YDQ Series Liquid Resistance Rotor Starter

The use of maintenance manual

 YDQ5 series liquid starter
Instruction manual

Catalog

1 Overview........................................................................................................................................3
2 Standard & criterion....................................................................................................................3
3 Working condition........................................................................................................................3
4 Commissioning...............................................................................................................................3
5 Maintenance...................................................................................................................................7
Appendix.............................................................................................................................................7

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 YDQ5 series liquid starter
Instruction manual

1 Overview

YDQ5 Series liquid starters (hereinafter referred to as starters) are the new kind of starting
devices developed for improving the starting feature of large- and medium sized wire-wound AC
asynchronous motors. Having solved the problems of frequency sensitive resistor starters which are
high in impact current, difficult in starting and not easy to operate, the starters of this series are
suitable for the heavy-load starting of the motors of ball grinding mills, air compressors, crushers,
large-sized blast fans and large-sized pumps which are used in the industrial branches of building
materials, metallurgy, chemical industry, mining. They are the ideal substitutes for frequency
sensitive starters and metal resistor starters.

2 Standard & criterion

GB4720-1984 electric control devices part I low-voltage electric control devices

GB4942.2-1993 low-voltage electric devices shell protection grade
GB/T5226.1-1996 industrial mechanical electric devices part I general technical condition
GB/T13384-2008 mechanical electric products casing general technical condition
GB14048.4-2003 low-voltage switch devices and control devices
low-voltage mechanical electric contactors and motor starters

3 Working condition

Upper limit of ambient temperature is no more than +50℃, and lower limit is no less than
-5℃.
The relative humidity is no more than 85 percent. The height above sea level is no more than
2000m.
It should be placed on an indoor place without obvious shake and impact, without fire and
explosive dangers and the vertical gradient is no more than 5º.
There must be no conductive dust and corrosive gas.
Power source is four-wire three-phase system of 380V/220V 20A, the undulation of voltage
must be guaranteed within 15 percent of rated voltage.
Note:1）The heater needs to be installed additionally when the ambient temperature is under
0℃ over a long period of time, the user should explain it while ordering goods.
2）If the voltage of power source needs spcial design, the user should explain it while
ordering goods.
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 YDQ5 series liquid starter
Instruction manual

4 Commissioning

4.1 Preparation of liquid resistor：

4.1.1 It would be the best if the distilled water is used as the water for preparing liquid, soft water
can also be used, the lowest limit is to use daily-life water that the deposit has been taken off after
purification.
4.1.2 Resistor solvent, i.e. resistor powder that our company will offer
4.1.3 Liquid starting resistor Ro should be determined using the formula：
U 2e k
R0  0.577  KF  t
I 2e kM

where

U2e: is the open circuit voltage (V) of the circuit of motor rotor;
Ize: is rated current (A) of the circuit of motor rotor
KF: is abundance-capacity multiple of the powerI of motor. If actual operating value I 1 of the
1e
current of motor stator is known, you may use K F= , where, I1e is the rated current of motor
I1
stator, if your equipment
Ne is a new one that has not been put into operation, the I 1 is unknown, you
may use K F  N , where, Ne is the rated power of motor and N1 is the power required by load
1

Kt: Temperature multiple, if temperature of the solution prepared is about 30℃, Kt≈1.2;
MQ
KM: is starting torque multiple, that is K M  , where MQ is the starting torque of motor
Me
during starting and Me is the rated torque of motor. As for starting the mechanical equipment with
full load, such as ball grinding mills, K M≈1.1~1.3, we normally suggest that you use 1.1, if capacity
of power network is large enough and load torque is over large, you may use 1.3.

4.1.4 Preparation of resistor

①Turn the dynamic plate to the starting position (upper limit position) first, fill the water
prepared to approximately two-thirds of specified level in water tank, you should pay attention to
that three liquid level marks should be equal basically.
②Weigh a certain amount of electric liquid powder.
③Pour the water prepared into a vessel, such as basin or bucket first. The poured water shall be
no more than two-thirds of the total volume of the vessel. Take one-third of weighed electric liquid
powder and put it into the vessel slowly, and stir continuously till the electric liquid powder is
dissolved fully. Then fill the solution into one phase of resistor box, the part of electric liquid
powder in block type that has not been dissolved shall be dissolved through adding hot water. If
there is still a little undissolved matter, you may give it away. If the vessel is so small that the
electric liquid powder cannot be dissolved one time, the electric liquid powder may be dissolved by
part to part.
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Instruction manual

④Repeat step for filling the dissolved electric liquid powder into other two phases of the
resistor box.
⑤Add water to each phase of the resistor box respectively to specified level. (The resistor box is
about 60mm from liquid level).
⑥Turn on and turn off test button to make plate move up and down two or three times and
allow resistor liquid in box to be stirred evenly.
⑦Use clean cloth to wipe water drops off the external surface of the box.
⑧Measuring for the liquid resistor
After making its dynamic plate more to starting position, add electricity of 50Hz to the points
between dynamic plate and static plate each phase using a self-coupling transformer. The current
I(A) shall be increased from zero to about 5A gradually. Record the readings of ampere A, and
measure the voltage-drop V(v) between two plates at the same time. The measuring liquid

V (v )
resistance is R(  )  and measuring circuit is as following：
I ( A)

where
Fu: Fuse 2A; A: AC ampere 5A, Grade 0.5; B: voltage adjuster 5KVA; V: AC voltmeter
Grade 0.5. The resistance value gained from measuring shall be near the calculation value R 0,
allowing an error of 0.5 percent.
⑨Adjustment of resistance: If the resistance is rather high, the concentration of the resistor
liquid shall be increased, otherwise, its concentration shall be decreased. The adjustment
method is to take out a part of liquid by using a piece of flexible pipe and add a certain
amount of water or electric liquid powder to it.
Note: (1) Dynamic plate must be in the upper limit position and rotor circuit shall be separated
from resistor box when resistance is measured. (2) The resistor liquid shall not be measured until it
is stirred evenly. (3) The phase line and zero line of voltage adjuster must not be connected
reversely.
4.2 Check the connection of control line and rotor cable
4.2.1 Check the connection of control line and rotor cable
4.2.2 Check whether the liquid starter uses a separate power source in three-phase four-wire system
or not.
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Instruction manual
4.2.3 As for connection of control line, allow the liquid starter to be connected to primary cabinet,
DCS system or interlocking control line between the medium control system well according to the
drawing.
4.2.4 Line of rotor should be connected to lower end of short contactor (line of rotor shall not be
fixed until the resistor is tested).
4.2.5 A careful check should be made on whether there are phenomenons of joint leakage, joint
mistake and looseness or not before it is powered on.
4.3 Action test of liquid starter
4.3.1 Make the dynamic plate be in the middle position from the upper limit position and lower
limit one by using the method running by hand, after the three phases of control power source is
confirmed to be in a normal state, let the “test” knob turn to operation position, turn on the air
switch in the cabinet, at this moment, if the plate goes upwards it should be in normal condition.
4.3.2 The travel switch of the upper limit position should stop going upwards if operating by hand,
if the plate goes down, the phase sequence should be mistaken. At this moment, turn off the power
supply and change two phases power source line.
4.3.3 Then, turn on the power supply and turn “test” knob rightward to “test” position, the plate
runs down to the lower limit position and stops, and KM2 sucks properly.
4.3.4 Turn “test” switch leftward, the plate is reset to the upper limit position, using a watch to
count out time when the plate runs from the upper limit position to the lower limit position,
rectified start protection time is 2 seconds more than this time.
Note: Please determine the phase sequence according to above-mentioned method if work
needs to change the control power source.
4.4 Turn on power for commissioning
4.4.1 Turn on the control power source of the starting cabinet and again do an action test for the
starting cabinet. “Test” knob shall be turned to operation position if the action test is in normal
condition.
4.4.2 Simulation commissioning
 Do not turn on the power source of the primary circuit of primary cabinet for the main
motor, turn on the control power source for primary cabinet and starting cabinet only.
 After “Allowable starting” indicating lamps of the starting cabinet lights, press down the
turn-on button of primary cabinet, the switch of primary cabinet is turned on this moment,
“starting” indicating lamp on the surface plate of the starting cabinet lights, at the same time, the
plate moves from upper side to lower side to the lower limit position, KM2 sucks properly. The
“Start” indicating lamp goes out and “Run” indicating lamp goes on. The above-mentioned
conditions show that both starting and operation are in normal conditions.
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Instruction manual
 Press down the switch-off button of primary cabinet, the switch of primary cabinet is
switched off, and KM2 is turned off, “Run” indicating lamp goes out, the plate moves from upper
side to lower side, at the same time, “Reset” indicating lamp goes on. When the plate moves to
upper limit position, “Reset” indicating lamp goes out, “allowable starting” indicating lamp goes
on. You should get ready for next start.
4.4.3 Starting commissioning
 Turn on the main power source of primary circuit and control power source of primary
cabinet and starting cabinet.
 Start motor in line with the order of simulation commissioning. Observe whether the
starting current is in specified range (1.1~1.3 I 1e) or not. If the starting current is too high at the
beginning, it shows that the resistor is low. The concentration of resistor liquid shall be decreased.
The method is to take a part of liquid out of water tank and fill the same amount of clear water,
commission again after the liquid is stirred evenly. If the starting current is too low at the beginning
and impact is too high when QF2 (KM2) circuit breaker (contact) is turned on, it shows that the
resistor prepared is too high, so it shall be made lower. The concentration of the resistor liquid shall
be increased. The method is to take out a part of liquid and add a suitable amount of electric liquid
powder to it. Care shall be taken to that electric liquid powder shall not be added to water too much
one time. The electric liquid powder must be fully dissolved in water tank. And adjust the resistor
until the starting current is in normal condition.

4.5 Trouble shooting（table 3）

Table 3
Trouble Cause Check and treatment method
Dynamic plate is in a) Turn off power source, run belt wheel to allow the
upper or lower limit dynamic plate to reset to normal position.
position b) Check whether stroke switch lose efficacy or not
Acousto- too low Liquid level a) Check whether liquid level switch loses efficacy or not
optical alarm b) add water to initial level
Too high liquid a)check the setting value of ST1（about 60℃）
temperature b)continuous starting would lead liquid temperature too
high
Overtime protection a)check winding of rotor short contactor
b) check auxiliary contact of rotor short contactor
Fault trip Too high impact a)check winding of rotor short contactor
current when switch b) check auxiliary contact of rotor short contactor
to full speed
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Instruction manual

5 Maintenance

5.1 Power source of the control cabinet must be turned on first before the equipment is started, it
will not be started until “allowable start” indicating lamp goes on.
5.2 Electrolytic liquid should be generally changed every 4 to 5 years, at the same time clean the
plate and insulation cabinet body before filling fresh electrolytic liquid. The plate should be again
cleaned with clear water after the conductive surface is first corroded with thin hydrochloric acid,
the insulation cabinet body should be dried in the air after it is first washed with clear water, then it
will be coated with epoxy resin several times (under general condition, it would be the best if you
do not wash the insulation cabinet body through disassembling, you should avoid it from shaking
and impacting so as not to make the cabinet body crack when you disassemble it).

Appendix

weight of electrolyte powder for different resistance value（Kg）

type YDQ5- YDQ5- YDQ5- YDQ5- YDQ5- YDQ5- YDQ5- Rem
0.2 0.4 0.6 1 2 3 4 ark
resistanc
e valueΩ
0.3 2.0 3.5 5.5 8.5 13.5 27.5 45.0
0.4 1.75 3.25 5.25 8.0 12.8 20.5 35.0
0.5 1.5 3.0 5.0 7.5 12.0 16.5 28.5
0.6 1.25 2.75 4.5 7.0 11.5 13.5 23.5
0.7 1.0 2.5 4.0 6.5 9.5 11.5 20.0
0.8 0.75 2.0 3.75 6.0 8.50 10.5 17.5
0.9 0.5 1.5 3.0 5.5 8.00 9.5 15.5
1.0 0.45 1.25 2.75 5.0 7.50 8.5 14.0
1.1 0.4 1.0 2.5 4.5 7.0 7.5 12.5
1.2 0.35 0.7 2.3 4.0 6.5 7.0 11.5
1.3 0.3 0.6 2.0 3.5 6.0 6.5 10.5

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Instruction manual
1.4 0.2 0.5 1.8 3.0 5.50 6.0 10.0
1.5 0.2 0.45 1.5 2.5 5.00 5.5 9.5
1.6 2.0 4.5 5.25 9.0
1.7 4.0 5.0 8.5
1.8 3.5 4.5 8.0
1.9 3.0 4.0 7.5
2.0 2.5 3.5 7.0

note ： the data are tested under normal temperature, the water is distilled water and electrolyte
powder is fully dissolved.（only for reference）

Beijing Big Pawer Haoran Electrical Technology Co.,Ltd.

Add ： 3rd floor,Building B, JinYun Mansion,A 43 North Great Street, Xizhi Gate, Haidian
District, Beijing
Tel: 010-62294288 010-62232358
Fax: 010-62232265 010-62246593
Service Hot Line：010-62232320

Big Pawer Electrical Technology Xiangyang Inc.Co.,Ltd

Add：Dali Road，NO.100 ,XiangYang,HuBei Province
Tel: 0710-3220078
Fax: 0710-3225414

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 YDQ5 series liquid starter
Instruction manual
Wuhan Technology Center
Add： GuangGu Business Street 10 building A block 10/22nd floor ,WuHan,HuBei Province
Tel: 027-87807132 027-87809755
Fax: 027-87170906 027-87770063

Edition Number：DLSYDQ2016-04
The product is subject to change without notice。

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