Operation Manual:

Electronic softstart system

LIFTSTART
L1 L2 L3

LIFTSTART

L1 L2 L3 T1 T2 T3

Table of contents: Page

1. General hints 2
2. Mounting instructions 2
3. Wiring 3
4. Commissioning instructions 4
5. Connection diagram 5
6. Modes of operation 6
7.1. Outline drawing A 7
7.2. Outline drawing B 8
7.3. Outline drawing C 9
8. Available types of LIFTSTART 10
9. List of types 11
10. Technical data 12
11. Basic connection 13, 14, 15, 16, 17
1. General hints:
The electronic softstarters "LIFTSTART" have been designed for starting and stopping
three phase electric motors without risking of uneven or jerky starts and stops. This greatly
reduces the wear on mechanical parts and prevents big current peak loads.
Starting and stopping the three phase motor without steps or transitions lengthens the
life of powerdriven machine mechanical elements, greatly reducing stress on trans-
mission and coupling parts.
The "LIFTSTART" range of solid state soft starters are electronic controlled 6 thyristors
devices designed to provide progressive acceleration for 3 phase induction motors.

The electronic softstarters type LIFTSTART consist of two parts:

a) Power-unit (thyristor moduls)

b) Control-unit

2. Mounting instructions

The LIFTSTART controller (IP 22) should be mounted vertically in a housing. The
upper and lower side of the heatsink must be kept free to allow cooling air to circulate
freely. Controllers with cooling fans must be mounted on a flat surface to ensure that
cooling air is channelled to the heat sink.

Additional points must be considered when mounting the unit:

- Vibration free environment

- Protection against hazardous environments
- Protection against dust and humidity

Please avoid to mount other components in distance of 100mm around the controller be-
cause the cooling system can be affected.

Minimum clearance
around the controller
of 100mm.

LIFTSTART

page 2
 3. Wiring
When wiring consider the following points to ensure correct and reliable operation.

--> Hazardous voltage are present to the LIFTSTART during operation.

--> The operation of the softstarter with a capacitive load at the output (e.g. for power
factor compensation) is not permissible.
--> Using an installation tester can damage the LIFTSTART
--> Connect the controller as shown in the following recommended connection.

Confirm the power side L1, L2 and L3 and motor side T1, T2 und T3
Take care of the following parts in regard to the control signals:
Install a surge suppressor on the relay exciting coil.
Use a shielded wirde for twisted wire for the control circuit wiring.
Distance this from the main circuit wiring.
High voltage wiring (L1, L2, L3, T1, T2, T3) should be physically and electrically
separated from low voltage signal wires or control wires.
Only qualified persons should work on or near these controllers. The succesful
and safe operation of these controllers is depended on proper transport, storage,
planning and installing as well as commissioning.
Please regard established safety practices like VDE 0100, VDE 0113, VDE 160.

These electronic can effect the movement of dangerous machinery or moving

constructions. The general safety precautions must be taken before putting into
operation.

Fuses:
Conventional short circuit protection of the connections to the controller and to the motor
in accordance with the wiring regulations must be provided. Circuit breakers, motor starters
or additional fuses can be used. The control voltage should be protected with 2A.
Start (Enable):
Command: "START" connect terminal 2
Connection of control terminals: to terminal 3.

Relay terminals: K3 K2 K1 K4 Monitoring signal "End of ramp":

Terminals 12/11 switch to 12/13 (K1)
(S2-Funktion).
Ground

Can use for switch on the briding

contactor.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 External control voltage:

230V 50/60Hz, terminals: look examples
Fault 1 Start of End of Fault 2 of standard wiring.
(St1) ramp ramp (St2)
Phase Input: PTC Over temperature:
loss The controller is fitted with a temperature
Start Heat sink
control circuit. This continously monitors
detaktion the temperature of the heat sink and
should this rise above 75°C the
LIFTSTART will shut down.
PTC-connection The red "Fault -LED St1" flashes and
the terminals 5/6 switch to 5/4.
page 3
4. Commissioning instructions

Confirm that no parts have been damaged during shipping. When not using the
LIFTSTART immediately after purchase, store it in a place with no dust and with
good ventilation.
The adjusting and connection work are to be accomplished according with
established safety practices.
For damages or accidents, caused by unsatisfactory installation or inexpert inter-
ferences in the Liftstart , the manufacturer can not be made liable.
The indicated mains voltage must agree with engine performance and the
same applies also to the existing frequency.

Device connection:

The devices can be connected on either with the six-pole circuit of

the three-phase motor (W3 - circuit) or between main and motor.
(See example wirings)

The start instruction can be released via bridge from terminal 2 to

terminal 3.

At LIFTSTART of the version "LIFTSTART X-6 TS ", thus

with two separate contactors, activation is caused with creation of
230VAC-starting voltage. The two separation contactors pull up
and activate by auxiliary contacts switched into row the electronic
system of the LIFTSTART.

Diagnostic display (LED´s):

For announcement of the different functional states the LIFTSTART possesses

6 LED displays, which flash dependent on the respective condition
of equipment.

Pok Power o.k (Control voltage available)

Tr Top of ramp (Softstart is finish)
SE Start (Enable of LIFTSTART)
S1 Drive running (The LED flashs during the motor is running)
St2 Fault 2 (Flashs at PTC-detection)
St1 Fault 1 (Flashs at phase loss, undervoltage, heat sink
overtemperature)
At fault 1 the operational status indicators Tr, SE and S1 expire.The LED "St1" flashes.
The fault signal can be reset by connecting of the control voltage or main voltage
or by activating of start. (RESET)
page 4
 5. Connection diagramm
Control unit
Potentiometers: LED´s: Connections of control terminals:

Relay terminals: K3 K2 K1 K4

SE S1 St1
Soft stop time Preset Run-down

GND
Tr/S2 St2
Toff Poff 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Pok
Fault 1 Start of End of Fault 2
Phase loss ramp ramp Input: PTC
Ton Pon Heat sink
detection
Soft start time Preset start Start

Bedeutung der Potentiometer: Attention:

At fault (St1) terminals 4, 5, 6 the
Ton Soft start time (2...8s) power unit will switched off.
Toff Soft stop time (2...8s) Fault (St2) only one message
Pon Preset start (0...90%) spends. The power unit is not
Poff Preset Run-down (0...100%) switched off.
(other values can be implemented when desired)

LED´s:
Pok (gn) Power o.k.
SE (gn) Start (Enable of LIFTSTART)
Tr/S2 (gn) Top of ramp (100%)
S1 (gn) Softstarter is running
St1 (red) Flaschs at phase loss, undervoltage, heat sink overtemperature and the relay contacts K3 switch from 5-4 to 5-6
St2 (red) Fault-LED PTC-detection the relay contacts K4 switch from 15-14 to 15-16

page 5
 6. Modes of operation:
U Motor

Top of the ramp

up Ru
Run- e ramp vol n-do
g
volta t a g wn
er
Preset am
(Soft stop) p
Preset
(Start)
Soft start time 100% - Continous operation Soft stop time
t

Command: "Start"
(Link terminals 2 and 3)
t

LED SE

LED S1 + relay K2
(drive running)
t

LED TR + relay K1

(For example used by by-pass contactor) t

page 6
7.1. Outline drawing

190mm

175mm
List of LIFTSTARTS:
Size "A"

Liftstart 9...
Liftstart 12... =6mm
Liftstart 16...
Liftstart 24...
Liftstart 33...

280mm

300mm
200mm

page 7
7.2. Outline drawing

300mm
List of LIFTSTARTS:
Size "B" 280mm
Liftstart 40...
Liftstart 60...

=6mm

280mm

300mm
170mm

page 8
7.3. Outline drawing

300mm

280mm
List of LIFTSTARTS:
Size "C"

Liftstart 77...
Liftstart 90...
=6mm

380mm

400mm
200mm

page 9
 8. Available types of LIFTSTARTS
L1 L2 L3 L1 L2 L3

Liftstart ... -3 Liftstart ... -6

Liftstart
Liftstart

M M
3~ 3~

The Liftstart is placed between line Six-clamps connection

and three-phase motor. without seperation contactors.
L1 L2 L3 L1 L2 L3

Liftstart ... -3/TS Liftstart ... -6/TS

Liftstart
Liftstart

M M
3~ 3~

The Liftstart is connected between Six-clamps connection of the

line and three-phase motor by two Liftstart with two seperation contactors.
seperation contactors.
L1 L2 L3

Liftstart ... -3/BY

Liftstart

M
3~

Completion of the Liftstart with integrated bypass contactors.

page 10
9. List of types:
Typ: Size: Motor power Motor current max. Numbers Recom. fast Wight Wire sizes Recommended L1 L2 L3
Start current of starts / Semiconductor reactance coil
(kW) (A) (A) h fuses
(kg) (mm²)
Liftstart 9-3 A 9 30 80 75 60A 3,5 4,0 NDR 36

Liftstart 12-3 A 12 42 110 75 60A 2,8 4,0 NDR 50

Liftstart 16-3 A 16 53 145 75 80A 4,0 6,0 NDR 50 Liftstart

Liftstart 24-3 A 24 68 220 75 100A 4,2 10,0 NDR 75

Liftstart 33-3 A 33 76 300 75 125A 5,5 16,0 NDR 75

Liftstart 40-3 B 40 110 360 75 200A 5,9 25,0 NDR 120

Liftstart 60-3 B 60 138 480 75 250A 6,4 35,0 NDR 160

M
Liftstart 77-3 C 77 180 600 40 400A 8,5 50,0 NDR 220 3~
Liftstart 90-3 C 90 220 750 30 500A 10,2 70,0 NDR 220

Typ: Size: Motor power Motor max. Number ofr Recom. fast Weight Wire sizes Recommended
L1 L2 L3
(kW) current (A) Start current Starts semiconduktor (kg) (mm²) reactance coil
3-pole W3- 3-pole W3- (A) /h fuses Input Output
connection circuit connection circuit W3-circuit 3-wire 6-wire
(like Liftstart...3) connec- connec-
tion tion
Liftstart 9-6 A 9 12 30 50 110 75 60A 3,6 4,0 4,0 NDR 50

Liftstart 12-6 A 12 16 42 70 145 75 60A 3,0 6,0 4,0 NDR 75

Liftstart 16-6 A 16 24 53 100 220 75 80A 4,2 10,0 6,0 NDR 100
Liftstart
Liftstart 24-6 A 24 33 68 120 290 75 100A 4,5 16,0 10,0 NDR 120
Liftstart 33-6 A 33 40 76 130 360 75 125A 6,0 25,0 16,0 NDR 160
Liftstart 40-6 B 40 60 110 190 480 75 200A 6,3 35,0 25,0 NDR 220
Liftstart 60-6 B 60 77 138 235 600 40 250A 7,0 50,0 35,0 NDR 280
Liftstart 77-6 C 77 90 180 310 750 30 400A 9,0 70,0 50,0 NDR 350 M
Liftstart 90-6 C 90 125 220 380 900 30 500A 10,5 95,0 70,0 NDR 420 3~

The specified values are approximate values. These can deviate in practice.
page 11
10. Technical data:

Rated voltage: 3x400VAC (-15...+15%)

Control voltage: 400V/230VAC (-15...+15%)

Frequency: 45Hz...65Hz (self adjustment)

Controlled Phases: 3 (L1, L2, L3)

Operating temperature: -20°…55°C normal operation)

Relative humidity: 95% (without condensation)

Max. altitude: 1500m

Control outputs: 250VAC / 8A or 24VDC / 3A

(loads of relay contacts)

Monitor of faults: heat sink over temperature > 75°C

PTC-detection
Phase loss
Undervoltage

Mounting position: vertical, power terminals at bottom

Control inputs: separated galvanically

Relevant standards: EN60947-4-2 (1996)

EN55011,
EN61000-4-2…
EN50178
CE conformity

Safety class system: IEC 536 (1976)

Protection: IP22 (EN60529

Page 12
11.1. Basic connections: Liftstart 9-3 to Liftstart 60-3

1 2 3 4 5 6 7 8 9 10 1112 13 1415 16

(T1) (T2) (T3)

U V W
L1 L2 L3 PE L1 N 8 9

L1 N
Enable "Start" End of ramp
with 230VAC (By-pass contactor)

M
L1 L2 L3 PE 3~
From main supply
(3x400V/50Hz/60Hz)

The main circuits are connected to the clamps L1, L2 and L3.The output of the Liftstart
are to connected with the clamping links U, V, W (T1, T2, T3).

page 13
11.2. Basic connections: Liftstart 9-3/TS to Liftstart 60-3/TS

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Seperation contactors

U1 V1 W1 W2 U2 V2
L1 L2 L3 PE L1 N 8 9

(T1) (T2) (T3)

L1 N
Enable "Start" End of ramp
with 230VAC (By-pass connector)
M
L1 L2 L3 PE
3~
From main supply
(3x400V/50Hz/60Hz)

The main circuits are connected to the clamps L1, L2 and L3. The outputs of the LIFT-
START are to connected with the clamping links U (T1), V (T2), W (T3).

page 14
11.3. Basic connectors: Liftstart 9-3/BY to Liftstart 60-3/BY

1 2 3 4 5 6 7 8 9 10 1112 13 1415 16

Bridging contactor

Arrangement
U V W of terminals
L1 L2 L3 PE L1 N 8 9

(T1) (T2) (T3)

Enable "Start"
with 230VAC
M
L1 L2 L3 PE 3~
From main supply
(3x400V/50Hz/60Hz)
Three phase connection
(Basic version)

The main circuits are connected to the clamps L1, L2 and L3. The outputs of the LIFT-
START are to connected with the clamping links U (T1), V (T2), W (T3).

page 15
11.4. Basic connection: Liftstart 9-6 to Liftstart 60-6

1 2 3 4 5 6 7 8 9 10 1112 13 1415 16

U1 V1 W1 W2 U2 V2
L1 L2 L3 PE L1 N 8 9

L1 N
Enable "Start" End of ramp
with 230VAC (By-pass contactor)
M
L1 L2 L3 PE
3~
From main supply
(3x400V/50Hz/60Hz)

The main circuits are connected to the clamps L1, L2 and L3. The output of the LIFTSTART
are to connected with the clamping links U1, V1, W1, U2, V2, W2.

page 16
11.5. Basic connections: Liftstart 9-6/TS to Liftstart 60-6/TS

1 2 3 4 5 6 7 8 9 10 1112 13 14 15 16

Seperation contactors

U1 V1 W1 W2 U2 V2
L1 L2 L3 PE L1 N 12 13

Enable "Start" End of ramp

with 230VAC (By-pass connector)

M
L1 L2 L3 PE
3~
From main supply
(3x400V/50Hz/60Hz)

The main circuits are connected to the clamps L1, L2 and L3. The outputs of the LIFT-
START have to be connected with the clamping links U1,V1,W1,W2,V2 and U2.

page 17