CSXi (user manual)
Contents
1. E D E F G H Weight Model mm mm mm mm mm mm kg lb inch inch inch inch inch inch CSXi 007 CSXi 015 CSXi 018 98 82 203 188 165 55 90 5 23 24 CSXi 022 39 2 eg a 65 ez Be 9 63 CSXi 030 CSXi 037 CSXi 045 145 124 215 196 193 110 5 37 43 CSXi 055 57 49 5 7 76 44 15 95 CSXi 075 CSXi 090 202 160 240 204 214 114 5 5l 6 8 CSXi 1 10 8 05 63 05 80 84 45 2 0 15 0 2 2 Physical Installation e e a aaa ja 6 6 6 0 o B T 3 e o 6 g s Ul ale 3 Soft Starter ras gt gt 4 oO CSXi 007 CSXi 055 Allow 100 mm 3 9 inches between soft starters CSX075 CSXi 1 10 Allow 200 mm 7 9 inches between soft starters 2 CSXi 007 CSXi 055 Allow 50 mm 2 0 inches between the soft starter and solid surfaces CSXi 075 CSXi 1 10 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 Page 2 CSxi 710 02408 00G Section 3 Electrical Installation ELECTRICAL INSTALLATION 3 1 Power Terminations2. The CSX includes the following types of protection for the motor and starter Excess Start Time Protection The CSX 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 e check that the Current Limit setting is high enough for the application e check that the Excess Start Time setting is long enough for the application e check that the load has not stalled or increased since the soft starter was installed Motor Overload Protection The CSX 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 Page 7 TROUBLESHOOTING 5 4 NOTE Motor overload protection does not protect the soft starter and does not protect the motor from short circuit Phase Imbalance Protection The CSX 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 m
3. L1 1 L2 3 L3 5 T1 2 T2 4 13 6 A1 A2 A3 01 02 B4 3 2 Control Voltages B5 13 14 23 24 mm2 AWG mm2 AWG 007 030 037 055 075 110 007 110 10 35 25 50 11 0 14 1 5 8 2 4 1 0 i 10 43 26 16 26 B85 Ce 1 02 0 33 10 35 14 25 50 14 103 033 0 14 1 5 re 8 2 0 55 4 1 0 0 55 26 16 0 24 mm inch mm inch mm inch mm inch Torx T20 Torx T20 3Nm 4Nm N A 2 2 ft lb 2 9 ft lb 7mm 7mm 3 5mm 3Nm 4Nm 0 5 Nm max 2 2ftlb 2 9ftlb 4 4 in lb max 032368 CSX soft starters can be supplied in either of two control voltage configurations CSXi Xxx xx C I 10 240 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 110 240 vwe paN 110 240 VAC 24 VAC VDC A2 9 24 VACIVDC o 01 e o 02 to A3 380 440 VAC o Al 380 440 VAC o A2 o 01 o o 02 03241 C Three wire o A3 Lo A1 o A2 o 01 Zz o 02 Ho A3 o A1 o A2 v o 02 Start stop To res
4. 3 Current Ratings AC53b 4 6 354 AC53b 4 20 340 lt 1000 metres lt 1000 metres 40 C 50 C 40 C SOAS CSXi 007 I8A I7A IZA ISA CSXi 015 34 A 32 A 30 A 28 A CSXi 018 42 A 40 A 36A 33 A CSXi 022 48 A 44 A 40 A 36A CSXi 030 60 A 55A 49 A 45 A AC53b 4 6 594 AC53b 4 20 580 lt 1000 metres lt 1000 metres 40 C 50 C 40 C 50 C CSXi 037 75 A 68 A 65 A 59 A CSXi 045 85 A 78 A 73A 67 A CSXi 055 100 A 100 A 96 A 87 A CSXi 075 140 A 133A 120 A LIOA CSXi 090 170A 157A 142 A 130 A CSXi 1 10 200 A 186 A 165A 152A 710 02408 00G CSXi Page SPECIFICATIONS 7 4 Semiconductor Fuses Semiconductor fuses can be used with CSX soft starters to reduce the potential for damage to SCRs from transient overload currents and for Type 2 coordination CSX soft starters have been tested to achieve Type 2 coordination with semiconductor fuses Suitable Bussman and Ferraz semiconductor fuses are detailed below Ferraz Fuse Bussmann Fuse CSX Model al European IEC Style Square Body ase an North American Style 170M 007 1150 eee 70M 1314 63 FE 015 8000 a 70M 1317 160 FEE 018 10500 eS 70M 1318 160 FEE 022 15000 a a 70M 1318 180 F 030 18000 a Or 70M 1319 180 F 037 51200 ee a 70M 1321 250 F 045 80000 aol a 70M 1321 250 F 055 97000 a rs 70M 1321 250 F 075 168000 GOURD IDORA 70M 1322 500 FMM A070URD3 xxx0450 6 6URD3 xxxA0450 090 245000 AO7OURD3 1300x0450 70M 3022 50
5. cpu a A ES 110 240 VAC 10 15 or 380 440 VAC 10 15 24 VACIVDC 20 lt 100 mA CSXi xxx xx C2 Current consumption during run Current consumption inrush ISS ADOC G a inpia aa Aai Adgang iaaiaee gat diated I0 A ES oo e E E cochlea tance aatiachattteecdDatetcadinth 2A Inputs Start terminal 01 Normally open 150 kQ 300 VAC and 5 6 kQ 24 VAC VDC w Normally closed 150 kQ 300 VAC and 5 6 KQ 24 VAC VDC Outputs Normally open 6 A 30 VDC resistive 2 A 400 VAC ACI Normally open 6A 30 VDC resistive 2 A 400 VAC ACI Environmental Degree of protection CSXi 007 to CSXi 055_ IP20 Degree of protection CSXi 075 to CSXi 1 10 IPOO 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 POUIUOIP ORONO 41 4 5 maa a Ana iia n a n Angi Pollution Degree 3 VIDALON aaia eaea a e af RAin RAA aA aah Aah IEC 60068 Test Fc Sinusoidal 4 Hz to 13 2 Hz mm displacement F 3 2 Hz to 200 Hz 0 7 g EMC Emission CTCL Cha EMC xan asengtt vmstat est Ug isd tsd evading Class A Conducted radio frequency emission z lt 90 dB uV z lt 76 dB uV Hz 80 60 dB uV z lt 30 dB uV m 230 MHz to 1000 MHz lt 37 dB uV m This product has been designed as Class A equipment Use of this product in domestic environments may cause
6. radio interference in which case the user may be required to employ additional mitigation methods EMC Immunity Electrostatic discharge Radio frequency electromagnetic field Rated impulse withstand voltage Fast transients 5 50 ns Voltage dip and short time interruption Harmonics and distortion Radiated radio frequency emission 4 kV contact discharge 8 kV air discharge 0 15 MHz to 1000 MHz 140 dB uV 2 kV line to earth kV line to line 100 ms at 40 nominal voltage IEC6 1000 2 4 Class 3 EN IEC6 800 3 Page 10 CSxi 710 02408 00G SPECIFICATIONS Short Circuit Rated short circuit current CSXi 007 to CSXi 037 Rated short circuit current CSXi 045 to CSXi 110 Heat Dissipation During Start 3 watts ampere During Run 10 watts typical Approvals Cv IEC 60947 4 2 UL C UL UL 508 GE ss IEC 60947 4 2 CCC GB 14048 6 Lloyds IEC 60947 4 2 Operational Life CSXi 007 055 1 000 000 operations Koo OE SID od oh chaos teria hh eea bul aeynn dam hide A sated cane wen uch dated Gaacedt 30 000 operations 7 2 Model Codes CSXi Control voltage Cl 110 240 VAC amp 380 440 VAC C2 24 VACIVDC Mains voltage V4 200 440 VAC V6 200 575 VAC Nominal kW rating 400 VAC lt 30 kW AC53b 4 6 354 2 37 kW AC53b 4 6 594 7
7. 0 FMM 6 6URD3 xxxA0450 110 320000 AO7OURD3 13000450 70M 3022 500 FMM xxx Blade Type Contact Ferraz for options Page 12 CSxi 710 02408 00G
8. AuComn es 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 e Isolate the soft starter completely from the power supply before attempting any work on the starter or motor e Cables to the control inputs must be segregated from mains voltage and motor cabling e Some electronic contactor coils are not suitable for direct switching with PCB mount relays Consult the contactor manufacturer supplier to confirm suitability e Do not apply incorrect voltages to the control input terminals e Do not connect power factor correction capacitors to the output of CSX 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 us
9. HOOTING Section 5 Troubleshooting 5 1 LED Ready Run Status Off No control power Motor not running On Ready Motor running at full speed Flash Starter tripped 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 5 Power Circuit Check mains supply LI L2 L3 motor circuit T 1 T2 T3 soft starter SCRs vxl and bypass relays x2 Excess Start Time Check load increase Current Limit or adjust Excess Start Time setting ad Y otor Overload Allow motor to cool reset soft starter and restart mx 3 The soft starter cannot be reset until the motor has cooled 5 otor Thermistor Check motor ventilation and thermistor connection B4 B5 Allow x4 motor to cool O x5 Phase Imbalance Check for mains supply or line current imbalance LI L2 L3 ad ae a Supply Frequency Check mains voltage is available and supply frequency is in range d x7 Phase Rotation Check for correct phase rotation X etwork Communication Failure between interface and network Check network mx 8 connections settings and configuration X Starter Communication Failure between starter and interface Remove and refit x accessory interface O x10 Bypass Overload Starter rating may be too low for the application 5 3 Protections
10. S 125 Sel 6s 14s 4s 16s 25 0s VO No Soft Stop Th ect the soft stop ramp time D Soft stop extends the time soft starter takes to reduce Itage to zero e ramp time does not control the time the motor will take to stop completely 04984 A B Excess Start Time Sel no do Configure the soft starter s excess start time protection ect a time slightly longer than the motor requires for a rmal healthy start The soft starter will trip if the start es not complete within the selected time E Auxiliary Relay Function PE WI 04977 A Trip Run ect the function of the soft starter s programmable put terminals 23 24 en set to Run the relay will operate when the soft start is complete When set to Trip the relay will RUN 03387 B operate when the soft starter trips B Phase Sequence Protection ANY es ANY Configure the soft starter s phase sequence protection WFW Se 049 ect the allowable phase sequences A setting of Fwd allows forward sequence positive rotation only and a setting of Any defeats the protection FWD ANY L1 ft BRED i soft 5 2 SARO x v3 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 TROUBLES
11. e Operational control Start Stop Reset Quick Stop e Starter status monitoring Ready Starting Running Stopping Tripped e Performance monitoring motor current motor temperature e Trip code display e 4 20 mA analog output Motor Current 6 3 Communication Interfaces CSX 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 e Operational control Start Stop Reset Quick Stop e Starter status monitoring Ready Starting Running Stopping Tripped e Performance monitoring motor current motor temperature To use WinMaster with the CSX the soft starter must be fitted with a Modbus Interface or a Remote Operator 710 02408 00G CSXi Page 9 SPECIFICATIONS Section 7 Specifications 7 1 General Technical Data Mains Supply Mains voltage LI L2 L3 CSXi xxx V4 a 3 x 200 VAC 440 VAC 10 15 CSXi xxx V6 3x 200 VAC 575 VAC 10 15 45 Hz to 66 Hz stira 600 VAC Bypassed semiconductor motor starter form Mains frequency at start Rated insulation voltage Form designation Control Voltage Al A2 A3 CEI SOOO pna thetic
12. e or application of this equipment WARNING ELECTRICAL SHOCK HAZARD CSX 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 branch circuit protection according to local electrical safety codes SHORT CIRCUIT CSX soft starters are not short circuit proof After severe overload or short circuit the operation of the soft starter should be fully tested Ce manuel est galement disponible en fran ais partir de www aucom com Dieses Handbuch ist auch in deutscher Sprache aus www aucom com Questo manuale disponibile anche in italiano da www aucom com Este manual tambi n esta disponible en espafiol a partir de www aucom com GROUNDING AND BRANCH CIRCUIT PROTECTION It is the responsibility of the user or person installing the soft starter to provide proper grounding and AF WHE AYE P EMA www aucom com 2007 2008 AuCom Electronics Ltd All Rights Reserved 710 02408 00G CSXi Page MECHANICAL INSTALLATION Section 2 Mechanical Installation 2 1 Dimensions and Weights
13. et a trip close then open 02 Start Stop To reset a trip close then open 02 710 02408 00G CSXi Page 3 ELECTRICAL INSTALLATION Motor Thermistor Motor thermistors can be connected directly to the CSX terminals B4 B5 If motor thermistors are not used there must be a link between B4 B5 the CSX is supplied with a link fitted B4 B4 5 B4 A o B5 o B5 T o B5 x Vv v 03247 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 trips The relay can be used to operate the shunt trip mechanism of an upstream circuit breaker in order to isolate the
14. 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 I Soft starter installed with a system Figure 2 Soft starter installed with a system protection circuit breaker complete with a shunt protection circuit breaker and main contactor tnp device gt mt Lm L 7a 271 D 4 4 2m ik g lt Ar 2 i i 3 L2 s Ue n 472 l ne Be 2 olga 4 T2 M A Ho P z J53 6 73 5 L3 eT3 i re ig ot i 1 l Do o I gt 13 3 14 I 24 3 gi KM1 BU th oe et ee ee T M Motor three phase KMI Main contactor 13 14 Main contactor output 23 24 Programmable output set to Trip Page 4 CSxi 710 02408 00G Section 4 Adjustments L 10 1 4 Current Ramp 5 B Current Ami B Motor Trip Class C ea TS TAZA a 1TA TE TATA JLOQOQQOOO e 03246 C oO Current Ramp apo Flo 15s take to reach full speed 4 Motor FLC B Soft Stop Time 6 Excess Start Time Auxiliary Relay Function B Phase Sequence Protection Select the initial start current A and ram
15. otor current is 50 or more of the programmed motor FLC If the soft starter frequently trips on phase imbalance e check that there is no imbalance on the mains voltage on the input side of the soft starter e insulation test the motor e move all input cables over one position move LI cable to L2 move L2 cable to L3 move L3 cable to LI 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 e all three input phases are lost while the soft starter is running e all three input phases fall below 120 VAC at start or while the soft starter is running e 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 e The soft starter will trip if it detects overcurrent at 600 of the programmed motor full load current e 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 starte
16. p time B 5 K Current ramp starting extends the time soft starter takes sls f lt to reach the current limit and is suitable for generator set EN orp VO E 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 03382 B 2 Current Limit 350 300 lt 3 250 450 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 400 200 03383 B 8 Motor Trip Class of 600 overload protection 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 Setting the motor trip class to Off disables motor Cold start curves tts 1000 100 Class 20 Class 10 0384 8 500600 700 FLC 300 4 Motor Full Load Current 70 _ _ 80 80 Dn 50 100 current FLC Configure the soft starter to match the motor s full load 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 Motor FLC Soft starter FLC 710 02408 00G CSXi Page 5 ADJUSTMENTS B Soft Stop Time 8s 10
17. r has not been selected correctly for the application 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 e In three wire control use the external stop pushbutton to momentarily open the stop input open Al 02 e In two wire control if the soft starter tripped with a start signal present remove the start signal open Al to Ol 02 e In two wire control if the CSX tripped with no start signal present eg CSX motor thermistor trip apply then remove the start signal close then reopen AI 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 6 1 Finger Guard Kit Finger guards may be specified for personnel safety and can be used on CSX soft starter models 075 10 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
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