ABB 1MRK002239-BBR04 Digital Controller

Product Detailed Description

• Core Function: The primary function is to smoothly start and stop AC induction motors by controlling the motor voltage and current. This reduces mechanical stress on the motor and connected equipment, prolongs equipment lifetime, and prevents voltage dips in the electrical supply during starting.

• Starting and Stopping Control:

• Smooth Ramping: Provides various ramp profiles (voltage ramp, current ramp, torque control) for optimized starting based on the application load.

• Torque Control: A key feature for applications like pumps, ensuring a soft pipe fill during start and eliminating water hammering during stop, significantly reducing wear on pipes and valves.

• Kick Start: Provides an initial torque boost for difficult loads.

• Soft Stop: Offers controlled deceleration to prevent mechanical shocks, especially useful for pumps and conveyors.

• Motor Protection: The PSTX integrates a wide range of motor protection features, often eliminating the need for external protection relays. These include:

• Overload protection (with selectable trip classes).

• Underload protection (e.g., for dry run protection of pumps).

• Phase unbalance and phase loss protection.

• Phase reversal protection.

• Over/under voltage protection.

• Stalled motor protection.

• Excessive start time protection.

• RTD (Resistance Temperature Detector) inputs for direct motor temperature monitoring (windings and bearings).

• Process Control Features:

• Pump Cleaning: A unique feature to prevent pump clogging by reversing the flow direction and applying a kick-start.

• Jog with Slow Speed: Allows running the motor at a very low speed for positioning or alignment purposes.

• Braking: Features for controlled braking of the motor.

• Communication & Connectivity:

• Built-in Modbus RTU communication for integration with PLCs, DCS, and SCADA systems.

• Optional fieldbus adapters for various protocols like Ethernet/IP, Profibus DP, Profinet, DeviceNet, Modbus TCP, allowing seamless integration into automation networks.

• Bypass Functionality: Integrated bypass contactors (for most sizes) reduce energy losses during run time, minimize heat dissipation, and allow for a more compact installation.

• User Interface: Intuitive graphical display with multiple languages, simplifying setup, monitoring, and troubleshooting. Detachable keypad for remote mounting.

• Adaptive Acceleration: Automatically adjusts the starting curve to variations in the load, ensuring optimal performance.

Product Parameters

(Note: Parameters vary significantly across the PSTX range depending on the current rating, voltage, and specific model. Always refer to the specific PSTX model's datasheet and manual for precise figures.)

• Operating Voltage (Ue): Typically 208 V AC to 690 V AC (3-phase).

• Control Voltage (Uc): Typically 100-250 V AC/DC.

• Rated Operational Current (Ie): Ranging from typically 30 A up to 1250 A (in-line connection) or higher for inside-delta connection.

• Motor Power Rating: Corresponding power ratings from approximately 5.5 kW up to 630 kW (in-line connection at 400V) or higher.

• Starting Modes: Voltage ramp, current ramp, torque control, soft start with current limit, kick start.

• Stopping Modes: Soft stop, coast to stop.

• Built-in Bypass: Yes (for most sizes).

• Motor Protection: Integrated, configurable (e.g., thermal overload class 10, 20, 30).

• RTD Inputs: Up to 3 RTD inputs (Pt100, Ni100, etc. configurable).

• Analog Outputs: Typically 2 programmable analog outputs (e.g., 4-20mA for motor current, thermal load).

• Digital Inputs/Outputs: Multiple programmable digital inputs and relay outputs for control and signaling.

• Communication: Modbus RTU built-in; Fieldbus adapters for various protocols.

• Display: Graphical LCD display.

• Degree of Protection: Typically IP00 (open type) to IP20/IP30 (depending on enclosure and mounting). Requires proper panel integration for higher IP ratings.

• Ambient Temperature: Operating range typically -25 °C to +60 °C (with derating above 40 °C).

• Mounting: Panel mounting.

• Certifications: CE, UL, CSA, CCC, RoHS, etc.

Product Advantages

• Seamless Motor Control: Provides exceptionally smooth starts and stops, eliminating mechanical shocks and extending the lifespan of motors, gearboxes, belts, and pipes.

• Enhanced Process Control: Advanced features like torque control (for pumps) and pump cleaning functions lead to optimized process performance, reducing maintenance and improving product quality.

• Energy Efficiency: Built-in bypass contactors minimize energy losses and heat generation during full-speed operation. Optimized starting currents also reduce demand charges.

• Increased System Reliability & Uptime: Comprehensive motor protection features safeguard the motor from various electrical and thermal stresses, preventing unexpected failures and reducing downtime.

• Reduced Installation and Maintenance Costs: Integration of many protection and control functions into one unit reduces wiring complexity, panel space, and overall installation time. Remote communication and diagnostics simplify maintenance.

• Global Support: As an ABB product, it benefits from ABB's extensive global service and support network.

Precautions

• Correct Sizing and Selection: Always select the soft starter based on the motor's full load current, application load type (normal duty, heavy duty), starting torque requirements, and duty cycle. Over/under-sizing can lead to inadequate protection or premature failure.

• Environmental Conditions: Ensure the soft starter is installed within its specified ambient temperature and humidity limits. Proper ventilation is crucial to dissipate heat, especially for higher power ratings. Derating may be necessary at higher temperatures or altitudes.

• Bypass Contactor: While many PSTX models have an integrated bypass, for some specific applications or very high power ratings, an external line contactor (contactor in series with the soft starter) and/or an external bypass contactor might be required. Always consult the wiring diagrams.

• Short-Circuit Protection: Soft starters do NOT provide short-circuit protection. Proper external short-circuit protection (fuses or circuit breakers) must always be installed upstream of the soft starter.

• Grounding: Ensure proper grounding of the soft starter and the motor as per national and local electrical codes.

• EMC Considerations: Follow ABB's recommendations for cabling (shielded cables for control, proper separation of power and control cables) to minimize electromagnetic interference (EMI). Use appropriate line reactors or filters if necessary.

• Commissioning: Careful commissioning and parameter setting are crucial. Incorrect settings can lead to motor damage or undesirable operation. Utilize ABB's software tools (e.g., Softstarter PC tool) for easier configuration.

• Maintenance: While reliable, regular preventive maintenance (checking connections, cleaning, checking ventilation) as recommended by ABB can further extend the product's life and ensure continued efficiency.

Product Applications

ABB high-performance soft starters (PSTX series) are ideally suited for a wide range of demanding industrial applications where motor control and protection are paramount:

• Pumps: Centrifugal pumps, submersible pumps, sewage pumps (preventing water hammering, dry run protection, pump cleaning function).

• Fans and Blowers: Large industrial fans, ventilation systems (reducing mechanical stress, quiet operation).

• Conveyors: Belt conveyors, roller conveyors (smooth start/stop, preventing product spillage, overload protection).

• Compressors: Reciprocating and rotary compressors (reducing mechanical shock, controlled start-up).

• Mixers and Agitators: Chemical mixers, food processing agitators (smooth acceleration, preventing splashing).

• Crushers and Mills: Heavy-duty applications with high inertia loads (reducing stress on mechanical components).

• Saws and Shredders: Applications requiring smooth starts to prevent mechanical shock.

• Escalators and Elevators: For smooth and comfortable passenger movement.

• Wood Processing Machinery: Saws, chippers, planers.

• Marine Applications: Pumps, fans, and propulsion systems on ships.

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