AuCom CSX-007 User manual

710-02407-00G CSX Page 1
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 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 use 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.
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 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.

MECHANICAL INSTALLATION
Page 2 CSX 710-02407-00G
2.1 Dimensions and Weights
A B C D E F G H Weight
Model mm
(inch)
mm
(inch)
mm
(inch)
mm
(inch)
mm
(inch)
mm
(inch)
mm
(inch)
mm
(inch)
kg (lb)
CSX-007
CSX-015
CSX-018 98 82 203 188 165 55 90.5 23 2.2
CSX-022 (3.86) (3.23) (7.99) (7.40) (6.50) (2.17) (3.56) (0.9) (4.85)
CSX-030
CSX-037
CSX-045 145 124 215 196 193 - 110.5 37 4.0
CSX-055 (5.71) (4.88) (8.46) (7.71) (7.60) (4.35) (1.46) (8.82)
CSX-075
CSX-090 202 160 240 204 214 - 114.5 51 6.1
CSX-110 (7.95) (6.30) (9.45) (8.03) (8.43) (4.50) (2.0) (13.45)
2.2 Physical Installation
CSX-007 ~ CSX-055: Allow 100 mm (3.94 inches) between soft starters.
CSX-075 ~ CSX-110: Allow 200 mm (7.88 inches) between soft starters.
CSX-007 ~ CSX-055: Allow 50 mm (1.97 inches) between the soft starter and solid surfaces.
CSX-075 ~ CSX-110: Allow 200 mm (7.88 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%.
.
Section 2 Mechanical Installation

ELECTRICAL INSTALLATION
710-02407-00G CSX Page 3
3.1 Power Terminations
0.14 - 1.5
(26 - 16)
0.14 - 1.5
(26 - 16)
N.A.
3.5 mm
0.5 Nm max
4.4 in-lb max
N.A.
N.A.
075 ~ 1 10
10 - 35
(8 - 2)
10 - 35
(8 - 2)
Torx (T20)
3Nm
2.2 f t-lb
7 mm
3Nm
2.2 f t-lb
007 ~ 030
25 - 50
(4 - 1/0)
25 - 50
(4 - 1/0)
Torx (T20)
4Nm
2.9 f t-lb
7 mm
4Nm
2.9 f t-lb
037 ~ 055 007 ~ 1 10
N.A.
N.A.
26
(1.02)
11
(0.43)
Ø 8.5
(0.33)
14
(0.55) 6
(0.24)
mm (inch) mm (inch)
14
(0.55)
mm (inch)
L1/1, L2/3, L3/5,T1/2,T2/4,T3/6
mm2(AWG)
A1, A2, A3, 01, 02, B4,
B5, 13, 14, 23, 24
mm2(AWG)
mm (inch)
03236.B
3.2 Control Voltages
CSX soft starters can be supplied in either of two control voltage configurations:
CSX-xxx-xx-C1 ..... 110-240 VAC (+ 10% / - 15%) or 380-440 VAC (+ 10% / - 15%)
CSX-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.
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.
Section 3 Electrical Installation

ELECTRICAL INSTALLATION
Page 4 CSX 710-02407-00G
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.
Run Output
The run output relay (terminals 23, 24) can be used to signal run status. This relay is normally open.
The relay operates when the soft start is complete, the bypass relays are closed and full voltage is being applied
to the 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 motor protection circuit breaker
Figure 2: Soft starter installed with a motor protection circuit breaker and main contactor.
Figure 3: Soft starter installed with a system protection circuit breaker, separate overload and main contactor
M Motor (three phase)
KM1 Main contactor
13, 14 Main contactor output

ADJUSTMENTS
710-02407-00G CSX Page 5
Initial Start Voltage
Start Ramp Time
Stop Ramp Time
Initial Start Voltage
Select the Initial Start Voltage (A).
Application Suggested Initial
Start Voltage
Centrifugal Pump 50%
Submersible Pump 60%
Screw Compressor
Conveyor
Crusher 70%
Fan
Other applications
Initial Start Time
Select the Initial Start Time (B).
The start ramp defines how long the soft starter will take to
increase voltage from the initial start voltage to full voltage.
The Initial Start Time does not control the time the motor will
take to reach full speed.
1. Set the Initial Start Time to 20 seconds.
2. Set the Initial Start Voltage as required for the application.
3. Attach a current monitoring device to output T1.
4. Start the motor under normal load conditions. Record the
time required for the measured current to fall to (or
below) the motor's rated full load current (t1) then stop
the motor.
5. Set Initial Start Time = t1.
NOTE
The Initial Start Time must be long enough for the motor to
reach full speed before the soft starter enters bypass mode.
Soft Stop Time
Select the soft stop ramp time (C).
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.
Section 4 Adjustments

TROUBLESHOOTING
Page 6 CSX 710-02407-00G
5.1 LEDs
LED
Status
Ready Run
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
x 1 Power Circuit: Check mains supply (L1, L2, L3), motor circuit (T1, T2, T3), soft starter SCRs
and bypass relays.
x 6 Supply Frequency: Check mains voltage is available and supply frequency is in range.
x 8 Network Communication Failure (between interface and network): Check network
connections, settings and configuration.
x 9 Starter Communication Failure (between starter and interface): Remove and refit
accessory interface.
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
5.3 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 wa start signal present, remove the start signal
(open 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.
Section 5 Troubleshooting

ACCESSORIES
710-02407-00G CSX Page 7
6.1 Finger Guard Kit
Finger guards may be specified for personnel safety and can be used on CSX 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 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)
To use WinMaster with the CSX, the soft starter must be fitted with a Modbus Interface or a Remote
Operator.
Section 6 Accessories

SPECIFICATIONS
Page 8 CSX 710-02407-00G
7.1 General Technical Data
Mains Supply
Mains voltage (L1, L2, L3)
CSX-xxx-V4 ............................................................................................... 3 x 200 VAC ~ 440 VAC (+ 10% / - 15%)
CSX-xxx-V6 ............................................................................................... 3 x 200 VAC ~ 575 VAC (+ 10% / - 15%)
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)
CSX-xxx-xx-C1 ............................................................................................................................. 110-240 VAC (+ 10% / - 15%)
..................................................................................................................................................... or 380-440 VAC (+ 10% / - 15%)
CSX-xxx-xx-C2 ............................................................................................................................................... 24 VAC/VDC (± 20%)
Current consumption (during run) .................................................................................................................................. < 100 mA
Current consumption (inrush)
CSX-xxx-xx-C1...............................................................................................................................................................................10 A
CSX-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
Run relay (terminals 23, 24) ...................................................................................................................................... Normally open
............................................................................................................................ 6 A, 30 VDC resistive / 2 A, 400 VAC, AC11
Environmental
Degree of protection CSX-007 to CSX-055 .......................................................................................................................... IP20
Degree of protection CSX-075 to CSX-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
Section 7 Specifications

SPECIFICATIONS
710-02407-00G CSX Page 9
Short Circuit
Rated short-circuit current CSX-007 to CSX-037 ............................................................................................................. 5 kA
Rated short-circuit current CSX-045 to CSX-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
CSX-007~055 ...................................................................................................................................................... 1,000,000 operations
CSX-075~110 ............................................................................................................................................................. 30,000 operations
7.2 Model Codes
CSX- - -
Control voltage
C1 = 110-240 VAC & 380-440 VAC
C2 = 24 VAC/VDC
Mains voltage
V4 = 200 ~ 440 VAC
V6 = 200 ~ 575 VAC
Nominal kW rating @400 VAC
≤30 kW AC53b 4-6-354
≥37 kW AC53b 4-6-594
7.3 Current Ratings
AC53b 4-6:354
< 1000 metres
AC53b 4-20:340
< 1000 metres
40 °C 50 °C 40 °C 50 °C
CSX-007 18 A 17 A 17 A 15 A
CSX-015 34 A 32 A 30 A 28 A
CSX-018 42 A 40 A 36 A 33 A
CSX-022 48 A 44 A 40 A 36 A
CSX-030 60 A 55 A 49 A 45 A
AC53b 4-6:594
< 1000 metres
AC53b 4-20 580
< 1000 metres
40 °C 50 °C 40 °C 50 °C
CSX-037 75 A 68 A 65 A 59 A
CSX-045 85 A 78 A 73 A 67 A
CSX-055 100 A 100 A 96 A 87 A
CSX-075 140 A 133 A 120 A 110 A
CSX-090 170 A 157 A 142 A 130 A
CSX-110 200 A 186 A 165 A 152 A

SPECIFICATIONS
Page 10 CSX 710-02407-00G
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.
CSX Model SCR I2T
(A2S)
Ferraz Fuse
European/IEC Style
(North American Style)
Bussmann Fuse
Square Body
(170M)
Bussmann Fuse
British Style (BS88)
007 1150 6.6URD30xxxA0063
(A070URD30xxx0063) 170M-1314 63 FE
015 8000 6.6URD30xxxA0125
(A070URD30xxx0125) 170M-1317 160 FEE
018 10500 6.6URD30xxxA0160
(A070URD30xxx0160) 170M-1318 160 FEE
022 15000 6.6URD30xxxA0160
(A070URD30xxx0160) 170M-1318 180 FM
030 18000 6.6URD30xxxA0160
(A070URD30xxx0160) 170M-1319 180 FM
037 51200 6.6URD30xxxA0250
(A070URD30xxx0250) 170M-1321 250 FM
045 80000 6.6URD30xxxA0315
(A070URD30xxx0315) 170M-1321 250 FM
055 97000 6.6URD30xxxA0315
(A070URD30xxx0315) 170M-1321 250 FM
075 168000 6.6URD31xxxA0450
(A070URD31xxx0450) 170M-1322 500 FMM
090 245000 6.6URD31xxxA0450
(A070URD31xxx0450) 170M-3022 500 FMM
110 320000 6.6URD31xxxA0450
(A070URD31xxx0450) 170M-3022 500 FMM
xxx = Blade Type. Contact Ferraz for options.

NOTES
710-02407-00G CSX Page 11

NOTES
Page 12 CSX 710-02407-00G