PCS compact soft startersSoft starting solutions for pumps, conveyors, compressors and fans, while providing integrated motor protection.

Sales 1300 NHP NHP nhp.com.auNHP Electrical Engineering Products Pty Ltd

MOTOR CONTROL AND DRIVES

Now available in a 24 V AC/DC control

variant for easy maintenance and

added safety

PCS Soft Starters—The Compact ChoiceThe PCS provides intelligence and consistent performance in a compact design for controlling your motor. PCS soft starters are suitable for motor starting applications up to 45 kW (3 wire) and 75 kW (6 wire) at 400/415 VAC. It features microprocessor-controlled electronic overload with adjustable trip class, motor and system diagnostics, configurable auxiliary contacts, and multiple start and stop modes. All of these combined features provide a highly accurate, reliable, and efficient soft starter with one of the smallest footprints in the industry.

The PCS AdvantageCompact size with integral bypass

From a slim 45 mm in width, the PCS integrates a bypass to minimise heat generation during run time. The bypass automatically closes when the motor reaches its nominal speed, resulting in a cooler-running component and reduction in enclosure size.

True three phase control

The PCS controls all t hree motor phases for smoother starting and minimal thermal stress on the motor.

3 wire / 6 wire motor connectionWith 3 wire and 6 wire motor connection compatibility as standard, the PCS offers you flexibility. When configured for 6 wire mode the PCS is able to control larger motors without any cost penalty to the user.

Choice of starting & stopping modes PCS soft starters provide the user with a selection of starting and stopping modes as standard. The ability to select and tailor the starting mode ensures the full benefits of soft starting can be achieved in any industrial motor starting application.

Side-by-side stacking at 40 ºC 1)The PCS can be stacked side-by-side thereby saving further panel space and reducing enclosure size.

24 V AC/DC control variantThe standard PCS has a wide control supply range of 100-240 V AC 50/60 Hz for ease of installation. In addition, a 24 V AC/DC control variant is available, maximising your control options.

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Notes: 1) The PCS can be stacked side-by-side with no space between units. However, frame size one models

(1…37 A) require the optional span-on fan attachment (retains same compact footprint). Frame size two models (43...85 A) include fan as standard.

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Easy to install, easy to operate

Configurable Auxiliary Contacts

As standard, the PCS provides a configurable (normal or up-to-speed) normally open (N/O) auxiliary contact for motor run status indication. The PCS has a line of side-mount configurable (normal or up-to-speed) auxiliary contacts, allowing you more flexibility.

Potentiometer

A clearly labeled potentiometer is used to adjust motor full load current setting. The lowest minimum Full Load Current (FLC) setting is one third of the soft starters’ current rating. The motor connected must have an FLC within this range. E.g: PCS-009-480 V has an overload range of 3 A to 9 A.

LED status indicationClear indication of all motor and system fault conditions via a ‘flash coded’ LED.

Marking tag holderUsed with marking tags to provide quick and accurate starter identification.

DIP switch set-upQuick, accurate and repeatable settings are assured through a simple to use DIP switch selection panel.

Integral motor overload/fault contactA normally open (N/O) fault contact for indication of motor overload/fault is included on the PCS.

Test / reset buttonThis dual purpose button allows testing of the trip function without motor current flow and fault resetting under normal operating conditions. Optional remote or standard local reset for your convenience.

DIN-rail mounting & screw fixing

Complete with DIN-rail mounting and screw fixing, the PCS is easy to install.

Seamless integration with Sprecher+Schuh switchgear

The PCS fully integrates with Sprecher+Schuh switchgear, forming complete soft starter solutions.

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PCS modes of operationTimed Voltage Ramp

The timed voltage ramp soft start mode offered by the PCS is for the most general application. User adjustments for initial torque and start ramp time allow the PCS to be configured for a variety of starting conditions. Typical applications include pumps, fans, conveyors and compressors.

The initial torque can be adjustable to 15 %, 25 %, 35 % or 65 % of locked rotor torque. The start ramp time can be adjusted to 2, 5, 10, 15, 20, 25 or 30 seconds.

Current Limit

The current limit start mode is used when it is necessary to limit the maximum starting current in order to reduce electrical stress on the motor and supply. The current limit setting can be adjusted to provide 150 %, 250 %, 350 % or 450 % of full load amps during start. The start time is also user adjustable to 2, 5, 10, 15, 20, 25 or 30 seconds.

Note: If the motor is not up to speed after the selected time elapses, the PCS will transition to full voltage.

Kickstart

The Kickstart function is intended for use on machines that present a high frictional starting characteristic. It provides a current pulse of 450 % FLC over a user adjustable period of 0 to 1.5 seconds, allowing the motor to develop the additional starting torque required to get the load moving.

Soft Stop

The soft stop function can be used to extend the stopping time of the motor and load. When enabled the ramp downtime can be set to either once, twice or three times the start ramp time setting.

The motor will stop when the output voltage from the PCS reaches the point where the load torque is greater than the motor torque.

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Protection featuresElectronic motor overload protection with user selectable trip class

The PCS soft starter provides electronic motor overload protection with adjustable trip class and automatic or manual reset selectivity as standard. Selecting a trip class that closely resembles the driven motor’s thermal withstand capabilities, minimises nuisance tripping and maximizes machine up-time and plant productivity.

The motor full load current is user adjusted via a blue potentiometer located on the front panel. Overload trip class (either OFF, 10, 15 or 20) and automatic or manual reset operation are DIP switch selectable.

Phase imbalance protection

The phase imbalance on a PCS is a measure of the difference in current between the highest and lowest phases. If the percentage of difference is 65 % or greater, the PCS will fault on a phase imbalance.

Shorted SCR

Prior to every start, the PCS checks the integrity of its power assembly (SCRs). If the PCS detects a shorted SCR, the start will be aborted.

Flash coded LED indication

When a fault is detected the PCS will trip and illuminate a flash coded fault LED to protect the motor and assist in the troubleshooting process.

Starter over-temperature protection

The PCS monitors the temperature of its power circuits (SCRs) by means of internal thermistors.

Phase sequence protection

The PCS provides a user selectable (ON or OFF) phase sequence protection function as standard. When selected, the PCS will monitor the incoming phases before application of power to the motor.

Phase loss protection

The PCS provides phase loss protection to both the line and load sides as standard to ensure the motor will not attempt to start when there is a power phase missing. This protects the motor from burnout resulting from single phase starting conditions.

Open circuit output (open load) protection

The PCS monitors the motor circuit to ensure the motor is connected before it commences its ramp. This feature is aimed at those installations which may have a motor isolator fitted between the starter and the motor, thus preventing a start when the isolator is in the ‘open’ position.

LED Description (Number of Flashes)

Solid RUN/ON x 1 Overload x 2 Starter over-temperature x 3 Phase reversal x 4 Phase loss/open load x 5 Phase imbalance x 6 Shorted SCR x 7 Test

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Typical PCS applications

FANS

COMPRESSORS

CHECK VALVE

DISCHARGE

SUCTION

 

 

Note:

The above applications are to be used as an indicative guide only. Consult NHP for further information.

Additional PCS applications: • Bottlewashers

• Debarkers

• Dustcollectors

• Edgers

• Grinders

• Hydraulicpowerpacks

• Planers

• Presses

• Circularsaws

• Slicers

Pumps Conveyors

Fans Filler lines

CrushersCompressors

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Approx. kW @ 415 V AC

Setting range Amps

100-240 V AC/DC Control Cat. No.

24 V AC/DC Control Cat. No.

AC 53b: INTERNAL BYPASS CONTACTOR

0.55...1.1 1…3 PCS-003-480V PCS-003-480V-024

1.1...4 3…9 PCS-009-480V PCS-009-480V-024

2.2...7.5 5.3…16 PCS-016-480V PCS-016-480V-024

3...9 6.3…19 PCS-019-480V PCS-019-480V-024

4...11 8.3…25 PCS-025-480V PCS-025-480V-024

5.5...15 10…30 PCS-030-480V PCS-030-480V-024

7.5...18.5 12.3…37 PCS-037-480V PCS-037-480V-024

7.5...22 14.3…43 PCS-043-480V PCS-043-480V-024

11...30 20…60 PCS-060-480V PCS-060-480V-024

15...45 28.3…85 PCS-085-480V PCS-085-480V-024

3 wire installation

6 wire installation

Fully enclosed solutions- see page 11

PCS Model Selection The PCS features 3 wire and 6 wire motor connection compatibility as standard, offering you flexibility.

Notes: 1) As standard, the PCS is capable of 3 wire and 6 wire motor connection. When using the PCS in 6 wire mode, the

overload current must be set to 58 % of the motor FLC. E.g., a 50 amp motor in 6 wire would use a PCS-030-480 V

and the overload current setting would be set to 29 Amps.

Approx. kW @ 415 V AC

Setting range Amps

100-240 V AC/DC Control Cat. No.

24 V AC/DC Control Cat. No.

AC 53b: INTERNAL BYPASS CONTACTOR

0.55...2.2 1.7…5.1 PCS-003-480V PCS-003-480V-024

2.2...7.5 5.1…16 PCS-009-480V PCS-009-480V-024

4...11 9.1…27.6 PCS-016-480V PCS-016-480V-024

4...15 10.9…32.8 PCS-019-480V PCS-019-480V-024

5.5...22 14.3…43 PCS-025-480V PCS-025-480V-024

7.5...22 17.3…52 PCS-030-480V PCS-030-480V-024

7.5...30 21…64 PCS-037-480V PCS-037-480V-024

11...37 25…74 PCS-043-480V PCS-043-480V-024

15...55 34.6…104 PCS-060-480V PCS-060-480V-024

22...75 50…147 PCS-085-480V PCS-085-480V-024

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AccessoriesSide-mounted auxiliary contacts 1) Cat. No.

1x N/O contact PCS-PA-10

1x N/C contact PCS-PA-01

2x N/O contacts PCS-PA-20

1x N/O and 1x N/C contact PCS-PA11

Contactor connection modules Cat. No.

Connects PCS-003…019 to CA7-9…23 PCS-23-CI23

Connects PCS-030…037 to CA7-30…37 PCS-23-CI37

Remote reset magnets Cat. No.

24 V AC coil CMR7-24VA

240 V AC coil CMR7-230VA

24 V DC coil CMR7-24VDC

Cooling fans Cat. No.

Frame 1: PCS-003…37 PCV-064

Frame 2: PCS-045…85 PCV-147 2)

Marking tags Cat. No.

Marking tag covers (x 100) CA7-FMP

Transparent cover (x 100) CA7-FMC

Marking tag stickers (x 100) CA7-FMS

Notes: 1) As standard, the PCS includes a configurable (normal or up-to-speed) normally open (N/O) auxiliary contact. 2) Frame size 2 cooling fans come complete as standard.

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SpecificationsCategory PCS - 3 wire operation PCS - 6 wire operation

Motor rating at 415 V AC 0.55 to 45 kW 0.55 to 75 kW

Current rating 1 to 85 Amps 1.7 to 147 Amps 1)

Motor connection 3 wire (line) 6 wire (inside delta)

Utilisation category to AS 3947-4-2 AC 53b (internal bypass contactor)

No. of controlled phases 3

No. of starts per hour Refer to curves (page 10)

Supply voltage range (3 phase) PCS-xxx-480-xxx V 200 to 480 V AC

Control voltage range (+10 % / -15 %) PCS-xxx-xxx V 100 to 240 V AC PCS-xxx-xxx V-024 24 V AC/DC

Supply frequency range 50/60 Hz, 3 phase supply and control

Soft start modes Timed voltage rampCurrent limitKickstart

Stop modes Soft stopCoast to stop

Selectable start times 2, 5, 10, 15, 20, 25, or 30 s

Selectable initial torque 15 %, 25 %, 35 % and 65 % of locked rotor torque

Selectable current limit 150 %, 250 %, 350 % and 450 % of full load current

Selectable kick start - 450 % FLC OFF, 0.5, 1.0, or 1.5 s

Selectable soft stop OFF, 100 %, 200 %, or 300 % of the start time setting when configured

Protective functions Electronic motor overload with adjustable trip class (OFF, 10, 15 or 20)Starter over-temperaturePhase sequence/reversalPhase lossPhase imbalanceShorted SCROpen load

Enclosure rating IP 2X

Ambient temperature 50º C standard

Altitude 2000 m

Relative humidity 5...95 % (non condensing)

Pollution degree 2

Certification

Notes: 1) As standard, the PCS is capable of 3 wire and 6 wire motor connection. When using the PCS in 6 wire mode, the overload current must be set to 58% of the motor FLC. For complete PCS specifications consult NHP.

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Overload relay trip curves

Starts per hour curves

Dimensions (mm) and weightsA

B

C

F

G

D

E

Cat. No. A B C D E F GMounting hole size

Weight (kg)

PCS-003...037 45 140 100 35 132 46.4 2 4.6 0.86

PCS-043...085 72 206 130 55 198 102 2 5.3 2.25

(3…37 A) (3…37 A)

Trip Class 10 Trip Class 15 Trip Class 20

PCS 3 Starts per hour (3...37 A) 40 º C, 100% Duty Cycle, 10 s, 350 % without fan

PCS 3 Starts per hour (3...37 A) 40 º C, 100% Duty Cycle, 10 s, 350 % with fan

PCS 3 Starts per hour (43...85 A) 40 º C, 100% Duty Cycle, 20 s, 350 % with standard fan

PCS-003...009

PCS-016...019

PCS025...037

Star

ts/H

our

Star

ts/H

our

Star

ts/H

our

Current (Amps)

PCS-003...009

PCS-016...019

PCS025...037

PCS-003...009

PCS-016...019

PCS025...037

Current (Amps) Current (Amps)

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Enclosed PCS solutions for 3 Wire applicationsThe PCS soft starters are also available in enclosed format and are provided as standard assemblies or manufactured to specifications. The enclosed PCS solutions listed below are suitable for 3 wire applications. Enclosed PCS solutions are also available for 6 wire applications, consult NHP for further information.

Insulated enclosed 0.55 kW to 45 kW•Insulatedpolycarbonateenclosure,IP66protection

Dimensions (mm)

Approx. kW @ 415 V AC

PCS Sof Starter

Line contactor

Setting rangeAmps Height Width Depth Cat. No.

0.55...1.1 PCS-003-480V CA7-9 1…3

280 280 180

SSPC7-1.1-240VAC

1.1...4 PCS-009-480V CA7-9 3…9 SSPC7-4-240VAC

2.2...7.5 PCS-016-480V CA7-16 5.3…16 SSPC7-7.5-240VAC

3...9 PCS-019-480V CA7-23 6.3…19 SSPC7-9-240VAC

4...11 PCS-025-480V CA7-30 8.3…25 SSPC7-11-240VAC

5.5...15 PCS-030-480V CA7-30 10…30 SSPC7-15-240VAC

7.5...18.5 PCS-037-480V CA7-37 12.3…37 280 380 180 SSPC7-18.5-240VAC

7.5...22 PCS-043-480V CA7-43 14.3…43

600 400 210

SSPC7-22-240VAC

11...30 PCS-060-480V CA7-60 20…60 SSPC7-30-240VAC

15...45 PCS-085-480V CA7-85 28.3…85 SSPC7-45-240VAC

Steel enclosed 0.55 kW to 45 kW•Qualitysteelenclosures,IP66protection

Notes: 1) Enclosed PCS soft starters are manufactured to order. Consult NHP for manufacturing lead time. Standard control voltage 240 VAC. 415 VAC available on request. Standard assembly includes line contactor, PCS soft starter with integral bypass contactor and electrical motor protection with adjustable trip class (off, 10, 15, 20), control circuit breaker as well as start, stop and reset pushbuttons.

Dimensions (mm)

Approx. kW @ 415 V AC

PCS Sof Starter

Line contactor

Setting rangeAmps Height Width Depth Cat. No.

0.55...1.1 PCS-003-480V CA7-9 1…3

300 300 210

MSSPC7-1.1-240VAC

1.1...4 PCS-009-480V CA7-9 3…9 MSSPC7-4-240VAC

2.2...7.5 PCS-016-480V CA7-16 5.3…16 MSSPC7-7.5-240VAC

3...9 PCS-019-480V CA7-23 6.3…19 MSSPC7-9-240VAC

4...11 PCS-025-480V CA7-30 8.3…25 MSSPC7-11-240VAC

5.5...15 PCS-030-480V CA7-30 10…30 MSSPC7-15-240VAC

7.5...18.5 PCS-037-480V CA7-37 12.3…37 400 300 210 MSSPC7-18.5-240VAC

7.5...22 PCS-043-480V CA7-43 14.3…43

500 400 210

MSSPC7-22-240VAC

11...30 PCS-060-480V CA7-60 20…60 MSSPC7-30-240VAC

15...45 PCS-085-480V CA7-85 28.3…85 MSSPC7-45-240VAC

NHP Electrical Engineering Products Pty LtdA.B.N.84004304812

NPCSCSSC 08/12 © Copyright NHP 2012

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