CSXi (user manual)

USER MANUAL

1.1 Caution Statements

Caution Statements cannot cover every potential cause of equipment damage but can highlight common causes of damage. It is the installer's responsibility to read and understand all instructions in this manual prior to installing, operating or maintaining the soft starter, to follow good electrical practice including applying appropriate personal protective equipment and to seek advice before operating this equipment in a manner other than as described in this manual.

 Isolate the soft starter completely from the power supply before attempting any work on the starter or motor.

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

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

 Do not apply incorrect voltages to the control input terminals.

 Do not connect power factor correction capacitors to the output of CSXi soft starters. If static power factor correction is employed, it must be connected to the supply side of the soft starter.

The examples and diagrams in this manual are included solely for illustrative purposes. The information contained in this manual is subject to change at any time and without prior notice. In no event will responsibility or liability be accepted for direct, indirect or consequential damages resulting from the use or application of this equipment.

WARNING - ELECTRICAL SHOCK HAZARD

CSX i soft starters contain dangerous voltages when connected to mains voltage. Only a competent electrician should carry out the electrical installation. Improper installation of the motor or the soft starter may cause equipment failure, serious injury or death. Follow this manual and local electrical safety codes.

GROUNDING AND BRANCH CIRCUIT PROTECTION

It is the responsibility of the user or person installing the soft starter to provide proper grounding and branch circuit protection according to local electrical safety codes.

SHORT CIRCUIT

CSX i soft starters are not short circuit proof. After severe overload or short circuit, the operation of the soft starter should be fully tested.

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© 2007-2008 AuCom Electronics Ltd. All Rights Reserved.

710-02408-00G CSXi

MECHANICAL INSTALLATION

Section 2 Mechanical Installation

2.1 Dimensions and Weights

Model

CSXi-007

CSXi-015

CSXi-018

CSXi-022

CSXi-030

CSXi-037

CSXi-045

CSXi-055

CSXi-075

CSXi-090

CSXi-110

A B C D E F G H Weight mm

(inch) mm

(inch) mm

(inch) mm

(inch) mm

(inch) mm

(inch) mm

(inch) mm

(inch) kg (lb)

98 82 203 188 165 55 90.5 23 2.4

(3.9) (3.2) (8.0) (7.4) (6.5) (2.2) (3.6) (0.9) (5.3)

145 124 215 196 193 - 110.5 37 4.3

(5.7) (4.9) (8.5) (7.7) (7.6) (4.4) (1.5) (9.5)

202 160 240 204 214 - 114.5 51 6.8

(8.05) (6.3) (9.5) (8.0) (8.4) (4.5) (2.0) (15.0)

2.2 Physical Installation

Page 2

CSXi-007 ~ CSXi-055: Allow 100 mm (3.9 inches) between soft starters.

CSX075 ~ CSXi-110: Allow 200 mm (7.9 inches) between soft starters.

CSXi-007 ~ CSXi-055: Allow 50 mm (2.0 inches) between the soft starter and solid surfaces.

CSXi-075 ~ CSXi-110: Allow 200 mm (7.9 inches) between the soft starter and solid surfaces.

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

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

CSXi 710-02408-00G

Section 3 Electrical Installation

ELECTRICAL INSTALLATION

3.1 Power Terminations

007 ~ 030

L1/1, L2/3, L3/5,T1/2, T2/4, T3/6 mm 2 (A WG)

037 ~ 055 075 ~ 1 10

A1, A2, A3, 01, 02, B4,

B5, 13, 14, 23, 24 mm

2

(AWG)

007 ~ 1 10

10 - 35

(8 - 2)

10 - 35

(8 - 2)

Torx (T20)

3 Nm

2.2 f t-lb

7 mm

3 Nm

2.2 f t-lb

14

(0.55) mm (inch)

25 - 50

(4 - 1/0)

25 - 50

(4 - 1/0)

Torx (T20)

4 Nm

2.9 f t-lb

7 mm

4 Nm

2.9 f t-lb

14

(0.55) mm (inch)

N.A.

N.A.

N.A.

N.A.

11

(0.43)

26

(1.02)

Ø 8.5

(0.33)

0.14 - 1.5

(26 - 16)

0.14 - 1.5

(26 - 16) mm (inch)

N.A.

3.5 mm

0.5 Nm max

4.4 in-lb max

6

(0.24) mm (inch)

3.2 Control Voltages

CSX i soft starters can be supplied in either of two control voltage configurations:

CSXi-xxx-xx-C1 .... 110-240 VAC (+ 10% / - 15%) or 380-440 VAC (+ 10% / - 15%)

CSXi-xxx-xx-C2 .... 24 VAC/VDC (± 20%)

WARNING

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

CAUTION

With 24 VAC/VDC use contacts rated for low voltage and low current (gold flash or similar).

3.3 Control Circuits

Two-wire Three-wire

Start/stop. To reset a trip, close then open 02.

Start.

Stop. To reset a trip, close then open 02.

710-02408-00G CSXi

ELECTRICAL INSTALLATION

Motor Thermistor

Motor thermistors can be connected directly to the CSX i terminals B4, B5. If motor thermistors are not used, there must be a link between B4, B5 (the CSX i is supplied with a link fitted).

B4 B4 B4

B5 B5 B5

WARNING

Isolate the soft starter completely from the power supply before attempting any work on the starter or motor. Control terminals may be at phase voltage potential.

3.4 Outputs

Main Contactor Output

The Main Contactor output (terminals 13, 14) closes as soon as the soft starter receives a start command and remains closed while the soft starter is controlling the motor (until the motor starts a coast to stop, or until the end of a soft stop). The Main Contactor output will also open if the soft starter trips.

The Main Contactor output can be used to directly control a main contactor coil.

Programmable Output

The programmable output relay (terminals 23, 24) can be used to signal either trip or run status. This relay is normally open.

Trip:

The relay closes when the CSX i trips. The relay can be used to operate the shunt-trip mechanism of an upstream circuit breaker (in order to isolate the motor branch circuit), or to signal the trip to an automation system or externally. The relay will open when the trip is reset.

Run:

The relay operates when the soft start is complete, the bypass relays are closed and full voltage is being applied tot he motor. The relay can be used to operate a contactor for power factor correction capacitors, or to signal soft starter run status to an automation system.

3.5 Electrical Schematics

Figure 1: Soft starter installed with a system protection circuit breaker complete with a shunt trip device

Figure 2: Soft starter installed with a system protection circuit breaker and main contactor

M Motor (three phase)

KM1 Main contactor

13, 14 Main contactor output

23, 24 Programmable output (set to Trip)

Page 4 CSXi 710-02408-00G

Section 4 Adjustments

Current Ramp

Current Limit

Motor Trip Class

Motor FLC

Soft Stop Time

Excess Start Time

Auxiliary Relay Function

Phase Sequence Protection

ADJUSTMENTS

Current Ramp

Current Limit

Select the initial start current (A) and ramp time (B).

Current ramp starting extends the time soft starter takes to reach the current limit and is suitable for generator set supplies, loads requiring an extended start time or applications with extreme load variation between starts.

The ramp time does not control the time the motor will take to reach full speed.

Select the current limit (C).

The current limit is the maximum level of current the soft starter will deliver to the motor during the soft start.

Motor Trip Class

Select the trip class for motor overload protection.

The trip class reflects the maximum time (in seconds) that the motor can run at locked rotor current. The

Motor Trip Class setting assumes a locked rotor current of 600%.

Setting the motor trip class to "Off" disables motor overload protection.

Motor Full Load Current

Configure the soft starter to match the motor's full load current (FLC).

Configure according to the motor's nameplate current.

Divide the motor's FLC by the soft starter's maximum current rating (on the soft starter's nameplate label).

710-02408-00G CSXi

ADJUSTMENTS

Soft Stop Time

Select the soft stop ramp time (D).

Soft stop extends the time soft starter takes to reduce voltage to zero.

The ramp time does not control the time the motor will take to stop completely.

Excess Start Time

Configure the soft starter's excess start time protection.

Select a time slightly longer than the motor requires for a normal healthy start. The soft starter will trip if the start does not complete within the selected time (E).

Auxiliary Relay Function

Select the function of the soft starter's programmable output (terminals 23, 24).

When set to "Run", the relay will operate when the soft start is complete. When set to "Trip", the relay will operate when the soft starter trips.

Phase Sequence Protection

Configure the soft starter's phase sequence protection.

Select the allowable phase sequences. A setting of "Fwd" allows forward sequence (positive rotation) only and a setting of "Any" defeats the protection.

NOTE

Auxiliary relay function and phase rotation are configured using a shared switch. Set the auxiliary relay function as required, then set phase rotation protection.

Page 6 CSXi 710-02408-00G

Section 5 Troubleshooting

5.1 LEDs

Off

On

LED

Status

Flash

Ready

No control power

Ready

Starter tripped

TROUBLESHOOTING

Run

Motor not running

Motor running at full speed

Motor starting or stopping

5.2 Trip Codes

The Ready LED will flash a different number of times to indicate the cause of the trip.

Ready LED Description

x 1

x 2

Power Circuit: Check mains supply (L1, L2, L3), motor circuit (T1, T2, T3), soft starter SCRs and bypass relays.

Excess Start Time: Check load, increase Current Limit or adjust Excess Start Time setting.

x 3

x 4

x 5

Motor Overload: Allow motor to cool, reset soft starter and restart.

The soft starter cannot be reset until the motor has cooled.

Motor Thermistor: Check motor ventilation and thermistor connection B4, B5. Allow motor to cool.

Phase Imbalance: Check for mains supply or line current imbalance (L1, L2, L3).

x 6

Supply Frequency: Check mains voltage is available and supply frequency is in range.

x 7

Phase Rotation: Check for correct phase rotation.

x 8

x 9

x 10

Network Communication Failure (between interface and network): Check network connections, settings and configuration.

Starter Communication Failure (between starter and interface): Remove and refit accessory interface.

Bypass Overload: Starter rating may be too low for the application.

5.3 Protections

The CSX i includes the following types of protection for the motor and starter:

Excess Start Time Protection

The CSX i will trip on excess start time if the motor does not successfully start within the time selected in the

Excess Start Time setting. This may indicate that the load has stalled.

If the soft starter frequently trips on excess start time:

 check that the Current Limit setting is high enough for the application

 check that the Excess Start Time setting is long enough for the application

 check that the load has not stalled or increased since the soft starter was installed

Motor Overload Protection

The CSX i will trip on motor overload if it calculates that the motor has been running above its operating range for longer than the time selected in the Motor Trip Class setting. Motor Trip Class should be set to match the motor's locked rotor time. If this information is not available from the motor datasheet, use the default setting

(Motor Trip Class = 10). Using a higher setting can damage the motor.

710-02408-00G CSXi

TROUBLESHOOTING

NOTE

Motor overload protection does not protect the soft starter, and does not protect the motor from short circuit.

Phase Imbalance Protection

The CSX i will trip on phase imbalance if the highest and lowest currents on the three phases vary by an average of 30% for more than 3 seconds. Phase imbalance protection is not adjustable, and is only active when the average motor current is 50% or more of the programmed motor FLC.

If the soft starter frequently trips on phase imbalance:

 check that there is no imbalance on the mains voltage (on the input side of the soft starter)

 insulation test the motor

 move all input cables over one position (move L1 cable to L2, move L2 cable to L3, move L3 cable to

L1) to rule out a cabling fault

Supply Frequency Protection

The soft starter will trip on supply frequency if the frequency rises above 72 Hz or falls below 40 Hz for more than five seconds while the soft starter is running. These trip points are not adjustable.

In pre-start, starting and stopping modes the high and low frequency limits both apply with no time delay.

A supply frequency trip will also occur if:

 all three input phases are lost while the soft starter is running

 all three input phases fall below 120 VAC at start or while the soft starter is running

 the line contactor opens while running

Bypass Overload Protection

Bypass overload protection protects the soft starter from severe operating overloads while running. The protection is not adjustable and has two components:

 The soft starter will trip if it detects overcurrent at 600% of the programmed motor full load current.

 The soft starter models the temperature of the internal bypass relays and will trip if the temperature exceeds the safe operating level.

If the trip occurs frequently, this indicates that the soft starter has not been selected correctly for the application.

5.4 Reset

Trips can be cleared by pressing the Reset button on the soft starter, sending a Reset command from the serial communications network, or by switching the control inputs.

To clear a trip via the control inputs, the soft starter requires a closed to open transition on the stop input (02).

 In three wire control, use the external stop pushbutton to momentarily open the stop input (open

A1-02).

 In two wire control, if the soft starter tripped with a start signal present, remove the start signal (open

A1 to 01, 02).

 In two wire control, if the CSX tripped with no start signal present (eg CSXi motor thermistor trip), apply then remove the start signal (close then reopen A1 to 01, 02).

The Reset button is located on the front of the unit, above the adjustment switches.

The soft starter will trip again immediately if the cause of the trip still exists.

Page 8 CSXi 710-02408-00G

Section 6 Accessories

ACCESSORIES

6.1 Finger Guard Kit

Finger guards may be specified for personnel safety and can be used on CSX i soft starter models 075~110.

Finger guards fit over the soft starter terminals to prevent accidental contact with live terminals. Finger guards provide IP20 protection when used with cable of diameter 22 mm or greater.

6.2 Remote Operator

The Remote Operator can control and monitor the soft starter's performance. Functionality includes:

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

 Starter status monitoring (Ready, Starting, Running, Stopping, Tripped)

 Performance monitoring (motor current, motor temperature)

 Trip code display

 4-20 mA analog output (Motor Current)

6.3 Communication Interfaces

CSX i soft starters support network communication using the Profibus, DeviceNet and Modbus RTU protocols.

6.4 Pump Application Interface

The Pump Application Interface expands the soft starter's input and output functionality for applications where greater control and feedback are required.

6.5 PC Software

WinMaster is a purpose-designed software suite for control and monitoring 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 WinMaster with the CSX i, the soft starter must be fitted with a Modbus Interface or a Remote

Operator.

710-02408-00G CSXi

SPECIFICATIONS

Section 7 Specifications

7.1 General Technical Data

Mains Supply

Mains voltage (L1, L2, L3)

..............................................................................................

CSXi-xxx-V6

Mains frequency (at start) .......................................................................................................................................... 45 Hz to 66 Hz

Rated insulation voltage ............................................................................................................................................................ 600 VAC

Form designation ........................................................................................ Bypassed semiconductor motor starter form 1

Control Voltage (A1, A2, A3)

CSXi-xxx-xx-C1 ............................................................................................................................ 110-240 VAC (+ 10% / - 15%)

..................................................................................................................................................... or 380-440 VAC (+ 10% / - 15%)

CSXi-xxx-xx-C2 .............................................................................................................................................. 24 VAC/VDC (± 20%)

Current consumption (during run) .................................................................................................................................. < 100 mA

Current consumption (inrush)

CSXi-xxx-xx-C1.............................................................................................................................................................................. 10 A

CSXi-xxx-xx-C2................................................................................................................................................................................. 2 A

Inputs

Start (terminal 01) ........................................................................................................................................................... Normally open

................................................................................................................... 150 k @ 300 VAC and 5.6 k @ 24 VAC/VDC

Stop (terminal 02) ......................................................................................................................................................... Normally closed

................................................................................................................... 150 k @ 300 VAC and 5.6 k @ 24 VAC/VDC

Outputs

Main contactor (terminals 13, 14) ......................................................................................................................... Normally open

............................................................................................................................ 6 A, 30 VDC resistive / 2 A, 400 VAC, AC11

Programmable relay (terminals 23, 24) ............................................................................................................... Normally open

............................................................................................................................ 6 A, 30 VDC resistive / 2 A, 400 VAC, AC11

Environmental

Degree of protection CSXi-007 to CSXi-055 ....................................................................................................................... IP20

Degree of protection CSXi-075 to CSXi-110 ....................................................................................................................... IP00

Operating temperature ....................................................................................................................................... - 10 °C to + 60 °C

Storage temperature ............................................................... -25 °C to + 60 °C (to +70 °C for less than 24 hours)

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

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

Vibration ................................................................................................................................................. IEC 60068 Test Fc Sinusoidal

....................................................................................................................................... 4 Hz to 13.2 Hz: ± 1 mm displacement

.................................................................................................................................................................. 13.2 Hz to 200 Hz: ± 0.7 g

EMC Emission

Equipment class (EMC) ................................................................................................................................................................ Class A

1

Conducted radio frequency emission ................................................................... 0.15 MHz to 0.5 MHz: < 90 dB (µV)

................................................................................................................................................... 0.5 MHz to 5 MHz: < 76 dB (µV)

.................................................................................................................................................. 5 MHz to 30 MHz: 80-60 dB (µV)

Radiated radio frequency emission .................................................................... 30 MHz to 230 MHz: < 30 dB (µV/m)

................................................................................................................................... 230 MHz to 1000 MHz: < 37 dB (µV/m)

1 This product has been designed as Class A equipment. Use of this product in domestic environments may cause radio interference, in which case the user may be required to employ additional mitigation methods.

EMC Immunity

Electrostatic discharge ......................................................................................... 4 kV contact discharge, 8 kV air discharge

Radio frequency electromagnetic field .............................................................. 0.15 MHz to 1000 MHz: 140 dB (µV)

Rated impulse withstand voltage (Fast transients 5/50 ns) ............................ 2 kV line to earth, 1 kV line to line

Voltage dip and short time interruption ...................................................................... 100 ms (at 40% nominal voltage)

Harmonics and distortion ................................................................................... IEC61000-2-4 (Class 3), EN/IEC61800-3

Page 10 CSXi 710-02408-00G

SPECIFICATIONS

Short Circuit

Rated short-circuit current CSXi-007 to CSXi-037 ........................................................................................................... 5 kA

Rated short-circuit current CSXi-045 to CSXi-110 ......................................................................................................... 10 kA

Heat Dissipation

During Start ..................................................................................................................................................................... 3 watts / ampere

During Run .......................................................................................................................................................................... 10 watts typical

Approvals

C ........................................................................................................................................................................................ IEC 60947-4-2

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

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

CCC ............................................................................................................................................................................................... GB 14048.6

Lloyds ....................................................................................................................................................................................... IEC 60947-4-2

Operational Life

CSXi-007~055 ..................................................................................................................................................... 1,000,000 operations

CSXi-075~110 ............................................................................................................................................................ 30,000 operations

7.2 Model Codes

voltage

C1 = 110-240 VAC & 380-440 VAC

C2 = 24 VAC/VDC voltage

V4 = 200 ~ 440 VAC

V6 = 200 ~ 575 VAC

Nominal rating

≤ 30 kW AC53b 4-6-354

≥ 37 kW AC53b 4-6-594

7.3 Current Ratings

CSXi-007

CSXi-015

CSXi-018

CSXi-022

CSXi-030

CSXi-037

CSXi-045

CSXi-055

CSXi-075

CSXi-090

CSXi-110

40 °C

18 A

34 A

42 A

48 A

AC53b 4-6:354

< 1000 metres

50 °C

17 A

32 A

40 A

44 A

60 A

AC53b 4-6:594

< 1000 metres

55 A

40 °C

75 A

50 °C

68 A

85 A

100 A

140 A

170 A

200 A

78 A

100 A

133 A

157 A

186 A

AC53b 4-20:340

< 1000 metres

40 °C

17 A

30 A

36 A

40 A

50 °C

15 A

28 A

33 A

36 A

49 A 45 A

AC53b 4-20 580

< 1000 metres

40 °C

65 A

50 °C

59 A

73 A

96 A

120 A

142 A

165 A

67 A

87 A

110 A

130 A

152 A

710-02408-00G CSXi

SPECIFICATIONS

7.4 Semiconductor Fuses

Semiconductor fuses can be used with CSX i soft starters to reduce the potential for damage to SCRs from transient overload currents and for Type 2 coordination. CSX i soft starters have been tested to achieve Type 2 coordination with semiconductor fuses. Suitable Bussman and Ferraz semiconductor fuses are detailed below.

CSX Model

SCR I

(A

2

2 T

S)

007 1150

015 8000

018 10500

022 15000

030 18000

037 51200

045 80000

055 97000

075 168000

090 245000

110 320000

Ferraz Fuse

European/IEC Style

(North American Style)

6.6URD30xxxA0063

(A070URD30xxx0063)

6.6URD30xxxA0125

(A070URD30xxx0125)

6.6URD30xxxA0160

(A070URD30xxx0160)

6.6URD30xxxA0160

(A070URD30xxx0160)

6.6URD30xxxA0160

(A070URD30xxx0160)

6.6URD30xxxA0250

(A070URD30xxx0250)

6.6URD30xxxA0315

(A070URD30xxx0315)

6.6URD30xxxA0315

(A070URD30xxx0315)

6.6URD31xxxA0450

(A070URD31xxx0450)

6.6URD31xxxA0450

(A070URD31xxx0450)

6.6URD31xxxA0450

(A070URD31xxx0450)

Bussmann Fuse

Square Body

(170M)

Bussmann Fuse

British Style (BS88) xxx = Blade Type. Contact Ferraz for options.

Page 12 CSXi 710-02408-00G