HPV 100 Hydraulic Elevator Soft-Starter Technical Manual

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1 HPV 100 Hydraulic Elevator Soft-Starter Technical Manual

2 WARRANTY Standard products manufactured by the Company are warranted to be free from defects in workmanship and material for a period of one year from the date of shipment, and any products which are defective in workmanship or material will be repaired or replaced, at the Company s option, at no charge to the Buyer. Final determination as to whether a product is actually defective rests with the Company. The obligation of the Company hereunder shall be limited solely to repair or replace, at the Company s discretion, products that fall within the foregoing limitations, and shall be conditioned upon receipt by the Company of written notice of any alleged defects or deficiency promptly after discovery and within the warranty period, and in the case of components or units purchased by the Company, the obligation of the Company shall not exceed the settlement that the Company is able to obtain from the supplier thereof. No products shall be returned to the Company without its prior consent. Products which the company consents to have returned shall be shipped prepaid f.o.b. the Company factory. The Company cannot assume responsibility or accept invoices for unauthorized repairs to its components, even though defective. The life of the products the Company depends, to a large extent, upon type of usage thereof and THE COMPANY MAKES NO WARRANTY AS TO FITNESS OF ITS PRODUCTS FOR THE SPECIFIC APPLICATIONS BY THE BUYER NOR AS TO PERIOD OF SERVICE UNLESS THE COMPANY SPECIFICALLY AGREES OTHERWISE IN WRITING AFTER PROPOSED USAGE HAS BEEN MADE KNOWN TO IT. This warranty does not apply to experimental products for which no warranty is made or given and Buyer waives any claim thereto. THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING, BUT LIMITED TO, ANY WARRANTY OF MECHANTIBILITY OR OF FITNESS FOR A PARTICULAR PURPOSE AND BUYER HEREBY WAIVES ANDY AND ALL CLAIMS THEREFORE. LIMITATIONS IN NO EVENT SHALL MAGNETEK BE LIABLE FOR LOSS OF PROFIT, OF LIABILITY INDIRECT, CONSEQUENTIAL OR INCIDENTAL DAMAGES WHETHER ARISING OUT OF WARRANTY, BREACH OF CONTRACT OR TORT. HPV 100 is a trademark of Magnetek, Inc. All rights reserved. No part of this publication may be reproduced or used in any form or by any means - graphic, electronic, or mechanical including photocopying, recording, taping, or information storage and retrieval systems - without written permission of the publisher Magnetek, Inc. ii

3 Table of Contents 1 INTRODUCTION Major Benefits Part Number Description Components 3 2 POWER AND CONTROL WIRING Power Wiring for 6-wire Starters Power Wiring for 3-wire Starters Control Wiring Fault Output Contacts Fault Output Contacts 8 3 SETUP AND OPERATION Starting Current Adjustment Overload Current Adjustment Motor Off Delay Selection ABC/CBA Phase Rotation Selection Control Voltage LED Indicator Motor Run LED Indicator Fault LED Indicator Fault Reset Pushbutton 13 4 OPERATION DIAGRAMS Normal Operation Stall Prevention Operation Fault Operation 16 5 TROUBLESHOOTING 17 APPENDIX 1 - ELECTRICAL DATA 18 APPENDIX 2 - FUSING REQUIREMENTS 19 APPENDIX 3 - DIMENSIONS / WEIGHTS 20 iii

4 HPV 100 Ratings Table Voltage rating 3-wire HP HP Vac Vac Rated Current not available 6-wire HP 200 Vac HP 230 Vac Rated Current Panel Size Model number* (1) HPV xSx-xx (1) HPV xSx-xx (1) HPV xSx-xx VAC (1) HPV xSx-xx 50/60 Hz (1) HPV xSx-xx (1) HPV xSx-xx (1) HPV xSx-xx (2) HPV xSx-xx Voltage rating 3-wire HP HP Vac Vac Rated Current not available 6-wire HP 460 Vac HP 575 Vac Rated Current Panel Size Model number* (1) HPV xSx-xx (1) HPV xSx-xx (1) HPV xSx-xx VAC (1) HPV xSx-xx 50/60 Hz (1) HPV xSx-xx (1) HPV xSx-xx (1) HPV xSx-xx (2) HPV xSx-xx Panel Size (1) in (w) x in (h) / cm (w) x cm (h) (2) in (w) x in (h) / cm (w) x cm (h) for more information on dimensions and mount holes see Appendix 3 * for more information on the model numbers, see Figure 2 Table 1 - HPV 100 Ratings Table iv

5 1 Introduction The HPV 100 is a digital solid state device that controls the voltage and current utilized to start the hydraulic pump motor. It is typically installed with, and actuated by, the elevator car controller. In comparison with conventional motor starters, the HPV 100 reduces operational cost, increases life and reliability, minimizes service and maintenance cost, plus eliminates several types of power line disturbances. The HPV100 soft-starter is designed to be used with three, six, and twelve lead wyedelta wound AC induction motors. These units are a more reliable, longer life alternative to electromechanical motor starters. Their compact size permits easy replacement of existing electromechanical motor starters. Current Control...rather than voltage control The HPV100 features current regulating circuitry, which limits the motor s inrush current draw from the power line on starting. The current regulating circuitry also provides a soft-start and smooth acceleration of the motor. The motor comes up to speed in one smooth stepless ramp. Eliminating Light Flicker Because the HPV 100 controls motor current directly, it makes it superior to other soft-starters that only control applied voltage. Voltage control allows high ripple current often observed as light flicker. The HPV 100 eliminates this light flicker. Stall Prevention Feature The unique stall prevention feature monitors motor speed. If the motor does not reach run speed within three seconds after the Run signal is applied, motor current is ramped up from its set current limit value to 340%. The current level is maintained at that value until the motor reaches run speed, or until the unit trips out due to an Overload or Over Temperature condition. Figure 1 - HPV 100 Soft Starter The Stall Prevention feature is extremely beneficial when hydraulic fluid viscosity is high due to cold temperatures or a result of extended periods of elevator non-use. The feature allows the motor torque to increase to overcome this initial extra load, then automatically return to normal operation. Panel Mounted with Fault Contactor The HPV 100 can be panel mounted along with a fault contactor. The fault contactor functions as a back-up disconnect in the event of a soft-starter failure or motor failure due to ground faults or shorts. The contactor energizes, as long as no faults exist, as soon as three phase power is applied to the unit and remains energized until three phase power is removed. Adjustable Settings with LED indicators Starting and Overload current is adjustable as a percent of full-load current (FLA). LED s indicate control voltage, motor speed and fault conditions. A switch is provided for phase rotation selection and a minipushbutton for fault reset. 1

6 1.1 Major Benefits Minimizes Peak Currents Elimination of damaging high inrush current Minimizes peak current demand; reduces feeder size Reduces voltage dips; eliminates associated light flicker Longer Life Eliminates need for an electromechanical motor starter Reduces motor heating, extending its life Eliminates across the line starting shock to motors and pumps Increased Reliability Power switching; only long life SCR controlled components are used Electromechanical contactor used only as a fault contactor, does not interrupt load amps at each stop Reduced down time; fewer parts to maintain & repair Minimizes Maintenance and Downtime No expensive electromechanical motor starter repairs, such as contact replacement Longer periods between routine maintenance maximizes in-service time, and can do away with unplanned stoppage or entrapment. 1.2 Part Number Description The diagram shown below describes the format used for the HPV 100 part number. HPV Hydraulic Elevator Soft starter input voltage 2 = 230 volt 4 = 460 volt output current chassis style 0 = HPV 100 & fault contactor mounted on panel (standard) 1 = HPV 100 & fault contactor in NEMA 1 enclosure 2 = HPV 100 by itself Figure 2 - HPV 100 Part Number software 00 = standard motor 0 = 6-wire 1 = 3-wire serial port S=serial port 2

7 1.3 Components The panel mounted HPV 100 consists of two main components, the soft-starter and the fault contactor. Soft-starter The soft-starter controls starting current and provides overload protection for the hydraulic pump motor. The soft-starter has six potential fault conditions: sync loss, incorrect phase rotation, motor overloads, shorted SCR, phase loss, over temperature, and instantaneous over current (wiring error). If any of the fault conditions occur, the soft-starter will turn off and the fault contactor will drop out. Fault Contactor The fault contactor closes as soon as the three phase power and control power are applied to the soft-starter. The contactor will remain closed until three phase power is removed from the input of the soft-starter or a fault condition occurs. Because the contacts of the fault contactor are wired in he delta legs, the current through them is only 58% of the line current. This lower current, and the fact that the fault contactor does not normally make and break the motor current, allows a general purpose contactor to be used instead of a larger across the line starter. Figure 3 - Component Layout Line current measured through each input phase L1 Leg current measured through each side of the delta is 58% the line current T3 L1 1L1 FC 2T1 T6 T1 Soft-starter with internal current sensors and overload relay Fault contactor T4 4T2 FC 3L2 L3 L3 5L3 6T3 T5 FC T2 L2 L2 Figure 4 - Component Power Schematic Diagram (6-wire Starters) 3

8 2 Power and Control Wiring 2.1 Power Wiring for 6-wire Starters Power wiring must be applied to the softstarter as shown below. This scheme puts the solid state soft-starter and the contacts of the fault contactor in the legs of a delta connected motor. Because of this, the current through the contacts of the fault contactor is only 58% of the line current. This lower current, and the fact that the fault contactor does not normally make and break the motor current, allows a general purpose L1 contactor to be used instead of a larger across the line starter. The Fault Contactor is energized and the contacts close as soon as three-phase power and control power are applied to the soft-starter. The contactor will remain energized until three-phase power is removed, or a fault occurs. L1 IMPORTANT The HPV 100 must be wired inside the delta as shown. Damage to the HPV 100 could occur if not wired correctly. Note: with a miswired motor: - an Instantaneous Over Current fault could occur (6 flashes) - no current will flow T3 T6 FC 2T1 1L1 T1 T4 4T2 FC 3L2 L3 L3 5L3 6T3 FC T5 T2 L2 L2 Figure 5 - Power Schematic Diagram (6-wire Starters) HPV100 Terminals T1 T2 T3 T4 T5 T6 JOIN Low voltage operation 1,7 2,8 3,9 4,10 5,11 6, High voltage operation 4& &8 6&9 Table 2-12-Lead Motor Connections 4

9 to three phase power = customer wiring 1L1 3L2 5L3 2T1 4T2 6T3 T1 T2 T3 T6 T4 T5 control power HI LO 120 VAC to motor to motor Figure 6 - Power Wiring Diagram (6-wire Starters) Figure 7 - Close-up of Terminal Torque Specification Labels 5

10 2.2 Power Wiring for 3-wire Starters to three phase power = customer wiring to motor 1L1 3L2 5L3 2T1 4T2 6T3 control power HI LO 120 VAC Figure 8 - Power Wiring Diagram (3-wire Starters) L1 T1 2T1 T6 FC 1L1 L2 T2 4T2 T4 FC 3L2 L3 T3 6T3 T5 FC 5L3 Figure 9 - Power Schematic Diagram (3-wire Starters) 6

11 2.3 Control Wiring Wiring to the control terminal block is explained below: Control Power Input 120 VAC at terminals 1 and 2 In order to operate properly, the soft-starter requires 120 VAC (5VA) to be applied to terminals 1 and 2. If the source is not supplied, the soft-starter will not operate. Motor Run Input 120 VAC at terminals 3 and 4 The soft-starter will turn on when 120 VAC is applied to terminals 3 and 4. When this source is removed, the soft-starter turns off. Motor Up To Speed Output terminals 5 and 6 A solid-state Motor Up To Speed Normally Open contact is provided for at terminals 5 and 6. This solid-state contact closes when the Motor Run LED Indicator goes to its ON state. Rated at 1A, 120Vac. This contact will remain closed and the Motor Run LED will remain ON until the 120 VAC source is removed from the Motor Run Input terminals 3 and 4, or a fault condition is detected. Two Fault Output Contacts: One N.O. Contact at terminals 7 and 8 One N.C. Contact at terminals 9 and 10 One normally open (N.O.) contact and one normally closed (N.C.) fault contact are provided for interface to fault protection circuits and devices. For more information, see section Rated at 8A, 120Vac. 7

12 2.3.1 Fault Output Contacts Normally Open Fault Contact Output terminals 7 and 8 When three phase power is applied to the soft-starter, the N. O. fault contact at terminals 7 and 8 will close. This fault contact is wired at the factory to be in series as the Fault Contactor. Thus, when this fault output contact closes (when three phase power is applied), the Fault Contactor will be energized or turned ON. The Fault Contactor will remain ON until three phase power is removed, or a fault condition is detected. If a fault condition occurs, the fault contact opens and the Fault Contactor will open. And remain open, until the fault is corrected and the Fault Reset pushbutton is pushed. Recycling three phase power will also clear, but not correct, the fault condition. Normally Closed Fault Contact Output terminals 9 and 10 When three phase power is applied to the soft-starter, the N. C. fault contact at terminals 9 and 10 will open. This fault contact will remain open until three phase power is removed, or a fault condition is detected. If a fault condition occurs, the fault contact will close and will remain closed until the control power is cycled or until the fault condition is corrected and the Fault Reset pushbutton is pushed. WARNING Never push the Fault Reset pushbutton while three phase power is applied along with 120 VAC applied to the Motor Run Input terminals 3 and 4. This will cause the soft-starter to turn on. Before restarting a fault, ALWAYS VERIFY THAT 120 VAC IS REMOVED FROM THE MOTOR RUN INPUT TERMINALS. NOTE Factory Wiring is shown Figure 10 - Control Wiring Terminal Connections 8

13 3 Setup and Operation Starting Current Adjustment - limits the maximum current (as a percentage of the HPV 100 nameplate current rating) the motor will be allowed to draw while starting. (see section 3.1) Overload Current Adjustment - sets the maximum current (as a percentage of the HPV 100 nameplate current rating) at which the motor would be allowed to operate at continuously. This function is the motor thermal overload protection. (see section 3.2) ABC/CBA Phase Rotation Selection - selects the ABC/CBA Phase Rotation of the incoming power lines. If there is an incorrect phase rotation, the Fault LED will indicate one flash. (see section 3.4) Motor Off Delay Selection - controls the time that the motor will continue to run once the Motor Run Signal is removed (120VAC on terminals 3 and 4). (see section 3.3) Control Voltage LED Indicator - monitors the status of the control voltage. (see section 3.5) Flashing: Control voltage low On: Control voltage OK Motor Run LED Indicator - monitors the status of the Motor Run signal and completion of the soft-start cycle. (see section 3.6) Flashing: Motor Run ON: Motor up to Speed Figure 11 - HPV 100 Front Panel Fault Reset Pushbutton can be used to reset HPV 100 after fault condition has been corrected. Warning: Never push the Fault Reset pushbutton while three phase power is applied along with 120 VAC applied to the Motor Run Input. This will cause the softstarter to turn on. (see section 0) Fault LED Indicator indicates a fault condition is present. (see section 3.7) 1 Flash: Phase Rotation Incorrect 2 Flashes: Motor Overload 3 Flashes: Shorted SCR 4 Flashes: Phase Loss 5 Flashes: Over Temperature 6 Flashes: Instantaneous Over Current ON: No Line Sync 9

14 3.1 Starting Current Adjustment The Starting Current adjustment limits the maximum current (as a percentage of the HPV 100 nameplate current rating) the motor will be allowed to draw while starting. While limiting the starting inrush current, the setting also affects the time it take to bring the motor up to speed, i.e., the lower the starting current, the longer it takes the motor to come up to speed. The Starting Current adjustment is set using a 16 position switch labeled from 0 through F. Figure 12 - Starting Current Setting Example The nameplate provides an adjustment table with a Switch Setting column vs. Starting Current (%) column. Starting Current Switch Setting Note: the setting of the switch is shown by the arrow (this example set to B) Starting Current Percentage (%) 0 115% 1 130% 2 145% 3 160% 4 175% 5 190% 6 205% 7 220% 8 235% 9 250% A 265% B 280% C 295% D 310% E 325% F 340% Table 3 - Starting Current Settings A good initial starting point would be to set this switch to the 250% position (switch setting 9), and to optimize this adjustment, either up or down, to obtain desired current and acceleration time. 3.2 Overload Current Adjustment This function is the motor thermal overload protection. The Overload Current adjustment sets the maximum current (as a percentage of the HPV 100 nameplate current rating) at which the motor would be allowed to operate at continuously. If the motor current exceeds this setting, the Motor Overload fault timing function will start. The adjustment is normally set to the equivalent % closest to motor FLA rating. Higher settings should be used only if other means of motor thermal protection is present. The Overload Current adjustment is set using a 16 position switch labeled from 0 through F. Note: the setting of the switch is shown by the arrow (this example set to 5) Figure 13 - Overload Current Setting Example The nameplate provides an adjustment table with a Switch Setting column vs. "Overload Current (%)" column. Overload Current Switch Setting Overload Current Percentage (%) 0 75% 1 80% 2 85% 3 90% 4 95% 5 100% 6 105% 7 110% 8 115% 9 120% A 125% B 130% C 135% D 140% E 145% F 150% Table 4 - Overload Current Settings 10

15 Since motor thermal ambient and duty cycle can vary considerably, adjust this setting as indicated by engineering or as instructed in the elevator manual. 3.3 Motor Off Delay Selection The Motor Off Delay selection controls the time that the motor will continue to run once the 120 VAC Motor Run Signal is removed from terminals 3 and 4 of the control terminal block. The Motor Off Delay selection is made using a 2-position dip switch labeled 0.5/0.0 sec Off Delay Figure 14 - Motor Off Delay Setting Example When the switch is set in the 0.5 position, the motor will continue to run for 0.5 seconds after the Motor Run Signal is removed. When the switch is in the 0.0 position, the motor will turn off as soon as the Motor Run Signal is removed. 3.4 ABC/CBA Phase Rotation Selection The ABC/CBA Phase Rotation selection is made using a 2-position dip switch labeled ABC/CBA Phase Rotation. It is set to the ABC position at the factory. ABC CBA Note: the rocker switch setting is determined by which side is pushed in. (this example set to 0.0) Note: the rocker switch setting is determined by which side is pushed in. (this example set to ABC) Figure 15 - Phase Rotation Setting Example The HPV 100 protects against incorrect phase sequence of the incoming power lines. If upon powering up, there is an incorrect phase rotation, the Fault LED will indicate one flash, which is the code for incorrect phase rotation. In addition, the fault contactor will not close. At this time, the dip switch can be changed to the CBA position. To change motor direction of rotation requires interchanging two of the incoming power leads. CAUTION Power must be removed by opening the safety switch, before touching leads. Follow secure lock-out and tagging procedures. Note: After switching the power leads, it will be necessary to move the dip switch to the alternate position, ABC/CBA. 3.5 Control Voltage LED Indicator The Control Voltage LED Indicator monitors the status of the control voltage. Flashing: Control voltage low On: Control voltage OK Whenever 120 VAC is applied to terminals 1 and 2 (Control Power Input) of the control terminal block, the Control Voltage LED will light and remain on until the voltage is removed. If the control voltage drops below 100VAC, the LED will start flashing, indicating a low voltage condition. 3.6 Motor Run LED Indicator The Motor Run LED Indicator is provided to monitor the status of the Motor Run signal and completion of the soft-start cycle. Flashing: Motor Run ON: Motor up to Speed When 120 VAC is applied to terminals 3 and 4 (Motor Run Input) of the control terminal block, the Motor Run LED Indicator will start flashing. This will occur only when both control power is applied and no faults exist. Once the soft starter senses the completion 11

16 of the soft-start cycle and that the motor is running at its normal running current, the Motor Run LED Indicator will light solid. The Motor Run LED Indicator will turn off after the 120 VAC signal is removed from the Motor Run Input, provided that the Off Delay switch is set to the 0.0 position. If the Off Delay switch is set to the 0.5 position, the LED will turn off in 0.5 seconds after the 120 VAC is removed. 3.7 Fault LED Indicator Only one fault LED indicator is provided. Several fault conditions are indicated by this LED by controlling the number of flashes for any given fault condition. ON: No Line Sync 1 Flash: Phase Rotation Incorrect 2 Flashes: Motor Overload 3 Flashes: Shorted SCR 4 Flashes: Phase Loss 5 Flashes: Over Temperature 6 Flashes: Instantaneous Over Current The fault conditions are explained below: ON: No Line Sync This LED will light solid if control power is applied and the input three-phase voltage on terminals L1, L2, and L3 is not. To clear this fault, simply apply the appropriate input three-phase voltage (208/230/460/575). There is no need to press the Fault Reset pushbutton. 1 Flash: Phase Rotation Incorrect If upon powering up, there is an incorrect phase rotation or a missing phase on the input three-phase voltage, the Fault LED indicates one flash, which is the code for incorrect phase rotation. In addition, the fault contactor will not close. Check the Phase Rotation switch. First change switch position. Then, check input three-phase power on terminals L1, L2, and L3. 2 Flashes: Motor Overload The Motor Overload fault will occur whenever the soft-starter detects that a motor thermal overload condition exists. This condition will cause the HPV 100 to turn off and the fault contactor to open, removing power to the motor. 3 Flashes: Shorted SCR The Shorted SCR fault will occur whenever the soft-starter detects an SCR short, while the motor is not running. When detected, the soft-starter will not turn on, the fault contactor will remain open, and the fault LED will start flashing. If a shorted SCR should occur while the motor is running, the soft-starter will not turn off until the 120 VAC control power is removed from the Motor Run Input (terminals 3 and 4) normally the next stop. Then the fault LED will start flashing, the Fault Contactor will open and the soft-starter will be prevented from starting. 4 Flashes: Phase Loss The Phase Loss fault will occur whenever the soft-starter detects that a single phasing condition exists. This condition will cause the soft-starter to turn off and the fault contactor will open, removing power to the motor. 5 Flashes: Over Temperature The Over Temperature fault will occur whenever the soft-starter detects that the temperature at the SCR heat sink is excessive. This condition will cause the softstarter to turn off and the fault contactor will open, removing power to the motor. 6 Flashes: Instantaneous Over Current The Instantaneous Over Current fault occurs: when the soft-starter detects currents greater the 400% of the unit s rating if starting current levels are 150% greater than the set level (usually meaning motor miswiring) Motor Run Input Issue (terminals 3 & 4) This fault can also be caused by rapidly toggling the run signal. The run input rated for 120VAC but has very low current draw. Verify that any relay used in the run input is rated for low current; gold plated or flashed contacts are preferred. Verify that all control wiring is secure and that the run signal is continuous for the duration of the run period. 12

17 3.8 Fault Reset Pushbutton A fault reset pushbutton is located below the fault LED and is labeled: Fault Reset (push). When a fault condition occurs, power is removed from the motor by opening the Fault Contactor. Once the fault has been corrected, the Fault Contactor will remain open until either control power is cycled or the Fault Reset (push) pushbutton is pushed. Warning Never push the Fault Reset pushbutton while three phase power is applied along with 120 VAC applied to the Motor Run Input terminals 3 and 4. This will cause the soft-starter to turn on. Before restarting a fault, ALWAYS VERIFY THAT 120 VAC IS REMOVED FROM THE MOTOR RUN INPUT TERMINALS. Note: The Motor Overload, Over Temperature and Over Current faults can be reset either by the Fault Reset pushbutton, or by toggling the Run signal after a 1 minute cool-down period. 13

18 4 Operation Diagrams 4.1 Normal Operation Motor Run Input Starting Current Setting Motor Off Delay (0.5 sec) Running Current Motor Current 200 msec Motor Off Delay (0.0 sec) 100% speed Motor Speed approx. 1 second Motor Off Delay (0.0 sec) Motor Up to Speed Input Figure 16 - Normal Operation Diagram 14

19 4.2 Stall Prevention Operation Motor Run Input 3 seconds Starting Current Setting 340% current Motor Off Delay (0.5 sec) Motor Current 200 msec Running Current Motor Off Delay (0.0 sec) 100% speed Motor Speed Motor Off Delay (0.0 sec) approx. 1 second Motor Up to Speed Input Figure 17 - Stall Prevention Operation Diagram 15

20 4.3 Fault Operation Motor Run Input Starting Current Setting Running Current Motor Current 200 msec Fault Occurs Fault Output approx. 1 second Motor Up to Speed Input Figure 18 - Fault Operation Diagram 16

21 5 Troubleshooting Indicator Possible Cause Corrective Action Flashing Control Voltage LED Indicator Low or Missing 120 VAC The 120 VAC applied to the Control Power Input at terminals 1 and 2 has Check and correct low or missing control power 120 VAC on terminals 1 and 2. On Fault LED Indicator 1 Flash Fault LED Indicator 2 Flashes Fault LED Indicator 3 Flashes Fault LED Indicator 4 Flashes Fault LED Indicator 5 Flashes Fault LED Indicator dropped below 100 VAC. No Line Sync With the control power applied (120VAC on terminal 1 and 2), no input three phase power is present on terminals L1, L2, and L3. Phase Rotation Incorrect Incorrect phase sequence or missing phase on the input three phase power. Motor Overload The HPV 100 detects a motor thermal overload condition as determined by the Overload Current setting. Shorted SCR The HPV 100 detected a shorted SCR. Phase Loss The HPV 100 detects an open lead between the motor and the soft starter. Over Temperature The HPV 100 detects the temperature at the SCR is excessive. Check and correct input three-phase power on terminals L1, L2, and L3. Check the Phase Rotation switch. First change switch position. Then, check input three-phase power on terminals L1, L2, and L3. Check the setting of the Overload Current setting (increase if necessary). Or correct high load condition HPV 100 may need to be replaced Check and repair open motor wire. Check and correct cooling issues. 6 Flashes Fault LED Indicator Motor not starting. Motor Run LED On indicating motor up to speed Motor takes to long to start. Instantaneous Over Current Occurs when: HPV 100 detects currents greater than 400% of unit s rating or the starting current levels are 150% greater then the Starting Current setting. Motor wiring error Input phases are wired back to themselves Motor wired for high voltage (i.e. 460v) and softstarter rated for low voltage (i.e. 230v) Starting Current Set To Low The setting to Starting Current setting is set to low. Check for motor miswiring or bad motor. Check for a toggling run input. Check for motor miswiring Increase setting of Starting Current. Table 5 - Troubleshooting 17

22 Appendix 1 Electrical Data Input Power Control Power: ± 10% of 120 VAC Input Voltage: ± 10% 200/230 VAC ± 10% of 460/575 VAC Frequency: ± 2% of 50/60 Hz Duty Cycle Rating 30% duty cycle; 80 starts per hour Motor Protection Adjustable Electronic Overload (75 to 150% of Nameplate) Phase Loss (faults at 1.5 seconds) Phase Sequence (faults if not correct) Starter Protection Faults in the event of a shorted SCR, but not while running Over Current Over Temperature Fusing provided by customer Adjustments and settings Current Limit: 115 to 340% of Nameplate Overload Current: 75 to 150% of Nameplate Off Delay Switch: 0.0 to 0.5 second positions Phase Rotation Switch: ABC and CBA positions Reset Pushbutton: Push to reset faults Reset Fault Circuit Overload Fault: reset by transition to "Run" 1 Min. after fault. All others faults require operation or the "Reset Pushbutton". Operating LED Indicators Control Voltage Low - Control Voltage OK Motor Run Motor Up to Speed Fault LED Indicators Phase Rotation Incorrect Shorted SCR Motor Overload Phase Loss Over Temperature Sync Loss Instantaneous Over Current Ambient Temperatures Operating: 0 to 50 C (32 to 122 F) Storage: -20 t0 80 C (-4 to 176 F) Operating Humidity Range 0 to 95% Non-condensing Maximum altitude 3300 ft. (1000M) without derating Vibration Resistance sinusoidal vibration, 3 axis, 10 to g acceleration Shock Resistance 30 g's, 3 pulses per axis, 11 ms pulse CSA listed 18

23 Appendix 2 Fusing Requirements CSA Requirement - To be in compliance of CSA this product must be protected on the AC input by 700VAC semiconductor fuses. Voltage rating 3-wire HP HP Vac Vac Fuse Rating not available 6-wire HP 200 Vac HP 230 Vac Fuse Rating Model number* HPV xSx-xx HPV xSx-xx HPV xSx-xx VAC HPV xSx-xx 50/60 Hz HPV xSx-xx HPV xSx-xx HPV xSx-xx HPV xSx-xx Voltage rating 3-wire HP HP Vac Vac Fuse Rating not available 6-wire HP 460 Vac HP 575 Vac Fuse Rating Model number* HPV xSx-xx HPV xSx-xx HPV xSx-xx VAC HPV xSx-xx 50/60 Hz HPV xSx-xx HPV xSx-xx HPV xSx-xx HPV xSx-xx 19

24 Appendix 3 Dimensions / Weights Figure 19 - Dimensions and Mounting Holes (23A to 105A) 20

25 Figure 20 - Dimensions and Mounting Holes (130A) 21

26 Figure 21 - Dimensions and Mounting Holes (softstarter) 22

27 23

28 HPV 100 Data subject to change without notice. HPV is a trademark of Magnetek, Inc. Magnetek Elevator Products W136 N4863 Campbell Drive Menomonee Falls, Wisconsin (800) , (262) , FAX (262) Magnetek Elevator Products Europe 20 Drake Mews, Crownhill Milton Keynes, Bucks MK8 OER UK +44(0) , FAX +44(0) TM Magnetek, Inc. 09/05 rev 02

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