mm [0.5in] to the soft starter vertical dimension, but does NOT change the clearance distance.

Frame Size 2: SR55-124 to SR55-180

Mount soft starter within 30° of vertical

Frame Size 3: SR55-242 to SR55-361 Mount soft starter within 30° of vertical

Book 2 (14.3) www.automationdirect.com/soft-starters Soft Starters eSS-29 For the latest prices, please check AutomationDirect.com. Stellar® SR55 Full-Featured Soft Starters SR55 Soft Starter Dimensions Dimensions = in [mm]

Frame Size 3: SR55-414 to SR55-477 Mount soft starter within 30° of vertical

Ventilation for Enclosures SR55 Minimum Clearance Distances * ( in [mm] ) SR55 Soft Starter Model Top Bottom Left Right Front Size 1: SR55-017 to SR55-096 3 [75] 1 [25] Size 2: SR55-124 to SR55-180 3.9 [100] 1.6 [40] 1 [25] Size 3: SR55-242 to SR55-477 4.9 [125] 2.4 [60] 1 [25] * For heat dissipation, the SR55 must not be mounted any closer to another object than these distances.

The addition of optional finger guards to size 1 and size 2 SR55 soft starters adds approximately 14mm [0.5in] to the soft starter vertical dimension, but does NOT change the clearance distance.

When fitting SR55 into an enclosure, ventilation Q = (4xWt) / (T - T ) must be provided if the heat output of the unit is max amb greater than the enclosure will dissipate. Use the formula at right to determine the fan requirement. Q = Volume of air (cubic meters per hour - m3/h) An allowance has been incorporated into the formula so that the figure for Q is the air delivery Wt = Heat produced by the unit and all other heat sources within the in the fan suppliers data. enclosure (Watts) The power dissipation of the thyristors are at their Tmax = Maximum permissible temperature within the enclosure peak when the SR55 is in energy saving mode (iERS), (50°C for a fully rated SR55) therefore causing the most heat generated from Tamb = Temperature of the air entering the enclosure (°C) the starter. Heat dissipated can be approximated (If you prefer to work in CFM, substitute °F for °C. Q is with the formula: now in CFM) Watts (SR55) = 1/2 x (SR55 current rating) x 3

Book 2 (14.3) eSS-30 Soft Starters 1-800-633-0405 For the latest prices, please check AutomationDirect.com. Stellar® SR55 Full-Featured Soft Starters SR55 Soft Starter Optional Accessories Modbus Serial Splitter Includes an SR55-RJ45-RJ12 adapter EtherNet/IP Module Finger Guards cable. Allows a Modbus network over The EtherNet/IP communication module For SR55 soft starter power-circuit line RS-485 to be constructed as plug-and- is intended to be installed in the SR55 and load side terminals; provides IP20 play with standard Ethernet cables. option slot, and allows the SR55 to be protection for soft starter sizes SR55-180 Customer must provide cable between connected to an EtherNet/IP network. and below (frame sizes 1 and 2). RS-485 master and the first splitter. Can The interface offers the following func- only be used with one master at a time on tionality: Remote Touchscreen the network, e.g. Remote Touchscreen, • CIP Parameter Object Support Allows remote monitoring, PLC, or HMI. Splitter includes (3) female • 2 Input Words from the network master configuration, and control of SR55 RJ45 ports. soft starters. Since the touchscreen is to SR55 RJ45 to RJ12 Adapter • 2 Output Words from SR55 to the a master RS-485 device, it can control network master multiple SR55 soft starters. Includes Allows connection of the Remote • Supports Explicit and Implicit Messaging a 3m Ethernet cable and an SR55- Touchscreen, Modbus Splitter, or other RJ45-RJ12 adapter. Modbus master to the RJ12 port on top Modbus TCP Module of the SR55 soft starter. Allows an SR55 soft starter to be Adapter has a male RJ12 connector and connected to a Modbus TCP network a female RJ45 connector (allows use of using TCP/IP protocol. standard Ethernet cables). The communication module supports 4 simultaneous (master) connections and USB Flash Drive allows access to all user parameters. 4GB USB Flash drive. Recommended for SR55 firmware updates and data logging. NOTE: Other flash drives may not work with SR55. Remote Touchscreen: SR55-KPD-REM USB-FLASH has been successfully tested with SR55. Single SR55 RS-485 network (SR55-SPLT optional) EtherNet/IP Module: SR55-CM-ENETIP

SR55-xxx

Multiple SR55 RS-485 network Modbus Serial Splitter: SR55-SPLT (one SR55-SPLT per starter recommended) SR55-SPLT

Modbus TCP Module: SR55-CM-MODTCP

SR55-xxx SR55-xxx SR55-xxx

RJ45 to RJ12 Adapter: SR55-RJ45-RJ12

Finger Guards: SR55-FG-1 & SR55-FG-2 USB Flash Drive: USB-FLASH RS-485 Network Examples SR55 Optional Accessories For SR55 Part Number Price Description Models EtherNet/IP communication module, optional, for Stellar SR55 series soft starters, dual RJ45 communication ports, complete SR55-CM-ENETIP $330.00 EtherNet/IP adapter, TCP/IP socket interface, CIP parameter object support, implicit and explicit messaging, transformer isolated all Ethernet interface, 10/100 Mbps full duplex. Modbus TCP communication module, optional, for Stellar SR55 series soft starters, dual RJ45 communication ports, complete SR55-CM-MODTCP $330.00 Modbus TCP server, up to 256 bytes of I/O data in each direction, transformer isolated interface, 100 Mbps full duplex, TCP/IP all socket interface, supports 4 simultaneous (master) connections. SR55-FG-1 $24.00 Finger guards, replacement, for size 1 Stellar SR55 series soft starter power terminals. Provides IP20 protection rating. Package of 2. -017 thru -096 SR55-FG-2 $24.00 Finger guards, replacement, for size 2 Stellar SR55 series soft starter power terminals, Provides IP20 protection rating. Package of 2. -124 thru -180 Touchscreen, optional remote, for Stellar SR55 series soft starters. Used to remotely monitor, configure, and control SR55 series SR55-KPD-REM $300.00 units without opening enclosures. Rated for NEMA 4/4X enclosures, no external power wiring required. Includes 3m RJ45 cable all and SR55-RJ45-RJ12 adapter. Serial Modbus communication splitter, optional, for Stellar SR55 series soft starters. Used for creating a Modbus network with SR55-SPLT $105.00 multiple SR55 series soft starters. Uses 3 serial RJ45 connectors for upstream/downstream connectivity and connection to the all starter. SR55-RJ45-RJ12 $5.00 RJ45 female to RJ12 male adapter, optional, for Stellar SR55 series soft starters. all USB-FLASH $20.00 USB Flash drive, SanDisk, 4GB (SanDisk P/N SDCZ50-004G-A46). all

Book 2 (14.3) www.automationdirect.com/soft-starters Soft Starters eSS-31 For the latest prices, please check AutomationDirect.com. Stellar® SR55 Full-Featured Soft Starters SR55 Soft Starter Accessory Dimensions Dimensions = in [mm] SR55-KPD-REM Remote Touchscreen Dimensions & Panel Mounting Cut-Out Dimensions

0.90 [23.5] 1.36 [34.5]

4x Mounting Holes

4.80 5.30 No.6 self tapping screws [134.0] [123.0] Ø1.69 or M3.5 Machine screws [Ø43.0] Diameter hole cut in panel Neoprene Gasket RJ45 Socket Reset Switch USB Socket

2.50 [63.0] 3.70 [94.0]

SR55 Soft Starter Replacement Parts

Replacement Touchscreen: SR55-KPD Replacement Fan: SR55-FAN-2 Replacement Fan: SR55-FAN-3

Replacement Fan: SR55-FAN-6 Replacement Fan: SR55-FAN-7 Replacement Fan: SR55-FAN-8 SR55 Spare/Replacement Parts * Part Number Price Description For SR55 Models SR55-FAN-2** $13.00 Cooling fan, replacement, for size 1 Stellar SR55 series soft starters, 60 x 60 x 15 mm -017 thru -096 SR55-FAN-3** $15.00 Cooling fan, replacement, for size 2 Stellar SR55 series soft starters, 80 x 80 x 15 mm -124 SR55-FAN-6** $15.00 Cooling fan, replacement, for size 2 Stellar SR55 series soft starters, 80 x 80 x 20 mm -156 thru -180 SR55-FAN-7** $35.00 Cooling fan, replacement, for size 3 Stellar SR55 series soft starters, 120 x 120 x 25 mm -242 thru -361 SR55-FAN-8** $93.00 Cooling fan, replacement, for size 3 Stellar SR55 series soft starters, 171 x 151 x 151 mm -414 thru -477 SR55-KPD $84.00 Touchscreen, replacement, for Stellar SR55 series soft starters all * These items are exact replacements for the comparable part that is originally installed on the applicable SR55. ** Fans include wiring connectors.

Book 2 (14.3) eSS-32 Soft Starters 1-800-633-0405