Hyper Engineering Sure Start soft start kit - Ziller Electric Inc

Canada_Guy · September 20th, 2014

I just installed a Hyper Engineering Sure Start soft start kit on my 5-ton Trane heat-pump. The model number is SS6S3.5-7-USL-230V.

I don't have the heat-pump on my generator (so wasn't a generator load issue that I was concerned about), but was always annoyed at the dimming lights every time it kicked on.

I read that Ziller sold these and recommended them. I'm handy with electrical/mechanical/electronics so did the install myself.

I measured the in-rush before and after using a current clamp and a Fluke scopemeter. I was able to measure the amount of inrush current and the duration.

Note: It looks like the model numbers are changing to reflect the RLA (Rated Load Amps) as opposed to the old model numbers that reflected the LRA (Locked Rotor Amps)
Old Model Number________LRA Rating_____New Model Number_____RLA Rating
SS6S0.5-1.75-USL-115V______29 - 80_________SS0A12-20SN___________12 - 20
SS6S2-3.5-USL-230V_________45 - 85_________SS1A08-16SN___________8 - 16
SS6S3.5-7-USL-230V_________86 - 185________SS1A16-32SN___________16 - 32

Under voltage protection:
The Sure-Start has an added feature of monitoring line voltage and not starting the compressor if the voltage is below a minimum threshold.
Upon closing of the contactor, there is a one-second delay before the Sure-Start initiates the compressor start sequence. This allows the Sure Start to boot-up check line voltage before engaging the compressor motor.

Before install:
The inrush was approximately 160 amps for a duration of about 175 ms (1/6 of a second).

After install:
The inrush was approximately 90 amps for a duration of about 350 ms (1/3 of a second). The light flicker was almost eliminated (virtually unnoticeable).

Here are some screenshots of the before/after start up current.

Before:

After:

.

ginahoy · September 21st, 2014

Thanks for posting this! Assuming your Sure-Start is functionally equivalent to the SS1A16-32SN, your heat pump's LRA is right in line with their example 5-ton compressor (pg 5). However, the 44% reduction you measured is much smaller than the ~70% claimed by the specs (http://bit.ly/1v5aj3N).

I understand you're happy with the performance in your application, but the result you documented would definitely be an issue for generator sizing and to be honest, gives me pause over this product.

DanS26 · September 21st, 2014

I installed the SureStart about 5 months ago.

The reason I installed it was that my 10k Generac went to its knees to try and start my 2 1/2 ton AC. It started the AC but the stress on the genny and the compressor was not good.

Installed it myself, but you have to be handy and understand line drawings. Genny doesn't even hiccup now when the AC starts.

But the best part of the install was no more lights dimming. Even my wife noticed that the lights were not dimming any more.

No need to over size these genny's to cover start up amps.

UPS · September 21st, 2014

Even though there appears to be no hard evidence, it seems reasonable that the reduced stress on the compressor would extend it's life - certainly to some extent.

Astro · September 22nd, 2014

In the doc's it say that multiple starts are needed to optimize the reduction in LRA.

SkipD · September 22nd, 2014

Quote:

Originally Posted by Astro

In the doc's it say that multiple starts are needed to optimize the reduction in LRA.

Is that due to an onboard computer analyzing the results of what the device is doing and optimizing its actions?

Astro · September 23rd, 2014

Quote:

Originally Posted by SkipD

Is that due to an onboard computer analyzing the results of what the device is doing and optimizing its actions?

I believe that is correct.

Canada_Guy · September 23rd, 2014

I did another capture after 15+ starts. The peak current looks similar, but the duration is shorter indicating lower overall power required to start the unit.

I had a note from Hyper Engineering about my results. They indicated that while the relation of rms current to peak current is 70.7% in Direct start (no Sure Start installed), the same is not true for a softstart as the current is non sinusoidal. The figure is more like 55-60%.

I'll explain about this a bit more. When we refer to household voltage and current, we use typically refer to 120 Volts AC. This voltage is measured in Volts RMS (Root Mean Square). If you were to look at the voltage at your wall socket on an oscilloscope, it wouldn't show as 120 volts. It would show around 340 volts from the top peak to the bottom peak (we call this peak-to-peak voltage). This is the same when measuring current with an oscilloscope as in the screen shots that I have shown above.

The calculation to convert from peak-to-peak to RMS is as follows: Volts (or current) peak-to-peak divided by 2 then multiplied by 0.707. If the oscilloscope measuring your wall socket showed 340 volts peak-to-peak, you would convert to RMS by dividing 340 by 2 to get 170 then multiply by 0.707 to get 120 Volts.

The measurement I show above of the start up current after the Sure-Start install is 255 amps peak-to-peak. This converts to 90 amps using the same formula (255 divided by 2=127.5 times 0.707= 90 amps.

Hyper Engineering indicates as the start up current through the Sure-Start is not a pure sine wave, the factor is not 0.707, but in the range of 0.55 to 0.60. Using this factors the start-up current would calculate to 70 to 76 amps.

Based on the pre Sure-Start start-up current of 160 amps, this would result in a 53-56% reduction in start-up current.

I expanded the capture and confirmed it wasn't a pure sine wave supporting their information.

Conclusion:
You can tell quite a bit from storage scopes and screen captures, but sometimes the proof is in more rudimentary techniques like looking at the room lights when the unit starts up. I've gone from very noticeable dimming of the lights, to not virtually unnoticeable unless I am focusing in on it when I hear the thermostat click in.

Here's the screen shot after 15+ starts on the Sure Start. As mentioned above, the peak current looks similar, but the duration is shorter indicating lower overall power required to start the unit.

Canada_Guy · September 23rd, 2014

Quote:

Originally Posted by ginahoy

Thanks for posting this! Assuming your Sure-Start is functionally equivalent to the SS1A16-32SN, your heat pump's LRA is right in line with their example 5-ton compressor (pg 5). However, the 44% reduction you measured is much smaller than the ~70% claimed by the specs (http://bit.ly/1v5aj3N).

I understand you're happy with the performance in your application, but the result you documented would definitely be an issue for generator sizing and to be honest, gives me pause over this product.

Thanks for the reply. If you find a better product, please let us know.

dskseller · October 13th, 2014

Our experience to date with the Sure Start as a distributor is that we always see 60% or more LRA reduction when properly installed and sized.

The device will often actually reduce LRA more during the first 10 starts then after it has gone through the "learning" process, but on single phase applications 60% reduction (or more) is always achieved. Also, duration of the inrush event is not reduced (or lengthened) by an appreciable amount. SureStart will/does reduce LRA by 60% when properly applied/installed and LRA is properly measured with a meter that measure and report accurate in-rush current (in LRA). For example: the Fluke 375 True RMS clamp meter.

I am not sure why the poster's results differ from Hyper Engineering (and Generac) testing of the device over multiple test environments. Hyper engineering does stand behind the 60% reduction and will replace or refund the unit if it does not achieve the claimed 60% reduction in LRA when properly sized and installed.

September 20th, 2014	#1
Canada_Guy Senior Member Join Date: Oct 2009 Location: Vancouver Island, BC, Canada Posts: 991	Hyper Engineering Sure Start soft start kit I just installed a Hyper Engineering Sure Start soft start kit on my 5-ton Trane heat-pump. The model number is SS6S3.5-7-USL-230V. I don't have the heat-pump on my generator (so wasn't a generator load issue that I was concerned about), but was always annoyed at the dimming lights every time it kicked on. I read that Ziller sold these and recommended them. I'm handy with electrical/mechanical/electronics so did the install myself. I measured the in-rush before and after using a current clamp and a Fluke scopemeter. I was able to measure the amount of inrush current and the duration. Note: It looks like the model numbers are changing to reflect the RLA (Rated Load Amps) as opposed to the old model numbers that reflected the LRA (Locked Rotor Amps) Old Model Number________LRA Rating_____New Model Number_____RLA Rating SS6S0.5-1.75-USL-115V______29 - 80_________SS0A12-20SN___________12 - 20 SS6S2-3.5-USL-230V_________45 - 85_________SS1A08-16SN___________8 - 16 SS6S3.5-7-USL-230V_________86 - 185________SS1A16-32SN___________16 - 32 Under voltage protection: The Sure-Start has an added feature of monitoring line voltage and not starting the compressor if the voltage is below a minimum threshold. Upon closing of the contactor, there is a one-second delay before the Sure-Start initiates the compressor start sequence. This allows the Sure Start to boot-up check line voltage before engaging the compressor motor. Before install: The inrush was approximately 160 amps for a duration of about 175 ms (1/6 of a second). After install: The inrush was approximately 90 amps for a duration of about 350 ms (1/3 of a second). The light flicker was almost eliminated (virtually unnoticeable). Here are some screenshots of the before/after start up current. Before: After: . __________________ Homeowner with 14kW air cooled Model 5612, Propane. Installed 9/2009 Last edited by Canada_Guy; September 20th, 2014 at 11:52 PM..

September 23rd, 2014	#8
Canada_Guy Senior Member Join Date: Oct 2009 Location: Vancouver Island, BC, Canada Posts: 991	I did another capture after 15+ starts. The peak current looks similar, but the duration is shorter indicating lower overall power required to start the unit. I had a note from Hyper Engineering about my results. They indicated that while the relation of rms current to peak current is 70.7% in Direct start (no Sure Start installed), the same is not true for a softstart as the current is non sinusoidal. The figure is more like 55-60%. I'll explain about this a bit more. When we refer to household voltage and current, we use typically refer to 120 Volts AC. This voltage is measured in Volts RMS (Root Mean Square). If you were to look at the voltage at your wall socket on an oscilloscope, it wouldn't show as 120 volts. It would show around 340 volts from the top peak to the bottom peak (we call this peak-to-peak voltage). This is the same when measuring current with an oscilloscope as in the screen shots that I have shown above. The calculation to convert from peak-to-peak to RMS is as follows: Volts (or current) peak-to-peak divided by 2 then multiplied by 0.707. If the oscilloscope measuring your wall socket showed 340 volts peak-to-peak, you would convert to RMS by dividing 340 by 2 to get 170 then multiply by 0.707 to get 120 Volts. The measurement I show above of the start up current after the Sure-Start install is 255 amps peak-to-peak. This converts to 90 amps using the same formula (255 divided by 2=127.5 times 0.707= 90 amps. Hyper Engineering indicates as the start up current through the Sure-Start is not a pure sine wave, the factor is not 0.707, but in the range of 0.55 to 0.60. Using this factors the start-up current would calculate to 70 to 76 amps. Based on the pre Sure-Start start-up current of 160 amps, this would result in a 53-56% reduction in start-up current. I expanded the capture and confirmed it wasn't a pure sine wave supporting their information. Conclusion: You can tell quite a bit from storage scopes and screen captures, but sometimes the proof is in more rudimentary techniques like looking at the room lights when the unit starts up. I've gone from very noticeable dimming of the lights, to not virtually unnoticeable unless I am focusing in on it when I hear the thermostat click in. Here's the screen shot after 15+ starts on the Sure Start. As mentioned above, the peak current looks similar, but the duration is shorter indicating lower overall power required to start the unit. __________________ Homeowner with 14kW air cooled Model 5612, Propane. Installed 9/2009 Last edited by Canada_Guy; September 23rd, 2014 at 09:55 PM.. Reason: Added more info

September 21st, 2014	#2
ginahoy Junior Member Join Date: Sep 2014 Posts: 7	Thanks for posting this! Assuming your Sure-Start is functionally equivalent to the SS1A16-32SN, your heat pump's LRA is right in line with their example 5-ton compressor (pg 5). However, the 44% reduction you measured is much smaller than the ~70% claimed by the specs (http://bit.ly/1v5aj3N). I understand you're happy with the performance in your application, but the result you documented would definitely be an issue for generator sizing and to be honest, gives me pause over this product.

September 21st, 2014	#3
DanS26 Senior Member Join Date: Mar 2012 Location: Steamboat Landing IN Posts: 173	I installed the SureStart about 5 months ago. The reason I installed it was that my 10k Generac went to its knees to try and start my 2 1/2 ton AC. It started the AC but the stress on the genny and the compressor was not good. Installed it myself, but you have to be handy and understand line drawings. Genny doesn't even hiccup now when the AC starts. But the best part of the install was no more lights dimming. Even my wife noticed that the lights were not dimming any more. No need to over size these genny's to cover start up amps.

September 21st, 2014	#4
UPS Senior Member Join Date: Jul 2013 Location: West of Boston Posts: 521	Even though there appears to be no hard evidence, it seems reasonable that the reduced stress on the compressor would extend it's life - certainly to some extent.

September 22nd, 2014	#5
Astro Senior Member Join Date: Oct 2011 Posts: 108	In the doc's it say that multiple starts are needed to optimize the reduction in LRA.

October 13th, 2014	#10
dskseller Junior Member Join Date: Jul 2014 Posts: 3	Our experience to date with the Sure Start as a distributor is that we always see 60% or more LRA reduction when properly installed and sized. The device will often actually reduce LRA more during the first 10 starts then after it has gone through the "learning" process, but on single phase applications 60% reduction (or more) is always achieved. Also, duration of the inrush event is not reduced (or lengthened) by an appreciable amount. SureStart will/does reduce LRA by 60% when properly applied/installed and LRA is properly measured with a meter that measure and report accurate in-rush current (in LRA). For example: the Fluke 375 True RMS clamp meter. I am not sure why the poster's results differ from Hyper Engineering (and Generac) testing of the device over multiple test environments. Hyper engineering does stand behind the 60% reduction and will replace or refund the unit if it does not achieve the claimed 60% reduction in LRA when properly sized and installed.