_ Technical

Page 2

Data
FtfectIve-~~~~~~~1999

Advantage Contactors and Starters Non-combination

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

Cutler-Hammer

Design Characteristics Optional Features Design Characteristics Configurations Open Types: -

and

various types of control functions ISTART/STOP. HAND/OFF/AUTO. etc.). Auxiliary Contact Module four (4)

gray

- W201: FVNA Contactor - W211: FVR Contactor - WZOO: FVNR, Non-combmatlon starter - W210: FVR. Non-combination starter Enclosed Types: - ECAOl: Full Voltage Nonreversing (FVNR) Contactor - ECAOP: Full Voltage fFVRI Contactor - ECAOI: starter Reversing

- NEMAType 4/4X enclosures are for indoor or outdoor applications and provide protection from splashing water, hosedirected water and wind-blown dust. Watertight conduit hubs are provided in the top and bottom. NEMA Sires 1 - 5 are in Type 4X made of a stainless steel 304 material. NEMA Size 6 devices are in a Type 4. painted steel enclosure. - NEMA Tvpe 12 is for indoor applications to protect from dripping liquids, falling dirt and dust. No knockouts or hubs are provided in NEMA Type 12 enclosures. They are painted with a polvester rethane powder coatpa/nt meeting UL reauirements. The color IS ANSI 61 gray. Standards -

- Each module provides separate contact sets.

- Contacts are single break, bifurcated, and isolated for no polarity restrictions. Bell Alarm Module - 1 NO-1 NC, isolated contacts with 5A continuous rating. Simply plugs into reset port. Mechanical Interlock -

- Cam operation actlo.

to insure positive contacts

- Electrical interlocking included (2NC). Remote Electrical

FVNR, Non-combination

Reset anywhere on

- Can be mounted
ellClOSUW.

- ECAOG: FVA. Non-combination starter - ECA07: FVNR, Non-combination Starter with Control Power Transformer (CPT) Addlhonal configurations are available and described in other publications and Technical Data publications. Cantactors - Available Swes 1 - 6, three-pole, ing and reversing. in NEMA non-revers-

- Optional lighted indication. Communications - WPONI module

reset for trip

UL listed: Oven & Enclosed -File #E19224. Guide #NLDX CSA certlfled: Enclosed - File #LR28548, Dwgned to meet or exceed NEMA standards. Ambient Overload Temperature Relay Standard 0 to 40C Features -

for IMPACC for

- WPONIDNA DeviceNet. Description

module

StartersAvailable in NEMA Sizes 1 6. three-phase, non-reversing and reversing, and non-reversing with control power transformers as standard. Open Devices-Three-point maunting up to and including Size 4. reversing and non-reversing contactors and starters. Enclosures - Contactors and starters are available in NEMA Type 1,3R, 4/4X and 12 enclosures. Ample wiring space meeting or exceeding the National Electrical Code (NE0 requirements is provided at the top and bottom for easy installation. - The NEMA Type 1,3R, 4/4X and 12 enclosures have external reset buttons as standard and there are four (41 holes plugged for cover controls. The doors can be padlocked to prevent unauthorized entry. The door is easily removableforwirina orformaintenance purposes. - NEMA Type 3R enclosures are for outdoor aoolications and are rated for rain; sleet and external ice buildup. They have knockouts in the bottom and provtsmns for a

- DIP switch selectable for Trip Class 10, Class 20 and Class 30 - DIP switch selectable or Automatic Reset. for Manual

Remote Reset and other operational reset options available. current sensing.

- Ground -

These products are a full line of advanced design contactors and starters that are setting a new standard in motor control. Revolutionary in design, the Cutler-Hammer Advantage mot& starters employ state-of-the-art technology in solving motor control application problems. The Advantage motor starrers and contactors extend operatfng life in a physical space requirement 20% to 80% of the size of conventional motor starters and contactors. Cutler-Hammer Advantage controllers maintain constant coil power, regardless of van/ing control circuit conditions, which eliminates coil burnout, contact chatter, and welding due to low voltage or fluctuating control signals. Multi-function overload protection options prowde application flexibility while reducing inventory. Communication capabilities allow the Advantage starters and contactors to be interactwely linked to control systems for monitoring, troubleshooting and control. Technological advances such as pre-start diagnostics, Increased accuracy, and the ability to communicate with other svstems are benefits not realized in traditional motor starters and contactors.

Phase loss protectIon. protection.

- Phase unbalance Optional Features

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

as in

Local Cover Control

on

- Available as factory Installed the enclosure or flange. -

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

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

F54u

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Cutler-Hammer

Advantage Contactors and Starters Non-combination

Technical
Effectwe:January 1999

Data
Page 3

Some of the unique this line are:

key features

of

,. Long Life- due to significantly less contact bounce, regulated power to the coil eliminating coil burnout, and no contact kiss position or chatter Smaller Physical Size - 20% to 80% smaller than conventional devices allows the use of smaller enclosures and control panel boxes. Solid-State Overload Relay - completely heaterless. Standard protection features Include phase loss and unbalance, selectable trip class, automatic/manual reset and ground current sensing. Communication Capability-offers low costcommunicationsof ON/OFF commands. status and motor data; can be linked to automated control systems. Microprocessor based-the contactor will not close on low control voltage, and the armature closina SDSSd is controlled to reduce contact bounce. Optimized coil power provides high contact force in a minimned physical sire. This hiqh contact force contributes to extended electrical life. 0 Reduced Heal Generation by using current sensors rather than heaters, temperature rise in the overload relay IS eliminated. Low coil holding power reduces heating in the magnet coil. High contact force results in less heat generated in the contact set. Advantage Control Modules (ACM) - provide a cost-effective alternative to pushbuttons, selector switches, indicating lights, reset mechanisms, and panel meters. Simple plug-in wiring reduces installation labor.

designed specifically for the Cutler Hammer Advantage starters and cone tactors. The same magnet assembly components used in conventional starters are used in this product linemaanet, toll, movino armature, stationary and moving contacts. The use of the SURE Chio. alono with current sensors, DIP switches, control wiring terminal and communications port, all on one circuit board, allows you to have significant benefits while staying smaller than the average contactor or starter. It gives you the full motor protection characteristics of a starter ~ from a contactor-sized unit. In addition, the SURE ChiDs operation crow ides extended mechanical and electrical life by lessening contact bounce and optlmwmg coil power and contact force. When a start signal is received by the starter, control circuit checks are made before power is applied to the COII. These checks verify that the start signal is valid, and prevent closing when conditions exist that would damage or destroy the device. The START signal is checked for three consecutive cycles to ensure that it IS not a false slgnal. The control voltage IS monitored to ensure sufficient voltage for closing The phase angle of the start signal is compared to the coil SIgnal. If phase angles are the same, the signal is considered valid. If the unit passes those verification checks, a power pulse to the coil IS sup plied. The coil cu.rrent is then read a&l if current is sufficient, a *r&De of optimum power is applied tothe coil. The Advantage starters experience a reduced contact bounce of only 0 - 2 milliseconds because ofthe optimized power applied to the coil, and the low velocity at which the magnet faces meet. Higher contact force lowers the resistance and subsequent heat given off

as a result of current passing through the contactor, which raises the current carrying capability of the device. IncreasIng contact force in conventional starters can only be achieved by mcreaslng the sze of the magnet and coil, and consequently the size of the device. The SURE Chip optimizes the power to the coil, providing high contact force while maintaining smaller physical sire. When a co11IS energized or de-energized in a conventional starter, a voltage spike may occur. Some devices on the circuit such as PLCs or computers, may be affected by this spike. In the Advantage contactors and starters, the coil is isolated from the line bv its electronic circultry. The voltage spike IS minimized, eliminating the need for costly surge suppressors. Contact chatter or kiss occurs when the control voltaqe is insufficient to completely close-the starter, when the voltage signal is varying. or when there is a drop in control voltage. The Advantage microprocessor first decides that there is sufficient voltage present to completely pull in and seal the magnet and armature. After this, the regulation of power to the coil makes the &tacts hold together tightly until the microprocessor determines that the voltage is no longer sufficient. At this point, the starter opens cleanly, never reaching the kiss oosition. It has the abilitv to ride through momentary loss orvariante in control power. Another feature of the Advantage controllers IS known as Distributed Opening. The starter stores the order in which the phases were opened in the previous stop. Then, the opening sequence is rotated between the phases to enaure even contact wear. This distributed opening is disabled if the starter is wired with two-wire control, where the control power applied to iE) terminal is interrupted.

The Advantage starters and contactors are microprocessor based. The patented SURE Chip is the brains of these devices. The SURE Chip is an application specific microprocessor

TO.BE02TE

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Technical
Page4

Data

Advantage ~~~~~~~~~~~~~~~~ 1999 Contactors and Starters Non-combination

Cutler-Hammer

Mechanical Table 1 -

Characteristics Mechanical Characteristics siz.

! I
6M 250 4% 16.25 2.00 6.50 2.50 4.96 16.25 2.w 8.00 3.68 5.54 29.44 8 00 Vert. Hariz 250 MCM 8 12 TWO_14 B.llO 3.68 5.54 2944 BOO Vert. How 250 MCM 8 12 Two-14 10.08 IO7 7.64 7127 30.00 vw., or,2 1008 7 07 7 64 7, 27 30.00 w-t, tlonz 2-5gOMCM 8 12 Two 14

Cinsnsions in lncher

Height Width Depth Panel Area I Square Inches Weightin Pounds Mechanical Interlock
Combinations

Available

en., Hor12. 8 AWG 8 12 Two-14

Ven.. Horn 4 AWG 8 12 Two-14

Maximum Cable Size/Phase

Copper IAWGIMCM) Auxiliary Electrical Circuits AvaIlable Mau. Wire Size for Aux. Elec. Circuit IAWGI MIX. Wire Size for Control Circuit IAWGWG) Table 2 -Circuit Conformal Coating DIP Switches Board Characteristics of Board

1 -MOMCM 8 12 Two 14

HumisealtlB31,Ac~lic

Type

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

Contactor

and Starter

Sizes over 600V AC. The contacts are rated at 10 hp. so if the unit is sat on the No Protection mode of the overload relay, it can be used as a contactor at 10 hp at f,nnv nc ___ _ The Sire 1 Upper current range starter orotects over an FLA range of 3.15to27Aata1.15to1.25SF.lican operate over a 2 to 10 hp range at 600V AC. NOTE: Unless a table is otherwise footnoted in this document, Size 1 refers to Size 1 contactors, Size 1 lower current range. and Size 1 upper current ranae starters.

The Size 1 contactors a 2 to 10 hp range.

can operate

There are two Size 1 starters lcontactar with overload relay) that cover the l/4 to 10 hp range and the .47 to 27 Full Load Amp range. e TheSize 1 Lower protects over an 3.81Aat a 1.15to can operate over current range starter FL4 range of .47 to 1.25 service factor. It a l/4 to 2 hp range at

FAra

TDSEOZTE

Cutler-Hammer

Advantage Contactors and Starters Non-combination

Technical
Effective: January 1999

Data
Page 5

Operating Characteristics Table 3 -Operating

Characteristics

ISlla 1

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Technical Page 5

Data
Effective: January1999

Advantage Contactors and Starters Non-combination

Cutler-Hammer

Electrical

Characteristics Characteristics

Table 4 -Electrical

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TD.8E.OZ.T E

Cutler-Hammer

Advantage Contactors and Starters Non-combination

Technical
Effectwe: January 1999

Data
Page 1

f \

Short-Circuit

Ratings symmetrical amperes) shown, in circults rated not more than the voltage shown in Tables 5 through 10, when rable 7 -Size protected by the SCPD shown

These motor controllers are suitable for use on circuits capable of delivering not more than the current (RMS able 5 -Size 1 Short-Circuit Ratings

3 Short-Circuit Ratings

-able 8 -Size

4 Short-Circuit Ratings

able 6 -

Size 2 Short-Circuit Ratings

Tae CE 0

hlsgnetlc OnlyO

5OA

Marked GMCP Marked HMCP

42,OOOA 25,OOOA

2NJV 4mlv

GMCP

100,OOOA 48oV

HMCP

TOGEOZTE

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Technical
Page 8

Data
Effective~~~~~~ 1999

Advantage Contactors and Starters Non-combination

Cutler-Hammer

1able 9 -Size

5 Short-Circuit Ratinss

Table 10 - Size 6 Short-Circuit Ratinas

Coil Characteristics Table 11 -Coil Characteristics sim 1

sire *
12OVffiO Hz or llOV150 Hz 54fO l45V -2% to t2% per utility

Sk. 3
12OV/60 Hz or llOVl50 Hz 54to t45v -2% to +2% per utility

Sk. 4
12OVI60 Hz or llOV/50Hz 5410 145v -2% tu 12% per utility

Size 5
120,60 HZ or llO",50HZ 54to 145v 2% to t2% per utility

Sire 5
120,60 Hz or llWi50 Hz 54to 145v -2% to t2% per utility

Control PDWW
Nommal operaung Control Voltage lxnas -v - Freq. Transtormer (65% 100 VA 250 VA 25VA 5W 78V 54V lOOVA 250 VA 25 VA 5W 78V 54 15OVA 500 VA 50 VA low 78V 54 15OVA 500 VA 5OVA low 78V 54V 300 VA 2600 VA 50 VA low 78V 54V 300 VA 2600 VA 50 VA low 78V 54V 12OVl60 Hz or llOVl50 Hz 54t0 145v -2% to +2% per utility

Control Power Recommended P&Up WI

AC Coil sS# Burden (Open VA PF= 501 (ClosedVA~PF=.28) (Closed Waftsi P,ck-p Volts @ Droo-OutVoltsa

Cutler-Hammer

Advantage Contactors and Starters Non-combination

Technical
Effective January 1999

Data
Page 5

Overload Relay Operation

The Advantage starters use a unique current sensor which outputs a voltage proportional to the change in current. The SURE Chip squares and integrates the value to achieve a true measure of motor heating. This approach allows for a linea@ motor protection curve which can protect to within a 2% accuracy level. No thermal elements in the Cutler-Hammer advanced design overload relay means no time lost for heat transfer from the element as in conventional starters. This device also has a nonvolatile operating memory, which allows it to remember that the motor is hot after control power is removed. Advantages unique current sensors offer a higher degree of accuracy than thermal overload relays. These sensow., combined with reliable solid-state circuitn/. allow multiple selectable prom tection options built right into the contactorframe. This allows the starterto be the same size as the contactor, and therefore, much smaller than conventional starters. To select the trip class and trip range of the overload relay, it is not necessary to replace any portion of the device. The usersimplyflipsfiveswitchesto setthe trip current rating and trip class. There are no heater coils to order. inventon/ or install. A DIP switch (Dual In-line Package) takes the place of all that. Select classes as follows: lil Class lo-To protect a hermetic motor (refrigeration compressor1 a submersible pump motor, or any quick starting motor such es an IEC design. Also use with Design E motors. L Class 30 - For long motor acceleration time. ii Class 20 For all other applications. s No Protection -Selecting this setting effectively transforms the starter into a contactor.

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Page 10

Data
~~~~~~~~ ~~~~~~ ,999

Advantage Contactors and Starters Non-combination

Cutler-Hammer

Further flexibility is provided by the two reset methods inherent in these devices, b Automatic Reset - Reset is automatIc on thermal overload trips only, and the time to reset is propor tional to the overload relay class. e Manual Reset -The starter will NOT reset automatically if it tripped on a thermal overload condition. A RESET button must be pressed manually. Protection is provided bye required cooling period before the overload relay C&I be reset. After an overload trip, once the cooling period has passed, the starter may also be reset by removing and then restoring control power. After a ground fault. phase loss, or phase unbalance trip, the be manually reset with control power ON.

Ground

Current

Sensing

Protection

Phase Unbalance If the unbalance of any two phases is greater than 30% of the DIP switch selected trip rating of the starter, a phase unbalance is declared and a trip occurs. No time delav is rewired for reset. This feature IS &and&d in the Cutler-Hammer Advantaae starter. To customize your protecti&, phase unbalance can be omitted by disabling the protection using a Advantage Programming Module (WAPM). Phase Loss The Advantage starter will trip on phase loss, after two seconds. if the current in any one phase is lower than the currents listed in Table 17. No time delay is required for reset. Phase loss protection IS standard on the CutlerHammer Advantage starter. As a option, this feature can be omitted by disabling the protection using a Advantage Programming Module (WAPM).

Cutler-Hammer Advantage starters with ground current sensing protection feature provide equipment pro&ction against ground currents between a facrory-set low level and a lockout current. It is designed to open the circuit when it senses the low-level and arcing ground currents often occurring in motor branch circuits. This feature is standard with the CutlwHammer Advantage starters. As an option. it can be omitted. NOTE: These devices are NOT Ground Fault Interrupters IGFlsl designed to protect people. Additionally, branch circuit short-circuit protective devices are to be used to clear faults that exceed the interrupting rating of the starter. The table below gives trip amperes and lockout amperes for each size of the starter. Lockout current is the sum of the phase current and ground current. Table 13 -Ground siza Trip curr.Rt Current Lockout EYrrell Sensing Trip nme

only

starter can

Short-Circuit

Withstandability

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

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Cutler-Hammer

Advantage Contactors and Starters Non-combination

Technical
Effective January 1999

Data
Page 11

Overload Table 14 -

Relay

Characteristics Relay Characteristics sin 1 size2 size3 size4 sin !! sizeI

Overload

Overload Accuracy XrnetoTq RepeatabIlIty Or,h Dueto Temperature

Ground Fault Trip Trip Range Stan D&y Trip O&y Tvsical Rerellimer 2 25 ml 45 min 5.75 mm Manual Only/ lmmed,ate Manual Only/ lmmed,are 2 25 mtn. 45 ml,. 5.75 mm Manual Only/ lmmedlale Manual Only/ lmmed,ate 2 25 mm 45 ml. 8 75 min Manual Only/ lmmed,ate Manual Only/ lmmed~ate 2.25 m,n 4.5 mm. 8.75 mm Manual Only/ Immediate Manual Only/ lmmedlate 2.25 min. 4.5 ml. 6.75 min. Manual Only/ Immediate Manual Only/ lmmed,ate 2 25 ml 4.5 ml. 6.75 ml. Manual Only/ ,mmed,ate Manual Only/ Immediate SeeTab,e 17 see .4 sec. 13,Page,G SeeTablel3.Page18 I7 set 4 set SeeTable 17 set 4sec 13,PagelD ;;~~ble13,Page18 .4 sec. SeeTable13,PagelO 17 xc 4 set SeeTablel3,Pqs,O 17 set 4 set

5%
25%llO~C

5%
25%/lO~C

:&WC

3% 2596110C

.5%
25%/lOC

.5%
25%/10c

at600% Tr,p Rat~ngsl Class IO Class 20 Class 38 Ground Fault

Phase Loss or Unbalance Trip/Cool Down on Loss of Power

I3 Phase

Thermal-If power IS restored aher this time expires. the unit w,, have automatically reset Phase Loss or Ground Fault 0 Reset Methods Auto Reset taca, Reset Remote Reset IMPACC Reset

2 25 ml

2 25 m,n

2 25 min

2 25 m,n

2 25 min

2 25 min.

N0WOlatlle INo Battery)

NO~YOl~,lI~ INa Battery)

N0WOlatlle INo BatteryI

N0n-VOlatlle iNo BattewO

NOll-Ol~tIl~ INa Batter/l

Non-volatile INo BatteryI

Thermal Only RI, Tr,ps Optional -All Trips Optional -AllTrips

Thermal Only All Trips OptionalAI,Trlps Opt~anal- All Trips

Thermal Only AllTrips Optional-AIlTrips Optional -AllTr~ps

Tbemla, Only All Tnps Optional -AllTrips Optional -AIlTrips

Thermal Only A,, Trips Optional -AllTr~ps Optional -AIlTrips

Thermal Only All Tnps OptionalA,, Trips Optional-All Trips

Table 15 -

Motor

FLA Current

Ranges

I I 0SF
Table 1.15to 1.25S.F.

NEH*Siza
Irn
1 2

3 3.153.43 45.03 455.Go 9.90 - 90.08 10.80 go 00

4 9.90 - 135.00 10.80 135.00

I 38.30 - 270.00 41 70 270 00 38.X - 54a co 41.70 - 540.00

.51
Data from

.47 - 3.81 4.14

3.15 - 27.00 3.43 27.00

16 -

NEC Motor iv

Amperes Pinperer zal &a

Tables 430 - 147 through 150 of 1996 at Full Load @J, Three-Phase AC

2aB veiis
2.4 35 4.8

230 Oltn
22 32 42

WI Il,l

571 VOID

l/2 3/4

25 37 4.8

11
16 2.1

9
13 17

5 7-l/2 10 15 ;: 30 40 50 60 76 100 125 150 2w

17.5 253 32.2 483 78.2 82.1 92 120 150 177 221 285 359 414 552

18.7 24 2 30.8 48 2 74.8 594 88 114 143 169 211 273 343 398 528

152 22 28 42 ; 80 lo4 130 154 192 248 312 360 4BO

7.8 11 14 21 34 27 40 52 85 77 96 124 156 180 240

81 9 II 17 :: 32 41 52 82 77 99 125 144 192

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Technical
Page 12

Data
Effective. Januar( 1999

Advantage Contactors and Starters Non-combination

Cutler-Hammer

Overload

Relay Settings

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

Remove the erc box cover to gain access. When a DIP switch handle is moved towards the position number (marked 8 through 1, left to right) that Dole is closed (represented bv 1). hhen a switch handle is away from the position number, the pole is open (represented by 0). Reset Method (for thermal overload trips only) -Set the type of reset desired using DIP position 8. L Manual-On thermal overload trips, reset time must elapse before pressing RESET button, or starter will not reset. L Automatic-Reset protection class. Table 18 time is based on

If a properly selected trip current setting results in an overload trip, move to a higher CLASS setting rather than to a higher trip-current setting. Select Class NONE when no overload, phase, or ground-fault protection is wanted. With NONE selected, the Class W200 Open Tvpe/ECA05 Enclosed Tvpe motor stane, will behave like a Class W201 Open Tvpe/ECAOl Enclosed Tvpe contactor. Table 19 -Overload susrlo~l I%** 10 20 Class DIP Settings PDSIIID r 0

Trip Current

Setting

The overload trip current of an Advantage starter is determined by its DIP switch setting I positions 5 through 1 as shown in Tables 20 throuah 26. Use only the table appropriate f& the starter and application involved. For motors with a marked temperature rise of not over 40C. or with a service factor of not less than 1.15. find in column A the range of motor FLA for the motor to be protected and use the settlng shown for DIP switch positions 5 through 1. For all other motors (ser. vice factor 1.0). select a range in Calumn B and use the setting shown for the DIP switches. Settings based on Column A give a trip rating of not more than 125% of motor FLA. Settings based on Column El give a trip rating of not more than 115% of motor FLA. Lower Current Range

POllsO I 6 II

Reset DIP Settinm

Overload

Class

Table 20 -

Size 1L Three-Phase

Starters,

Use the Class 10 (Fast Trip) setting for hermetic refrigerant motor compressors, submersible pumps, and similar apolications, as well as for protecting g&ml-purpose motors where the load permits the motor to reach rated speed without the overload protection circuit tripping. Use the Class 30 (Slow Trip) setting for special motors driving high inertia loads such as ball mills, reciprocating pumps, loaded conveyors, and the like. Use the Class 20 (Standard Trip) setting for all other motor applications. Most NEMA-rated, general-purpose motors will be protected by a Class 20 setting. 1.47ml.61 162 1.77 I 7s I 96 196G2.14 2 15 - 2.36 237 -260 3.26 3.58 394 4Y / lW,Q 10011 1OlW 10101

ItTaN

TO.SE.02.T.E

Cutler-Hammer

Advantage Contactors and Starters Non-combination

e able 23 -Size e ]

Technical
Effectwe January 1999

Data
Page 13

I Three-Phase Starters. Uppal

3 Three-Phas

itartern
rip Rating
hlpwes, IP Switch so %3*i,i0na.) iml,

3 I5 3 47 3.82-

3.46 3.81 4.19

4.20 4.62 5.1

4.61 5.0 55

QQQQQ QQQQI 00010 0001I

00100 00101 00110 00111 01000 OlOOl 01010 QlOll 01100 01101 QlllQ Q,,ll 10000 10001

109-11.9 ,20&13. 132-14.4 145-15.8 159-17.4

9.9 - 10.6

10.8-11.7 118-12.9 130-142 143-156 157-172 173-18.9 19.0 - 20.9 21 .o 22.9 23 0 - 25.2 25 3 - 27.6 27 9 30.6 30.7 33.6 33 7 - 37.0 37, -408 409-449 450-49.4 49 5 54.3 544-59.7 598-657 658-723 72 4 - 79.6 79.7 - 87.7 87.8 90.0

124 136 15.0 16.5 IS.1 19.9 21 9 24 26.5 29.1 32.1 35.3 427 47.0 51.7 56.9 62.6 66.6 15.1 63.3 91.6 101 111

QQQQQ 00401 QQQlQ 00011 00100 QQlQl

175-19.2 193-21.1 21 2-23.2 233-256 257-281 282-30.9 31.0-341 34.2 37.5 376-413 4, 4 -45.4 45 5 50.0 50 55 0 - 60.5 606-665 666 -73.2 733-80.7 808-88.7 888 900

00110 00111 01000 01001 0,010 01011 01100 01101 Q,llQ Q,lll 10000 lOOQ1 10010 1OOll 10100 10101 10110 10111

36 8

I 54.9

175 -192

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

lOOlD 10011 lOlO 10101 10110

able 22 -

Siz

34s 376m 4144 56 50 55

375 413 455 4.99 54 6.0

3 93 4.33 4.77 5.26 5.77 6.35 6.9 7.7 8.5 9.3 IQ.2 11.2 124 13.6 150 16.5 18.1 19.9 21.9 24.1 26.5 29.1 32.1 35 3 38.9 42.8 47.0 51 6

QQQW 00001 OOOlQ OQOl1 001m 00101 00110 OQlll 01000 01001 01010 01011 01100 01101 0,110 01111 10000 lOQQl 1OQlQ 10011 10100 1OlQl IOllQ 10111 Iloo llW1 11010 ,,Qll

1
7

I Three-Phase Starters

9.9IQ.9 lZ.Q13.2 l4.G 15.9 -

10.8 11.9 13.1 14.4 158 174

H
ytim

NIP Switch

sming

00000
00041 00010

00011 QQlw OOlOl 00110 00111 OlOW 01001 01010 01011 OllQQ QllQl 01110 Ollll lOoDD 10031 10010 10011 10100 10101 lOl10 10111 1lQQQ 11001 11010 11011

61 - 65 66 - 72 73 - 80 81 - 66 8.9 96 97 -106 107 118 130 143 156 173 190 !I0 !3.0 Z5.3 179 30.6 338 17.1 10.8 19.9 -117 -129 -14.2 -15.7 172 -189 -209 -229 25.2 27 8 -30.5 -337 -370 -40.7 mu.6 450

21.2 23.2 23 3 25.6 25.7 - 28.1 28 2 - 30 9 31 Q 34.2 37.6 41.4 45.5 50134.1 37.5 41 3 454 5c 0 549

55 0 60.5 60.6 - 66.5 66.6 - 73.2 73.3 80.7 80 6 66 7 86 8 - 97 5 97.6 - 106 IO7 - 117 1,s - 129 130 135

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Technical Page 18

Data
~~~~~~~~~~~~~~ IW

Advantage Contactors and Starters Non-combination

Cutler-Hammer

IMPACC

Communications

The 9600 baud IMPACC Network 1sone communication networkavailablewith the Cutler-Hammer Advantage line of motor controls. This network ties toaether monitorina. protection and control devices. There are a variety of IQ and other IMPACC compatible devices This important feature of the Advantage products allows for: * Data COlleCtlOn 4 Troubleshooting h Monitoring Control from remote locations

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

hard contact may be used to selectively enable or disable the output of the control functions from the module without affecting its ability to monitor. A feedback input is provided so that the state of an auxiliary contact may be read over the DeviceNet network. Three bicolor LEDs indicate: i DeviceNet address

1_ ON, OFF, and RESET control s Data-in - Current the form of in three phases

- Phase unbalance - Control voltage - Status (ON. OFF, TRIPPED, RESPONSE) - Overload alert (YES or NO) or NO i

Network status (including connected, not connected, not powered) Module status (including normal operation, minor fault, needs commissioning) commu-

- Trip Cause and Trip Data - DIP switch settings - AUTO/MANUAL Overload Trip rating SoftWsre Several interface/software options available which utilize IMPACC: are reset

The module gives Advantage nication capabilities of: F 500K baud Master/Slave = Polled I/O connection Explicit Message connection

relay Class

lil Adheres to ODVA (Open DeviceNet Vendor Association) motor starter profiles, with additional functionality The communication 5 ON/OFF control features offered sre:

NOTE: Other IMPACC devices can be intermixed with WZOO on the same twisted pair network i.e.: IQ, AEM, Addressable Relay, etc. As maw as 1.000 comoatible devices. installed in vsr~ous assemblies, can communicate over an IMPACC Svstern. These devices may be moniiored and controlled by a computer in a remote location up to 7500 feet away. Hardware To utilize the IMPACC network, a simple plug-in, snap-on Product Network Interface (PONI) is reauired for each device with which co&nunication is desired. The catalog designator for the device designed to work with the CutlerHammer Advantage starters and contsctors IS WPONI. It prowdes data and control functions as well as address wheels for addressing up to 1000 devices. Each WPONI is set to a different address and twisted pair wire is daisy-chained between the dewces. Advantage controllers and existing IQ or other IMPACC products can be intermixed on a single IMPACC network.

h SERIES Ill -a comprehensive Windows@ -based package with graphics capabilities and other control and monitoring functions. Series Ill uses the INCOM protocol. a Other software packages which may be used with IMPACC or an IMPACC driver include: Indelec, Inc.: MultivlewB Intellution, DMACS@ Inc.: The Fix@ and

d Trip reset jl Three-phase + Average motor current

motor current

L Starter status (OFF, POWER ON, RUNNING, TRIPPED) i Percent phase unbalance mal capacity and ther-

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

Iconics, Inc.: Genesis Communication Module

DeviceNet

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

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Technical
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Data
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Wiring Control

Options Power and Terminals Trip Indicator/Reset Options Communications Port and trip indicaare shown

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

Wiring for the four trip indicators and/or reset buttons are as follows: Remote Reset and Trip Indicator

The communications tar/reset connections below.

The location trol terminal

and function is:

of each con-

kI3 -Terminal

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

or

Local Trip lndwtor

Only Communications devices must be plugged into the front SIX pins as shown. This connection is keyed to prevent improper connection. Trip indication or reset devices must be plugged into the back two pins as shown. Only one such device may be used. Control Options

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

or

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

Remote

Reset Onlv

A nonweversing motor controller may be used with 2-wire control or any one of three J-wire control schemes. The four point (3-P-E-C) terminal block shown in Figure 5 is attached to the shock-mounted circuit board and will give approximately l/l6 inch under screwdriver pressure. No Remote Reset or Trip Indication In all cases, control power to terminals 3-P-E-C must be in phase. An interposing relay must be used whenever the controlling signal to 3 or P is a different ohase anale (reference to ground) than the voltage supplied to E and C. (See Two-Wire Control later in this publication.) NOTE: Emergency stop should break the E connection. A maintsined NC

For Local Reset only, no wiring required.

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Cutler-Hammer

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

The recommended method of wiring the Advantage controllers is 3-wire control using internal electronic holding. In this instance: a The momentary to terminal 3. * The maintained to terminal P. start signal is wired stop signal is wired

L No holding circuit interlock is required. The START/STOP signals may vary in voltage wlthin the specification listed earlier. This is the recommended method of wiring because it provides the full range of communications and product features. All IMPACC functions are available. The virtues of 3.wire control can also be obtained without an external auxiliary contact and jumper by using the internal holding circuit. Wire as shown in Figures 10 through 13 shown on Pages20 and 21. Attach and route wires to a remote reset/trip indicator module where provided. NOTE: When wiring according Fig we 11, you are breaking power to the board on drop-out. This will cause a momentary no response condition over the communications port.

to

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Data
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Attach a WPONI communications module and connect it to the IMPACC network daisv-chain fashion as shown in Figure 12. When wired as shown the motor can be reset, started via the IMPACC order to start the motor control circuit terminal energized. in Figure 12, stopped and network. In ~a IMPACC. P must be
TO Other

IMPACC NetwOrk Devices

NOTE: Sizes 5 and 6 horizontal rwersing cc&actors have their Forward and Reverse contactor arrangement reversed. Reverse contactor is on left and Forward contactor is on the right. Three-Wire Control Holdinq Circuit with Conventional

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

route

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Data
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Advantage Contactors and Starters Non-combination

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

Cutler-Hammer

Three-Wire

Control with Joa Option

The contacts of a two-position NORMAL - JOG selector switch can be added to the circuit between point 2 and 3 of Figure 15 where an external electrical interlock IS used as the holding circuit. Install a 14, 16 or 18 AWG stranded wwe iumoerfrom 3 to P. Where the internal iold/ng circuit is used. wire as shown in Figure 14. No jumper is needed. Attach and route wires RESETIKYIP indicator module where provided.

control

IMPACC with the Selector switch in either mode. Ttle motOr can only be reset via IMPACC when wired as shown I Figure 15.

toa remote

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

r
I I I

I I I
I I I IP

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Data
Page 23

Two-Wire

Control

Wire as shown in Figure 16. Install 14, 16 or 18 AWG stranded wire jumper from 3 to P. Attach and route wires to a remote RESET/TRIP indicator module where provided. NOTE: Automatic reset should not be used with Z-wire control circuits where automatic starting of the motor may be hazardous. With Communications Attach a WPONI communications module and connect it to the IMPACC network daisy-chain fashion as shown in Figure 16. When wired control, the stopped via can be only via IMPACC used. as shown with two-wire motor cannot be started or IMPACC The motor starter reset and data obtained where two-wire control is

PLC Interface With the addition of the 3 and P terminals, a number of PLC wiring options exist. Various~pesofPLCoutputdevices may be used to control an Advantage starter. The following three output types are addressed in this section: I I Relay Output Transistor at 12OV AC. at 24V DC. Interface interface

1 Solid-State

(Triac) Output at 120VAC. Output

Benefits

of Discrete

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

18K ohms

)* Universal interface-same for all sizes due to low power required. No interposing relays are needed for Sizes 1 - 6. lb Dry contact compatible. * Phase detection for noise immunity, during SURE-Stan diagnostics. Relay Output at 12OV AC

The relay output creates a 12OV AC dry contactsignaItothestarterterminals3 and/or P, channeling power to the control inputs. This p&ides relay output control for Sizes 1 through 6 without the use of interposing relays because co11 power IS not being switched. NOTE: This is the recommended method of PLC control. Figure 17 shows the wiring diagram for starter control by Relay Output.

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Advantage Contactors and Starters Non-combination

Cutler-Hammer

Solid-State

(Triac) Output

at 120V

AC

Triac crutputs possess two unique characteristics: ii Need for a sufficient load current in order to latch the device on $c Leakage current in the OFF state

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

The load current needed to latch in the triac output boards may require a resistor placed across the terminalLsl3 and/or P The high impedance of these input terminals may not support the minimum current required to maintain the ON state of the triac (Figure 181. Typically. a 50 mA load will latch all triac output modules; however, It is recommended that You check the specificatrons of the board manufacturer. To find the resistor needed and minimum watts required, based on the manufacturers specrfications, use the formulae below. RN=120/lL where RN is the resistor needed, and IL is the Latch-In Current from PLC specs. The minimum should be: watts for the resistor

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

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

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Effectwe.January 1999

Data
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Leakaqe Current

in OFF State
3

Triac outouts possess another unique characte;istic-they produce leakage current in the OFF state. If this leakage current is high enough, the Advantage controller may fail to drop out when a *top signal is given. The Advantage contactor is designed to remain closed when AC voltages in the range of IZOV to 132V AC are applied to the P (run permit) terminal. The Cutler-Hammer Advantage Starter has an input impedance of approximat& 18K ohms. A leakage current highe; than 1.3 mA might irevent the unit from opening when it receives a stop signal. To correct certain leakage problems in the field, a voltage divider can be added. The resistance values shown below will result in the application of 24V to the P and 3 terminals when IOOV is supphed by a triac output. This 24V is sufficient to close the Advantage controller. In the OFF state. with the leakage currents shown, the voltage at the P terminal will be 3V or less. This will ensure the dropout of the Advantage controller (Figure 20). Transistor Outout at 24V DC

--I
R,

R2

12OV AC

Transistor output module literature tvoicallv shows leakaoe currents rangi&from .l to 3.5 mArThis OFF stateleakage could be misinterpreted as a true signal. The Advantage starters were reliably controlled without an interposIng load to drain this leakage current. Ho&ver, Cutler-Hammer cannot guarantee tram sistor leakage in the field or that a particular application would not experience false turn-on due to output leakage currents. A resistor load circuit could be added to drain this leakage current (Figure 21). Table 37 indicates recommended veles of Rl and R2 for typical maximum 24V transistor leakage CurrentS

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Advantage Contactors and Starters Non-combination

Cutler-Hammer

Drive Applications
When using Advantage starters and contactors in drive apphcatlons, certain considerations must be made first. Parallel Applications Both the contactors and starters have filters to eliminate any response to the high frequency noise put on the power bus by solid-state drives. Therefore, applications involving Advantage cont&tors and starters in parallel circuits (Figure 221 will not experience interference problems.
Power Disconnecr

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

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

Motor

Cutler-Hammer

Advantage Contactors and Starters Non-combination

in Inches and Shipping Weights
Clrcut Aux.

Technical
Effecttue January1939

Data
Page27

Approximate

Dimensions

I
E

1
L

Table 38 NEW. sne

Open Type: Non-reversing Wids p1 HighB

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Data

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Advantage

COi'ItaCtOrS and Starters

Cutler-Hammer

Non-combination

Approximate Dimensions in Inches and Shipping Weights

NOTE: For Dimensionsof Open ReversingStarter using ACM modules-Contact

Table 39 -

Cutler-Hammer.

OpenType:Reversing Hi#l B Widl A NEMI SIZ@

onpc

MDuning D

MO,i~ E

RI,*

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Technical
Effective: January 1999

Data
Page 29

Approximate

Dimensions in Inches and Shipping Weights

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Data
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Advantage Contactors and Starters Non-combination

Cutler-Hammer

Approximate Dimensions in Inches and Shipping Weights

-l

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Advantage Contactors and Starters Non-combination

Technical
Effective January 1999

Data
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Other Advantage Publications

Advantage Application Color Brochure Guide -SA-412 -TD.8.5.T.E Inc., 1999. 02

Copyright Cutler-Hammer All Rights Reserved

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Data
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Advantage Contactors and Starters Non-combination

Cutler-Hammer

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