Single Phase Soft Starters

Specification Catalog
 Single Phase Soft Starters

Table of Contents

Introduction............................................................................. 4
SureStart ................................................................................ 4
Background ............................................................................. 5
In-Rush Current......................................................................... 5
Measuring In-Rush ...................................................................... 5
Hard Start Kits vs SureStart .......................................................... 6
Other Compressor Starting Technologies ........................................... 6
The SureStart Difference ............................................................. 7
Increasing Utility Regulation ......................................................... 8
Off-Grid and Generators .............................................................. 9
SureStart Operation ..................................................................10
LED Flash Codes .......................................................................10
Operation Flow Chart ................................................................12
Model Nomenclature .................................................................13
Selection Example ....................................................................13
Dimensional Data .....................................................................14
Mounting Positions ....................................................................14
Characteristics ........................................................................15
Application Notes .....................................................................16
Installation Notes .....................................................................16
SureStart Compatibility Guide ......................................................17
Schematics .............................................................................17
Declaration of Conformity ...........................................................18
Definitions ..............................................................................19
Revision Table .........................................................................21

Page 3
Introduction Optional Custom SureStart Versions:
The SureStart Series soft-starter was the first of its (Consult Hyper Engineering)
kind invented by Hyper Engineering over a decade ago • Non air-conditioning applications (ie. submersible
in Wollongong, Australia. It was originally invented for pumps, gate automation)
use in the residential heating, ventilation, and air- • Non-equalized pressure (compressors without bleed
conditioning (HVAC) industry in Australia and Europe. In type expansion valves)
recent years, Hyper has expanded SureStart technology
into commercial HVAC by offering 3 phase versions
in commercial voltages. Whether it is for residential Background
or commercial applications, SureStart’s continued In air conditioning and heat pump applications,
success worldwide is a testament to its reliability and energy is moved through the air conditioner by a
performance that can be rivaled by none other. compressor which is an electrically driven pump that
compresses refrigerant as it pumps to a heat exchanger.
SureStart Compressors are the heart of air conditioning equipment
so it is important to protect them against failure.
SureStart Series is the original single-phase soft starter Inside of every compressor is an electric motor that
specifically targeted to reduce light flicker caused by draws a significant electrical current at startup. This
the startup of fixed speed permanent split-capacitor startup current is often referred to as the instantaneous
motors (PSC). These motors are often of the scroll current, in-rush current, locked-rotor amps (LRA), or
compressor types which are commonly used in air- direct-on-line (DOL) current. In-rush current on your
conditioning and heat pump applications. The SureStart home air conditioner is generally between 5-8 times
has the latest in innovations from Hyper Engineering higher than the current consumed by the compressor
that includes several new features: during normal operation. As the name suggests, in-rush
current is very brief lasting for a fraction of a second
• 60-70% reduction in direct on-line (DOL) or until the motor begins operating at normal speed. This
in-rush current. time period may appear trivial; however, it is the cause
• Sophisticated under voltage protection of many issues for homeowners, power companies, and
• Motor reversal protection. equipment manufacturers. Here are some common
problems created by high in-rush current.
• Self-adjusting up to nominal 7 hp for optimal start
performance. • Flickering of lights
• 50/60 Hz compatible. • Nuisance trips on safety protection equipment
• ETL, CE, EMC, and RoHs compliant. • Disrupts sensitive electronics such as computers
• Tolerant to “dirty power” conditions. • Increased stress on the motor which reduces the
• Versions available for retrofit installations or OEM reliability of the air conditioning equipment.
production use. • Higher installation cost due to insufficient
• Fault LED transformer sizing
• Internal Current Limiting • Increased noise and vibration at compressor startup

SureStart Module Most contractors install hard start kits to eliminate

these problems. Unfortunately, hard start kits don’t
provide a complete solution to the problem. Hard start
kits do not reduce the startup current but only the
startup time which may give a perceived improvement
in light flicker, but still stress the compressor during
every start. Mechanical shock is also increased to the
compressor by use of a hard start device. Installing
a SureStart corrects these problems by significantly
reducing the start current, optimizing the start time
to the compressor size, power supply and loading
while providing vital protection to the compressor, and
promoting improved reliability at startup.

Page 4
 Single Phase Soft Starters

In-Rush Current very low values. Low values will shift the average
down making it appear less significant. The faster the
Motor in-rush occurs due to low resistance in motor
event the less likely the DMM is to display accurate
windings essentially acting like a short circuit. This
results. Furthermore, the DMM is limited on the type
temporary short circuit causes an immediate spike in
of signal that it can detect. If the signal is smooth and
current and simultaneous drop in supply Voltage. Voltage
characteristic of an ideal sine waveform; then it is
drops for air conditioning compressors are often 15%
likely to be okay. However, if the signal is a complicated
or more which is 3-4 times greater than what most
waveform like measuring with a SureStart in the circuit;
electrical power distributors prefer. The more frequently
then it won’t be accurate. This is an important concept
the compressor starts, the more noticeable the problem
since the wrong tool used for measurement may lead to
becomes. For most homes in the US, air conditioners
false interpretation therefore not actually solving the
usually start at a rate of 6-10 starts per hour.
problem. For example, hard start kits provide a start
boost to the compressor which reduces the start time.
To add to the problem, the standard of living in the
It doesn’t lower the actual spike in current instead just
US has increased over time where air conditioning
makes it less noticeable by speeding up the time. A
has become a basic want for most homeowners. As
DMM might show that the spike is reduced; however, it
government regulations tighten, calling for higher
is due to a longer period of lower running current value
efficiency air conditioning, compressor manufacturers
offsetting the average.
have responded with higher efficiency motors in the
compressors. The downside to improved efficiency
is that in-rush current generally goes up as motor SureStart In-Rush Reduction
efficiency increases. Also, the larger home size results
in larger air conditioning units, and ultimately result in HVAC Compressor Before After %
higher in-rush currents. Figure 1 is a graph of typical Tons RLA In-Rush SureStart Reduction
in-rush current for air conditioners in the US along with 1.5 9 48 15 69
the SureStart reduced in-rush current.
2.0 14 73 22 70
Measuring In-Rush 2.5 17 79 24 69
3.0 20 109 33 70
The effect of these electrical spikes can be observed
by watching the lights flicker; however, this does not 4.0 26 134 40 71
help quantify the problem. In order to properly measure 5.0 30 158 47 71
in-rush current, the right tool is needed for the job. 7.0 32 185 56 54
In this case, that tool is an oscilloscope which has the
ability to observe electrical signals with great detail.
Oscilloscopes are used by engineers in a laboratory
Figure 1: Normal 5.0 Ton LRA vs SureStart
environment to study the magnitude and shape of
signals at specific points in time. An oscilloscope is an
expensive device that is more powerful than what is 200
needed by most service technicians for diagnostic use 180
in the field. Instead technicians carry a handheld device 160
called a digital multi-meter (DMM) that is capable of SureStart
Current (A)

140
basic current, voltage, and resistance measurements. 60 - 70% Normal LRA
Some DMMs are also able to capture maximum 120 Reduction
amperage or current value as well. It is likely that a 100
technician will use a DMM when trying to capture the 80
in-rush current of compressor at start-up. This can be 60
accomplished before and after adding hard start kit
to observe the reduced in-rush value. Unfortunately,
40
it is likely this maximum value does not reflect the 0
true instantaneous spike in current. The DMM is only 0 150 300 450
capable of recording current at defined time intervals. Time (ms)
If the time interval of the event is too fast the DMM
will have a portion of the interval where it recorded

Page 5
Hard Start kits vs. SureStart Before
Off-the-shelf products, such as a hard start kit, are Locked Rotor Amperage (LRA)
available for service technicians to install on an air
conditioner to solve the light flicker problem. It is Tek Ɣ Acq Complete M Pos: 150.0ms CH1
relatively low cost and simple to install to attempt Coupling
to satisfy the homeowner complaints. As previously DC
mentioned, hard start kits are a simple device that is BW Limit
used to provide a boost to the compressor to start it On
faster. It does not reduce the in-rush current, therefore 20MHz
does not eliminate problems created by high in-rush Volts/Div
4
current. A hard start also adds additional stress; hence Coarse
the name “hard start”. Compressors contain mechanical Probe
moving parts and like most mechanical parts don’t 100X
respond well to extra stress. When hard starts are used Voltage
the startup torque is increased which reduces life of Invert
the compressor. In contrast, SureStart provides optimal Off
mechanical advantage keeping torque at a minimum;
M 50.0ms CH4 / 24.0A
therefore, improving long term reliability. CH4 50.0ABW <10Hz

Other Compressor Starting Technologies

Conventional soft start philosophy adopts a simple
After
voltage reduction to contain this large starting current.
Using SureStart
This begins by ramping up the input from say 30 % to
full voltage in a fixed time interval. This, however badly
impacts the starting torque. So, under heavily loaded Tek Ɣ Acq Complete M Pos: 150.0ms CH1
conditions, the motor might stall. This implies poor Coupling
efficiency during starting. In any case, this simplistic DC
solution will not reduce the staring current by more BW Limit
than 30 to 40% and light flicker is not reduced due to a On
significantly increased start time. 20MHz

Volts/Div
4
Coarse
Probe
100X
Voltage
Invert
Off
M 50.0ms CH4 / 24.0A
CH4 50.0ABW <10Hz

Page 6
 Single Phase Soft Starters

The SureStart Difference HVAC/R

The term “softstart” is used generically when referring

to devices such as SureStart. It is worthwhile to
note that SureStart is not a “hard start” device. As
the name implies, it is a SureStartTM which ensures
the compressors starts optimally every time by not
delivering too much nor too little torque.

SureStart applies power electronics combined with Irrigation Pumps

intelligent software to provide optimal mechanical
advantage during motor starting. SureStart technology
maintains optimal torque while maximizing starting
efficiency over a range of power supply conditions.

By comparison, other softstarters normally have only a

Voltage ramp up where run and start windings are not
controlled separately.
Marine
• SureStart does not compromise the torque or the
time needed to achieve rotational speed.
• It compensates for poor power conditions such as
high cable impedance, low Voltage or both.
• It has a sophisticated learning algorithm to optimize
the starting time performance based upon various
factors some of them being: the line impedance
(reflected from the input voltage to motor) and
the time it takes for the motor to reach up to RV/Luxury Buses
full speed. This ensures auto regulation of start
performance for different sized motors without any
human intervention.
• The SureStart also reduces the voltage dip in the
power line during starting.
• Light flickering reduced by up to 10 times during
start up when units have a SureStart in the circuit.
• Built-in firmware inside SureStart helps eliminate arc
damage to the motor contactor due to chattering. Military/Government
• SureStart is out of the circuit after startup. It
consumes less than 2W average in running mode.
• The SureStart protects against motor reversal by
preventing restarts in event of intermittent lapse
in power supply. Motor reversal is possible during
turn off cycles when the back pressure forces the
compressor to rotate in reverse direction.
• SureStart will protect the motor by not allowing it to Solar Power
start under adverse low voltage conditions.
• Loss of power detection includes sensing of low
voltage sags and intermittent power drop outs
(lasting 0.1-3 seconds).

Application Types
The SureStart is versatile enough to be used in many
applications other than HVAC/R with guidance from our Backup Generators
Hyper Engineering Technical Support.
• HVAC/R • Irrigation/Submersible Pumps
• Marine • RV/Truck
• Compressors • Military/Government
• Solar Power

Page 7
Increasing Utility Regulation to emerge from utility companies on the West Coast.
The in-rush current listed in the table is a standard air
Most of the problems discussed so far relate specifically
conditioning scroll compressor that would be used in a
to the homeowner. However, power distribution
residential application.
companies experience issues when it comes to in-
rush current. Depending on whether the utility is
Other countries such as the United Kingdom, Ireland,
dealing with an existing network or working on plans
Germany, and Australia have already implemented
for a network expansion, additional investment and
regulations that limit the inrush current that can be
operational costs could be required. As more homes
installed on a residence. This is often referred to as the
get retrofitted or built with air conditioning it will
“45 Amp Rule” where the in-rush current is limited to
require utilities to boost distribution equipment sizing
45 A. If adopted in the US, it would limit most homes
such as transformers and conductors accordingly. This
to 1.5 ton air conditioning system. Most homes in the
additional cost is driven higher since they must size the
US are larger than homes in European countries and
equipment for worst case scenario. As stated previously,
generally require a minimum of 2-3 tons of capacity.
in-rush current is 5-8 times greater than operating
Larger homes can require up to 4-5 tons which is
current; therefore, in-rush current is a significant
almost 3 times the European limit. However, when a
parameter to the power distribution company. Even if
SureStart is installed it reduces those values by 70%. A
the time period is very fast they still must overcome the
compressor with 158 Amp in-rush will be reduced to 47
instantaneous demand of the in-rush current. Currently,
A. Since the US power supply and distribution network
the in-rush current regulations in the US are lenient.
was designed differently from other countries, it is
As energy costs continue to rise, it is only a matter of
likely these limits, if established, will be slightly higher
time before limits are established for in-rush. The table
than the 45 A European model and unique for North
below illustrates some of the limits that have started
American countries.

Utility Regulation on Motor Starting Current

Anaheim Vancouver Scroll Compressor
Air Conditioner Maui Electric Company PG&E
Electric Electric Manufacturer
(Tons) 240V
240V 208V 240V 240V Copeland Danfoss
1 & Less 36 60 100 - 48 - -
1.5 48 60 100 - - 48 -
2 60 60 100 60 60 73 -
3 80 60 100 80 80 109 115
4 - - - - - 134 150
5 120 60 100 120 120 158 145
7.5 170 60 100 170 - 185 145
10 220 60 100 - 220 - -

Off-Grid & Generators each start. The excess surge due to in-rush current can
easily lead to brown outs, light flicker and even cause
SureStart offers an ideal solution for homeowners or
other equipment in same circuit to trip. The obvious
industrial solutions looking to use their HVAC units on
consequence is the need to oversize the local generator
off-grid power or unstable power supply conditions.
and inverters to avoid this issue. SureStart can reduce
This is especially applicable for situations in remote
the cost of going off-grid by reducing the generator size.
locations where power is limited or where long cable
layouts are required, or necessitate use of generator or
SureStart easily overcomes this by reducing the peak
solar based service.
surge demand at start. In single phase, it is sufficient
enough to size the generator surge requirements to
Without a softstart or even installations incorporating a
roughly 2.5 times the kW rating of the motor. For three
hard start kit, one would have to ensure that generator
phase applications, it is recommended to size the
or inverter surge capacity is sized to at least 5 times
generator surge requirements to 4 times the kW rating
motor rating. Higher efficiency compressor motors can
of the motor.
even demand 6-7 times its nominal kW rating at start.
This is to ensure that the motor does not stall during

Page 8
 Single Phase Soft Starters

Generator Sizing Methods Power (kW) Rating Method

If SureStart is used in systems which are powered Multiply the Power (kW) rating of the compressor by 2.5
through an inverter setup fed from alternate renewable times for the generator capacity required for SureStart
energy sources like photovoltaic cells or generators, a and 6 times without the SureStart.
new installation will easily benefit from lower demands
on inrush requirements through lower inverter and solar Model 064 without SureStart:
panel sizing. Depending on kW rating of the installation, Equipment kW = 3.7 therefore 3.7 kW * 6 = 22.2 kW
this could easily lead to potential savings higher than Generator Size kW (Column G) = 25 kW
cost of the SureStart device itself.
Model 064 with SureStart:
The following are two methods of sizing the generator Equipment kW = 3.7 therefore 3.7 kW * 2.5 = 9.3 kW
to show the reduction effect of a SureStart upon Generator Size kW (Column G) = 10 kW
generator size in each method. These are for example
only and do not account for other potential equipment So the reduction is over 60% with SureStart due to the
loads such as lighting and appliances. It may be reduction in LRA.
advisable to average the two for the most conservative
approach. These are examples only and a professional Locked Rotor/Start Power Rating Method
should select and size a generator for your home using When more detailed compressor data is available the
guidelines from the generator manufacturer. Locked Rotor/Start power method can be more precise.
Using locked rotor current and starting power, select a
Example Generators generator by rounding up to the nearest generator size.
Residential Surge
Rated Output Capability Model 064 without SureStart:
Generator (Running Amps) (LRA @ 30% Startup Amps (Column A) = 118, Start Power (Column B)
Model Size 240V 1ph Voltage Dip) = 15.3 kW
(kW) 240V 1ph
Generator Size kW (Column G) = 16 kW with 117 amp
Column F Column G LRA capability.
7 29 46
Model 064 with SureStart:
10 42 63
Startup Amps (Column C) = 41.3, Start Power (Column D)
13 54 95 = 5.4 kW
16 67 117 Generator Size kW (Column G) = 7 kW with 46 amp
18 75 133 LRA capability.
20 83 145
25 104 138 So the reduction is a little more than 50% with SureStart
due to the reduction in LRA.
30 125 205
35 146 225
Warning! Always consult with the generator
45 188 292 manufacturer for specific sizing guidelines.

Example Heat Pumps

No SureStart With SureStart Normal
Normal Accessory Operation Continuous
Equipment Starting Starting Starting Starting Operation Pumps w/Accessory Power
Example Amps Power Amps Power
Tonnage Pumps
HP
[kW]
(A) (kW) (A) (kW) (kW)
(A) (A) (A)
Column A Column B Column C Column D Column E
Model 026 2 [1.5] 52 6.8 18.2 2.4 7.4 1.0 8.4 1.7
Model 038 3 [2.2] 82 10.7 28.7 3.7 10.7 1.0 11.7 2.4
Model 049 4 [3.0] 96 12.5 33.6 4.4 14.3 2.0 16.3 3.4
Model 064 5 [3.7] 118 15.3 41.3 5.4 19.6 2.0 21.6 4.5
Model 072 6 [4.5] 150 19.5 52.5 6.8 22.2 2.0 24.2 5.0

Page 9
SureStart Operation Led Flash Codes
When the system control calls for compressor operation, A Red LED indicator will flash under the following
the compressor contactor will energize. If the supply conditions.
voltage to the SureStart is less than “Minimum Startup
Voltage”, a 50 second delay is initiated. At the end of [NOTE: LED fault indicator is turned off in normal
the delay, another attempt to start the compressor will running mode.]
begin unless the supply voltage remains unchanged.
SureStart uses an optimized starting process that learns a) Rapid Flash (10 / sec) : Low Voltage
the starting characteristics of the compressor to further b) Triple Flash Every Three Seconds (3 / 3 secs):
refine the starting cycle on each recurring start. If the Lockout on Three Failed Starts
compressor fails to start, the module will terminate the c) Slow Flash (1 / 3 secs): Lockout on Over Current
start attempt after 1 second and initiate a 3 minute d) Slow Steady Flash (1 / sec): Cycle Delay / Fault Mode
lockout before attempting a restart. If the supply
voltage falls below “Shutdown on Low voltage” limit Flash Code (Rapid Flash (10 / sec) : Low Voltage)
for 2 seconds or below 130 volts for 0.1 seconds while - Displayed for “Low supply voltage” before or after
the compressor is running the module will stop the a softstart.
compressor and initiate a 3 minute lockout. A restart - If Low voltage is detected before a start, a re-start
will be attempted after 3 minutes if the supply voltage is attempted after 50 seconds.
is equal to “Minimum Startup Voltage” or higher. This is - If Low voltage is detected after a start, a re-start is
done to protect the compressor against a sudden drop attempted after 3 minutes.
in supply voltage.
Flash Code (Triple Flash every three seconds
SureStart is able to detect an interruption in power, (3 / 3 secs): Lockout on Three Failed Starts)
when the interruption is 0.1 seconds or longer. When
a power interrupt is detected, SureStart will shut - Displayed after failure to start on “Three
down the compressor for 3 minutes. SureStart is consecutive start attempts”.
also able to determine if the compressor is running - Re-start is attempted after 50 minutes.
backwards. If this condition is detected, SureStart will - Standard lockout period is revised to 3 minutes
stop the compressor for 3 minutes before a restart is after a successful start.
attempted. A power interrupt that is shorter duration
than 0.1 seconds may result in a compressor running In circumstances where the compressor may have
backwards, which the SureStart can detect and stop seized or is unable to startup due to failure of other
compressor operation. components in the HVAC system, the software will
check for three consecutive failed starts. On the third
If the run capacitor is faulty or has failed, SureStart sequential failed start, the program goes into Lockout
will shutdown the compressor for 3 minutes before for 50 mins. On failing to get a good start even after 50
attempting a restart. mins, it will re-attempt start again after duration of 50
mins. Once a good start is eventually achieved, it will
reset the hardstart counter and will require 3 failed
starts again to force it back into Lockout mode. Lockout
can be cleared anytime through a power reset of the
SureStart device.

Page 10
 Single Phase Soft Starters

Flash Code (Slow Flash (1 / 3 secs): Lockout on

Over current)
- Displayed for “Overcurrent” in running mode of the
compressor motor.
- Overcurrent limit is “25A for 08-16A version” and
“50A for 16-32A rated version”.
- Also displayed, if internal Klixon of the compressor
trips out on overheat.
- Re-start is attempted after 10 minutes.

To limit the current in compressors from extending

abnormally beyond its stated capacities, SureStart is
also equipped with Overcurrent limit protection. For
models rated from 16-32A, SureStart is designed to trip
out in overload conditions exceeding 50A. In smaller
models, it is designed to cutoff power to the compressor
if the current drawn exceeds 25A. On overcurrent
lockout, SureStart attempts a re-start automatically
after 10 minutes.

Both failed start lockout and overcurrent limit

protection have been designed to prevent the
compressor from drawing abnormal currents in
conditions not feasible for the compressor operation.

Flash Code (Slow Steady Flash (1 / sec): Cycle

Delay / Fault Mode)
- Displayed for “Cycle delay” between two consecutive
softstarts or other faults mentioned below.
- Re-start is attempted after a default period of
3 minutes.
- Other possible reasons for this Fault mode indicator
can be due to
- incorrect wiring during installation,
- a failed Softstart attempt,
- intermittent power loss (duration longer
than 100ms),
- frequency out of range, or
- failed run capacitor.

Page 11
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Page 12
 Single Phase Soft Starters

Model Nomenclature

1 2 3 4 5-9 10 11
S S 0 B 12-20 S N

Auxiliary Alarm Relay

Type
N – None
S – SureStart
Standard
Contactor Function
S – Standard
P – Primary1
S – Secondary2
Full Load Amps (FLA)
(Corresponds to Compressor Run Load Amps (RLA))
Nominal Voltage Rating
12-20 – (115V Single Phase)
0 – 115/60/1
08-16 – (230V Single Phase)
1 – 208-230/50-60/1
16-32 – (230V Single Phase)
Vintage
B – Current, Single-Phase
Rev.: 27 February 2014D

Notes:
1 – Not available in the United States.
2 – Primary includes a contactor. Secondary operates in series with contactor.

Selection Example

1. Locate Compressor Data. Example Copeland ZPS40 in

Model 049 Geothermal Unit. Electrical Table is below.

Dual Capacity Unit with Variable Speed ECM Motor

Compressor HWG Ext Blower Total Min Max
Rated Voltage
Model Pump Loop Motor Unit Circ Fuse/
Voltage Min/Max MCC RLA LRA LRA**
FLA FLA FLA FLA Amp HACR
026 208-230/60/1 187/253 18.2 11.6 58.3 21.0 0.4 5.4 4.0 21.4 24.4 35
038 208-230/60/1 187/253 23.8 15.2 83.0 30.0 0.4 5.4 4.0 25.0 28.8 40
038* 208-230/60/1 187/253 23.8 15.2 83.0 30.0 0.4 5.4 7.0 28.0 31.8 50
049 208-230/60/1 187/253 33.0 21.1 104.0 37.0 0.4 5.4 4.0 30.9 36.2 50
049* 208-230/60/1 187/253 33.0 21.1 104.0 37.0 0.4 5.4 7.0 33.9 39.2 60
064 208-230/60/1 187/253 42.3 27.1 152.9 54.0 0.4 5.4 7.0 39.9 46.6 70
072 208-230/60/1 187/253 46.3 29.6 179.2 63.0 0.4 5.4 7.0 42.4 49.8 70
7/15/13

2. or from the equipment nameplate. 3. Find rated FLA (RLA for Compressor),
and Rated Voltage:
• Compressor RLA is 21.1 Amps from chart or
Model 049 Heat Pump
nameplate for Model 049
Voltage 208-230/60/1
• Compressor Rated Voltage is 208-230V/60 Hz/ 1 ph
Compressor MCC 33.0 A
Compressor RLA 21.1 A
4. Select SureStart Model From Nomenclature:
Compressor LRA 104 A
• SS1B16-32SN rated for 208-230V/60/1 and 16-32
Fan Mtr FLA 4.0 A
FLA (RLA on compressors)
Access FLA 5.8 A
Total FLA 30.9 A
Min Circ Amp 36.2 A
Max Fuse/HACR 50 A

Page 13
Dimensional Data
Single Phase

2.94”
5.30
D
LE

1.96”

3.80

3.80

3.16
0.65

3.16 Mounting Bracket

Approved Mounting Positions

LED

1 2
LED

3 4 Not Approved

7
LED

5 6
8
LED

Page 14
 Single Phase Soft Starters

Physical Characteristics
Single Phase
SureStart Model
SS0B12-20 SS1B08-16 SS1B16-32
Storage Temperature, oF [oC] -40 [-40] to 185 [85]
Case Material ABS Flameproof UL-94 V0
IP Rating IP207
Line Conductor, AWG 14 - 6 14 - 6 14 - 6
Line Conductor Strip Length, in. [mm] 0.47 [12] 0.47 [12] 0.47 [12]
Minimum Line Conductor Length, in. [mm] 15.7 [400] 15.7 [400] 15.7 [400]
Line Terminal Tightening Torque, in-lbs [N-m] 11.5 [1.3] 11.5 [1.3] 11.5 [1.3]
Start Winding & Compressor Common, AWG 16-12 16-12 16-12
03/06/14

Operating Characteristics
Single Phase
SureStart Model
SS0B12-20 SS1B08-16 SS1B16-32
Rated Voltage, VAC 115 208-230 208-230
Rated Phase 1 1 1
Rated Frequency, Hz 60 50/60 50/60
Maximum Load Current, Amps 20 16 32
Maximum Starting Current, Amps 35 35 65
Control input, VAC Auto-Start at Power Up
Number of Starts/Hour (Evenly Distributed) 15 15 15
Short Circuit Current Rating (SCCR), kA 5 5 5
Shutdown on Low Voltage 98 175 175
Minimum Startup Voltage 103 180 180
Maximum High Voltage 126 253 253
Operating Ambient, oF [oC] -4 [-20] to 140 [60]
Life Expectancy (At Maximum Rated Load) Minimum 100,000 Operations
03/06/14

Software Characteristics
Single Phase
SureStart Model
SS0B12-20 SS1B08-16 SS1B16-32

Software Fault Delay, seconds 300 300 300

Initial Power on Delay, seconds, 60 Hz [50Hz] 1 [2] 1 [2] 1 [2]
Power Loss Reset, milliseconds 100 100 100
Contactor Chatter Protection Yes Yes Yes
Motor Reversal Protection Yes Yes Yes
Software Optimization Auto tune
10/01/13

Page 15
Application Notes Application
Use of SureStart with compressors that have nameplate
Scroll Compressors RLA values above 32 amps must be tested by the
system designer to ensure that the application of the
SureStart technology can be applied to most scroll
compressor does not exceed the operating limits of
compressors as long as they fall within the correct
the SureStart module. SureStart can be applied with
range of Full Load amperage rating of the listed models.
the Copeland Scroll compressors listed in the SureStart
All scroll compressors have an internal equalization
Compatibility Guide.
mechanism. SureStart is not compatible with all Digital
scroll compressors. Consult Hyper Engineering when
using SureStart on Digital compressors. Installation Notes
WARNING!
Reciprocating & Rotary Compressors
Remove all other starters (e.g. PTC,
SureStart technology can be applied to most hardstarters). Do not swap the run and
reciprocating and rotary compressors as long as they start windings. The module shall not be
fall within the correct range of Full Load amperage installed into an enclosure smaller than
rating of the listed models. Systems using these types 10x8x6 inches.
of compressors must equalize differential pressure
across the compressor during off cycle. SureStart is Allow two minutes to discharge run
not intended to start compressors that are under a capacitor before disconnecting.
large differential pressure at startup. Doing so will
compromise the life of the SureStart.

Other Applications
For all other applications please consult Hyper
Engineering Technical Support

Inverter Driven Compressors

SureStart cannot be applied to inverter
driven compressors.

Schematics
Refer to the wiring diagram Figure 1, which shows how
the SureStart module should be wired into a new or
existing system. The wiring diagram illustrates SureStart
wired with a two pole contactor. SureStart can be also
be used with a one pole contactor with the contacts
located in either the L1 or L2 lines. If the compressor
is wired with a conventional start capacitor and relay,
PTCR start device, or other type of hard start kit,
those devices should be removed. Run capacitor values
must match the specifications listed by compressor
manufacturer. To determine the specified run capacitor
value refer to the nameplate of the Copeland Scroll®
compressor. The compressor must be wired as a
permanent split capacitor (PSC) with the SureStart
module. SureStart is compatible with Comfort Alert®
technology. Conductor type shall be stranded copper
with a 75°C minimum temperature rating. The system
must be grounded and all applicable codes adhered to.

Page 16
 Single Phase Soft Starters

SureStart Compatibility Guide

Single Phase
Nominal Supply Voltage*
SS0B12-20 SS1B08-16 SS1B16-32
115/60/1 ●
208-230/50-60/1 ● ●
Full Load Amperage, FLA (Typical) 12-20 08-16 16-32
* - Voltage/Hz/Phase 11/21/13

Wiring Schematics

RUN WINDING
COMP RUN CAPACITOR
CONT
SureStart

ACTIVE (T2)
L2 T2 RUN
CAP
START WINDING
R S
NOT USED
COMP
CONT C
COMPRESSOR
COMMON
L1 T1
230V with Two Pole Contactor

RUN WINDING
COMP RUN CAPACITOR
CONT
ACTIVE (T)
SureStart

RUN CAUTION: SureStart must be installed in

L T CAP a location that ensures that the external
START WINDING heat from a hot gas line, compressor
R S discharge piping, or similar heat source will
NOT USED not cause damage. Minimum 3” [76mm]
C clearance is recommended.
COMPRESSOR/MOTOR
COMMON
N

115V/230V with Single Pole Contactor

Page 17
Declaration of Conformity
SureStart technology has been tested and certified under the following standards that apply.

For United States, Canada, & Mexico

UL 508/ CSA 22.2 # 14 (ETL control # 4004190)

For European Union, Australia, and other countries accepting CE Marking

Low Voltage Directive (LVD)

IEC/ EN 60947-4-2: Low Voltage switchgear and control gear: contactors and motor-starters
IEC/ EN 60335-1 & IEC/ EN 60335-2-40: Safety requirements for electrical heat pumps, air conditioners, dehumidifiers.

Electromagnetic Compliance (EMC)

IEC/ EN 55014-1 Conducted & radiated emissions
IEC/ EN 61000-3-11 Flicker
IEC/ EN 61000-3-12 Harmonics emissions
IEC/ EN 61000-3-2 Harmonic current emissions
IEC/ EN 55014-2 Conducted & radiated immunity
IEC/ EN 61000-6-1 Immunity for residential, light commercial, and light industrial
IEC EN 61000-3-3 Voltage fluctuations
IEC/ EN 61000-4-2 Electrostatic discharge (ESD) immunity test
IEC/ EN 61000-4-3 Radiated, radio-frequency, electromagnetic field immunity test
IEC/ EN 61000-4-4 Electrical fast transient/burst immunity test
IEC/ EN 61000-4-5 Surge Immunity Test
IEC/ EN 61000-4-6 Conducted radio-frequency immunity
IEC/ EN 61000-4-11 Voltage dips, short interruptions, and voltage variations immunity tests

EMC compliance tested in accordance with:

ANSI C63.4
EN55022 + A1:2000 + A2:2003
CISPR16 and CISPR22
VCCI V-3/2007.04

Page 18
 Single Phase Soft Starters

Definitions
Case Material – SureStart enclosure material

Line conductor – Wiring that connects to the “run winding” and “active” terminations on single phase SureStart.

Line Conductor Strip Length – This is the length of insulation stripped away in order to properly insert into the SureStart.

Line Terminal Tightening Torque – The necessary torque needed to secure line conductors to the SureStart.

Rated Voltage – This is the nominal supply voltage to the SureStart.

Rated Frequency – This is the nominal frequency, Hz, of the power supply to the SureStart.

Maximum Starting Current – The maximum current at motor startup for the largest motor that can be applied to the SureStart.

Control Input – Any AC/DC voltage that needs to be applied in addition to active supply to SureStart.

Short Circuit Current Rating – This is the maximum fault current that can be applied without damaging the SureStart.

Shutdown on Low Voltage – SureStart will shutdown motor if the supply voltage falls below this threshold.

Maximum High Voltage – The maximum voltage that can be applied to SureStart.

Maximum Operating Ambient – The maximum temperature the SureStart can properly operate.

Maximum Load Current – This is the maximum current the SureStart is capable of handling.

Minimum Startup Voltage – SureStart will not attempt a motor start if the supply voltage is below this limit.

Software Fault Delay – This is the time delay that will initiate if the SureStart encounters a problem during motor operation.

Initial Power Delay – The time delay from when the SureStart receives power and motor start occurs.

Power Loss Reset – SureStart is designed to turn motor off in the event power is lost for more than this time period.

Contactor Chatter Protection – SureStart can detect faulty contactor conditions and shut the motor off.

Motor Reversal Protection – SureStart will prevent a single phase motor from reverse rotation due to intermittent power outages.

Software Optimization – The maximum number of starts required to achieve optimized motor starting.

Page 19
Notes

Page 20
 Single Phase Soft Starters

Revision Guide
Pages: Description: Date: By:
All First Published 23 Apr 2014 DS

Page 21
 Contact Information:
Hyper Engineering, Pty. Ltd. www.hypereng.com
4 / 14 Ralph Black Dr sales@hypereng.com
Wollongong Nth, NSW 2500 (+61) 2 4229 2069
AUSTRALIA C US

©2014 Hyper Engineering, Pty. Ltd., 4 / 14 Ralph Black Dr, Wollongong Nth, 2500 AUSTRALIA. Hyper Engineering has a policy of continual product research and development and reserves the right to change
design and speci cations without notice.

SC5600HM 04/14