Digistart IS Getting Started Guide

Digistart IS Getting Started Guide

Getting Started Guide

Digistart IS

7.5 - 800kW (23A - 1600A)

200V, 400V, 575V, 690V

0477-0007-01

www.controltechniques.com

English

General information

The manufacturer accepts no liability for any consequences resulting from inappropriate, negligent or incorrect installation or adjustment of the optional parameters of the equipment or from mismatching the starter with the motor.

The contents of this guide are believed to be correct at the time of printing. In the interests of commitment to a policy of continuous development and improvement, the manufacturer reserves the right to change the specification of the product or its performance, or the content of the guide without notice.

All rights reserved. No parts of this guide may be reproduced or transmitted in any form or by any means, electrical or mechanical including, photocopying, recording or by an information storage or retrieval system, without permission in writing from the publisher.

Software version

This product is supplied with the latest version of user-interface and machine control software. If this product is to be used in a new or existing system with other starters, there may be some differences between their software and the software in this product. These differences may cause the product to function differently. This may also apply to starters returned from the Control Techniques

Service Centre.

If there is any doubt, please contact Control Techniques or your local Distributor.

Environmental statement

Control Techniques is committed to minimising the environmental impacts of its manufacturing operations and of its products throughout their life cycle. To this end, we operate an Environmental Management System (EMS) which is certified to the

International Standard ISO 14001. Further information on the EMS, our Environment Policy and other relevant information is available on request.

When the products eventually reach the end of their useful life, they can very easily be dismantled into their major component parts for efficient recycling. Many parts snap together and can be separated without the use of tools, while other parts are secured with conventional screws. Virtually all parts of the product are suitable for recycling.

Product packaging is of good quality and can be re-used. Large products are packed in wooden crates, while smaller products come in strong cardboard cartons which themselves have a high recycled fibre content. If not re-used, these containers can be recycled.

Polythene, used on the protective film and bags from wrapping product, can be recycled in the same way. Control Techniques's packaging strategy favours easily recyclable materials of low environmental impact, and regular reviews identify opportunities for improvement.

When preparing to recycle or dispose of any product or packaging, please observe local legislation and best practice.

REACH legislation

EC Regulation 1907/2006 on the Registration, Evaluation, Authorisation and restriction of Chemicals (REACH) requires the supplier of an article to inform the recipient if it contains more than a specified proportion of any substance which is considered by the

European Chemicals Agency (ECHA) to be a Substance of Very High Concern (SVHC) and is therefore listed by them as a candidate for compulsory authorisation.

For current information on how this requirement applies in relation to specific Control Techniques products, please approach your usual contact in the first instance. Control Techniques position statement can be viewed at: www.controltechniques.com

/REACH

Copyright © October 2009 Control Techniques Ltd

Issue: 1

Product Version: 1

Contents

1.

Safety Information ............................................................................................................................................ 5

1.1

Warnings, cautions and notes ................................................................................................................................................ 5

1.2

Electrical safety - general warning .......................................................................................................................................... 5

1.3

System design and safety of personnel .................................................................................................................................. 5

1.4

Environmental limits ............................................................................................................................................................... 5

1.5

Compliance with regulations .................................................................................................................................................. 5

1.6

Motor ..................................................................................................................................................................................... 5

1.7

Adjusting parameters ............................................................................................................................................................. 5

1.8

Electrical installation .............................................................................................................................................................. 6

2.

Rating Data ........................................................................................................................................................ 7

2.1

Model code ............................................................................................................................................................................ 7

2.2

Current ratings ....................................................................................................................................................................... 7

3.

Mechanical Installation ................................................................................................................................... 10

3.1

Dimensions and weights ...................................................................................................................................................... 10

3.2

Physical Installation ............................................................................................................................................................. 11

4.

Electrical Installation ...................................................................................................................................... 12

4.1

Terminal layout .................................................................................................................................................................... 12

4.2

Control connections ............................................................................................................................................................. 15

4.3

Power connections ............................................................................................................................................................... 16

4.4

Fuses ................................................................................................................................................................................... 19

4.5

Bypass contactor ................................................................................................................................................................. 21

4.6

Main contactor ..................................................................................................................................................................... 21

4.7

Circuit breaker ..................................................................................................................................................................... 21

4.8

EMC (electromagnetic compatibility) .................................................................................................................................... 21

5.

Keypad and Status .......................................................................................................................................... 22

5.1

Keypad ................................................................................................................................................................................ 22

5.2

Displays ............................................................................................................................................................................... 22

6.

Operation ......................................................................................................................................................... 24

6.1

Start, stop and reset commands........................................................................................................................................... 24

6.2

Using the soft starter to control a motor ................................................................................................................................ 24

6.3

Soft start methods ................................................................................................................................................................ 24

6.4

Stop methods ....................................................................................................................................................................... 25

6.5

Jog ....................................................................................................................................................................................... 26

6.6

Inside delta operation ........................................................................................................................................................... 26

7.

Programming Menu ........................................................................................................................................ 27

7.1

Programming menu ............................................................................................................................................................. 27

7.2

Access code ........................................................................................................................................................................ 27

7.3

Adjustment lock ................................................................................................................................................................... 28

7.4

Load defaults ....................................................................................................................................................................... 28

7.5

Quick setup details ............................................................................................................................................................... 29

7.6

Standard menu .................................................................................................................................................................... 30

7.7

Advanced menu ................................................................................................................................................................... 31

7.8

Parameter descriptions ........................................................................................................................................................ 31

8.

Quick Start Commissioning ........................................................................................................................... 37

8.1

Control wiring ....................................................................................................................................................................... 37

8.2

Setup procedure .................................................................................................................................................................. 37

9.

Diagnostics ...................................................................................................................................................... 38

9.1

Protection responses ........................................................................................................................................................... 38

9.2

Trip messages ..................................................................................................................................................................... 38

9.3

General faults ...................................................................................................................................................................... 41

10.

Technical Data ................................................................................................................................................. 43

11.

Maintenance .................................................................................................................................................... 45

11.1

Care ..................................................................................................................................................................................... 45

11.2

Measuring the motor current ................................................................................................................................................ 45

Digistart IS Getting Started Guide

Issue: 1 www.controltechniques.com

3

11.3

Measuring the input and output power ................................................................................................................................. 45

11.4

Exchanging products ........................................................................................................................................................... 45

12.

Options ............................................................................................................................................................ 46

4

www.controltechniques.com

Digistart IS Getting Started Guide

Issue: 1

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation Programming

Status

Menu

Quick Start

Commissioning

Diagnostics Technical

Data

Maintenance Options

1. Safety Information

1.1 Warnings, cautions and notes

A Warning contains information which is essential for avoiding a safety hazard.

WARNING

A Caution contains information which is necessary for avoiding a risk of damage to the product or other equipment.

CAUTION

NOTE

A Note contains information which helps to ensure correct operation of the product.

1.2 Electrical safety - general warning

The voltages used in the starter can cause severe electrical shock and/or burns, and could be lethal. Extreme care is necessary at all times when working with or adjacent to the starter.

Specific warnings are given at the relevant places in this guide.

1.3 System design and safety of personnel

The starter is intended as a component for professional incorporation into complete equipment or a system. If installed incorrectly, the starter may present a safety hazard.

The starter uses high voltages and currents, carries stored electrical energy, and is used to control equipment which can cause injury.

Close attention is required to the electrical installation and the system design to avoid hazards either in normal operation or in the event of equipment malfunction. System design, installation, commissioning and maintenance must be carried out by personnel who have the necessary training and experience. They must read this safety information and this guide carefully.

The STOP function of the starter does not isolate dangerous voltages from the output of the starter or from any external option unit.

The supply must be disconnected by an approved electrical isolation device before gaining access to the electrical connections.

None of the starter functions must be used to ensure safety of personnel, i.e. they must not be used for safety-related

functions.

Careful consideration must be given to the functions of the starter which might result in a hazard, either through their intended behaviour or through incorrect operation due to a fault. In any application where a malfunction of the starter or its control system could lead to or allow damage, loss or injury, a risk analysis must be carried out, and where necessary, further measures taken to reduce the risk.

The system designer is responsible for ensuring that the complete system is safe and designed correctly according to the relevant safety standards.

1.4 Environmental limits

Instructions regarding transport, storage, installation and use of the starter must be complied with, including the specified environmental limits. Starters must not be subjected to excessive physical force.

1.5 Compliance with regulations

The installer is responsible for complying with all relevant regulations, such as national wiring regulations, accident prevention regulations and electromagnetic compatibility (EMC) regulations. Particular attention must be given to the cross-sectional areas of conductors, the selection of fuses or other protection, and protective ground connections.

Within the European Union, all machinery in which this product is used must comply with the following directives:

98/37/EC: Safety of machinery.

2004/108/EC: Electromagnetic Compatibility.

1.6 Motor

Ensure the motor is installed in accordance with the manufacturer’s recommendations. Ensure the motor shaft is not exposed.

The values of the motor parameters set in the starter affect the protection of the motor. The default values in the starter should not be relied upon. It is essential that the correct value is entered in Pr 1A Motor Full Load Current. This affects the thermal protection of the motor.

1.7 Adjusting parameters

Some parameters have a profound effect on the operation of the starter. They must not be altered without careful consideration of the impact on the controlled system. Measures must be taken to prevent unwanted changes due to error or tampering.

Digistart IS Getting Started Guide

Issue: 1 www.controltechniques.com

5

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation Programming

Status

Menu

Quick Start

Commissioning

Diagnostics Technical

Data

Maintenance Options

1.8 Electrical installation

1.8.1 Electrical shock risk

The voltages present in the following locations can cause severe electric shock and may be lethal:

AC supply cables and connections

Output cables and connections

Many internal parts of the starter, and external option units

The AC supply must be disconnected from the starter using an approved isolation device before any cover is removed from the starter or before any servicing work is performed.

The busbar and heatsink on models IS4x0360N to IS561600N are live while the unit is operating (starting, running or stopping). If the starter is installed without a main contactor, the busbar and heatsink are live whenever mains voltage is connected (including when the starter is ready or tripped).

1.8.2 Power-up procedure

Always apply control voltage before (or with) mains voltage.

IS1x0023B to IS2x0220B: After transportation, mechanical shock or rough handling there is a possibility that the bypass contactor may have latched into the on state. To prevent the possibility of the motor starting immediately, on first commissioning or operation after transportation, always ensure that the control supply is applied before the power, so that the contactor state is initialised.

1.8.3 STOP function

The STOP function does not remove dangerous voltages from the starter, the motor or any external option units.

1.8.4 Stored charge

The starter contains capacitors that remain charged to a potentially dangerous voltage after the AC supply has been disconnected.

If the starter has been energised, the AC supply must be isolated at least two minutes before work may continue.

Normally, the capacitors are discharged by an internal resistor. Under certain, unusual fault conditions, the capacitors may fail to discharge. Do not assume that the capacitors have discharged. To protect the user and the equipment, take due care when carrying out any work on the starter.

1.8.5 Equipment supplied by plug and socket

The control supply terminals of the starter are connected to the internal capacitors through rectifier diodes which are not intended to give safety isolation. If the plug terminals can be touched when the plug is disconnected from the socket, a means of automatically isolating the plug from the starter must be used (e.g. a latching relay).

1.8.6 Short circuit

Digistart IS soft starters are not short circuit proof. After severe overload or short circuit, the operation of the soft starter should be fully tested by an authorised service agent.

1.8.7 Auto-start

Use the auto-start feature with caution. Read all the notes related to auto-start before operation.

6

www.controltechniques.com

Digistart IS Getting Started Guide

Issue: 1

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation Programming

Status

Menu

Quick Start

Commissioning

Diagnostics Technical

Data

Maintenance Options

2. Rating Data

2.1 Model code

IS

Figure 2-1 Model code explanation

3 4 0 2 5 5 N

Bypass

B = Internal

N = Non-bypassed

Nominal current rating

Mains voltage

4 = 200 to 440 Vac

6 = 380 to 690 Vac

Frame size

2.2 Current ratings

Contact your local supplier for ratings under operating conditions not covered by these ratings charts.

2.2.1 Current ratings for bypass operation

AC53b utilisation code

The AC53b utilisation code defines the current rating and standard operating conditions for a bypassed soft starter (internally bypassed, or installed with an external bypass contactor).

The soft starter’s current rating determines the maximum motor size it can be used with. The soft starter's rating depends on the number of starts per hour, the length and current level of the start, and the amount of time the soft starter will be off (not passing current) between starts.

The soft starter’s current rating is only valid when used within the conditions specified in the utilisation code. The soft starter may have a higher or lower current rating in different operating conditions.

Figure 2-2 AC53b utilisation code

80 A : AC-53b 3.5 - 15 : 345

Off time (seconds)

Start time (seconds)

Start current (multiple of motor full load current)

Starter current rating (amperes)

Starter current rating: The full load current rating of the soft starter given the parameters detailed in the remaining sections of the utilisation code.

Start current: The maximum available start current.

Start time: The maximum allowable start time.

Off time: The minimum allowable time between the end of one start and the beginning of the next start.

Digistart IS Getting Started Guide

Issue: 1 www.controltechniques.com

7

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation Programming

Status

Menu

Quick Start

Commissioning

Diagnostics Technical

Data

Maintenance Options

Table 2-1 Current ratings - in-line connection, bypassed operation

Model

IS1x0023B

IS1x0043B

IS1x0053B

Model

IS1x0076B

IS1x0097B

IS1x0105B

IS2x0145B

IS2x0170B

IS2x0200B

IS2x0220B

IS3x0255N

IS4x0360N

IS4x0430N

IS4x0650N

IS4x0790N

IS4x0930N

IS561200N

IS561410N

IS561600N

AC53b 3.0-10:350

40 ºC <1000 metres

23 A

43 A

53 A

AC53b 3.0-10:590

40 ºC <1000 metres

76 A

97 A

105 A

145 A

170 A

200 A

220 A

255 A

360 A

430 A

650 A

790 A

930 A

1200 A

1410 A

1600 A

AC53b 3.5-15:345

40 ºC <1000 metres

20 A

37 A

53 A

AC53b 3.5-15:585

40 ºC <1000 metres

64 A

82 A

105 A

123 A

145 A

189 A

210 A

231 A

360 A

430 A

650 A

790 A

930 A

1200 A

1410 A

1600 A

AC53b 4.0-20:340

40 ºC <1000 metres

17 A

31 A

46 A

AC53b 4.0-20:580

40 ºC <1000 metres

55 A

69 A

95 A

106 A

121 A

160 A

178 A

201 A

310 A

368 A

561 A

714 A

829 A

1200 A

1319 A

1600 A

AC53b 4.5-30:330

40 ºC <1000 metres

15 A

26 A

37 A

AC53b 4.5-30:570

40 ºC <1000 metres

47 A

58 A

78 A

90 A

97 A

134 A

148 A

176 A

263 A

309 A

455 A

579 A

661 A

1071 A

1114 A

1353 A

NOTE

Models IS3x0255N to IS561600N must be externally bypassed.

Table 2-2 Current ratings - inside delta connection, bypassed operation

Model

IS1x0023B

IS1x0043B

IS1x0053B

Model

IS1x0076B

IS1x0097B

IS1x0105B

IS2x0145B

IS2x0170B

IS2x0200B

IS2x0220B

IS3x0255N

IS4x0360N

IS4x0430N

IS4x0650N

IS4x0790N

IS4x0930N

IS561200N

IS561410N

IS561600N

AC53b 3.0-10:350

40 ºC <1000 metres

35 A

65 A

80 A

AC53b 3.0-10:590

40 ºC <1000 metres

114 A

146 A

158 A

218 A

255 A

300 A

330 A

383 A

540 A

645 A

975 A

1185 A

1395 A

1800 A

2115 A

2400 A

AC53b 3.5-15:345

40 ºC <1000 metres

30 A

59 A

80 A

AC53b 3.5-15:585

40 ºC <1000 metres

96 A

123 A

158 A

184 A

217 A

283 A

315 A

346 A

540 A

645 A

975 A

1185 A

1395 A

1800 A

2115 A

2400 A

2.2.2 Current ratings for continuous operation (not bypassed)

AC53b 4.0-20:340

40 ºC <1000 metres

26 A

51 A

69 A

AC53b 4.0-20:580

40 ºC <1000 metres

83 A

104 A

143 A

159 A

181 A

241 A

268 A

302 A

465 A

552 A

842 A

1071 A

1244 A

1800 A

1979 A

2400 A

AC53b 4.5-30:330

40 ºC <1000 metres

22 A

44 A

55 A

AC53b 4.5-30:570

40 ºC <1000 metres

70 A

87 A

117 A

136 A

146 A

200 A

223 A

264 A

395 A

464 A

683 A

868 A

992 A

1606 A

1671 A

2030 A

AC53a utilisation code

The AC53a Utilisation Code defines the current rating and standard operating conditions for a non-bypassed soft starter.

The soft starter’s current rating determines the maximum motor size it can be used with. The soft starter's rating depends on the number of starts per hour, the length and current level of the start, and the percentage of the operating cycle that the soft starter will be running (passing current).

The soft starter’s current rating is only valid when used within the conditions specified in the utilisation code. The soft starter may have a higher or lower current rating in different operating conditions.

8

www.controltechniques.com

Digistart IS Getting Started Guide

Issue: 1

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation Programming

Status

Menu

Quick Start

Commissioning

Diagnostics Technical

Data

Maintenance Options

Figure 2-3 AC53a utilisation code

351 A : AC-53a 3.5 - 15 : 50 - 6

Starts per hour

On-load duty cycle (%)

Start time (seconds)

Start current (multiple of motor full load current)

Starter current rating (amperes)

Starter current rating: The full load current rating of the soft starter given the parameters detailed in the remaining sections of the utilisation code.

Start current: The maximum available start current.

Start time: The maximum allowable start time.

On-load duty cycle: The maximum percentage of each operating cycle that the soft starter can operate.

Starts per hour: The maximum allowable number of starts per hour.

Table 2-3 Current ratings - in-line connection, non-bypassed operation

Model

IS3x0255N

IS4x0360N

IS4x0430N

IS4x0650N

IS4x0790N

IS4x0930N

IS561200N

IS561410N

IS561600N

AC53a 3-10:50-6

40 ºC <1000 metres

255 A

360 A

430 A

650 A

790 A

930 A

1200 A

1410 A

1600 A

AC53a 3.5-15:50-6

40 ºC <1000 metres

222 A

351 A

413 A

629 A

790 A

930 A

1200 A

1355 A

1600 A

AC53a 4-20:50-6

40 ºC <1000 metres

195 A

303 A

355 A

532 A

694 A

800 A

1135 A

1187 A

1433 A

Table 2-4 Current ratings - inside delta connection, non-bypassed operation

Model

IS3x0255N

IS4x0360N

IS4x0430N

IS4x0650N

IS4x0790N

IS4x0930N

IS561200N

IS561410N

IS561600N

AC53a 3-10:50-6

40 ºC <1000 metres

383 A

540 A

645 A

975 A

1185 A

1395 A

1800 A

2115 A

2400 A

AC53a 3.5-15:50-6

40 ºC <1000 metres

334 A

527 A

620 A

943 A

1185 A

1395 A

1800 A

2033 A

2400 A

AC53a 4-20:50-6

40 ºC <1000 metres

293 A

455 A

533 A

798 A

1041 A

1200 A

1702 A

1780 A

2149 A

AC53a 4.5-30:50-6

40 ºC <1000 metres

171 A

259 A

301 A

437 A

567 A

644 A

983 A

1023 A

1227 A

AC53a 4.5-30:50-6

40 ºC <1000 metres

257 A

388 A

451 A

656 A

850 A

966 A

1474 A

1535 A

1840 A

Digistart IS Getting Started Guide

Issue: 1 www.controltechniques.com

9

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation Programming

Status

Menu

Quick Start

Commissioning

Diagnostics Technical

Data

Maintenance Options

3. Mechanical Installation

Digistart IS models IS2x0145B to IS561600N weigh in excess of 15 kg (33 lb). Use appropriate safeguards when lifting these models.

WARNING

WARNING

Models IS2x0145B to IS561600N are intended to be mounted in an enclosure which prevents access except by trained and authorised personnel, and which prevents the ingress of contamination. The complete range is designed for use in an environment classified as Pollution Degree 3 in accordance with IEC60664-1. This means conductive pollution or dry, non-conductive pollution which becomes conductive due to condensation is acceptable.

Models IS2x0145B to IS2x0220B can be installed with optional finger guards, in which case they do not need to be mounted in an enclosure.

3.1 Dimensions and weights

Figure 3-1 Unit dimensions

A

B

E

H

I

A

B

E

D C C

C D

F

G

Model

IS1x0023B

IS1x0043B

IS1x0053B

IS1x0076B

IS1x0097B

IS1x0105B

IS2x0145B

IS2x0170B

IS2x0200B

IS2x0220B

IS3x0255N

IS4x0360N

IS4x0430N

IS4x0650N

IS4x0790N

IS4x0930N

IS561200N

IS561410N

IS561600N

NOTE

394

(15.51)

430

(16.93)

430

(16.93)

574

(22.60)

A mm

(in)

156.4

(6.16)

156.4

(6.16)

282

(11.10)

320

(12.60)

320

(12.60)

320

(12.60)

500

(19.69)

B mm

(in)

124.0

(4.88)

124.0

(4.88)

250

(9.84)

460

(18.11)

556

(21.89)

556

(21.89)

750

(29.53)

C mm

(in)

294.6

(11.60)

294.6

(11.60)

438

(17.24)

400

(15.75)

522

(20.55)

522

(20.55)

727

(28.62)

D mm

(in)

278.0

(10.94)

278.0

(10.94)

380

(14.96)

284

(11.18)

302

(11.89)

302

(11.89)

364

(14.33)

E mm

(in)

196.2

(7.72)

226.7

(8.92)

254

(10.00)

F mm

(in)

n/a n/a n/a n/a n/a

5.5

(0.22)

5.5

(0.22)

8.5

(0.33)

G mm

(in)

n/a n/a n/a n/a n/a

104.5

(4.11)

104.5

(4.11)

132.5

(5.22)

H mm

(in)

n/a n/a n/a n/a n/a

104.5

(4.11)

104.5

(4.11)

129

(5.08)

I mm

(in)

n/a n/a n/a n/a n/a

5.5

(0.22)

5.5

(0.22)

5

(0.20)

25 (55.12)

50.5

(111.33)

53.5

(117.95)

140

(308.65)

Dimensions F, G, H and I are the additional space required for the output and input busbars, in addition to the overall chassis measurement (C).

Weight kg

(lb)

3.2

(7.05)

3.5 (7.22)

4.8

(10.58)

16

(35.27)

10

www.controltechniques.com

Digistart IS Getting Started Guide

Issue: 1

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation Programming

Status

Menu

Quick Start

Commissioning

Diagnostics Technical

Data

Maintenance Options

3.2 Physical Installation

Figure 3-2 Mounting clearances

1

2

3 4

2

1

IS1x0023B to IS3x0255N: Allow 100 mm (3.94 in) between soft starters.

IS4x0360N to IS561600N: Allow 200 mm (7.88 in) between soft starters.

IS1x0023B to IS2x0220B: Allow 50 mm (1.97 in) between the soft starter and solid surfaces.

IS3x0255N: Allow 100 mm (3.94 in) between the soft starter and solid surfaces.

IS4x0360N to IS561600N: Allow 200 mm (7.88 in) between the soft starter and solid surfaces.

3

Soft starters may be mounted side by side with no clearance.

4

The soft starter may be mounted on its side. Derate the soft starter's rated current by 15%.

Digistart IS Getting Started Guide

Issue: 1 www.controltechniques.com

11

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation Programming

Status

Menu

Quick Start

Commissioning

Diagnostics Technical

Data

Maintenance Options

4. Electrical Installation

Always apply control voltage before (or with) mains voltage.

WARNING

Always follow the specified tightening torque for all power and ground terminal connections.

WARNING

For specifications and detailed technical data, see Technical Data on page 43.

4.1 Terminal layout

4.1.1 Power terminations

Use only copper stranded or solid conductors, rated for 75 ºC.

Figure 4-1 Cable sizes and maximum torque settings (IS1x0023B to IS1x0105B)

NOTE

For personnel safety, the power terminals on models up to IS1x0105B are protected by snap-off tabs. When using large cables, it may be necessary to break off these tabs.

Models which are internally bypassed do not require an external bypass contactor.

Figure 4-2 Busbar dimensions and maximum torque settings (IS2x0145B to IS561600N)

IS2x0145B

8.5 Nm (6.3 ft-lb)

IS2x0170B to IS2x0220B

8.5 Nm (6.3 ft-lb)

IS3x0255N

17 Nm (12.5 ft-lb)

10.5 mm

10.5 mm

IS4x0360N to IS4x0930N

38 Nm (28.5 ft-lb)

32 mm

IS561200N to IS561600N

58 Nm (42.7 ft-lb)

6 mm

12

32 mm 13 mm www.controltechniques.com

Digistart IS Getting Started Guide

Issue: 1

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation Programming

Status

Menu

Quick Start

Commissioning

Diagnostics Technical

Data

Maintenance Options

4.1.2 Ground terminals

Ground terminals are located at the back of the soft starter.

IS1x0023B to IS1x0105B have one terminal on the input side.

IS2x0145B to IS561600N have two terminals, one on the input side and one on the output side.

The ground terminal may also be used for a ground shield connection if necessary.

Tighten the cables as follows:

Table 4-1 Ground terminal maximum torque settings

Models

IS1x0023B to IS1x0105B

IS2x0145B to IS3x0255N

IS4x0360N to IS561600N

Terminal size

M6

M8

M10

Torque

3 Nm

5 Nm

8.5 Nm

Figure 4-3 Ground terminal locations

IS1x0023B to IS1x0105B IS2x0145B to IS561600N

4.1.3 Control terminals

CAUTION

Always connect control voltage to the correct terminals:

110 to 210 Vac: CSL-CSR or

220 to 440 Vac: CSH-CSR

The installer must ensure that the external control circuits are insulated from human contact by at least one layer of insulation (supplementary insulation) rated for use at the AC supply voltage.

WARNING

Control terminations use 2.5mm

2

plug-in terminal blocks. Unplug each block, complete the wiring, then reinsert the block.

Figure 4-4 Control terminal layout

220~440 VAC

110~210 VAC

Digistart IS Getting Started Guide

Issue: 1 www.controltechniques.com

13

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation Programming

Status

Menu

Quick Start

Commissioning

Diagnostics Technical

Data

Maintenance Options

4.1.4 Control wiring

The Digistart IS has three fixed inputs for remote control. These inputs should be controlled by contacts rated for low voltage, low current operation (gold flash or similar).

Figure 4-5 Control wiring options

Start/stop

Reset

1

DI1

+24V

DI2

+24V

DI3

+24V

Start

Stop

Reset

2

DI1

+24V

DI2

+24V

DI3

+24V

Start

Stop

Reset

3

DI1

+24V

DI2

+24V

DI3

+24V

1

Two-wire control

2

Three-wire control

3

Four-wire control

CAUTION

E E E

Do not apply voltage to the control input terminals. These are active 24 Vdc inputs and must be controlled with potential free contacts.

Cables to the control inputs must be segregated from mains voltage and motor cabling.

4.1.5 Relay outputs

The Digistart IS provides four relay outputs, one fixed and three programmable.

The Run output closes when the soft start is complete (when the starting current falls below 120% of the programmed motor full load current) and remains closed until the beginning of a stop (either soft stop or coast to stop).

Operation of the programmable outputs is determined by the settings of Pr 4A to 4I.

If assigned to Main Contactor, the output activates as soon as the soft starter receives a start command and remains active while the soft starter is controlling the motor (until the motor starts a coast to stop, or until the end of a soft stop).

If assigned to a trip function, the output activates when a trip occurs.

If assigned to a flag, the output activates when the specified flag is active (Pr 7A to 7C).

Some electronic contactor coils are not suitable for direct switching with PCB mount relays. Consult the contactor manufacturer/supplier to confirm suitability.

CAUTION

Three additional outputs are available on the input/output expansion card.

4.1.6 Motor thermistors

Motor thermistors can be connected directly to the Digistart IS. The soft starter will trip when the resistance of the thermistor circuit exceeds approximately 3.6 k

Ω.

Figure 4-6 Motor thermistor connection

No motor thermistors

Motor thermistors

TH1

TH2

TH1

TH2

Thermistor input

E

NOTE

If no motor thermistors are connected to the Digistart IS thermistor input terminals TH1, TH2 must be open. If TH1, TH2 are shorted, the Digistart IS will trip.

The thermistor circuit should be run in screened cable and must be electrically isolated from ground and all other power and control circuits.

14

www.controltechniques.com

Digistart IS Getting Started Guide

Issue: 1

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation Programming

Status

Menu

Quick Start

Commissioning

Diagnostics Technical

Data

Maintenance Options

4.2 Control connections

Figure 4-7 Digistart IS electrical schematic

220-440 VAC

+10%

-15%

110-210 VAC

CSH

CSL

+10%

-15%

CSR

1

5

+24V

0V

DI1

+24V

DI2

+24V

DI3

+24V

DI4

+24V

DI5

+24V

2 6

COM1

RLO1

COM2

RLO2

COM3

RLC3

RLO3

COM4

RLC4

RLO4

TH1

TH2

3

PT3

PT4

PT5

PT3

PT4

PT5

A

PT3

PT4

PT5

4

7

AO1

0V

E

C

1

2

3

4A

4B

4C

5

6

7

Control voltage

Remote control inputs

Motor thermistor input

RTD/PT100 input - 2-wire

RTD/PT100 input - 3-wire

RTD/PT100 input - 4-wire

24 Vdc output

Relay outputs

Analog output

DI1, +24V

DI2, +24V

DI3, +24V

DI4, +24V

Start

Stop

Reset

Programmable input A

DI5, +24V

COM1, RLO1

COM2, RLO2

Programmable input B

Relay output A

Run relay output

COM3, RLC3, RLO3 Relay output B

COM4, RLC4, RLO4 Relay output C

The Digistart IS can be commanded to emergency stop the motor, ignoring the soft stop mode set in Pr 2H.

When the circuit across DI4, +24V is opened, the soft starter allows the motor to coast to stop.

To use the emergency stop function, set Pr 3A to 'Emergency Stop' (this is the default setting).

If emergency stop is not required, change the setting of Pr 3A or connect a link across DI4, +24V.

For keypad control, the soft starter requires:

• control supply connections (terminals CSH, CSL, CSR depending on the control voltage)

• programmable input A (DI4, +24V) must be closed or Pr 3A Input A Function must be changed from Emergency Stop

Digistart IS Getting Started Guide

Issue: 1 www.controltechniques.com

15

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation Programming

Status

Menu

Quick Start

Commissioning

Diagnostics Technical

Data

Maintenance Options

4.3 Power connections

4.3.1 In-line installation

• In-line installation, internally bypassed

Figure 4-8 Power connections - in-line installation, internally bypassed

KM1 F1

1/L1 2/T1

3/L2 4/T2

3

M

5/L3 6/T3

E

COM1

RLO1

KM1

KM1

F1

Main contactor (optional)

Semiconductor fuses (optional)

NOTE

Main contactor is the default setting for Pr 4A Relay A Function (COM1, RLO1).

• In-line installation, externally bypassed

Non-bypassed models have dedicated bypass terminals, which allow the Digistart IS to continue providing protection and monitoring functions even when bypassed via an external bypass contactor. The bypass contactor must be connected to the bypass terminals and controlled by the soft starter's run output (terminals COM2, RLO2).

Figure 4-9 Power connections - in-line installation, externally bypassed

KM1

KM2

F1

NOTE

16

Main contactor (optional)

Bypass contactor

Semiconductor fuses (optional)

The bypass terminals on IS3x0255N are T1B, T2B, T3B. The bypass terminals on IS4x0360N to IS561600N are L1B,

L2B, L3B.

The fuses can be installed on the input side if required. www.controltechniques.com

Digistart IS Getting Started Guide

Issue: 1

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation Programming

Status

Menu

Quick Start

Commissioning

Diagnostics Technical

Data

Maintenance Options

NOTE

Main contactor is the default setting for Pr 4A Relay A Function (COM1, RLO1). Output relay COM2, RLO2 is dedicated to Run output operation and is ideal for managing an external bypass contactor.

• In-line installation, non-bypassed

Figure 4-10 Power connections - in-line installation, non-bypassed

KM1

F1

Main contactor (optional)

Semiconductor fuses (optional)

4.3.2 Inside delta installation

When connecting the Digistart IS in inside delta configuration, always install a main contactor or shunt trip circuit breaker.

CAUTION

• Inside delta installation, internally bypassed

Figure 4-11 Power connections - inside delta installation, internally bypassed

KM1

KM1

F1

Main contactor

Semiconductor fuses (optional)

F1

1/L1

3/L2

4/L3

E

2/T1

4/T2

U1(1) U2(4)

V1(2)

W1(3)

3

M

V2(5)

W2(6)

6/T3

COM1

RLO1

KM1

Digistart IS Getting Started Guide

Issue: 1 www.controltechniques.com

17

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation Programming

Status

Menu

Quick Start

Commissioning

Diagnostics Technical

Data

Maintenance Options

• Inside delta installation, externally bypassed

Non-bypassed models have dedicated bypass terminals, which allow the Digistart IS to continue providing protection and monitoring functions even when bypassed via an external bypass contactor. The bypass contactor must be connected to the bypass terminals and controlled by the soft starter's run output (terminals COM2, RLO2).

Figure 4-12 Power connections - inside delta installation, externally bypassed

KM1

KM2

F1

Main contactor

Bypass contactor

Semiconductor fuses (optional)

NOTE

The bypass terminals on IS3x0255N are T1B, T2B, T3B. The bypass terminals on IS4x0360N to IS561600N are L1B,

L2B, L3B.

The fuses can be installed on the input side if required.

• Inside delta installation, non-bypassed

Figure 4-13 Power connections - inside delta installation, non-bypassed

KM1

F1

18

Main contactor

Semiconductor fuses (optional) www.controltechniques.com

Digistart IS Getting Started Guide

Issue: 1

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation Programming

Status

Menu

Quick Start

Commissioning

Diagnostics Technical

Data

Maintenance Options

4.4 Fuses

Semiconductor fuses can be used for Type 2 coordination and to reduce the risk of damage to SCRs from transient overload currents.

HRC fuses (such as Ferraz AJT fuses) can be used for Type 1 coordination.

NOTE

Adaptive Control controls the motor's speed profile, within the programmed time limit. This may result in a higher level of current than traditional control methods.

IS1x0023B

IS1x0043B

IS1x0053B

IS1x0076B

IS1x0097B

IS1x0105B

IS2x0145B

IS2x0170B

IS2x0200B

IS2x0220B

IS3x0255N

IS4x0360N

IS4x0430N

IS4x0650N

IS4x0790N

IS4x0930N

IS561200N

IS561410N

IS561600N

For applications using Adaptive Control to soft stop the motor with stop times greater than 30 seconds, motor branch protection should be selected as follows:

• standard HRC line fuses: minimum 150% motor full load current

• motor rated line fuses: minimum rating 100/150% motor full load current

• motor control circuit breaker minimum long time setting: 150% motor full load current,

• motor control circuit breaker minimum short time setting: 400% motor full load current for 30 seconds

NOTE

Fuse selection is based on a 400% FLC start for 20 seconds in conjunction with standard published starts per hour, duty cycle, 40°C ambient temperature and up to 1000 m altitude. For installations operating outside these conditions, consult your local supplier.

These fuse tables contain recommendations only. Always consult your local supplier to confirm the selection for your particular application.

Table 4-2 Bussman fuses - square body (170M)

Model SCR I

2 t (A

2 s)

1150

8000

15000

15000

51200

125000

125000

320000

320000

320000

320000

238000

320000

1200000

2530000

4500000

4500000

6480000

12500000

* Two parallel connected fuses required per phase.

Supply Voltage

(< 440 Vac)

170M1314

170M1316

170M1318

170M1319

170M1321

170M1321

170M1321

170M2621

170M2621

170M2621

170M2621

170M6010

170M6011

170M6015

170M6017

170M6019

170M6021

––

170M6019*

Supply Voltage

(< 575 Vac)

170M1314

170M1316

170M1318

170M1319

170M1321

170M1321

170M1321

170M2621

170M2621

170M2621

170M2621

170M6010

170M6011

170M6015

170M6017

170M6019

––

––

––

Supply Voltage

(< 690 Vac)

170M1314

170M1316

170M1318

170M1318

170M1319

170M1321

170M1321

170M2621

170M2621

170M2621

170M2621

170M6010

––

170M6014

170M6016

170M6019

––

––

––

Digistart IS Getting Started Guide

Issue: 1 www.controltechniques.com

19

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation Programming

Status

Menu

Quick Start

Commissioning

Diagnostics Technical

Data

Maintenance Options

Table 4-3 Ferraz fuses - HSJ

Model

IS1x0023B

IS1x0043B

IS1x0053B

IS1x0076B

IS1x0097B

IS1x0105B

IS2x0145B

IS2x0170B

IS2x0200B

IS2x0220B

IS3x0255N

IS4x0360N

IS4x0430N

IS4x0650N

IS4x0790N

IS4x0930N

IS561200N

IS561410N

IS561600N

SCR I

2 t (A

2 s)

1150

8000

15000

15000

51200

125000

125000

320000

320000

320000

320000

238000

320000

1200000

2530000

4500000

4500000

6480000

12500000

Supply Voltage

(< 440 Vac)

HSJ40**

HSJ80**

HSJ110**

HSJ125**

HSJ175

HSJ225

HSJ250

HSJ300

HSJ350

HSJ400**

HSJ450**

Not suitable

Supply Voltage

(< 575 Vac)

HSJ40**

HSJ80**

HSJ110**

HSJ125**

HSJ175**

HSJ225

HSJ250**

HSJ300

HSJ350

HSJ400**

HSJ450**

Not suitable

Supply Voltage

(< 690 Vac)

Not suitable

** Two series connected fuses required per phase.

Table 4-4 Ferraz fuses - European style (PSC 690)

Model SCR I

2 t (A

2 s) Supply Voltage

(< 440 Vac)

IS1x0023B

IS1x0043B

IS1x0053B

IS1x0076B

IS1x0097B

IS1x0105B

IS2x0145B

IS2x0170B

IS2x0200B

IS2x0220B

IS3x0255N

IS4x0360N

IS4x0430N

IS4x0650N

IS4x0790N

IS4x0930N

IS561200N

IS561410N

IS561600N

1150

8000

15000

15000

51200

125000

125000

320000

320000

320000

320000

238000

320000

1200000

2530000

4500000

4500000

6480000

12500000

6.9URD30D11A0050

6.9URD30D11A0125

6.9URD30D11A0125

6.9URD30D11A0160

6.9URD30D11A0200

6.9URD30D11A0315

6.9URD30D11A0315

6.9URD30D11A0315

6.9URD31D11A0450

6.9URD31D11A0450

6.9URD31D11A0450

6.9URD33D11A0630

6.9URD33D11A0700

6.9URD33D11A1000

6.6URD33D11A1400

6.6URD33D11A1400

6.9URD233PLAF2200

6.9URD233PLAF2200

6URD233PLAF2800

Supply Voltage

(< 575 Vac)

6.9URD30D11A0050

6.9URD30D11A0125

6.9URD30D11A0125

6.9URD30D11A0160

6.9URD30D11A0200

6.9URD30D11A0315

6.9URD30D11A0315

6.9URD30D11A0315

6.9URD31D11A0450

6.9URD31D11A0450

6.9URD31D11A0450

6.9URD33D11A0630

6.9URD33D11A0700

6.9URD33D11A1000

6.6URD33D11A1400

6.6URD33D11A1400

6.9URD233PLAF2200

6.9URD233PLAF2200

6URD233PLAF2800

Supply Voltage

(< 690 Vac)

6.9URD30D11A0050

6.9URD30D11A0125

6.9URD30D11A0125

6.9URD30D11A0160

6.9URD30D11A0200

6.9URD30D11A0315

6.9URD30D11A0315

6.9URD30D11A0315

6.9URD31D11A0450

6.9URD31D11A0450

6.9URD31D11A0450

6.9URD33D11A0630

6.9URD33D11A0700

6.9URD33D11A1000

6.6URD33D11A1400

6.6URD33D11A1400

––

6.9URD233PLAF2200

––

20

www.controltechniques.com

Digistart IS Getting Started Guide

Issue: 1

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation Programming

Status

Menu

Quick Start

Commissioning

Diagnostics Technical

Data

Maintenance Options

Table 4-5 Ferraz fuses - AJT

Model SCR I

2 t (A

2 s)

IS1x0023B

IS1x0043B

IS1x0053B

IS1x0076B

IS1x0097B

IS1x0105B

IS2x0145B

IS2x0170B

IS2x0200B

IS2x0220B

IS3x0255N

IS4x0360N

IS4x0430N

IS4x0650N

IS4x0790N

IS4x0930N

IS561200N

IS561410N

IS561600N

1150

8000

15000

15000

51200

125000

125000

320000

320000

320000

320000

238000

320000

1200000

2530000

4500000

4500000

6480000

12500000

Supply Voltage

(< 440 Vac)

Supply Voltage

(< 575 Vac)

AJT25

AJT50

AJT60

AJT80

AJT100

AJT125

AJT150

AJT175

AJT200

AJT250

AJT300

AJT400

AJT25

AJT50

AJT60

AJT80

AJT100

AJT125

AJT150

AJT175

AJT200

AJT250

AJT300

AJT400

AJT450

A4BQ800

AJT450

A4BQ800

A4BQ1200 A4BQ1200

A4BQ1200 / A4BT1100 A4BQ1200 / A4BT1100

A4BQ1600

A4BQ2000

A4BQ1600

A4BQ2000

A4BQ2500 / A4BT1800 A4BQ2500 / A4BT1800

Supply Voltage

(< 690 Vac)

Not suitable

4.5 Bypass contactor

Digistart IS soft starters with model numbers IS1x0023B to IS2x0220B are internally bypassed and do not require an external bypass contactor.

Digistart IS soft starters with model numbers IS3x0255N to IS561600N are not internally bypassed and may be installed with an external bypass contactor. Select a contactor with an AC1 rating greater than or equal to the full load current rating of the connected motor.

4.6 Main contactor

A main contactor must be installed if the Digistart IS is connected to the motor in inside delta format and is optional for in-line connection. Select a contactor with an AC3 rating greater than or equal to the full load current rating of the connected motor.

4.7 Circuit breaker

A shunt trip circuit breaker may be used instead of a main contactor to isolate the motor circuit in the event of a soft starter trip. The shunt trip mechanism must be powered from the supply side of the circuit breaker or from a separate control supply.

4.8 EMC (electromagnetic compatibility)

For additional details, see the Digistart IS User Guide available on the supplied CD.

Digistart IS Getting Started Guide

Issue: 1 www.controltechniques.com

21

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and Status

Operation Programming

Menu

Quick Start

Commissioning

Diagnostics Technical

Data

Maintenance Options

5. Keypad and Status

5.1 Keypad

Figure 5-1 Keypad and display

1

2

3

2 min

Menu navigation buttons.

M: Enter a menu or parameter, or save a parameter change

: Exit the menu or parameter, or cancel a parameter change.

: Scroll to the next or previous status screen, menu or parameter, or change the setting of the current parameter.

Shortcut buttons for quick access to common tasks.

Four-line display for status and programming details.

Status LEDs

Soft starter local control buttons.

4

LCL

RMT

5

08349.A

Table 5-1 Feedback LEDs

LED

Ready Ready

Run

Trip

Local

On

Running

Starter tripped

Local control mode

Blinking

Restart delay or motor temperature check

Starting/ stopping

Warning n/a

No control power

Off

Not running, starting or stopping

Normal operation

Remote control mode

5.2 Displays

The keypad displays a wide range of performance information about the soft starter.

The top half of the screen shows real-time information on starter status, motor temperature and motor power.

Use the and buttons to select the information shown on the bottom half of the screen.

Current

Last start information

Date and time

5.2.1 Starter status

The starter status screen shows details of the starter's operating status, motor temperature and motor power.

Ready

M1 000% 000.0kW

5.2.2 Average current

The average current screen shows real-time average current.

0.0A

5.2.3 Programmable screen

The Digistart IS's user-programmable screen can be configured to show the most important information for the particular application.

Use Pr 9B to 9E to select which information to display.

22

www.controltechniques.com

Digistart IS Getting Started Guide

Issue: 1

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and Status

Operation Programming

Menu

Quick Start

Commissioning

Diagnostics Technical

Data

Maintenance Options

000.0A

00000hrs

0.0pf

000kWh

5.2.4 Current

The current screen shows real-time line current on each phase. If the RTD/PT100 and ground fault protection card is fitted, the screen will also show ground current.

000.0A

Phase Currents

000.0A 000.0A

5.2.5 Voltage

The voltage screen shows real-time line voltage across each phase.

440V

Line Voltages

441V 440V

NOTE

Voltage monitoring is only available if the voltage measurement card is installed.

5.2.6 Last start information

The last start information screen shows details of the most recent successful start:

• start duration (seconds)

• maximum start current drawn (as a percentage of motor full load current)

• calculated rise in motor temperature

Last start

350 % FLC

010 s

∆ Temp 5%

5.2.7 Date and time

The date/time screen shows the current system date and time (24 hour format).

DD MMM YYYY

HH:MM:SS

5.2.8 Performance graph

The performance graph provides a real-time display of operating performance. Use Pr 9F to 9I to select which information to display.

000.0 A 0-400%

For additional details, see the Digistart IS User Guide available on the supplied CD.

Digistart IS Getting Started Guide

Issue: 1 www.controltechniques.com

23

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation

Programming

Status

Menu

Quick Start

Commissioning

Diagnostics Technical

Data

Maintenance Options

6. Operation

6.1 Start, stop and reset commands

The soft starter can be controlled in three ways:

• using the buttons on the keypad

• via remote inputs

• via a serial communication link

The LCL/RMT button controls whether the Digistart IS will respond to local control (via the keypad) or remote control (via the remote inputs).

The Local LED on the keypad is on when the soft starter is in local control mode and off when the soft starter is in remote control mode.

The Remote LED on the Digistart IS is on when the soft starter is in Remote mode and off when in Local mode. The Remote

LED is located on the main body of the starter (behind the keypad) and is only visible if the keypad is remotely mounted.

The STOP button on the keypad is always enabled.

6.2 Using the soft starter to control a motor

To soft start the motor, press the START button on the keypad or activate the Start remote input. The motor will start using the start mode selected in Pr 2A.

To stop the motor, press the STOP button on the keypad or activate the Stop remote input. The motor will stop using the stop mode selected in Pr 2H.

To reset a trip on the soft starter, press the RESET button on the keypad or activate the Reset remote input.

6.3 Soft start methods

Soft starters offer a variety of methods to control motor starting. Each soft start method uses a different primary control parameter.

Table 6-1 Soft start methods

Soft Start Method Parameter Controlled Performance Parameters Influenced

Timed Voltage Ramp

Constant Current

Torque Control

Adaptive Acceleration Control

Voltage

Current

Torque

Acceleration

Start current, start torque, acceleration

Start torque, acceleration

Start current, acceleration

Start current, start torque

Best results are obtained by selecting the soft start method that directly controls the parameter of most importance for the application. Typically soft starters are used to limit motor start current or control load acceleration and/or deceleration.

The Digistart IS offers Constant Current or Adaptive Acceleration Control. Use Pr 2A to select the soft start method.

Table 6-2 Control functions of soft start methods

Motor Start Current

Motor/Load Acceleration

To Control

Constant Current

Adaptive Acceleration Control

Use

6.3.1 Constant current

Constant current is the traditional form of soft starting, which raises the current from zero to a specified level and keeps the current stable at that level until the motor has accelerated.

Constant current starting is ideal for applications where the start current must be kept below a particular level.

Figure 6-1 Constant current soft start

700%

600%

500%

400%

300%

200%

100%

3

1

2

1: Initial current (Pr 2C)

2: Current limit (Pr 2B)

3: Full voltage current

24

10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Rotor speed (% full speed) www.controltechniques.com

Digistart IS Getting Started Guide

Issue: 1

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation

Programming

Status

Menu

Quick Start

Commissioning

Diagnostics Technical

Data

Maintenance Options

6.3.2 Current ramp

Current ramp soft starting raises the current from a specified starting level (1) to a maximum limit (3), over an extended period of time (2).

Current ramp starting can be useful for applications where:

• the load can vary between starts (for example a conveyor which may start loaded or unloaded). Set the initial current (Pr 2C) to a level that will start the motor with a light load, and the current limit (Pr 2B) to a level that will start the motor with a heavy load.

• the load breaks away easily, but starting time needs to be extended (for example a centrifugal pump where pipeline pressure needs to build up slowly).

• the electricity supply is limited (for example a generator set), and a slower application of load will allow greater time for the supply to respond.

Figure 6-2 Current ramp soft start

700%

600%

500%

400%

300%

200%

100%

4

2

1

3

1: Initial current (Pr 2C)

2: Start ramp time (Pr 2D)

3: Current limit (Pr 2B)

4: Full voltage current

Time

6.3.3 Adaptive control for starting

Adaptive Acceleration Control is a new intelligent motor control technique. In an adaptive control soft start, the Digistart IS adjusts the current in order to start the motor within a specified time and using a selected acceleration profile.

For additional details, see the Digistart IS User Guide available on the supplied CD.

NOTE

Adaptive Acceleration Control cannot start the motor faster than a direct on-line (DOL) start. If the start ramp time (Pr

2D) is shorter than the motor's DOL start time, starting current may reach DOL levels.

6.3.4 Kickstart

Kickstart provides a short boost of extra torque at the beginning of a start, and can be used in conjunction with current ramp or constant current starting.

Kickstart can be useful to help start loads that require high breakaway torque but then accelerate easily (for example flywheel loads such as presses).

For additional details, see the Digistart IS User Guide available on the supplied CD.

Kickstart subjects the mechanical equipment to increased torque levels. Ensure the motor, load and couplings can handle the additional torque before using this feature.

CAUTION

6.4 Stop methods

Soft starters offer a variety of methods for the control of motor stopping.

Table 6-3 Soft stop methods

Stop Method Performance Result

Coast To Stop

TVR Soft Stop

Adaptive Deceleration Control

STV Stop

Brake

Natural load run down

Extended run down time

Extended run down time according to selected deceleration profile

Extended run down time

Reduced run down time

Soft starters are often used in pumping applications to eliminate the damaging effects of fluid hammer. Adaptive Control should be the preferred stop method for these applications.

6.4.1 Coast to stop

Coast to stop lets the motor slow at its natural rate, with no control from the soft starter. The time required to stop will depend on the type of load.

Digistart IS Getting Started Guide

Issue: 1 www.controltechniques.com

25

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation

Programming

Status

Menu

Quick Start

Commissioning

Diagnostics Technical

Data

Maintenance Options

6.4.2 TVR soft stop

Timed voltage ramp reduces the voltage to the motor gradually over a defined time. The load may continue to run after the stop ramp is complete.

Timed voltage ramp stopping can be useful for applications where the stop time needs to be extended, or to avoid transients on generator set supplies.

Figure 6-3 TVR soft stop

100%

90%

80%

70%

60%

50%

40%

30%

20%

10%

1

1: Stop time (Pr 2I)

04749.B

Time

6.4.3 Adaptive control for stopping

In an adaptive control soft stop, the Digistart IS controls the current in order to stop the motor within a specified time and using a selected deceleration profile. Adaptive Deceleration Control can be useful in extending the stopping time of low inertia loads.

For additional details, see the Digistart IS User Guide available on the supplied CD.

NOTE

Adaptive control does not actively slow the motor down and will not stop the motor faster than a coast to stop. To shorten the stopping time of high inertia loads, use brake.

6.4.4 STV stop

STV soft stop is based on simple phase angle control of the SCRs.

For additional details, see the Digistart IS User Guide available on the supplied CD.

NOTE

STV soft stop does not actively slow the motor and will not stop the motor faster than a coast to stop.

6.4.5 Brake

When brake is selected, the Digistart IS uses DC injection to slow the motor.

Digistart IS braking:

Does not require the use of a DC brake contactor

Controls all three phases so that the braking currents and associated heating are evenly distributed through the motor.

For additional details, see the Digistart IS User Guide available on the supplied CD.

6.5 Jog

Jog runs the motor at reduced speed, to allow alignment of the load or to assist servicing. The motor can be jogged in either forward or reverse direction.

For additional details, see the Digistart IS User Guide available on the supplied CD.

6.6 Inside delta operation

Adaptive Control, Jog, Brake and PowerThrough functions are not supported with inside delta (six-wire) operation.

26

www.controltechniques.com

Digistart IS Getting Started Guide

Issue: 1

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation

Programming

Status

Menu

Quick Start

Commissioning

Diagnostics Technical

Data

Maintenance Options

7. Programming Menu

The motor data parameters are critical to the correct operation of the soft starter's thermal model, and to the motor overload protection. Always set Pr 1A to suit the motor's characteristics.

WARNING

7.1 Programming menu

The Programming Menu lets you view and change programmable parameters that control how the Digistart IS operates.

To open the Programming Menu, press the M button while viewing the monitoring screens.

To navigate through the Programming Menu:

• to scroll through parameter groups, press the or button.

• to open a submenu, press the M button.

• to view the parameters in a group, press the M button.

• to return to the previous level, press the button.

• to close the Programming Menu, press repeatedly.

To change a parameter value:

• scroll to the appropriate parameter in the Programming Menu and press M to enter edit mode.

• to alter the parameter setting, use the and buttons. Pressing or once will increase or decrease the value by one

(1). If the button is held for longer than five seconds, the value will increase or decrease at a faster rate.

• to save changes, press M. The setting shown on the display will be saved and the keypad will return to the parameter list.

• to cancel changes, press . The keypad will ask for confirmation, then return to the parameter list without saving changes.

The Programming Menu contains the following sub-menus.

Table 7-1 Programming menu structure

Quick Setup Menu

Standard Menu

Advanced Menu

Setup Tools

Simulations

I/O State

Logs

Counters

The Quick Setup Menu allows you to select common applications and guides you through the parameter setup process for these applications.

The Standard Menu provides access to commonly used parameters, allowing you to configure the

Digistart IS to suit your application.

The Advanced Menu provides access to all the Digistart IS's programmable parameters, allowing experienced users to take advantage of advanced features.

Setup Tools provides access to functions to save the current parameter settings to a file, load parameters from a previously saved file, or reset all parameters to default values.

Simulations allows you to simulate operation of the soft starter, including input and output functions.

I/O State provides access to information on the current state of the analog and digital inputs and outputs.

The Logs Menu provides access to the Trip Log and Event Log.

The Counters Menu provides access to information on the starter's operating history.

For full details of the advanced menu, setup tools, simulations, I/O state, and logs and counters, see the Digistart IS User Guide available on the supplied CD.

7.2 Access code

Critical parameters (parameter group 15 and higher) are protected by a four-digit security access code, preventing unauthorised users from viewing or modifying parameter settings.

When a user attempts to enter a restricted parameter group, the keypad prompts for an access code. The access code is requested once for the programming session, and authorisation continues until the user closes the menu.

To enter the access code, use the and M buttons to select a digit, and the and buttons to change the value. When all four digits match your access code, press M. The keypad will display an acknowledgement message before continuing.

Enter Access Code

0###

Access Allowed

SUPERVISOR

M

To change the access code, use Pr 15A.

The simulation tools and counter resets are also protected by the security access code.

The default access code is 0000.

Digistart IS Getting Started Guide

Issue: 1 www.controltechniques.com

27

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation

Programming

Status

Menu

Quick Start

Commissioning

Diagnostics Technical

Data

Maintenance Options

7.3 Adjustment lock

You can lock the Programming Menu to prevent users from altering parameter settings. The adjustment lock can be turned on and off using Pr 15C.

To lock the programming menu:

4.

5.

6.

1.

2.

3.

Open the Programming Menu.

Open the Advanced Menu.

Select 'Restricted'

Enter the Access Code

Select Pr 15C Adjustment Lock.

Select and store 'Read Only'

If a user attempts to change a parameter value when the adjustment lock is active, an error message is displayed:

Access Denied

Adj Lock is On

7.4 Load defaults

Load Defaults restores the starter to the factory default settings for all parameters except Pr 9A Language. This does not reset the access code.

To load defaults:

1. Open the Programming Menu and select Setup Tools. Enter the access code.

2. Scroll to the required function and press the M button.

3. At the confirmation prompt, select YES to confirm or NO to cancel and then M to load/save the selection.

When the action has been completed, the screen will briefly display a confirmation message, then return to the status screens.

No

Yes

Load Defaults

Load Backup

Save User Set 1

Load Defaults

28

www.controltechniques.com

Digistart IS Getting Started Guide

Issue: 1

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation

Programming

Status

Menu

Quick Start

Commissioning

Diagnostics Technical

Data

Maintenance Options

7.5 Quick setup details

To access the Quick Setup Menu, press the M button and select Quick Setup Menu.

The Quick Setup Menu makes it easy to configure the Digistart IS for common applications. The Digistart IS selects the parameters relevant to the application and suggests a typical setting, and you can adjust each parameter to suit your exact requirements.

Always set Pr 1A Motor Full Load Current to match the motor's nameplate full load current. The suggested value is the starter's minimum full load current.

Table 7-2 Quick setup menu

Application

Pump Centrifugal

Pump Submersible

Fan Damped

Fan Undamped

Compressor Screw

Compressor Recip

Conveyor

Crusher Rotary

Parameter

Motor Full Load Current

Start Mode

Adaptive Start Profile

Start Ramp Time

Current Limit

Stop Mode

Adaptive Stop Profile

Stop Time

Motor Full Load Current

Start Mode

Adaptive Start Profile

Start Ramp Time

Current Limit

Stop Mode

Adaptive Stop Profile

Stop Time

Motor Full Load Current

Start Mode

Adaptive Start Profile

Start Ramp Time

Current Limit

Motor Full Load Current

Start Mode

Adaptive Start Profile

Start Ramp Time

Current Limit

Excess Start Time

Locked Rotor Time

Motor Full Load Current

Start Mode

Adaptive Start Profile

Start Ramp Time

Current Limit

Motor Full Load Current

Start Mode

Adaptive Start Profile

Start Ramp Time

Current Limit

Motor Full Load Current

Start Mode

Adaptive Start Profile

Start Ramp Time

Current Limit

Stop Mode

Adaptive Stop Profile

Stop Time

Motor Full Load Current

Start Mode

Adaptive Start Profile

Start Ramp Time

Current Limit

Excess Start Time

Locked Rotor Time

Pr

Number

1A

2A

2E

2D

2B

1A

2A

2E

2D

2B

1A

2A

2E

2D

2B

5A

1C

1A

2A

2E

2D

2B

2H

2K

2I

1A

2A

2E

2D

2B

1A

2A

2E

2D

2B

2H

2K

2I

1A

2A

2E

2D

2B

5A

1C

1A

2A

2E

2D

2B

2H

2K

2I

Suggested value

Model dependent

Adaptive Control

Early Acceleration

5 seconds

350%

Adaptive Control

Late Deceleration

15 seconds

Model dependent

Adaptive Control

Early Acceleration

5 seconds

350%

Adaptive Control

Late Deceleration

5 seconds

Model dependent

Adaptive Control

Constant Acceleration

15 seconds

350%

Model dependent

Adaptive Control

Constant Acceleration

20 seconds

400%

30 seconds

20 Seconds

Model dependent

Adaptive Control

Constant Acceleration

10 seconds

400%

Model dependent

Adaptive Control

Constant Acceleration

10 seconds

450%

Model dependent

Adaptive Control

Late Acceleration

15 seconds

400%

Adaptive Control

Constant Deceleration

5 seconds

Model dependent

Adaptive Control

Constant Acceleration

20 seconds

400%

30 seconds

20 seconds

Digistart IS Getting Started Guide

Issue: 1 www.controltechniques.com

29

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation

Programming

Status

Menu

Quick Start

Commissioning

Diagnostics Technical

Data

Maintenance Options

Application

Crusher Jaw

Start Mode

Current Limit

Parameter

Motor Full Load Current

Adaptive Start Profile

Start Ramp Time

Excess Start Time

Locked Rotor Time

Pr

Number

1A

2A

2E

2D

2B

5A

1C

Suggested value

Model dependent

Adaptive Control

Constant Acceleration

30 seconds

450%

40 seconds

30 seconds

Parameter Group

1 - Primary Motor Set

2 - Start/Stop Modes-1

3 - Digital Inputs

4 - Digital Outputs

5 - Protection Settings

7.6 Standard menu

The standard menu provides access to commonly used parameters. For parameter details, see Parameter Descriptions on page 31.

Table 7-3 Standard menu

M 1A

M

M 3A

3B

3C

3D

3E

3F

3G

3H

3I

3J

M 4A

4B

4C

4D

4E

4F

4G

4H

4I

M 5A

5D

5E

5F

2A

2B

2C

2D

2H

2I

2O

2P

2Q

2R

Parameters

Motor Full Load Current

Start Mode

Current Limit

Initial Current

Start Ramp Time

Stop Mode

Stop Time

Auto-Start Type

Auto-Start Time

Auto-Stop Type

Auto-Stop Time

Input A Function

Input A Name

Input A Trip

Input A Initial Delay

Input A Trip Delay

Input B Function

Input B Name

Input B Trip

Input B Initial Delay

Input B Trip Delay

Relay A Action

Relay A On Delay

Relay A Off Delay

Relay B Action

Relay B On Delay

Relay B Off Delay

Relay C Action

Relay C On Delay

Relay C Off Delay

Excess Start Time

Phase Sequence

Underpower

Overpower

Default Value

Model dependent

Adaptive Control

350%

350%

00:10 (minutes:seconds)

Coast to Stop

00:03 (minutes:seconds)

Off

00:01 (hours: minutes)

Off

00:01 (hours: minutes)

Emergency Stop

Emergency Stop

Always Active

00:00 (minutes:seconds)

00:00 (minutes:seconds)

Input Trip (N/O)

Input Trip

Always Active

00:00 (minutes:seconds)

00:00 (minutes:seconds)

Main Contactor

00:00 (minutes:seconds)

00:00 (minutes:seconds)

Run

00:00 (minutes:seconds)

00:00 (minutes:seconds)

Trip

00:00 (minutes:seconds)

00:00 (minutes:seconds)

00:20 (minutes:seconds)

Any Sequence

20%

400%

30

www.controltechniques.com

Digistart IS Getting Started Guide

Issue: 1

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation

Programming

Status

Menu

Quick Start

Commissioning

Diagnostics Technical

Data

Maintenance Options

Parameter Group Parameters Default Value

6 - Protection Delays

7 - Set Points

9 - Display

M

M

M

6B

6C

7A

7B

7C

9A

9B

9C

9D

9E

9J

9K

9M

Underpower Delay

Overpower Delay

Low Current Flag

High Current Flag

Motor Temperature Flag

Languages

User Screen - Top Left

User Screen - Top Right

User Screen - Bottom Left

User Screen - Bottom Right

F1 Button Action

F2 Button Action

Display A or kW

00:05 (minutes:seconds)

00:00 (minutes:seconds)

50%

100%

80%

Motor Current

Motor pf

Hours Run kWh

Auto-Start/Stop Menu

None

Current

7.7 Advanced menu

The Advanced Menu gives access to all the programmable parameters in the Digistart IS. For additional details, see the Digistart IS

User Guide available on the supplied CD.

7.8 Parameter descriptions

7.8.1 Group 1 - Primary Motor Set

The motor data parameters are critical to the correct operation of the soft starter's thermal model, and to the motor overload protection. Always set Pr 1A to suit the motor's characteristics.

WARNING

No

1A

Function

Motor Full Load Current

Range

Model dependent

Default

Model dependent

Matches the starter to the connected motor's full load current. Set to the full load current (FLC) rating shown on the motor nameplate.

7.8.2 Group 2 - Start/Stop Modes-1

For details of soft start and stop control methods, see Soft start methods on page 24 and Stop methods on page 25.

No

2A Start Mode

Function

Selects the soft start mode.

Range

Constant Current, Adaptive Control

Default

Adaptive Control

No

2B Current Limit

Function Range

100 to 600% FLC

Default

350%

Sets the current limit for constant current and current ramp soft starting, as a percentage of motor full load current.

No

2C Initial Current

Function Range

100 to 600% FLC

Default

350%

Sets the initial start current level for current ramp starting, as a percentage of motor full load current. Set so that the motor begins to accelerate immediately after a start is initiated.

If current ramp starting is not required, set the initial current equal to the current limit.

No

2D

Function

Start Ramp Time

Range

00:01 to 03:00 (minutes:seconds)

Default

00:10

Sets the total start time for an Adaptive Acceleration Control start or the ramp time for current ramp starting (from the initial current to the current limit).

No

2H Stop Mode

Function Range

Coast To Stop, TVR Soft Stop, Adaptive

Control, Brake, STV Soft Stop

Default

Coast To Stop

Selects the stop mode.

Digistart IS Getting Started Guide

Issue: 1 www.controltechniques.com

31

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation

Programming

Status

Menu

Quick Start

Commissioning

Diagnostics Technical

Data

Maintenance Options

No

2I Stop Time

Function Range

00:00 to 04:00 (minutes:seconds)

Default

00:03

Sets the time for soft stopping the motor using timed voltage ramp or Adaptive Deceleration Control.

If a main contactor is installed, the contactor must remain closed until the end of the stop time. Use the run output (terminals COM2,

RLO2) to control the main contactor. Sets the total stopping time when using brake.

Auto-start and auto-stop

The Digistart IS can be programmed to start and stop automatically, after a specified delay or at a specified time of day. Auto-start and auto-stop can be set separately. Auto-start/stop is only available in Remote mode.

WARNING

This function should not be used in conjunction with remote two-wire control.

The soft starter will still accept start and stop commands from the keypad, remote inputs or serial communication network. To disable local or remote control, use Pr 3M.

If auto-start is enabled and the user is in the menu system, auto-start will become active if the menu times out (if no keypad activity is detected for five minutes).

No

2O

Function

Auto-Start Type

Range

Off, Timer, Clock

Selects whether the soft starter will auto-start after a specified delay, or at a time of day.

No

2P

Function

Auto-Start Time

Sets the time for the soft starter to auto-start, in 24 hour clock format.

Range

00:01 to 24:00 (hours:minutes)

No

2Q

Function

Auto-Stop Type

Range

Off, Timer, Clock

Selects whether the soft starter will auto-stop after a specified delay, or at a time of day.

No

2R

Function

Auto-Stop Time

Sets the time for the soft starter to auto-stop, in 24 hour clock format.

Range

00:01 to 24:00 (hours:minutes)

Default

Off

Default

00:01

Default

Off

Default

00:01

7.8.3 Group 3 - Digital Inputs

The Digistart IS has two programmable inputs, which allow remote control of the soft starter. If required, two extra inputs are available on the input/output expansion card.

No

3A

Function

Input A Function

Range

Motor Set Select, Input Trip (N/O), Input

Trip (N/C), Local/Remote Select,

Emergency Run, Emergency Stop, Jog

Forward, Jog Reverse

Default

Emergency Stop

Selects the function of Input A.

Motor Set Select

Input Trip (N/O)

Input Trip (N/C)

Local/Remote Select

Emergency Run

Emergency Stop

The Digistart IS can be configured with two separate sets of motor data.

To use the secondary motor data, Pr 3A must be set to Motor Set Select and

DI4, +24V must be closed when a start command is given. The Digistart IS checks which motor data to use at a start, and will use that motor data for the entire start/stop cycle.

Input A can be used to trip the soft starter. When Pr 3A is set to Input Trip

(N/O), a closed circuit across DI4, +24V trips the soft starter.

When Pr 3A is set to Input Trip (N/C), an open circuit across DI4, +24V trips the soft starter.

Input A can be used to select between local and remote control, instead of using the LCL/RMT button on the keypad. When the input is open, the starter is in local mode and can be controlled via the keypad. When the input is closed, the starter is in remote mode. The START and LCL/RMT buttons are disabled, and the soft starter will ignore any Local/Remote select command from the serial communications network.

To use Input A to select between local and remote control, Pr 3M must be set to LCL/RMT Anytime or LCL/RMT when Off.

In emergency run the soft starter continues to run until stopped, ignoring all trips and warnings (see Pr 15B for details).

Closing the circuit across DI4, +24V activates emergency run.

Opening the circuit ends emergency run and the Digistart IS stops the motor.

The Digistart IS can be commanded to emergency stop the motor, ignoring the soft stop mode set in Pr 2H.

When the circuit across DI4, +24V is opened, the soft starter allows the motor to coast to stop.

32

www.controltechniques.com

Digistart IS Getting Started Guide

Issue: 1

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation

Programming

Status

Menu

Quick Start

Commissioning

Diagnostics Technical

Data

Maintenance Options

Jog Forward

Jog Reverse

Activates jog operation in a forward direction (will operate only in Remote mode).

Activates jog operation in reverse direction (will operate only in Remote mode).

No

3B Input A Name

Function Range

Input Trip, Low Pressure, High Pressure,

Pump Fault, Low Level, High Level, No

Flow, Emergency Stop, Controller, PLC,

Vibration Alarm

Default

Emergency Stop

Selects a message for the keypad to display when Input A is active. This setting is only relevant if Pr 3A is set to input trip (N/O or

N/C).

No

3C Input A Trip

Function

Selects when an input trip can occur.

Always Active

Operating Only

Run Only

Range

Always Active, Operating Only, Run Only

Default

Always Active

A trip can occur at any time when the soft starter is receiving power.

A trip can occur while the soft starter is running, stopping or starting.

A trip can only occur while the soft starter is running.

No

3D

Function

Input A Initial Delay

Range

00:00 to 30:00 (minutes:seconds)

Default

00:00

Sets a delay before an input trip can occur. The initial delay is counted from the time a start signal is received. The state of the input is ignored until the initial delay has elapsed.

Default

00:00

No

3E

Function

Input A Trip Delay

Sets a delay between the input activating and the soft starter tripping.

Range

00:00 to 04:00 (minutes:seconds)

No

3F

3G

3H

3I

3J

Function

Input B Function

Input B Name

Input B Trip

Input B Initial Delay

Input B Trip Delay

See Pr 3A to 3E for details of parameter options.

Range

Motor Set Select, Input Trip (N/O), Input

Trip (N/C), Local/Remote Select,

Emergency Run, Emergency Stop, Jog

Forward, Jog Reverse

Input Trip, Low Pressure, High Pressure,

Pump Fault, Low Level, High Level, No

Flow, Emergency Stop, Controller, PLC,

Vibration Alarm

Always Active, Operating Only, Run Only

00:00 to 30:00 (minutes:seconds)

00:00 to 04:00 (minutes:seconds)

Default

Input Trip (N/O)

Input Trip

Always Active

00:00

7.8.4 Group 4 - Digital Outputs

The Digistart IS has three programmable outputs, which can be used to signal different operating conditions to associated equipment. Three additional outputs are available on the input/output expansion card.

No

4A

Function

Relay A Action

Range

Off, Main Contactor, Run, Trip, Warning,

Low Current Flag, High Current Flag, Motor

Temp Flag, Input A Trip, Input B Trip, Motor

Overload, Current Imbalance, Underpower,

Overpower, Frequency, Ground Fault,

Heatsink Overtemp, Phase Loss, Motor

Thermistor, Changeover Contactor

Default

Main Contactor

Selects the function of Relay A (normally open). Relay A is terminals COM1, RLO1.

Off

Main Contactor

Run

Trip

Warning

Low Current Flag

High Current Flag

Motor Temp Flag

Input A Trip

Input B Trip

Relay A is not used.

The relay closes when the Digistart IS receives a start command, and remains closed as long as the motor is receiving voltage.

The relay closes when the starter changes to run state.

The relay closes when the starter trips.

The relay closes when the starter issues a warning.

The relay closes when the low current flag activates (see Pr 7A

Low Current Flag).

The relay closes when the high current flag activates (see Pr 7B

High Current Flag).

The relay closes when the motor temperature flag activates (see

Pr 7C Motor Temperature Flag).

The relay closes when Input A activates to trip the soft starter.

The relay closes when Input B activates to trip the soft starter.

Digistart IS Getting Started Guide

Issue: 1 www.controltechniques.com

33

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation

Programming

Status

Menu

Quick Start

Commissioning

Diagnostics Technical

Data

Maintenance Options

Motor Overload

Current Imbalance

Underpower

Overpower

Frequency

Ground Fault

Heatsink Overtemp

Phase Loss

Motor Thermistor

Changeover Contactor

No

4B

4C

Function

Relay A On Delay

Relay A Off Delay

Sets the delay for closing or re-opening Relay A.

The relay closes when the starter trips on Motor Overload.

The relay closes when the starter trips on Current Imbalance.

The relay closes when the starter trips on Underpower.

The relay closes when the starter trips on Overpower.

The relay closes when the starter trips on Frequency.

The relay closes when the starter trips on Ground Fault.

The relay closes when the starter trips on Heatsink

Overtemperature.

The relay closes when the starter trips on Phase Loss.

The relay closes when the starter trips on Motor Thermistor.

The relay closes when the high rotor resistance current ramp has reached full voltage, allowing use with a slip-ring motor.

Range

00:00 to 05:00 (minutes:seconds)

Default

00:00

No

4D

Function

Relay B Action

4E

4F

Relay B On Delay

Relay B Off Delay

See Pr 4A to 4C for details of parameter options.

No

4G

Function

Relay C Action

Range

Off, Main Contactor, Run, Trip, Warning,

Low Current Flag, High Current Flag, Motor

Temp Flag, Input A Trip, Input B Trip,

Motor Overload, Current Imbalance,

Underpower, Overpower, Frequency,

Ground Fault, Heatsink Overtemp, Phase

Loss, Motor Thermistor, Changeover

Contactor

00:00 to 05:00 (minutes:seconds)

Default

Run

00:00

Default

Trip

4H

4I

Relay C On Delay

Relay C Off Delay

See Pr 4A to 4C for details of parameter options.

Range

Off, Main Contactor, Run, Trip, Warning,

Low Current Flag, High Current Flag, Motor

Temp Flag, Input A Trip, Input B Trip,

Motor Overload, Current Imbalance,

Underpower, Overpower, Frequency,

Ground Fault, Heatsink Overtemp, Phase

Loss, Motor Thermistor, Changeover

Contactor

00:00 to 05:00 (minutes:seconds) 00:00

7.8.5 Group 5 - Protection Settings

These parameters determine when the soft starter's protection mechanisms will activate. The activation point for each protection mechanism can be set to suit the installation.

The soft starter responds to protection events by tripping, warning, or writing the event to the event log. The response is determined by the Protection Action settings (parameter group 16). The default response is a trip.

The protection settings are vital for safe operation of the soft starter and motor. Defeating the protection may compromise the installation and should only be done in the case of emergency.

CAUTION

No

5A

Function

Excess Start Time

Range

00:00 to 04:00 (minutes:seconds) 00:20

Default

Excess start time is the maximum time the Digistart IS will attempt to start the motor. If the motor does not transition to Run mode within the programmed limit, the starter will trip. Set for a period slightly longer than required for a normal healthy start. A setting of 0 disables excess start time protection.

No

5D

Function

Phase Sequence

Range

Any Sequence, Positive Only, Negative

Only

Default

Any Sequence

Selects which phase sequences the soft starter will allow at a start. During its pre-start checks, the starter examines the sequence of the phases at its input terminals and trips if the actual sequence does not match the selected option.

34

www.controltechniques.com

Digistart IS Getting Started Guide

Issue: 1

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation

Programming

Status

Menu

Quick Start

Commissioning

Diagnostics Technical

Data

Maintenance Options

No

5E Underpower

Function

Sets the trip point for underpower protection. Set as required.

Range

0 to 100%

Default

20%

No

5F Overpower

Function

Sets the trip point for overpower protection. Set as required.

Range

80 to 600%

Default

400%

7.8.6 Group 6 - Protection Delays

Protection delays slows the Digistart IS's response to the trip condition, avoiding trips due to momentary fluctuations.

No

6B

6C

Function

Underpower Delay

Overpower Delay

Range

00:00 to 04:00 (minutes:seconds)

00:00 to 01:00 (minutes:seconds)

Default

00:05

00:00

7.8.7 Group 7 - Set Points

The Digistart IS has low and high current flags to give early warning of abnormal operation. The current flags can be configured to indicate an abnormal current level during operation, outside the normal operating level. The flags can signal the situation to external equipment via one of the programmable outputs. The flags clear when the current returns within the normal operating range by 10% of the programmed motor full load current.

No

7A

7B

7C

Function

Low Current Flag

High Current Flag

Motor Temperature Flag

Range

1% to 100% FLC

50% to 600% FLC

0% to 160%

Default

50%

100%

80%

Sets the level at which the motor temperature flag operates, as a percentage of the motor's thermal capacity.

7.8.8 Group 9 - Display

No

9A Languages

Function Range

English, Français, Italiano, Deutsch,

Español, Chinese

Selects which language the keypad will use to display messages and feedback.

Default

No

9B

Function

User Screen - Top Left

Range

Blank, Starter State, Motor Current, Motor pf, Mains Frequency, Motor kW, Motor HP,

Motor Temp, kWh, Hours Run, Analog

Input, Mains Voltage, Motor kVA, % Rated kW, Motor Parameter Set

Default

Motor Current

Selects which information will be displayed on the programmable monitoring screen.

Blank

Starter State

Motor Current

Motor pf

Mains Frequency

Motor kW

Motor HP

Motor Temp

kWh

Hours Run

Analog Input

Mains Voltage

Motor kVA

% Rated kW

Motor Parameter Set

Displays no data in the selected area, allowing long messages to be shown without overlapping.

The starter's operating state (starting, running, stopping or tripped). Only available for top left and bottom left positions on the screen.

The average current measured on three phases.

The motor's power factor, measured by the soft starter.

The average frequency measured on three phases.

The motor's running power in kilowatts.

The motor's running power in horsepower.

The motor's temperature, calculated by the thermal model.

The number of kilowatt hours the motor has run via the soft starter.

The number of hours the motor has run via the soft starter.

The level of analog input A (see Pr 8A to 8C). This setting is only available if the input/output expansion option is installed.

The average voltage measured on three phases (this setting is only available if the voltage measurement option is installed).

The motor's apparent running power in kVA.

The motor's running power as a percentage of rated kW. Power factor is assumed to be 1.0 at 100% kW.

Whether the starter is controlling the motor using the primary motor set (M1) or the secondary motor set (M2).

Digistart IS Getting Started Guide

Issue: 1 www.controltechniques.com

35

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation

Programming

Status

Menu

Quick Start

Commissioning

Diagnostics Technical

Data

Maintenance Options

No

9C

9D

9E

Function

User Screen - Top Right

User Screen - Bottom Left

User Screen - Bottom Right

Range

Blank, Motor Current, Motor pf, Mains

Frequency, Motor kW, Motor HP, Motor

Temp, kWh, Hours Run, Analog Input,

Mains Voltage, Motor kVA, % Rated kW

Blank, Starter State, Motor Current, Motor pf, Mains Frequency, Motor kW, Motor HP,

Motor Temp, kWh, Hours Run, Analog

Input, Mains Voltage, Motor kVA, % Rated kW, Motor Parameter Set

Blank, Motor Current, Motor pf, Mains

Frequency, Motor kW, Motor HP, Motor

Temp, kWh, Hours Run, Analog Input,

Mains Voltage, Motor kVA, % Rated kW

Default

Motor pf

Hours Run kWh

No

9J

9K

Function

F1 Button Action

F2 Button Action

Selects the function of the shortcut buttons on the keypad.

Range

None, Setup Auto-Start/Stop

Jog Forward, Jog Reverse

Default

Setup Auto-Start/Stop

None

NOTE

If the adjustment lock is on (Pr 15C Adjustment Lock is set to Read Only), users will not be able to change the auto-start/stop settings.

No

9M

Function

Display A or kW

Range

Current, Motor kW

Selects whether the Digistart IS will display current (amperes) or motor kilowatts on the main monitoring screen.

Default

Current

36

www.controltechniques.com

Digistart IS Getting Started Guide

Issue: 1

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation Programming

Status

Menu

Quick Start

Commissioning

Diagnostics Technical

Data

Maintenance Options

8. Quick Start Commissioning

This procedure is written from default parameter settings as the starter would be delivered from the factory.

Always apply control voltage before (or with) mains voltage.

WARNING

8.1 Control wiring

Figure 8-1 Control terminals for basic connection

F1

CSH

220-440 VAC +10%

-15%

110-210 VAC

+10%

-15%

CSL

CSR

DI1

+24V

DI2

+24V

DI3

+24V

CSH-CSR or CSL-CSR

DI1, +24V

DI2, +24V

DI3, +24V

F1

Control supply

Start

Stop

Reset

Fuse (optional)

DI4

+24V

E

Power up the starter

Program parameters

For keypad control, the soft starter requires:

• control supply connections (terminals CSH, CSL, CSR depending on the control voltage) programmable input A (DI4, +24V) must be closed or Pr 3A Input A Function must be changed from Emergency Stop

8.2 Setup procedure

Table 8-1 Basic setup procedure

Action

Before power-up

Detail

Ensure:

The starter is not receiving a start signal

The motor is connected to the starter

The motor connection is correct

The correct supply voltage is available

Ensure:

The Ready LED activates

The Quick Setup Menu makes it easy to configure the Digistart IS for common applications. The

Digistart IS selects the parameters relevant to the application and suggests a typical setting, and you can adjust each parameter to suit your exact requirements.

The following applications are available through the Quick Setup Menu:

Pump (centrifugal, submersible)

Fan (damped, undamped)

Compressor (screw, reciprocating)

Conveyor

Crusher (rotary, jaw)

For more information on the Quick Setup Menu, see Quick setup details on page 29.

For applications not covered by the Quick Setup Menu, the following parameters should be set to suit the requirements of the application:

1A Motor Full Load Current

2A Start Mode

2B Current Limit

2D Start Ramp Time

2I Stop Time

2H Stop Mode (if required)

For parameter details, see Parameter descriptions on page 31.

Digistart IS Getting Started Guide

Issue: 1 www.controltechniques.com

37

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation Programming

Status

Menu

Quick Start

Commissioning

Diagnostics

Technical

Data

Maintenance Options

9. Diagnostics

NOTE

The Digistart IS soft starter is not user serviceable. The unit should only be serviced by authorised service personnel.

Unauthorised tampering with the unit will void the product warranty.

9.1 Protection responses

When a protection condition is detected, the Digistart IS will write this to the event log and may also trip or issue a warning. The soft starter's response to some protections may depend on the Protection Action settings (parameter group 16).

If the Digistart IS trips you will need to reset the soft starter before restarting. If the Digistart IS has issued a warning, the soft starter will reset itself once the cause of the warning has been resolved.

Some protections cause a fatal trip. This response is pre-defined and cannot be overridden. These protection mechanisms are designed to protect the soft starter, or can be caused by a fault within the soft starter.

9.2 Trip messages

This table lists soft starter's protection mechanisms and the probable cause of the trip. Some of these can be adjusted using parameter group 4 Protection Settings and parameter group 16 Protection Action, other settings are built-in system protections and cannot be set or adjusted.

Table 9-1 Trip messages

Display

Analog Input Trip

Battery/Clock

Current Imbalance

Excess Start Time

FLC Too High

Frequency

Ground Fault

Possible cause/Suggested solution

This fault only occurs if the Input/Output expansion card is fitted. Identify and resolve the condition which caused Analog Input A to activate.

Related Pr: 8A, 8B, 8C

A verification error has occurred on the real time clock, or the backup battery voltage is low. If the battery is low and the power is off, date/time settings will be lost. Reprogram the date and time.

Related Pr: 16O

Current imbalance can be caused by problems with the motor, the environment or the installation, such as:

An imbalance in the incoming mains voltage

A problem with the motor windings

A light load on the motor

Current imbalance can also be caused by incorrect cabling between the external bypass contactor and the soft starter or an internal problem with the soft starter, particularly an SCR that has failed open circuit.

A failed SCR can only be definitely diagnosed by replacing the SCR and checking the starter's performance.

Related Pr: 5C, 6A, 16C

Please contact Control Techniques or your local distributor.

Excess start time trip can occur in the following conditions:

Pr 1A Motor Full Load Current is not appropriate for the motor

Pr 2B Current Limit has been set too low

Pr 2D Start Ramp Time has been set greater than the setting for 5A Excess Start Time setting

Pr 2D Start Ramp Time is set too short for a high inertia load when using Adaptive Acceleration

Control

Related Pr: 1A, 2B, 2D, 5A, 5B, 11A, 12B, 12D, 16B

The Digistart IS can support higher motor full load current values when connected to the motor using inside delta configuration rather than in-line connection. If the soft starter is connected in-line but the programmed setting for Pr 1A Motor Full Load Current is above the in-line maximum, the soft starter will trip at start.

Related Pr: 1A, 11A

The mains frequency has gone beyond the specified range.

Check for other equipment in the area that could be affecting the mains supply (particularly variable speed drives).

If the Digistart IS is connected to a generator set supply, the generator may be too small or could have a speed regulation problem.

Related Pr: 5I, 5J, 6F, 16H

This fault only occurs if the RTD/PT100 and Ground Fault card is fitted. Test the insulation of the output cables and the motor. Identify and resolve the cause of any ground fault.

Related Pr: 5K, 6H, 16P

38

www.controltechniques.com

Digistart IS Getting Started Guide

Issue: 1

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation Programming

Status

Menu

Quick Start

Commissioning

Diagnostics

Technical

Data

Maintenance Options

Display

Heatsink Overtemp

Input A Trip

Input B Trip

Internal Fault X

L1 Phase Loss

L2 Phase Loss

L3 Phase Loss

L1-T1 Shorted

L2-T2 Shorted

L3-T3 Shorted

Motor Overload

Motor 2 Overload

Motor Connection

Motor Thermistor

Network Comms

Overpower

Overvoltage

Possible cause/Suggested solution

Check if cooling fans are operating. If mounted in an enclosure check if ventilation is adequate.

On models with internal bypass, the cooling fans will operate:

During the Start sequence and for 10 minutes after transition to Run.

For 10 minutes after Stop.

Models without internal bypass will operate the cooling fans from a Start until 10 minutes after a Stop.

Related Pr: 16N

Identify and resolve the condition which caused Input A to activate.

Related Pr: 3A, 3B, 3C, 3D, 3E, 16I

Identify and resolve the condition which caused Input B to activate.

Related Pr: 3F, 3G, 3H, 3I, 3J, 16J

The Digistart IS has tripped on an internal fault. Contact your local supplier with the fault code (X).

Related Pr: None

During pre-start checks the starter has detected a phase loss as indicated.

In run state, the starter has detected that the current on the affected phase has dropped below 3.3% of the programmed motor FLC for more than 1 second, indicating that either the incoming phase or connection to the motor has been lost.

Check the supply and the input and output connections at the starter and at the motor end.

Phase loss can also be caused by a failed SCR, particularly an SCR that has failed open circuit. A failed

SCR can only be definitely diagnosed by replacing the SCR and checking the starter's performance.

Related Pr: None

Please contact Control Techniques or your local distributor.

During pre-start checks the starter has detected a shorted SCR or a short within the bypass contactor as indicated. If the starter is connected in-line with the motor, consider using PowerThrough to allow operation until the starter can be repaired.

Related Pr: 15D

The motor has reached its maximum thermal capacity. Overload can be caused by:

The soft starter protection settings not matching the motor thermal capacity

Excessive starts per hour

Excessive throughput

Damage to the motor windings

Resolve the cause of the overload and allow the motor to cool.

Related Pr: 1A, 1B, 1C, 1D, 16A

See 'Motor Overload' above

Note: Applicable only if the second motor set has been programmed.

Related Pr: 11A, 11B, 11C, 11D, 11E, 16A

The motor is not connected correctly to the soft starter for in-line or inside delta use.

Check individual motor connections to the soft starter for power circuit continuity.

Check connections at the motor terminal box.

The motor thermistor input has been enabled and:

The resistance at the thermistor input has exceeded 3.6 k

Ω

for more than one second.

The motor winding has overheated. Identify the cause of the overheating and allow the motor to cool before restarting.

The motor thermistor input has been opened.

Note: If a valid motor thermistor is no longer used, a 1.2 k

Ω

resistor must be fitted across terminals TH1,

TH2.

Related Pr: 16K

The network master has sent a trip command to the starter, or there may be a network communication problem.

Check the network for causes of communication inactivity.

Related Pr: 16M

The motor has experienced a sharp rise in power, probably caused by a locked rotor condition while running. This may indicate a jammed load.

Related Pr: 5F, 6C, 16E

There has been a voltage surge on the mains. Causes can include problems with a transformer tap regulator or off-loading of a large transformer load.

Check that the starter is configured appropriately for local conditions.

Monitor the mains voltage to determine the cause of the voltage fluctuation, and resolve the cause.

Related Pr: 5H, 6E, 16P

Voltage data is only available from the Digistart IS if the voltage measuring card is installed.

Digistart IS Getting Started Guide

Issue: 1 www.controltechniques.com

39

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation Programming

Status

Menu

Quick Start

Commissioning

Diagnostics

Technical

Data

Maintenance Options

Display

Par xx Out of Range

Phase Sequence

Power Loss

RTD/PT100 A

RTD/PT100 B to G

RTD/PT100 X Circuit

Starter/Comms

Thermistor Cct

Time - Overcurrent

Underpower

Undervoltage

Unsupported Option

Possible cause/Suggested solution

A parameter value is outside the valid range.

The keypad will indicate the first invalid parameter. This can occur if:

An error occurred loading data from the EEPROM to RAM when the keypad powered up.

The parameter set or values in the keypad do not match the parameters in the starter.

"Load User Set" has been selected but no saved file is available.

Reset the fault then reload the default settings. If the problem persists, contact your local distributor.

Related Pr: None

The phase sequence on the soft starter's input terminals (L1, L2, L3) is not valid.

Check the phase sequence on L1, L2, L3 and ensure the setting in Pr 5D is suitable for the installation.

Related Pr: 5D

The starter is not receiving mains supply on one or more phases when a Start Command is given.

Check that the main contactor closes when a start command is given, and remains closed until the end of a soft stop.

Related Pr: None

The RTD/PT100 set temperature has been exceeded and tripped the soft starter. Identify and resolve the condition which caused the appropriate input to activate.

: PT100 B to PT100 G are applicable only if a RTD/PT100 and Ground Fault card is fitted.

Related Pr: 14A, 14B, 14C, 14D, 14E, 14F, 14G, 16Q to 16W

Indicates that the indicated RTD/PT100 has short circuited. Check and resolve this condition.

Related Pr: None.

There is a problem with the connection between the soft starter and the optional communications module. Remove and reinstall the module. If the problem persists, contact your local distributor.

There is an internal communications error within the soft starter. Contact your local distributor.

Related Pr: 16L

The thermistor input has been enabled and:

The resistance at the input has fallen below 20

Ω

(the cold resistance of most thermistors will be over this value) or

A short circuit has occurred. Check and resolve this condition.

Related Pr: None

The Digistart IS is internally bypassed and has drawn high current during running. (The 10A protection curve trip has been reached or the motor current has risen to 600% of the motor FLC setting.)

Related Pr: None

The motor has experienced a sharp drop in power, caused by loss of load. Causes can include broken components (shafts, belts or couplings), or a pump running dry.

Related Pr: 5E, 6B, 16D

Mains voltage has fallen below the level selected in Pr 5G. Causes can include an undersized supply or adding a large non-linear load to the system.

Check that the starter is configured appropriately for local conditions.

Monitor the mains voltage to determine the cause of voltage fluctuation.

Related Pr: 5G, 6D, 16H

Voltage data is only available from the Digistart IS if the voltage measuring card is installed.

The selected function is not available (e.g. jog is not supported in inside delta configuration).

Related Pr: None

40

www.controltechniques.com

Digistart IS Getting Started Guide

Issue: 1

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation Programming

Status

Menu

Quick Start

Commissioning

Diagnostics

Technical

Data

Maintenance Options

9.3 General faults

This table describes situations where the soft starter does not operate as expected but does not trip or give a warning.

Table 9-2 General faults

Symptom

Soft starter does not respond to commands.

The soft starter does not control the motor correctly during starting.

Motor does not reach full speed.

Erratic motor operation.

Soft stop ends too quickly.

Corrupted text shown on keypad display.

Adaptive Control, brake, jog and

PowerThrough functions not working

A reset does not occur after an

Auto-Reset, when using a remote two-wire control.

Remote start/stop command is overriding Auto Start/Stop settings when using remote two-wire control.

Probable Cause

If the soft starter does not respond to the START or RESET button on the keypad:

- The soft starter may be in Remote control mode. When the soft starter is in

Remote control mode, the Remote LED on the keypad is active. Press the

LCL/RMT button once to change to Local control (see Pr 3M Local/Remote for details).

If the soft starter does not respond to commands from the control inputs:

- The soft starter may be in Local control mode. When the soft starter is in Local control mode, the Remote LED on the keypad is not active. Press the LCL/RMT button once to change to Remote control (see Pr 3M Local/Remote for details).

- The control wiring may be incorrect. Check that the remote start, stop and reset

inputs are configured correctly (see Control Wiring on page 14 for details).

- The signals to the remote inputs may be incorrect. Test the signalling by activating each input signal in turn. The appropriate remote control input LED should activate on the keypad.

- The soft starter will only execute a start command from the remote inputs if the remote reset input is activated. Check that the remote reset input is also active (the

Reset LED on the starter will be on).

If the soft starter does not respond to a start command from either the local or remote controls:

- The soft starter may be waiting for the restart delay to elapse. The length of the restart delay is controlled by Pr 6G Restart Delay.

- The motor may be too hot to permit a start. If Pr 5L Motor Temperature Check is set to Check, the soft starter will only permit a start when it calculates that the motor has sufficient thermal capacity to complete the start successfully. Wait for the motor to cool before attempting another start.

- The emergency stop function may be active. If Pr 3A or 3F is set to Emergency

Stop and there is an open circuit on the corresponding input, the Digistart IS will not start. If the emergency stop situation has been resolved, close the circuit on the input.

Start performance may be unstable when using a low Motor Full Load Current setting (Pr 1A). This can affect use on a small test motor with full load current between 5 A and 50 A.

Power factor correction (PFC) capacitors must be installed on the supply side of the soft starter. To control a dedicated PFC capacitor contactor, connect the contactor to run relay terminals.

If the start current is too low, the motor will not produce enough torque to accelerate to full speed. The soft starter may trip on excess start time.

NOTE

Make sure the motor starting parameters are appropriate for the application and that you are using the intended motor starting profile. If

Pr 3A or 3F is set to Motor Set Select, check that the corresponding input is in the expected state.

The load may be jammed. Check the load for severe overloading or a locked rotor situation.

The SCRs in the Digistart IS require at least 5 A of current to latch. If you are testing the soft starter on a motor with full load current less than 5 A, the SCRs may not latch correctly.

The soft stop settings may not be appropriate for the motor and load. Review the settings of Pr 2H, 2I, 12H and 12I.

If the motor is very lightly loaded, soft stop will have limited effect.

The keypad may not be screwed down, resulting in an intermittent connection.

Screw down the keypad or hold squarely in place.

These features are only available with in-line installation. If the Digistart IS is installed inside delta, these features will not operate.

The remote 2-wire start signal must be removed and reapplied for a re-start.

Auto Start/Stop function should only be used in Remote mode, 3 and 4-wire control.

Digistart IS Getting Started Guide

Issue: 1 www.controltechniques.com

41

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation Programming

Status

Menu

Quick Start

Commissioning

Diagnostics

Technical

Data

Maintenance Options

Symptom

After selecting Adaptive Control the motor used an ordinary start and/or the second start was different to the first.

Non-resettable THERMISTOR FAIL trip, when there is a link between the thermistor input TH1, TH2 or when the motor thermistor connected between

TH1, TH2 is permanently removed.

Display is distorted

Parameter settings cannot be stored.

Probable Cause

The first Adaptive Acceleration Control start is current limit so that the starter can learn from the motor characteristics. Subsequent starts use Adaptive Acceleration

Control.

The thermistor input is enabled once a link is fitted and short circuit protection has activated.

- Remove the link then load the default parameter set. This will disable the thermistor input and clear the trip.

- Place a 1k2

Ω resistor across the thermistor input.

- Turn thermistor protection to 'Log only' (Pr 16K).

Check that the keypad has not been screwed down too tightly. Loosen screws slightly.

Make sure you are saving the new value by pressing the M button after adjusting a parameter setting. If you press , the change will not be saved.

Check that the adjustment lock (Pr 15C) is turned off. If the adjustment lock is on, settings can be viewed but not changed. You need to know the security access code to change the adjustment lock setting.

The EEPROM may be faulty on the keypad. A faulty EEPROM will also trip the soft starter, and the keypad will display the message Parameter Out Of Range.

Contact your local supplier for advice.

42

www.controltechniques.com

Digistart IS Getting Started Guide

Issue: 1

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation Programming

Status

Menu

Quick Start

Commissioning

Diagnostics

Technical

Maintenance Options

Data

10. Technical Data

Supply

Mains voltage (L1, L2, L3)

IS4xxxx ......................................................................................................................................... 200 Vac to 440 Vac (± 10%)

IS6xxxx .................................................................................... 380 Vac to 600 Vac (± 10%) (in-line or inside delta connection)

IS6xxxx .................................................................................. 380 Vac to 690 Vac (± 10%) (grounded star supply system only)

Control voltage (CSH, CSL, CSR) .................................................................. 110 to 210 Vac or 220 to 440 Vac (+ 10% / -15%), 1 A

Recommended fuse .......................................................................... 1 A continuous (30 A max, 10 A typical half cycle inrush)

Mains frequency ........................................................................................................................................................ 45 Hz to 66 Hz

Rated insulation voltage to ground ....................................................................................................................................... 600 Vac

Rated impulse withstand voltage ................................................................................................................................................ 4 kV

Form designation ................................................................................ Bypassed or continuous, semiconductor motor starter form 1

Short circuit capability

Coordination with semiconductor fuses ................................................................................................................................... Type 2

Coordination with HRC fuses ................................................................................................................................................... Type 1

IS1x0023B to IS1x0105B .................................................................................................................. prospective current 10 kA

IS2x0145B to IS2x0220B .................................................................................................................. prospective current 18 kA

IS3x0255N to IS4x0930N .................................................................................................................. prospective current 85 kA

IS561200N to IS561600N ............................................................................................................... prospective current 100 kA

Electromagnetic capability (compliant with EU Directive 89/336/EEC)

EMC Emissions .............................................................................................................................................. IEC 60947-4-2 Class B

EMC Immunity ............................................................................................................................................................. IEC 60947-4-2

Inputs

Input rating ............................................................................................................................................. Active 24 Vdc, 8 mA approx

Start (DI1, +24V) ........................................................................................................................................................ Normally open

Stop (DI2, +24V) ...................................................................................................................................................... Normally closed

Reset (DI3, +24V) .................................................................................................................................................... Normally closed

Programmable inputs

Input A (DI4, +24V) ............................................................................................................................................ Normally open

Input B (DI5, +24V) ............................................................................................................................................ Normally open

Motor thermistor (TH1, TH2) .................................................................................................................... Trip >3.6 k

Ω, reset <1.6kΩ

PT100 RTD (PT3, PT4, PT5) ........................................ Accuracy 0 to 100 °C

± 0.5 °C, 100 °C to 150 °C ± 2 °C, -20 to 0 °C ± 2°C

Outputs

Relay outputs ................................................................................................. 10A @ 250 Vac resistive, 5A @ 250 Vac AC15 pf 0.3

Run relay (COM2, RLO2) ........................................................................................................................................... Normally open

Programmable outputs

Relay A (COM1, RLO1) ..................................................................................................................................... Normally open

Relay B (COM3, RLC3, RLO3) ............................................................................................................................... Changeover

Relay C (COM4, RLC4, RLO4) .............................................................................................................................. Changeover

Analog output (AO1, 0V) ................................................................................................................ 0-20 mA or 4-20 mA (selectable)

Maximum load ................................................................................................................................... 600

Ω (12 Vdc @ 20 mA)

Accuracy ........................................................................................................................................................................... ± 5%

24 Vdc output (+24V, 0V) Maximum load ............................................................................................................................... 200 mA

Accuracy ......................................................................................................................................................................... ± 10%

Environmental

Protection

IS1x0023B to IS1x0105B ................................................................................................................................................... IP20

IS2x0145B to IS561600N ................................................................................................................................................... IP00

Keypad (when installed with remote mounting kit) ........................................................................................... IP65 & NEMA12

Operating temperature ..................................................................................................... -10

˚C to 60 ˚C, above 40 ˚C with derating

Storage temperature .............................................................................................................................................. - 25

˚C to + 60 ˚C

Operating altitude ................................................................................................................. 0 - 1000 m, above 1000 m with derating

Humidity .............................................................................................................................................. 5% to 95% Relative Humidity

Pollution degree ................................................................................................................................................... Pollution Degree 3

Vibration .................................................................................................................................................................... IEC 60068-2-6

Digistart IS Getting Started Guide

Issue: 1 www.controltechniques.com

43

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation Programming

Status

Menu

Quick Start

Commissioning

Diagnostics

Technical

Maintenance Options

Data

Heat dissipation

During start ...................................................................................................................................................... 4.5 watts per ampere

During run

IS1x0023B to IS1x0053B ..............................................................................................................................

≤ 39 watts approx

IS1x0076B to IS1x0105B ..............................................................................................................................

≤ 51 watts approx

IS2x0145B to IS2x0220B ............................................................................................................................

≤ 120 watts approx

During run

IS3x0255N to IS4x0930N ............................................................................................................. 4.5 watts per ampere approx

IS561200N to IS561600N ............................................................................................................ 4.5 watts per ampere approx

Certification

UL/ C-UL ................................................................................................................................................................................ UL 508

IS1x0023B to IS1x0105B ....................................................................................................... IP20 & NEMA1, UL Indoor Type 1

IS2x0145B to IS561600N ................................................................................................................. IP00, UL Indoor Open Type

CE .......................................................................................................................................................................... IEC 60947-4-2

RoHS ................................................................................................................................. Compliant with EU Directive 2002/95/EC

44

www.controltechniques.com

Digistart IS Getting Started Guide

Issue: 1

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and

Operation Programming

Status

Menu

Quick Start

Commissioning

Diagnostics Technical

Maintenance

Options

Data

11. Maintenance

NOTE

The Digistart IS soft starter is not user serviceable. The unit should only be serviced by authorised service personnel.

Unauthorised tampering with the unit will void the product warranty.

Before carrying out any work, disconnect and lock the starter's power supply and wait 2 minutes to ensure that the capacitors have discharged.

When the starter trips, fatal residual voltages may remain at the output terminals and in the starter.

During maintenance operations performed with the starter switched on, the operator must stand on an insulated surface which is not connected to ground.

During work on a motor or its power supply cables, ensure that the power supply of the corresponding starter is disconnected and locked.

Protective covers must remain in place during tests.

There are very few maintenance and repair operations for the user to perform on Digistart IS soft starters. Regular servicing operations and simple methods for checking that the starter is operating correctly are described below.

11.1 Care

Printed circuits and internal components do not normally require any maintenance. Contact your local distributor or the nearest approved repair company in the event of a problem,

Do not dismantle the printed circuits while the starter is still under warranty. Unauthorised tampering with the unit will void the product warranty.

CAUTION

Do not touch the integrated circuits or the microprocessor either with your fingers or with materials which are charged or live.

Ground yourself, as well as the workbench or the soldering iron, while performing any work on the circuits.

From time to time, check that the power circuits are correctly tightened.

11.2 Measuring the motor current

The current drawn by the motor and the starter input current can be measured approximately using a conventional moving coil ammeter.

11.3 Measuring the input and output power

The starter input and output power can be measured using an electrodynamic instrument.

11.4 Exchanging products

Products must be returned in their original packaging or, if this is not possible, in similar packaging, to prevent their being damaged. Otherwise, replacement under warranty could be refused.

CAUTION

Digistart IS Getting Started Guide

Issue: 1 www.controltechniques.com

45

Safety

Information

Rating

Data

Mechanical

Installation

Electrical

Installation

Keypad and Operation Programming

Status Menu

Quick Start

Commissioning

Diagnostics Technical

Data

Maintenance

Options

12. Options

Table 12-1 Digistart IS options

Option name

Digistart - DeviceNet

Interface

Digistart - Modbus

Interface

Digistart - Profibus

Interface

Function

Fieldbus communications modules

Picture

DSSoft

DSSoft can be used with Control Techniques soft starters to provide the following functionality for networks of up to 99 soft starters:

Operational control (Start, Stop, Reset, Quick Stop)

Starter status monitoring (Ready, Starting, Running,

Stopping, Tripped)

Performance monitoring (motor current, motor temperature)

To use DSSoft with the Digistart IS, the soft starter must be fitted with a Modbus Module.

Digistart IS - Finger Guard Finger guards may be specified for personnel safety and can be used on Digistart IS soft starter models 0145B to 0220B. Finger guards fit over the soft starter terminals to prevent accidental contact with live terminals. Finger guards provide IP20 protection.

Digistart IS - I/O

Expansion

Digistart IS - RTD/PT100 and Ground Fault Card

The input/output expansion card provides the following additional inputs and outputs:

2 x inputs

3 x output relays

1 x analog input

1 x analog output

The RTD/PT100 and ground fault protection card provides the following additional inputs:

6 x PT100 RTD inputs

1 x ground fault input

To use ground fault protection a 1000:1, 5 VA current transformer is also required.

Digistart IS - Volt Measure

Card

Digistart IS - Keypad

Mounting Kit

The voltage measurement card provides additional functionality for voltage monitoring and protection.

Allows remote mounting of the keypad up to 3 m away from the soft starter.

Packing list: 1 x cable, 1 x gasket, 4 x screw M3, 4 x flat washer

M3, 4 x spring washer M3, 4 x nut M3, 2 x jack screw, 1 x instructions.

46

www.controltechniques.com

Digistart IS Getting Started Guide

Issue: 1

Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project