EATON S801+series soft starter

EATON S801+series soft starter

Basic Information and Core Product Specifications

Product positioning and applicable scenarios

Equipment type: Panel/shell mounted three-phase induction motor soft starter, which controls the motor terminal voltage by adjusting the SCR conduction time to achieve smooth starting (mechanical+electrical), and closes the internal contactor bypass SCR after starting to improve efficiency;

Applicable fields: Designed specifically for industrial equipment such as chillers, pumps, and machine tools, suitable for scenarios where the starting torque is lower than the rated torque of the motor;

Core advantage: It has multiple motor protection functions, supports two starting modes, and adapts to a wide range of motor power requirements.

Core hardware and model division

Framework and rated parameters: Divided into five major frameworks: N/R/T/U/V, the core parameters are shown in the following table:

Rated current range of frame (A) Weight (kg) Applicable motor power (kW/50Hz 400V) Number of bolts Fixed torque (Lb in/Nm)

N 11-66 2.6 10-37 4 15/1.7

R 32-135 4.8 30-80 4 25/2.8

T 56-304 18.6 51-185 6 30/3.4

U 112-500 18.6 110-300 6 30/3.4

V 112-1000 41.4 110-525 8 50/5.6

Core configuration: Built in Control Interface Module (CIM), supporting parameter configuration and fault diagnosis; Six sets of SCR full wave power bridges, equipped with electronic thermal overload protection, phase sequence detection and other functions;

Control power supply: 24 Vdc SELV/PELV, allowable voltage range 18-30 Vdc, peak withstand 35 Vdc (<100ms); Control power consumption of 25W (steady state) and 240W (impulse, 150ms).

Environmental and compliance parameters

Environmental adaptability: operating temperature -40 ℃~50 ℃, storage temperature -50 ℃~70 ℃, humidity 0-95%, no condensation; Altitude ≤ 2000m (with a capacity reduction of 0.5% for every 100m above sea level);

Compliance standards: Complies with UL 508, CSA 22.2-14-1995, IEC 60947-4-2, CCC GB14048, and has CE certification;

EMC compatibility: Anti static discharge (4kV contact/8kV air), anti electromagnetic radiation (10V/m 80-1000MHz).

Safety regulations and core taboos

Personnel and operational requirements

Qualification requirements: Installation, operation, and maintenance personnel must be professional technical personnel familiar with high-voltage safety operation standards;

Core taboos:

It is prohibited to perform live maintenance on equipment (including wiring and parameter adjustment). All power sources must be disconnected and tested first;

It is prohibited to install isolation switches on the output side (unless a shutdown linkage mechanism is configured), otherwise it may cause equipment failure or personnel danger;

The control terminal is only allowed to connect to a 24 Vdc power supply and is prohibited from connecting to 120 Vac (which will permanently damage the circuit board);

Prohibit failure to take safety measures in Auto Reset mode (which may result in accidental restart after fault clearance).

Core security risks and preventive measures

Potential risk prevention measures

During high-voltage electric shock operation, stand on an insulation pad and operate with one hand; The equipment is well grounded, and the cross-sectional area of the grounding wire is ≥ 1.5mm ²

SCR overheating ensures good ventilation and avoids frequent start-up (following start-up interval requirements); Ensure that the contactor bypasses normally after startup

Verify and save data loss parameters after configuration; Avoid power failure during parameter writing

Motor damage, correct configuration of FLA and protection parameters (such as overload trip level), prohibit disabling critical protection functions

Avoid severe vibrations during mechanical shock transportation and installation, and suitable lifting equipment is required for heavy frames (such as V-frames)

Installation process and specifications

Installation prerequisites

Installation location: inside the control cabinet/panel, can be installed horizontally or vertically; The SD card slot cannot face downwards (to prevent the card from falling off);

Spacing requirements: ventilation gap ≥ 30mm, distance from heat sources (such as transformers) ≥ 15cm;

Installation surface requirements: Panel thickness 2-5mm (N/R frame) or 1.5/2mm (V frame), flatness ≤ 0.5mm.

Cable and wiring specifications

Power cable:

Frame wire specification (Cu 75 ℃) Wiring torque (Lb in/Nm) Terminal type

N 10-2 AWG 35-50/4.0-5.6 Box Terminal

R 14-3/0 AWG 90-100/10.1-11.3 Box Terminal

T/U 4/0-500 MCM 225-250/25.5-28.3 requires EML series terminal kit

V 4/0-500 MCM 225-250/25.5-28.3 requires EML series terminal kit

Control cable: 22-12 AWG (0.33-4.0mm ²), wiring torque 3.5 Lb in (0.4 Nm); The 24 Vdc power cord should be ≥ 14 AWG (2.5mm ²) to avoid voltage drop;

Grounding specification: The equipment needs to be grounded for protection. The cross-sectional area of the grounding wire should be ≥ 1.5mm ², the length should be ≤ 350mm, and the tightening torque should be 1.3 Nm;

Phase requirement: The default incoming phase sequence is ABC. If the motor rotates in the wrong direction, the motor end or soft starter output end can be switched between two phases (switching input ends is prohibited as it may trigger phase sequence faults).

Equipment fixation and sealing

Fixing method: Fix with 4-8 bolts according to the frame (4 N/R frames, 6 T/U frames, 8 V frames), with bolt grade ≥ 5.8;

Sealing requirements: Ensure that the terminal cover plate and sealing strip are intact during installation, and install a ventilation fan (500 ft ³/min) on the V-frame as required.

Operation and Configuration

Startup and control mode

Startup mode:

Voltage ramp start (default): gradually increase the voltage from the initial torque (0% -85%), start for 0.5-180 seconds, and bypass SCR after the motor reaches synchronous speed;

Current limited startup: Constant voltage control, limiting startup current, suitable for scenarios with limited grid capacity (not recommended for variable torque loads such as fans/pumps);

Kick Start auxiliary function: outputting 0-2s torque pulses (0% -85%) during startup, used to overcome static friction or high inertia loads;

Control method:

Local terminal control: Start stop and fault reset are achieved through terminals P (allow), 1 (start), 2 (Jog), and 4 (reset);

CIM configuration: Set FLA, boot mode, protection parameters, and view fault codes through CIM.

Core parameter configuration

Required parameters:

Parameter Name Configuration Range Default Value Description

Motor FLA 32% -100% frame rating frame minimum value needs to match motor nameplate FLA to ensure overload protection is effective

Overload trip level 5-30s 20s corresponding to motor overload withstand time

Start time: 0.5-180s, 20s. The time for the voltage ramp to reach the rated voltage

Initial torque 0% -85% 45%. The proportion of starting initial torque to locked rotor torque

Reset mode manual/automatic manual/automatic mode may cause a restart after the fault is cleared

Protection parameters (enabled by default, can be disabled): overload, phase loss, phase sequence error, locked rotor, SCR overheating, overcurrent, phase imbalance.

Fault diagnosis and handling

Fault code reading: Long press the CIM reset button or apply 24 Vdc to terminal 4, and identify the fault code by the number of LED flashes (e.g. 3 flashes+2 flashes=fault code 32);

Common fault codes and solutions:

Fault code, fault type, solution

Reduce motor load due to thermal overload, check FLA configuration, wait for cooling (3-9 minutes)

22. Check the incoming power supply, fuses, and wiring tightness for phase loss

14 phase sequence error exchange motor end or soft starter output end two-phase

32 SCR short circuit/phase loss power-off measurement SCR resistance (normal ≈ 10k Ω, short circuit<5 Ω), contact maintenance

12 motor stalling, clearing load obstacles, increasing starting time or initial torque

Maintenance and Accessories

routine maintenance

Regular inspection: wiring tightness, ventilation hole cleanliness, contactor status (no abnormal noise);

Periodic verification: validity of protection parameters, rationality of startup curve, and zeroing of fault records;

Attention: After an overload fault, wait for the cooling time (3 minutes for one fault, 6 minutes for two faults, and 9 minutes for three faults). The cooling timer cannot be reset when the power is turned off.

Accessory selection

Terminal kit: EML22-26 for T/U frame, EML28-33 for V frame;

Installation accessories: installation board (EMM13 series), vibration board (EMM14 series), IP20 protection kit (SS-IP20 series);

Replacement parts: CIM module (EMA71), control cable connector (EMA75).

Storage and disposal

Storage and transportation

Storage conditions: Temperature -50 ℃~70 ℃, humidity 0-95%, no condensation, avoid corrosive environment and severe vibration;

Transportation requirements: Use original packaging, heavy frames need to be transported with air cushions to prevent equipment damage.

Disposal standards

The equipment contains electronic components (SCR, circuit board) and metal parts, which need to be classified and recycled according to local environmental regulations;

Do not dispose of the equipment at will. You can contact Eaton or authorized dealers to dispose of the scrapped equipment.