AuCom CSXI-007 User manual

CAUTION STATEMENTS
710-02408-00H CSXi Page 1
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 i 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.
AuCom cannot guarantee the correctness or completeness of the translated information in this document.
In case of dispute the master document in English is the Reference Document.
WARNING - ELECTRICAL SHOCK HAZARD
CSX i soft starters contain dangerous voltages when connected to mains voltage. Only a qualified
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 by an authorised service agent.
Ce manuel est également disponible en français à partir de www.aucom.com.
Dieses Handbuch ist auch in deutscher Sprache aus www.aucom.com.
Questo manuale è disponibile anche in italiano da www.aucom.com.
Este manual também está disponível em Português no site www.aucom.com.
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该手册也可在中国从 www.aucom.com.
1Caution Statements
© 2012 AuCom Electronics Ltd. All Rights Reserved.

MECHANICAL INSTALLATION
Page 2 CSXi 710-02408-00H
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)
CSXi-007
CSXi-015
CSXi-018
98
82
201
188
165
55
90.5
23
2.2
CSXi-022
(3.85)
(3.22)
(7.91)
(7.40)
(6.49)
(2.16)
(3.6)
(0.9)
(4.85)
CSXi-030
CSXi-037
CSXi-045
145
124
215
196
193
-
110.5
37
4.0
CSXi-055
(5.70)
(4.88)
(8.46)
(7.71)
(7.59)
(4.4)
(1.5)
(8.81)
CSXi-075
CSXi-090
200
160
240
216
214
-
114.5
51
6.5
CSXi-110
(7.87)
(6.29)
(9.44)
(8.50)
(8.42)
(4.5)
(2.0)
(14.33)
2.2 Physical Installation
CSXi-007 ~ CSXi-055: Allow 100 mm (3.9 inch) between soft starters.
CSXi-075 ~ CSXi-110: Allow 200 mm (7.9 inch) between soft starters.
CSXi-007 ~ CSXi-055: Allow 50 mm (2.0 inch) between the soft starter and solid surfaces.
CSXi-075 ~ CSXi-110: Allow 200 mm (7.9 inch) between the soft starter and solid surfaces.
Soft starters may be mounted side by side with no clearance (that is, if mounted without
communications modules).
The soft starter may be mounted on its side. Derate the soft starter's rated current by 15%.
2Mechanical Installation

ELECTRICAL INSTALLATION
710-02408-00H CSXi Page 3
3.1 Power Terminations
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)
007 - 030
037 - 055
075 - 110
007 - 110
10427.A
10 - 35
(8 - 2)
10428.A
14 (0.55)
mm (inch)
25 - 50
(4 -
1/10)
10428.A
14 (0.55)
mm
(inch)
N.A.
26
(1.0 2 )
11
(0.4 3 )
Ø 8. 5
(0 .3 3 )
104 2 9 .A
mm
(inch)
0.14 - 1.5
(26 - 16)
10428.A
6 (0.24)
mm (inch)
Torx (T20)
3 Nm
2.2 ft-lb
Torx (T20)
4 Nm
2.9 ft-lb
N.A.
N.A.
7 mm
3 Nm
2.2 ft-lb
7 mm
4 Nm
2.9 ft-lb
N.A.
3.5 mm
0.5 Nm max
4.4 in-lb max
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, open then close 02.
Start.
Stop. To reset a trip, open then close 02.
3Electrical Installation

ELECTRICAL INSTALLATION
Page 4 CSXi 710-02408-00H
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).
B 4
B 5
B 4
B 5
B 4
B 5
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 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
Soft starter installed with a system
protection circuit breaker complete with a
shunt trip device
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)
6 /T 3
4 /T 2
2 /T 1
5 /L 3
3 /L 2
1 /L 1
13
14
M
23
24
K M 1
6 /T 3
4 /T 2
2 /T 1
5/ L 3
3/ L 2
1/ L 1
1 3
1 4
M
KM 1
K M 1
2 3
2 4

ADJUSTMENTS
710-02408-00H CSXi Page 5
03246.D
1
6
4
3
25
87
Current Ramp
Current Limit
Motor Trip Class
Motor FLC
Soft Stop Time
Excess Start Time
Auxiliary Relay Function
Phase Sequence Protection
Current Ramp
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.
Current
Time
Current Limit
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.
Current
Time
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).
4Adjustments

ADJUSTMENTS
Page 6 CSXi 710-02408-00H
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.
Voltage
Time
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).
Current
Time
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.
Time
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.

TROUBLESHOOTING
710-02408-00H CSXi Page 7
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 2
Excess Start Time: Check load, increase Current Limit or adjust Excess Start Time setting.
x 3
Motor Overload: Allow motor to cool, reset soft starter and restart.
The soft starter cannot be reset until the motor has cooled.
x 4
Motor Thermistor: Check motor ventilation and thermistor connection B4, B5. Allow motor
to cool.
x 5
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
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.
x 10
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.
NOTE
Motor overload protection does not protect the soft starter, and does not protect the motor
from short circuit.
5Troubleshooting

TROUBLESHOOTING
Page 8 CSXi 710-02408-00H
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 button 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 CSXi tripped with no start signal present (eg CSX i 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.

ACCESSORIES
710-02408-00H CSXi Page 9
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 (x 6) 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, Modbus RTU and USB
protocols.
6.4 PC Software
WinMaster can be used with AuCom 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 WinMaster with the CSX i , the soft starter must be fitted with a USB interface, Modbus Interface or
a Remote Operator.
6Accessories

SPECIFICATIONS
Page 10 CSXi 710-02408-00H
7.1 Model Code
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
Motor protection
Blank = Without motor protection
i = With motor protection
7.2 Current Ratings
AC53b 4-6:354
< 1000 metres
AC53b 4-20:340
< 1000 metres
40 °C
50 °C
40 °C
50 °C
CSXi-007
18 A
17 A
17 A
15 A
CSXi-015
34 A
32 A
30 A
28 A
CSXi-018
42 A
40 A
36 A
33 A
CSXi-022
48 A
44 A
40 A
36 A
CSXi-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
CSXi-037
75 A
68 A
65 A
59 A
CSXi-045
85 A
78 A
73 A
67 A
CSXi-055
100 A
100 A
96 A
87 A
CSXi-075
140 A
133 A
120 A
110 A
CSXi-090
170 A
157 A
142 A
130 A
CSXi-110
200 A
186 A
165 A
152 A
7Specifications

SPECIFICATIONS
710-02408-00H CSXi Page 11
7.3 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 Bussmann and Ferraz semiconductor fuses are
detailed below.
Model
SCR I2T
(A2S)
Ferraz Fuse
European/IEC Style
(North American Style)
Bussmann Fuse
Square Body
(170M)
Bussmann Fuse
British Style (BS88)
CSXi-007
1150
6.6URD30xxxA0063
(A070URD30xxx0063)
170M-1314
63 FE
CSXi-015
8000
6.6URD30xxxA0125
(A070URD30xxx0125)
170M-1317
160 FEE
CSXi-018
10500
6.6URD30xxxA0160
(A070URD30xxx0160)
170M-1318
160 FEE
CSXi-022
15000
6.6URD30xxxA0160
(A070URD30xxx0160)
170M-1318
180 FM
CSXi-030
18000
6.6URD30xxxA0160
(A070URD30xxx0160)
170M-1319
180 FM
CSXi-037
51200
6.6URD30xxxA0250
(A070URD30xxx0250)
170M-1321
250 FM
CSXi-045
80000
6.6URD30xxxA0315
(A070URD30xxx0315)
170M-1321
250 FM
CSXi-055
97000
6.6URD30xxxA0315
(A070URD30xxx0315)
170M-1321
250 FM
CSXi-075
168000
6.6URD31xxxA0450
(A070URD31xxx0450)
170M-1322
500 FMM
CSXi-090
245000
6.6URD31xxxA0450
(A070URD31xxx0450)
170M-3022
500 FMM
CSXi-110
320000
6.6URD31xxxA0450
(A070URD31xxx0450)
170M-3022
500 FMM
xxx = Blade Type. Contact Ferraz for options.
7.4 General Technical Data
Mains Supply
Mains voltage (L1, L2, L3)
V4 ............................................................................................................. 3 x 200 VAC ~ 440 VAC (+ 10% / - 15%)
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)
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

SPECIFICATIONS
Page 12 CSXi 710-02408-00H
Outputs
Main contactor relay (terminals 13, 14) ...................................................................................................... Normally open
..................................................................................................................................... 6 A, 30 VDC / 6 A, 250 VAC resistive
Programmable relay (terminals 23, 24) ....................................................................................................... Normally open
..................................................................................................................................... 6 A, 30 VDC / 6 A, 250 VAC resistive
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
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)
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
Short Circuit
Rated short-circuit current CSXi-007 to CSXi-022 ...................................................................................................... 5 kA
Rated short-circuit current CSXi-030 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
710-02408-00H