Air-conditioner (Single Phase) Soft Start Controller

Introduction

The RUIJING soft start controller - RJ-ASSU220P5 provides an effective solution in reduction of start-up current, typically up to 70%, but still provides full startup torque for compressors and motors. Across the line starting of air-conditioner compressor or induction motors is accompanied by inrush currents up to 7-8 times higher than running current, and starting torque up to 3 times higher than running torque. The increased unnecessary torque results in sudden mechanical stress on the machine which leads to increased wear and higher service costs and reduced service life. Moreover, the high inrush current and current peaks may stress the power supply system to increased mains and generator loads which may lead to voltage dips results in breaking down of other valuable equipment or system function.

RJ-ASSU220P5 is an embedded design air-conditioner (for single phase power system) soft start controller. It regulates the start-up voltage of the compressor/motor intelligently to effectively reduce the inrush and surge current while starting-up, thus consume much less power from the public utility network or on-site AC power supply system but still provides full startup torque for compressors and motors. RJ-ASSU220P5 effective limits the inrush current and so improves stability of the power supply and reduces transient voltage drops that may affect or break down other loads. This will eliminate the need of over dimension of the power supply system which results in reduce capital expenditure investment in power supply capacity, charge meter, circuit breaker and power wire line capacity etc..and extend the service life of the motor or compressor effectively.

RJ-ASSU220P5 is a compact size, light weight cost effective soft start controller with fire proofed housing and sealed by resin make it capable to resist extreme weather and survive in harsh environment (air-conditioner outdoor unit), this makes RJ-ASSU220P5 a cost effective solution with high reliability and stability.

Features:

Limits inrush currentEliminates current surges & voltage dropsExtends motor/compressor service life with built-in electronic overload protective relayIntegral bypass contactor reduces heat generationProduces smoother starts and stops by controlling torqueReduces vibration and mechanical damageRelieves shock and drive train stress on startupEasy to wire and install and decreases equipment downtime High reliability and long life

Specification:

Electrical:Nominal Working Voltage: 220Vac (187~266Vac), single phaseMaximum continuous working voltage: 266VAC.Maximum continuous working current: 30AOver Current limit: 30A/1 minuteMaximum non-repetitive inrush current: 170A (<20 ms).Maximum surge current: 120A (<350 ms).Soft start-up time: 1±0.5sCurrent consumption: 48mA (Capacitive 220VAC)Power consumption: less than 15VAOperation hours: better than 45,000 hours (rated working temperature)Effective soft start on/off service: >100,000 times (soft start interval not less than 3 minutes)Protection:The insulation resistance between housing and chassis: > 300 M Ω.Withstand voltage between housing and chassis: >3000 VAC in 1 minute.Shock resistance better than 200m/s2 and 11ms.Anti vibration: 10~55mm(double amplitude, 1.5mm)Protection restart time interval: 60 secondEnvironmentWorking temperature: -40 to 85 ºC.Working Humidity: 0~95% RH (<40 ºC). MechanicalController housing made by non-flammable plasticPackaged and sealed by epoxy resin with excellent durable to severe environmentDimension: 120 mm × 70mm × 40mm Weight: 200g

e) Application

Air-conditioner (apply to single-phase 220V 4P/5P) Preparation:

Additional start-up capacitor, 161~193uF/330VAC, CD60 type or other suitable type, please refer to wiring instruction.Additional bleeder resistor, 15K ohm, 2 watt, carbon film resistor: if current A/C start-up capacitor already has bleeder resistor then is not needed, please refer to wiring instruction.Additional AC contactor for proper control of A/C, if needed make sure selects suitable voltage and current rating of AC contactor.#250 Terminal, FemaleSuitable AC power wireNo special tool is required

DEFINITIONS AND INTERPRETATIONS of WIRING INSTRUCTION

AC: Alternate Current

A/C: Air-Conditioner

C: Air-conditioner compressor power input terminal

R: Air-conditioner compressor running coil terminal

S: Air-conditioner compressor start-up coil terminal

Live: Live wire of Utility AC power supply

Neutral: Neutral wire of Utility AC power supply

G: Ground (chassis ground)

ON: Control voltage signal send out from A/C control board to signals the compressor to turn on and off. This signal can be high voltage (100~120Vac/220~240Vac) or low voltage ac/dc signal.

AC Contactor: The AC Contactor in your A/C unit, also known as the contact switch, to provide large AC power to energize/de-energize compressor coil by the ON signal sent out by A/C control board (thermostat)

You should know about "ON" signal and "AC Contactor" of your A/C before start:

"ON" signal

The "ON" signal or voltage is the control signal output by the A/C thermostat of the main control PC board of A/C, to control compressor on or off either send to compressor directly or via AC Contactor to energize and de-energize the compressor coil.

AC Contactor

The air conditioner AC Contactor is basically a switch that is located in the condensing unit (outdoor unit) to control compressor on/off. The "switch" consists of a control coil, a metal plunger, and one or more sets of electrical contacts. The control coil has a voltage rating, normally be written on the coil itself. The control voltage can be 12/24 VAC/DC or A/C working voltage (100~120Vac/220~240Vac). When control voltage - "ON" signal is supplied to the AC Contactor coil will control the compressor to turn on and off during operation.

Due to soft start controller RJ-ASSU220P5 only accept "ON" signal equal to working voltage at 187-265VAC range (same as compressor working voltage), therefore base on different type of "ON" signal maybe of your A/C unit (see below), please refer to appropriate Wiring Instruction base on your A/C condition.

The "ON" signal is the same with A/C working voltage, between 187-265VAC ranges, from the A/C control board send to compressor directly without AC contactor, please refer to Wiring Instruction A.The "ON" signal is the working voltage between 187-265VAC ranges, from the A/C control board (maybe via a small replay on board) send to AC Contactor coil to control compressor on and off, please refer to Wiring Instruction B.The "ON" signal is a low AC/DC voltage or out of 187-265VAC ranges, from the A/C control board sends to AC contactor coil to control compressor on and off, please refer to Wiring Instruction C.

NOTE!!!

ON signal to KM-6 must from LIVE wire (Hot) and in phase with Live wire connect to compressor C terminal!

NOTE!!!

KM-6 Acceptable Working Voltage is Live between 187-265VAC!

NOTE!!!

LIVE and NEUTRAL wire must connect to Soft Start Controller correctly!