Emerson Leroy Somer DIGISTART D3 User manual

2015.04 / f
DIGISTART D3
User guide
DIGISTART D3
Reference: 4259 en -

Copyright © April 2015 LEROY SOMER
Issue: F
General Information
The manufacturer accepts no liability for any consequences resulting from inappropriate, negligent or incorrect installation or
adjustment of the optional parameters of the equipment or from mismatching the starter with the motor.
The contents of this guide are believed to be correct at the time of printing. In the interests of commitment to a policy of continuous
development and improvement, the manufacturer reserves the right to change the specification of the product or its performance, or
the content of the guide without notice.
All rights reserved. No parts of this guide may be reproduced or transmitted in any form or by any means, electrical or mechanical
including, photocopying, recording or by an information storage or retrieval system, without permission in writing from the publisher.
Software Version
This product is supplied with the latest version of user-interface and machine control software. If this product is to be used in a new
or existing system with other starters, there may be some differences between their software and the software in this product. These
differences may cause the product to function differently. This may also apply to starters returned from the LEROY SOMER Service
Centre.
If there is any doubt, please contact LEROY SOMER or your local Distributor.
Environmental Statement
LEROYSOMER is committed to minimising the impacts of its manufacturing operations. To this end, we operate an Environmental
Management System (EMS) which is certified to the International Standard ISO 14001.
When the products eventually reach the end of their useful life, they can very easily be dismantled into their major component parts
for efficient recycling. Many parts snap together and can be separated without the use of tools, while other parts are secured with
conventional screws.
Product packaging is of good quality and can be re-used. Large products are packed in wooden crates, while smaller products come
in strong cardboard cartons which themselves have a high recycled fibre content. If not re-used, these containers can be recycled.
Polythene, used on the protective film and bags from wrapping product, can be recycled in the same way.
When preparing to recycle or dispose of any product or pa ckaging, please observe local legislation and best practice.
REACH Legislation
EC Regulation 1907/2006 on the Registration, Evaluation, Authorisation and restriction of Chemicals (REACH) requires the supplier
of an article to inform the recipient if it contains more than a specified proportion of any substance which is considered by the
European Chemicals Agency (ECHA) to be a Substance of Very High Concern (SVHC) and is therefore listed by them as a
candidate for compulsory authorisation.
For current information on how this requirement applies in relation to specific LEROY SOMER products, please approach your usual
contact in the first instance.
For the latest manuals and software, please visit our website.

Digistart D3 User Guide 3
Issue: F
Contents
1.Safety Information ............................................................................................................................................5
1.1Warnings, cautions and notes....................................................................................................................................................5
1.2Electrical safety - general warning .............................................................................................................................................5
1.3System design and safety of personnel .....................................................................................................................................5
1.4Environmental limits ...................................................................................................................................................................5
1.5Compliance with regulations ......................................................................................................................................................5
1.6Motor ..........................................................................................................................................................................................5
1.7Adjusting parameters .................................................................................................................................................................5
1.8Electrical installation...................................................................................................................................................................6
2.Rating Data........................................................................................................................................................7
2.1Model code.................................................................................................................................................................................7
2.2Current ratings ...........................................................................................................................................................................7
3.Mechanical Installation...................................................................................................................................12
3.1Dimensions and weights ..........................................................................................................................................................12
3.2Physical installation..................................................................................................................................................................15
3.3Busbar adjustment procedure ..................................................................................................................................................15
4.Electrical Installation ......................................................................................................................................17
4.1Terminal layout.........................................................................................................................................................................17
4.2Control connections .................................................................................................................................................................21
4.3Power connections...................................................................................................................................................................22
4.4Fuse information ......................................................................................................................................................................26
4.5Bypass contactor......................................................................................................................................................................32
4.6Main contactor..........................................................................................................................................................................32
4.7Circuit breaker..........................................................................................................................................................................32
4.8Power factor correction ............................................................................................................................................................32
4.9EMC (electromagnetic compatibility)........................................................................................................................................32
5.Keypad and Status..........................................................................................................................................33
5.1Keypad .....................................................................................................................................................................................33
5.2Removing and replacing the keypad........................................................................................................................................33
5.3Synchronising the keypad and the starter................................................................................................................................34
5.4Displays....................................................................................................................................................................................34
6.Quick Start Commissioning ...........................................................................................................................36
6.1Control wiring ...........................................................................................................................................................................36
6.2Setup procedure.......................................................................................................................................................................37
7.Operation.........................................................................................................................................................38
7.1Start, stop and reset commands ..............................................................................................................................................38
7.2Soft start methods ....................................................................................................................................................................38
7.3Stop methods ...........................................................................................................................................................................40
7.4Jog operation ...........................................................................................................................................................................44
7.5Inside delta operation...............................................................................................................................................................44
8.Programming...................................................................................................................................................45
8.1Programming menu..................................................................................................................................................................45
8.2Access code.............................................................................................................................................................................45
8.3Adjustment lock........................................................................................................................................................................46
8.4Load defaults............................................................................................................................................................................46
8.5Quick setup details...................................................................................................................................................................47
8.6Standard menu.........................................................................................................................................................................48
8.7Advanced menu .......................................................................................................................................................................49
8.8Parameter descriptions ............................................................................................................................................................53
8.9Maintenance tools ....................................................................................................................................................................67
9.Diagnostics......................................................................................................................................................71
9.1Protection responses ...............................................................................................................................................................71
9.2Trip messages..........................................................................................................................................................................71
9.3General faults...........................................................................................................................................................................74
10.Application Examples.....................................................................................................................................76
10.1Installation with main contactor................................................................................................................................................76
10.2Installation with external bypass contactor ..............................................................................................................................77
10.3Emergency run operation.........................................................................................................................................................78
10.4Auxiliary trip circuit ...................................................................................................................................................................79

4 Digistart D3 User Guide
Issue: F
10.5DC brake with external zero speed sensor ..............................................................................................................................80
10.6Soft braking ..............................................................................................................................................................................81
10.7Two-speed motor .....................................................................................................................................................................82
10.8Slip-ring motor..........................................................................................................................................................................83
11.Technical Data.................................................................................................................................................85
11.1UL compliant installation ..........................................................................................................................................................87
12.Maintenance ....................................................................................................................................................88
12.1Care .........................................................................................................................................................................................88
12.2Measuring the motor current ....................................................................................................................................................88
12.3Measuring the input and output power.....................................................................................................................................88
12.4Exchanging products................................................................................................................................................................88
13.Options ............................................................................................................................................................89

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Digistart D3 User Guide 5
Issue: F
1. Safety Information
1.1 Warnings, cautions and notes
WARNING
A Warning contains information which is essential for avoiding a safety hazard.
A Caution contains information which is necessary for avoiding a risk of damage to the product or other equipment.
NOTE
A Note contains information which helps to ensure correct operation of the product.
1.2 Electrical safety - general warning
The voltages used in the starter can cause severe electrical shock and/or burns, and could be lethal. Extreme care is necessary at
all times when working with or adjacent to the starter.
Specific warnings are given at the relevant places in this guide.
1.3 System design and safety of personnel
The starter is intended as a component for professional incorporation into complete equipment or a system. If installed incorrectly,
the starter may present a safety hazard.
The starter uses high voltages and currents, carries stored electrical energy, and is used to control equipment which can cause
injury.
Close attention is required to the electrical installation and the system design to avoid hazards either in normal operation or in the
event of equipment malfunction. System design, installation, commissioning and maintenance must be carried out by personnel who
have the necessary training and experience. They must read this safety information and this guide carefully.
None of the starter functions must be used to ensure safety of personnel, ie they must not be used for safety-related
functions.
Careful consideration must be given to the functions of the starter which might result in a hazard, either through their intended
behaviour or through incorrect operation due to a fault. In any application where a malfunction of the starter or its control system
could lead to or allow damage, loss or injury, a risk analysis must be carried out, and where necessary, further measures taken to
reduce the risk.
The system designer is responsible for ensuring that the complete system is safe and designed correctly according to the relevant
safety standards.
1.4 Environmental limits
Instructions regarding transport, storage, installation and use of the starter must be complied with, including the specified
environmental limits. Starters must not be subjected to excessive physical force.
1.5 Compliance with regulations
The installer is responsible for complying with all relevant regulations, such as national wiring regulations, accident prevention
regulations and electromagnetic compatibility (EMC) regulations. Particular attention must be given to the cross-sectional areas of
conductors, the selection of fuses or other protection, and protective ground connections.
Within the European Union, all machinery in which this product is used must comply with the following directives:
2006/42/EC: Safety of machinery.
2004/108/EC: Electromagnetic Compatibility.
1.6 Motor
Ensure the motor is installed in accordance with the manufacturer’s recommendations. Ensure the motor shaft is not exposed.
The values of the motor parameters set in the starter affect the protection of the motor. The default values in the starter should not
be relied upon. It is essential that the correct value is entered in Pr 1A Motor Full Load Current. This affects the thermal protection of
the motor.
1.7 Adjusting parameters
Some parameters have a profound effect on the operation of the starter. They must not be altered without careful consideration of
the impact on the controlled system. Measures must be taken to prevent unwanted changes due to error or tampering.
CAUTION

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6 Digistart D3 User Guide
Issue: F
1.8 Electrical installation
1.8.1 Electrical shock risk
The voltages present in the following locations can cause severe electric shock and may be lethal:
AC supply cables and connections
Output cables and connections
Many internal parts of the starter, and external option units
The AC supply must be disconnected from the starter using an approved isolation device before any cover is removed from the
starter or before any servicing work is performed.
WARNING - ELECTRICAL SHOCK HAZARD
Models D3-1x-0500-B to D3-16-1600-N: The busbar and heatsink must be treated as live whenever the unit has mains
voltage connected (including when the starter is tripped or waiting for a command).
1.8.2 Power-up procedure
Always apply control voltage before (or with) mains voltage.
D3-1x-0023-B to D3-1x-0105-B: After transportation, mechanical shock or rough handling there is a possibility that the bypass
contactor may have latched into the on state. To prevent the possibility of the motor starting immediately, on first commissioning or
operation after transportation, always ensure that the control supply is applied before the power, so that the contactor state is
initialised.
1.8.3 STOP function
The STOP function does not remove dangerous voltages from the starter, the motor or any external option units.
1.8.4 Stored charge
The starter contains capacitors that remain charged to a potentially dangerous voltage after the AC supply has been disconnected.
If the starter has been energised, the AC supply must be isolated at least two minutes before work may continue.
Normally, the capacitors are discharged by an internal resistor. Under certain, unusual fault conditions, the capacitors may fail to
discharge. Do not assume that the capacitors have discharged. To protect the user and the equipment, take due care when carrying
out any work on the starter.
1.8.5 Equipment supplied by plug and socket
The control supply terminals of the starter are connected to the internal capacitors through rectifier diodes which are not intended to
give safety isolation. If the plug terminals can be touched when the plug is disconnected from the socket, a means of automatically
isolating the plug from the starter must be used (e.g. a latching relay).
1.8.6 Short circuit
Digistart D3 soft starters are not short circuit proof. After severe overload or short circuit, the operation of the soft starter should be
fully tested by an authorised service agent.
1.8.7 Auto-start
Use the auto-start feature with caution. Read all the notes related to auto-start before operation.
WARNING

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Digistart D3 User Guide 7
Issue: F
2. Rating Data
2.1 Model code
Figure 2-1 Model code explanation
D3 – 1 4 – 0 2 5 5 – N
Bypass
B = internally bypassed
N = non-bypassed
Nominal current rating
Mains voltage
14 = 200 to 440 Vac (± 10%)
16 = 380 to 600 Vac (± 10%)
or 380 to 690 Vac (± 10%) - grounded star supply system only
CAUTION
Digistart D3 can only be used on 690V IT supply equipped with surge protectors. Please contact LEROY-SOMER or
your local distributor.
2.2 Current ratings
Contact your local supplier for ratings under operating conditions not covered by these ratings charts.
2.2.1 Current ratings for bypass operation
AC53b utilisation code
The AC53b utilisation code defines the current rating and standard operating conditions for a bypassed soft starter (internally
bypassed, or installed with an external bypass contactor).
The soft starter’s current rating determines the maximum motor size it can be used with. The soft starter's rating depends on the
number of starts per hour and the length and current level of the start.
The soft starter’s current rating is only valid when used within the conditions specified in the utilisation code. The soft starter may
have a higher or lower current rating in different operating conditions.
Figure 2-2 AC53b utilisation code
80 A : AC-53b 3.5 - 15 : 345
Off time (seconds)
Start time (seconds)
Start current (multiple of motor full load current)
Starter current rating (amperes)
Starter current rating: The full load current rating of the soft starter given the parameters detailed in the remaining sections of the
utilisation code.
Start current: The maximum available start current.
Start time: The maximum allowable start time.
Off time: The minimum allowable time between the end of one start and the beginning of the next start.

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8 Digistart D3 User Guide
Issue: F
Table 2-1 Current ratings - in-line (3-wire) connection, bypassed operation
Model
AC53b 3.0-10:350
40 ºC <1000 metres
AC53b 3.5-15:345
40 ºC <1000 metres
AC53b 4.0-20:340
40 ºC <1000 metres
AC53b 4.5-30:330
40 ºC <1000 metres
D3-1x-0023-B 23 A 20 A 17 A 15 A
D3-1x-0043-B 43 A 37 A 31 A 26 A
D3-1x-0053-B 53 A 53 A 46 A 37 A
Model
AC53b 3.0-10:590
40 ºC <1000 metres
AC53b 3.5-15:585
40 ºC <1000 metres
AC53b 4.0-20:580
40 ºC <1000 metres
AC53b 4.5-30:570
40 ºC <1000 metres
D3-1x-0076-B 76 A 64 A 55 A 47 A
D3-1x-0097-B 97 A 82 A 69 A 58 A
D3-1x-0105-B 105 A 105 A 95 A 78 A
D3-1x-0145-B 145 A 123 A 106 A 90 A
D3-1x-0170-B 170 A 145 A 121 A 97 A
D3-1x-0200-B 200 A 189 A 160 A 134 A
D3-1x-0220-B 220 A 210 A 178 A 148 A
D3-1x-0255-B 255 A 231 A 201 A 176 A
D3-1x-0350-B 350 A 329 A 284 A 244 A
D3-1x-0425-B 425 A 411 A 355 A 305 A
D3-1x-0500-B 500 A 445 A 383 A 326 A
D3-1x-0700-B 700 A 592 A 512 A 438 A
D3-1x-0820-B 820 A 705 A 606 A 516 A
D3-1x-0920-B 920 A 804 A 684 A 571 A
D3-1x-1000-B 1000 A 936 A 796 A 664 A
NOTE
For models D3-1x-0255-N to D3-16-1600-N, these ratings are valid only when externally bypassed using a suitable
contactor.
Table 2-2 Current ratings - in-line (3-wire) connection, externally bypassed
Model
AC53b 3.0-10:590
40 ºC <1000 metres
AC53b 3.5-15:585
40 ºC <1000 metres
AC53b 4.0-20:580
40 ºC <1000 metres
AC53b 4.5-30:570
40 ºC <1000 metres
D3-1x-0255-N 255 A 231 A 201 A 176 A
D3-1x-0360-N 360 A 360 A 310 A 263 A
D3-1x-0430-N 430 A 430 A 368 A 309 A
D3-1x-0650-N 650 A 650 A 561 A 455 A
D3-1x-0790-N 790 A 790 A 714 A 579 A
D3-1x-0930-N 930 A 930 A 829 A 661 A
D3-16-1200-N 1200 A 1200 A 1200 A 1071 A
D3-16-1410-N 1410 A 1410 A 1319 A 1114 A
D3-16-1600-N 1600 A 1600 A 1600 A 1353 A

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Digistart D3 User Guide 9
Issue: F
Table 2-3 Current ratings - inside delta (6-wire) connection, bypassed operation
Model
AC53b 3.0-10:350
40 ºC <1000 metres
AC53b 3.5-15:345
40 ºC <1000 metres
AC53b 4.0-20:340
40 ºC <1000 metres
AC53b 4.5-30:330
40 ºC <1000 metres
D3-1x-0023-B 34 A 30 A 26 A 22 A
D3-1x-0043-B 64 A 59 A 51 A 44 A
D3-1x-0053-B 79 A 79 A 69 A 55 A
Model
AC53b 3.0-10:590
40 ºC <1000 metres
AC53b 3.5-15:585
40 ºC <1000 metres
AC53b 4.0-20:580
40 ºC <1000 metres
AC53b 4.5-30:570
40 ºC <1000 metres
D3-1x-0076-B 114 A 96 A 83 A 70 A
D3-1x-0097-B 145 A 123 A 104 A 87 A
D3-1x-0105-B 157 A 157 A 143 A 117 A
D3-1x-0145-B 217 A 184 A 159 A 136 A
D3-1x-0170-B 255 A 217 A 181 A 146 A
D3-1x-0200-B 300 A 283 A 241 A 200 A
D3-1x-0220-B 330 A 315 A 268 A 223 A
D3-1x-0255-B 382 A 346 A 302 A 264 A
D3-1x-0350-B 525 A 494 A 427 A 366 A
D3-1x-0425-B 638 A 617 A 533 A 458 A
D3-1x-0500-B 750 A 668 A 575 A 490 A
D3-1x-0700-B 1050 A 889 A 768 A 658 A
D3-1x-0820-B 1230 A 1058 A 910 A 774 A
D3-1x-0920-B 1380 A 1206 A 1026 A 857 A
D3-1x-1000-B 1500 A 1404 A 1194 A 997 A
NOTE
For models D3-1x-0255-N to D3-16-1600-N, these ratings are valid only when externally bypassed using a suitable
contactor.
Table 2-4 Current ratings - inside delta (6-wire) connection, externally bypassed
Model
AC53b 3.0-10:590
40 ºC <1000 metres
AC53b 3.5-15:585
40 ºC <1000 metres
AC53b 4.0-20:580
40 ºC <1000 metres
AC53b 4.5-30:570
40 ºC <1000 metres
D3-1x-0255-N 382 A 346 A 302 A 264 A
D3-1x-0360-N 540 A 540 A 465 A 395 A
D3-1x-0430-N 645 A 645 A 552 A 464 A
D3-1x-0650-N 975 A 975 A 842 A 683 A
D3-1x-0790-N 1185 A 1185 A 1071 A 868 A
D3-1x-0930-N 1395 A 1395 A 1244 A 992 A
D3-16-1200-N 1800 A 1800 A 1800 A 1606 A
D3-16-1410-N 2115 A 2115 A 1979 A 1671 A
D3-16-1600-N 2400 A 2400 A 2400 A 2030 A

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10 Digistart D3 User Guide
Issue: F
2.2.2 Current ratings for continuous operation (not bypassed)
AC53a utilisation code
The AC53a Utilisation Code defines the current rating and standard operating conditions for a non-bypassed soft starter.
The soft starter’s current rating determines the maximum motor size it can be used with. The soft starter's rating depends on the
number of starts per hour, the length and current level of the start, and the percentage of the operating cycle that the soft starter will
be running (passing current).
The soft starter’s current rating is only valid when used within the conditions specified in the utilisation code. The soft starter may
have a higher or lower current rating in different operating conditions.
Figure 2-3 AC53a utilisation code
351 A : AC-53a 3.5 - 15 : 50 - 6
Starts per hour
On-load duty cycle (%)
Start time (seconds)
Start current (multiple of motor full load current)
Starter current rating (amperes)
Starter current rating: The full load current rating of the soft starter given the parameters detailed in the remaining sections of the
utilisation code.
Start current: The maximum available start current.
Start time: The maximum allowable start time.
On-load duty cycle: The maximum percentage of each operating cycle that the soft starter can operate.
Starts per hour: The maximum allowable number of starts per hour.
Table 2-5 Current ratings - in-line (3-wire) connection, non-bypassed operation
Model
AC53a 3-10:50-6
40 ºC <1000 metres
AC53a 3.5-15:50-6
40 ºC <1000 metres
AC53a 4-20:50-6
40 ºC <1000 metres
AC53a 4.5-30:50-6
40 ºC <1000 metres
D3-1x-0255-N 255 A 222 A 195 A 171 A
D3-1x-0360-N 360 A 351 A 303 A 259 A
D3-1x-0430-N 430 A 413 A 355 A 301 A
D3-1x-0650-N 650 A 629 A 532 A 437 A
D3-1x-0790-N 790 A 790 A 694 A 567 A
D3-1x-0930-N 930 A 930 A 800 A 644 A
D3-16-1200-N 1200 A 1200 A 1135 A 983 A
D3-16-1410-N 1410 A 1355 A 1187 A 1023 A
D3-16-1600-N 1600 A 1600 A 1433 A 1227 A
Table 2-6 Current ratings - inside delta (6-wire) connection, non-bypassed operation
Model
AC53a 3-10:50-6
40 ºC <1000 metres
AC53a 3.5-15:50-6
40 ºC <1000 metres
AC53a 4-20:50-6
40 ºC <1000 metres
AC53a 4.5-30:50-6
40 ºC <1000 metres
D3-1x-0255-N 382 A 334 A 293 A 257 A
D3-1x-0360-N 540 A 527 A 455 A 388 A
D3-1x-0430-N 645 A 620 A 533 A 451 A
D3-1x-0650-N 975 A 943 A 798 A 656 A
D3-1x-0790-N 1185 A 1185 A 1041 A 850 A
D3-1x-0930-N 1395 A 1395 A 1200 A 966 A
D3-16-1200-N 1800 A 1800 A 1702 A 1474 A
D3-16-1410-N 2115 A 2033 A 1780 A 1535 A
D3-16-1600-N 2400 A 2400 A 2149 A 1840 A

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Digistart D3 User Guide 11
Issue: F
2.2.3 Minimum and maximum current settings
Table 2-7 Minimum and maximum current settings, internally bypassed models
In-line connection Inside delta connection
Model Minimum Maximum Minimum Maximum
D3-1x-0023-B 5 A 23 A 5 A 34 A
D3-1x-0043-B 9 A 43 A 9 A 64 A
D3-1x-0053-B 11 A 53 A 11 A 79 A
D3-1x-0076-B 15 A 76 A 15 A 114 A
D3-1x-0097-B 19 A 97 A 19 A 145 A
D3-1x-0105-B 21 A 105 A 21 A 157 A
D3-1x-0145-B 29 A 145 A 29 A 217 A
D3-1x-0170-B 34 A 170 A 34 A 255 A
D3-1x-0200-B 40 A 200 A 40 A 300 A
D3-1x-0220-B 44 A 220 A 44 A 330 A
D3-1x-0255-B 51 A 255 A 51 A 382 A
D3-1x-0350-B 70 A 350 A 70 A 525 A
D3-1x-0425-B 85 A 425 A 85 A 638 A
D3-1x-0500-B 100 A 500 A 100 A 750 A
D3-1x-0700-B 140 A 700 A 140 A 1050 A
D3-1x-0820-B 164 A 820 A 164 A 1230 A
D3-1x-0920-B 184 A 920 A 184 A 1380 A
D3-1x-1000-B 200 A 1000 A 200 A 1500 A
Table 2-8 Minimum and maximum current settings, externally bypassed models
In-line connection Inside delta connection
Model Minimum Maximum Minimum Maximum
D3-1x-0255-N 51 A 255 A 51 A 382 A
D3-1x-0360-N 72 A 360 A 72 A 540 A
D3-1x-0430-N 86 A 430 A 86 A 645 A
D3-1x-0650-N 130 A 650 A 130 A 975 A
D3-1x-0790-N 158 A 790 A 158 A 1185 A
D3-1x-0930-N 186 A 930 A 186 A 1395 A
D3-16-1200-N 240 A 1200 A 240 A 1800 A
D3-16-1410-N 282 A 1410 A 282 A 2115 A
D3-16-1600-N 320 A 1600 A 320 A 2400 A

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12 Digistart D3 User Guide
Issue: F
3. Mechanical Installation
WARNING
Digistart D3 models D3-1x-0145-B to D3-16-1600-N weigh in excess of 15 kg (33 lb). Use appropriate safeguards
when lifting these models.
WARNING
Models D3-1x-0145-B to D3-1x-1000-B and D3-1x-0255-N to D3-16-1600-N are intended to be mounted in an
enclosure which prevents access except by trained and authorised personnel, and which prevents the ingress of
contamination. The complete range is designed for use in an environment classified as Pollution Degree 3 in
accordance with IEC60664-1. This means conductive pollution or dry, non-conductive pollution which becomes
conductive due to condensation is acceptable.
It is the installer's responsibility to ensure that any enclosure which allows access to models D3-1x-0145-B to
D3-1x-1000-B and D3-1x-0255-N to D3-16-1600-N while the product is energized, provides protection against contact
and ingress requirements of IP20.
Models D3-1x-0145-B to D3-1x-1000-B can be installed with optional finger guards, in which case they do not need to
be mounted in an enclosure.
3.1 Dimensions and weights
NOTE
For further details on Digistart D3 dimensions and corresponding CAD drawings please visit www.leroy-somer.com.
Table 3-1 Dimensions and weights
Model
Size A
mm
(in)
B
mm
(in)
C
mm
(in)
D
mm
(in)
E
mm
(in)
F
mm
(in)
G
mm
(in)
H
mm
(in)
I
mm
(in)
Weight
kg
(lb)
D3-1x-0023-B
D3-1x-0043-B
192 4.2
D3-1x-0053-B G1B 156 124 295 278 (7.6)
(9.3)
D3-1x-0076-B (6.1) (4.9) (11.6) (10.9) n/a n/a n/a n/a
4.5 (9.9)
D3-1x-0097-B
223 5.0
D3-1x-0105-B
(8.8) (11.0)
D3-1x-0145-B
14.0 (30.9)
D3-1x-0170-B G2B 282 250 438 380 250 n/a n/a n/a n/a 14.2 (31.3)
D3-1x-0200-B (11.1) (9.8) (17.2) (15.0) (9.8) 15
D3-1x-0220-B
(33.1)
D3-1x-0255-B 424 376 440 392 298
26 (57.3)
D3-1x-0350-B G3B (16.7) (14.8) (17.3) (15.4) (11.7) n/a n/a n/a n/a 29.4
D3-1x-0425-B
(64.8)
D3-1x-0500-B
50.0 (110.2)
D3-1x-0700-B 433 320 640 600 297
63.5
D3-1x-0820-B G4B (17.0) (12.6) (25.2) (23.6) (11.7) n/a n/a n/a n/a (140.0)
D3-1x-0920-B
64.0
D3-1x-1000-B
(141.1)
D3-1x-0255-N G3N 390
(15.4)
320
(12.6)
460
(18.1)
400
(15.7)
279
(11.0) n/a n/a n/a n/a 23
(50.7)
D3-1x-0360-N 36
D3-1x-0430-N 430 320 689 522 300 104.5 104.5 5.5 8.5 (79.4)
D3-1x-0650-N G4N (16.9) (12.6) (27.1) (20.6) (11.8) (4.1) (4.1) (0.2) (0.3) 39.5
D3-1x-0790-N
(87.1)
D3-1x-0930-N
51.5 (113.5)
D3-16-1200-N
128.5 (283.3)
D3-16-1410-N G5N 574 500 883 727 361 132.5 129 5 8.5 130 (286.6)
D3-16-1600-N (22.6) (19.7) (34.8) (28.6) (14.2) (5.2) (5.1) (0.2) (0.3) 140 (308.7)
NOTE
Dimensions F, G and H are the additional space required for the output and input busbars, in addition to the overall
chassis measurement (C).

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Digistart D3 User Guide 13
Issue: F
Figure 3-1 Unit dimensions (bypassed models)
D3-1x-0023-B, D3-1x-0043-B, D3-1x-0053-B,
D3-1x-0076-B, D3-1x-0097-B, D3-1x-0105-B
D3-1x-0145-B, D3-1x-0170-B,
D3-1x-0200-B, D3-1x-0220-B
14268.A
14269;A
A
B
C
E
D
D3-1x-0255-B, D3-1x-0350-B, D3-1x-0425-B D3-1x-0500-B, D3-1x-0700-B, D3-1x-0820-B,
D3-1x-0920-B, D3-1x-1000-B
14270;A
A
B
C
E
D
A
B
C
E
D
14271.A

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14 Digistart D3 User Guide
Issue: F
Figure 3-2 Unit dimensions (non-bypassed models)
D3-1x-0255-N
A
B
CD
14272.A
D3-1x-0360-N, D3-1x-0430-N, D3-1x-0650-N, D3-1x-0790-N,
D3-1x-0930-N, D3-16-1200-N, D3-16-1410-N, D3-16-1600-N
CD
FI
G
H
E
A
B
14273.A

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Digistart D3 User Guide 15
Issue: F
3.2 Physical installation
Figure 3-3 Mounting clearances
1
3 4
2
08338.A
1 D3-1x-0023-B to D3-1x-0220-B: Allow 100 mm (3.94 in) between soft starters.
D3-1x-0255-B to D3-1x-1000-B: Allow 200 mm (7.88 in) between soft starters.
D3-1x-0255-N: Allow 100 mm (3.94 in) between soft starters.
D3-1x-0360-N to D3-16-1600-N: Allow 200 mm (7.88 in) between soft starters.
2 D3-1x-0023-B to D3-1x-0220-B: Allow 50 mm (1.97 in) between the soft starter and solid surfaces.
D3-1x-0255-B to D3-1x-1000-B: Allow 200 mm (7.88 in) between the soft starter and solid surfaces.
D3-1x-0255-N: Allow 100 mm (3.94 in) between the soft starter and solid surfaces.
D3-1x-0360-N to D3-16-1600-N: Allow 200 mm (7.88 in) between the soft starter and solid surfaces.
3 Soft starters may be mounted side by side with no clearance (that is, if mounted without communications modules).
4 The soft starter may be mounted on its side. Derate the soft starter's rated current by 15%.
3.3 Busbar adjustment procedure
The busbars on non-bypassed models D3-1x-0360-N to D3-16-1600-N can be adjusted for top or bottom input and output as
required.
WARNING
It is the user's responsibility to follow these instructions correctly. LEROY-SOMER cannot be held responsible for any
damage to the starter or associated equipment from incorrect practice.
Figure 3-4 Busbar configuration options (D3-1x-0360-N to D3-16-1600-N)
Input/Output Output Input
08350.A
Input/Output Input Output
NOTE
Many electronic components are sensitive to static electricity. Voltages so low that they cannot be felt, seen or heard,
can reduce the life, affect performance, or completely destroy sensitive electronic components. When performing
service, proper ESD equipment should be used to prevent possible damage from occurring.

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16 Digistart D3 User Guide
Issue: F
All units are manufactured with input and output busbars at the bottom of the unit as standard. The input and/or output busbars can
be moved to the top of the unit if required.
08604.A
1. Remove all wiring and links from the soft starter before
dismantling the unit.
2. Remove the unit cover (4 screws).
3. Remove the keypad faceplate, then gently remove the
keypad (2 screws).
4. Remove the control terminal plugs.
5. Gently fold the main plastic away from the starter (12
screws).
6. Unplug the keypad loom from CON 1 (see note).
7. Label each SCR firing loom with the number of the
corresponding terminal on the backplane PCB, then unplug
the looms.
8. Unplug the thermistor, fan and current transformer wires
from the model board.
9. Remove the plastic tray from the starter (four screws).
NOTE
Remove the main plastic slowly to avoid damaging the keypad wiring loom which runs between the main plastic and
the backplane PCB.
08605.A
10. Unscrew and remove the magnetic bypass plates (models
D3-1x-0430-N to D3-16-1600-N only).
11. Remove the current transformer assembly (three screws).
12. Identify which busbars are to be moved. Remove the bolts
holding these busbars in place then slide the busbars out
through the bottom of the starter (four bolts per busbar).
08606.A
13. Slide the busbars in through the top of the starter. For input
busbars, the short curved end should be outside the starter.
For output busbars, the unthreaded hole should be outside
the starter.
14. Replace the dome washers with the flat face towards the
busbar, then tighten the bolts holding the busbars in place
to 20 Nm.
15. Place the current transformer assembly over the input
busbars and screw the assembly to the body of the starter
(see note).
16. Run all wiring to the side of the starter and secure with
cable ties.
NOTE
If moving the input busbars, the current transformers (CTs) must also be reconfigured.
1. Label the CTs L1, L2 and L3 (L1 is leftmost when looking from the front of the starter). Remove the cable ties and
unscrew the CTs from the bracket.
2. Move the CT bracket to the top of the starter. Position the CTs for the correct phases, then screw the CTs to the
bracket. For models D3-1x-0360-N to D3-1x-0930-N, the CTs must be placed on an angle (the left hand legs of
each CT will be on the top row of holes and the right hand legs will be on the bottom tabs).

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Digistart D3 User Guide 17
Issue: F
4. Electrical Installation
WARNING
Always apply control voltage before (or with) mains voltage.
WARNING
Always follow the specified tightening torque for all power and ground terminal connections.
For specifications and detailed technical data, see Technical Data on page 85.
4.1 Terminal layout
4.1.1 Power input and output configurations
Internally bypassed models
Models D3-1x-0023-B to D3-1x-0220-B have power inputs at the top of the unit and outputs at the bottom of the unit.
Internally bypassed models D3-1x-0255-B to D3-1x-0425-B have output busbars at the bottom of the unit and input busbars at both
the top and bottom of the unit. The AC supply can be connected 'Top in, Bottom out' or 'Bottom in, Bottom out'.
Internally bypassed models D3-1x-0500-B to D3-1x-1000-B have input and output busbars at the top and bottom of the unit. The AC
supply can be connected 'Top in, Bottom out', 'Top in, Top out', 'Bottom in, Bottom out' or 'Bottom in, Top out'.
Figure 4-1 Power input and output terminals (D3-1x-0023-B to D3-1x-1000-B)
D3-1x-0023-B to
D3-1x-0105-B
D3-1x-0145-B to
D3-1x-0220-B
D3-1x-0255-B to D3-1x-0425-B D3-1x-0500-B to D3-1x-1000-B
D3-1x-0255-N
D3-1x-0255-N has dedicated bypass terminals at the bottom of the unit. The bypass terminals are T1B, T2B, T3B.
Figure 4-2 Power input and output terminals (D3-1x-0255-N)
D3-1x-0360-N to D3-16-1600-N
D3-1x-0360-N to D3-16-1600-N have dedicated bypass terminals, on the input busbars. The bypass terminals are L1B, L2B, L3B.
The busbars on non-bypassed models D3-1x-0360-N to D3-16-1600-N can be adjusted for top or bottom input and output as
required. See Busbar adjustment procedure for step-by-step instructions. All units are manufactured top in/bottom out.
For models D3-1x-0360-N to D3-16-1600-N to be UL compliant, these must be mounted Top In, Bottom Out or Top Out, Bottom
In. Refer to UL Compliant Installation on page 87 for more information.
Ready
Run
LocalTrip
LCL
RMT
Reset
F2F1
M
Re ady
Run
Loc alTrip
LCL
RMT
Reset
F2F1
M
6/T34/T 22/T1
5/L33/ L21/L1
Read y
Run
Loc alTri p
LCL
RMT
Reset
F2F1
M
6/T34/T 22/T1 5/L33/L21/L1
6/ T 34/T22/T1 5/L33/L21/L 1
Re ady
Run
LocalTrip
LCL
RMT
Reset
F2F1
M
6/T 34/ T22/T1 5/L33/L 21/L1
5/L33/ L21/ L1
1/L1, 3/L2, 5/L3
2/T1, 4/T2, 6/T3
1/L1 3/L2 5/L3
2/T1 4/T2 6/T3
1/L1 3/L2 5/L3
2/T1 4/T2 6/T3
1/L1 3/L2 5/L3
2/T1 4/T2 6/T3
1/L1 3/L2 5/L3
1/L1 3/L2 5/L3
2/T1 4/T2 6/T3
1498 7.A
Ready
Run
LocalTr ip
LCL
RMT
Reset
F2F1
M
1
/
L1 3
/
L2 5
/
L3
T1B T2B T3B
2/T1 4/T2 6/T3
14990.A
NOTE

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18 Digistart D3 User Guide
Issue: F
4.1.2 Power terminations
Use only copper stranded or solid conductors, rated for 75 ºC or higher.
NOTE
Some units use aluminium busbars. When connecting power terminations, we recommend cleaning the surface
contact area thoroughly (using an emery or stainless steel brush) and using an appropriate jointing compound to
prevent corrosion.
NOTE
For personnel safety, the power terminals on models up to D3-1x-0105-B are protected by snap-off tabs. When using
large cables, it may be necessary to break off these tabs.
Figure 4-3 Cable sizes, busbar dimensions and maximum torque settings
D3-1x-0023-B to D3-1x-0105-B
4 Nm (2.9 ft-lb)
14 mm (0.55 in) 5-60 mm2(10-1/0 AWG) T20 x 150 7 mm x 150
D3-1x-0145-B D3-1x-0170-B to D3-1x-0220-B
19 Nm (14.0 ft-lb) 38 Nm (28.0 ft-lb)
D3-1x-0255-B D3-1x-0350-B to D3-1x-0425-B
38 Nm (28.0 ft-lb) 38 Nm (28.0 ft-lb)
D3-1x-0500-B to D3-1x-1000-B D3-1x-0255-N
38 Nm (28.0 ft-lb) 38 Nm (28.0 ft-lb)
D3-1x-0360-N to D3-1x-0930-N D3-16-1200-N to D3-16-1600-N
38 Nm (28.0 ft-lb) 66 Nm (48.7 ft-lb)
11290.A
11291.A
6mm19 mm
8.5 mm
(M8)
08351.B
08352.B
6mm19 mm
10.5 mm
(M10)
5mm
28 mm
11 mm
(M10)
13181.B
6mm
28 mm
11 mm
(M10)
14543.A
13 mm
32 mm
11 mm
(M10)
09866.B
6mm
32 mm
10.5 mm
(M10)
08353.B
13 mm32 mm
10.5 mm
(M10)
08354.B
16 mm51 mm
12.5 mm
(M12)
08355.B

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Digistart D3 User Guide 19
Issue: F
4.1.3 Ground terminals
Ground terminals are located at the back of the soft starter.
D3-1x-0023-B to D3-1x-0105-B have one terminal on the input side (top).
D3-1x-0145-B to D3-1x-1000-B and D3-1x-0255-N to D3-16-1600-N have two terminals, one on the input side (top) and
one on the output side (bottom).
The ground terminal may also be used for a ground shield connection if necessary.
Tighten the cables as follows:
Table 4-1 Ground terminal maximum torque settings
Models Terminal size Torque
D3-1x-0023-B to D3-1x-0105-B M6 3 Nm
D3-1x-0145-B to D3-1x-0255-B M8 5 Nm
D3-1x-0255-N M8 5 Nm
D3-1x-0350-B to D3-1x-1000-B M10 8.5 Nm
D3-1x-0360-N to D3-16-1600-N M10 8.5 Nm
Figure 4-4 Ground terminal locations
D3-1x-0023-B to D3-1x-0105-B D3-1x-0255-B to D3-1x-1000-B D3-1x-0145-B to D3-1x-0220-B, D3-1x-0255-N to
D3-16-1600-N
4.1.4 Control terminals
CAUTION
Always connect control voltage to the correct terminals:
110 to 210 Vac: CSL-CSR or
220 to 440 Vac: CSH-CSR
WARNING
The installer must ensure that the external control circuits are insulated from human contact by at least one layer of
insulation (supplementary insulation) rated for use at the AC supply voltage.
Control terminations use 2.5mm2plug-in terminal blocks. Unplug each block, complete the wiring, then reinsert the block.
Figure 4-5 Control terminal layout
08339.A
220~440 VAC
110~21 0 VAC

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20 Digistart D3 User Guide
Issue: F
4.1.5 Start/stop control logic
The Digistart D3 has three fixed inputs for remote control. These inputs should be controlled by contacts rated for low voltage, low
current operation (gold flash or similar).
The maximum cable run is determined by the type of cable used, provided the maximum resistance of this cable does not exceed
100 Ohms. The cables must be twisted in pairs and shielded. The shield must be grounded at one end only, that is, at the soft
starter end. To avoid any EMC disturbance from the motor power cables, the thermistor cable must be separated from the motor
power cables by a minimum parallel distance of 300 mm.
Figure 4-6 Control wiring options
1 2 3
+24V
DI2
+24V
DI1
+24V
DI3
EEE
+24V
DI2
+24V
DI1
+24V
DI3
+24V
DI2
+24V
DI1
+24V
DI3
08340.A
Start/stop
Reset
Start
Stop
Reset
Start
Stop
Reset
1 Two-wire control
2 Three-wire control
3 Four-wire control
NOTE
For comprehensive information on control connection, see Control connections on page 21.
CAUTION
Do not apply voltage to the control input terminals. These are active 24 Vdc inputs and must be controlled with
potential free contacts.
Cables to the control inputs must be segregated from mains voltage and motor cabling.
NOTE
You can set the Reset input to either NO or NC (default). See Pr 3N Remote Reset Logic.
4.1.6 Relay outputs
The Digistart D3 provides four relay outputs, one fixed and three programmable.
The Run output closes when the soft start is complete (when the starting current falls below 120% of the programmed motor full load
current) and remains closed until the beginning of a stop (either soft stop or coast to stop).
Operation of the programmable outputs is determined by the settings of Pr 4A to 4I.
If assigned to Main Contactor, the output activates as soon as the soft starter receives a start command and remains
active while the soft starter is controlling the motor (until the motor starts a coast to stop, or until the end of a soft stop).
If assigned to a trip function, the output activates when a trip occurs.
If assigned to a flag, the output activates when the specified flag is active (Pr 7A to 7C).
CAUTION
Some electronic contactor coils are not suitable for direct switching with PCB mount relays. Consult the contactor
manufacturer/supplier to confirm suitability.
Three additional outputs are available on the input/output expansion card.
4.1.7 Motor thermistors
Motor thermistors can be connected directly to the Digistart D3. The soft starter will trip when the resistance of the thermistor circuit
exceeds approximately 3.6 kor falls below 20 .
Figure 4-7 Motor thermistor connection
No motor thermistors
Motor thermistors
TH2
TH1
TH2
TH1
08528.A
E
Thermistor input
NOTE
If no motor thermistors are connected to the Digistart D3 thermistor input terminals TH1, TH2 must be open. If TH1,
TH2 are shorted, the Digistart D3 will trip.
The thermistor circuit should be run in screened cable and must be electrically isolated from ground and all other power
and control circuits.