Revision F Instructions for Class W200, W201, Sizes 5 and ...

1 17405 Revision FInstructions for Class W200, w201 , Sizes 5 and 6, ThreePhase Non-Reversing magnetic Motor Starters and ContactorsFig. 1 Class W200 Size 6 StarterADVANTAGE MOTOR CONTROLA dvantage NEMA Size 5 and 6 electrically-operatedstarters and contactors (motor controllers) have the samephysical size, but differ with respect to mechanical partsand settings motor starters ( Class W200) include a solid statecurrent-sensing unit that provides overload protection,phase loss protection, phase imbalance protection, andground current-sensing motor rated contactors ( Class w201 ) do not includeoverload, phase loss, phase imbalance, or ground current-sensing protection, but they do have the same coil controllerthat prevents a contact kiss position on pickup anddropout when the coil voltage supply drops starters and contactors have this low voltage require a separate source of control power, preferablytaken from the motor supply circuit via a control combination of the coil controller and the solid statecurrent-sensing unit results in an energy efficient motorstarter.

2 Coil and magnet losses and overload sensinglosses are significantly less than those with equipmentfunctions by conventional 6/01 RATINGSThe maximum horsepower ratings of these motor con-trollers are shown in Table I. Kilowatt ratings equivalentto the horsepower ratings shown in Table I are shown inTable I - MAXIMUM HORSEPOWER RATINGS(60HZ)ControllerThree Phase Horsepower AtSize200V230V460V575V575100200200615020 0400400 TABLE II - MAXIMUM KILOWATT RATINGS(50HZ)ControllerThree Phase Horsepower AtSize220V380V415V500V660V56311012515015 06132220250300300 PROGRAMMED FEATURESA dvantage NEMA Size 5 starters and contactors areassembled with identical parts except for the circuit boardto which the control wires are attached. These circuitboards differ with respect to components and the softwareprogram they Size 6 starters and contactors are similar.

3 Theydiffer from Size 5 devices by virtue of larger contacts,higher ratings, provision for two conductors per phase,and different software Loss Protection - Advantage starters with thisoption automatically open (trip) within 2 seconds afterthey sense a current less than 27 amperes through anyphase after power is applied to the motor. This protectionprevents damage when a lead in a motor branch circuithas been Imbalance Protection - Advantage starters withthis option automatically open (trip) within 12 secondsafter they sense an imbalance between two phase currentsthat is greater than 30% of the Trip Rating shown in TablesIV and V. This protection prevents motor damage whena lead in a distribution system has been 17405 Page 2 Effective 6/01 TABLE III - WIRING DATAWireTighteningControllerCircuitRange TorqueSizeConductor(AWG)(lb-in)5 Power(1) #00-500 kcmil300-3756 Power(2) #00-500 kcmil225-3005 & 6 Auxiliary#22-127 Contact5 & 6 Control#18-14*6 Wire with copper conductors only.

4 Use wire rated 75oC orhigher based on the ampacity of 75oC wire * Strip control wires for terminals 3-P-E-C not more than 1 Current-Sensing Protection - Advantage starterswith this option automatically open (trip) seconds aftersensing ground current greater than 240 amps duringmotor running. There is a 17-second delay that preventsground protection from opening (tripping) during the total current in any phase is greater than 1045 amp-eres, ground current-sensing protection will be locked outto allow ground protection to be provided by other industrial type control is designed to be installed,operated, and maintained by adequately trained Instructions do not cover all details, variations, orcombinations of the equipment, its storage, delivery, in-stallation, checkout, safe operation, or maintenance. Caremust be exercised to comply with local, state, and nationalregulations as well as safety practices for this Class devices are full voltage motor controllers capableof starting, stopping, and interrupting the locked rotor cur-rent of motors within their ratings.

5 They must be protectedagainst short circuits by providing motor branch circuitprotection in accordance with the National Electrical Code(NEC) or the applicable electrical an enclosure with a volume of not less than 14,777cubic inches, mount the motor controller on a verticalplane with its long axis either horizontal or vertical. Thepreferred orientation is with the line terminals above theirrespective load terminal. The control circuit terminals,marked 3-P-E-C on the nameplate, are accessible withoutremoving the arc box cover via the shelf directly abovethe center load terminal. They are suitable for one or twoconductors per terminal in any combination of Sizes . Keepstrip length of these conductors to between 3/16 and 1/4inch. It may be more convenient to remove the arc boxcover. See Figure 2 for outline and mounting dimensionsand Table III for wiring COIL AND COIL CONTROLLERThe contactor portion of these motor controllers is a con-ventional design except for the circuit board and coil con-troller.

6 The coil controller prevents the contacts fromtouching without spring pressure ( contact kiss position)when the control voltage is low or dips. It prevents coilenergization when the control voltage is too low for properpickup, and yet maintains the armature sealed to the mag-net with reduced current when adequate control voltageis present. Maximum benefit of this low voltage responsefeature is obtained where the control voltage (110 VAC,50HZ or 120 VAC, 60HZ) is supplied by a control powertransformer with its primary fed by the motor CONDITIONSP hase loss, phase imbalance, and ground current-sensingprotection are provided in a Class W200 motor starter un-less the catalog number includes Y4 (phase loss andphase imbalance protection omitted), Y7 (ground current-sensing protection omitted), Y10 (phase loss protectionomitted), and/or Y11 (phase imbalance protection omit-ted).

7 Check the Test Verification label on the side of themotor controller to determine which features are Advantage starter trips (turns itself OFF) when it recog-nizes that phase loss, phase imbalance, ground current,or significant overload conditions exist. The starter mustbe RESET after tripping before it can be turned on protection functions can be nullified by a DIP switchsetting. See OVERLOAD SETTINGS. The phase andground functions can be added or deleted from the starterwith the use of the optional Advantage ProgrammingModule (WAPM).A trip condition is shown by the lighting of the light emit-ting diode (LED) at the side of the starter where this ac-cessory (Catalog No. WLED) has been added. This LEDcan be replaced by a remote reset and trip indicator (Cata-log No. WRSTKL). Both trip indicators require that controlpower be supplied to the starter to light.

8 Reset any trip bymanual means with the power on. Manual resetting con-sists of completing an electrical circuit between internalterminals, with either the reset button provided on thestarter or a remote reset PROTECTIONA Class W200 motor starter offers overload protection asa Class 10, Class 20, or Class 30 overload relay withoutthe need for heater elements and the resulting heat lossesof a thermal overload is obtained by three closely coupled currentsensors in combination with a microprocessor that 17405 Page 3 Effective 6/01units of the line current squared (I2), the heating effectwithin the motor. The sensors are coils wound in the formof toroidal helixes around a customized iron core with acontrolled air gap. This combination of coil, core, and airgap results in greater accuracy than thermal overloadrelays, without the fuss of heater elements.

9 The storedcount decreases whenever the line current is less thanthe maximum motor full load current specified for theoverload setting selected. This decrease represents thenatural motor winding cooling that occurs as the motorruns at full load current or an Advantage starter is equipped with an optionalinternal or external trip indicator, the LED in the indicationwill blink very 4 to 5 seconds when power is applied tothe starter. If the starter is in an overcurrent condition, theLED will blink every second. Whenever the motor is in anovercurrent condition and turns full ON indicating a trippedcondition, a reset is required before the motor can be re-started. If a ground current condition exists and the starterhas the catalog suffix Y7 (ground protection omitted),the LED will blink twice every second, but no trip will internal trip indicator is visible only with the enclosuredoor SETTINGSThe cutout in the arc box cover that provides access tothe DIP switch is designed to accept a snap-in clear plasticwindow.

10 Insert the window after initial DIP switch settingshave been made by engaging the hooks of one cornerand pushing on the opposite corner. To change a DIPFig. 2 Size 5 and 6 Outline and Mounting Dimensions (dimensions in inches)switch setting after the window has been installed, removethe arc box cover by loosening the four captive coverscrews accessible through the the eight-position (8 pole) DIP switch to select themethod of reset (MANUAL or AUTOMATIC), the overloadprotection Class (10, 20, 30, or NONE), and the trip currentrating appropriate for the motor full load current in amperes(FLA). When a DIP switch handle is moved towards theposition number (marked 8 through 1, left to right), thatpole is closed (represented by 1 ). When a switch handleis moved away from the position number, the pole is open(represented by 0 ).