Leroy-Somer DIGISTART D3 User manual

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4373 en - 2010.09 / b
Electronic Soft Starter
Getting started guide
D
IGISTART

Copyright © September 2010 LEROY SOMER
Issue: B 2:noisreVtcudorP
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
LEROY SOMER is committed to minimising the environmental impacts of its manufacturing operations and of its products
throughout their life cycle. 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. Virtually all parts of the product are suitable for recycling.
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. LEROY SOMER's
packaging strategy favours easily recyclable materials of low environmental impact, and regular reviews identify opportunities for
improvement.
When preparing to recycle or dispose of any product or packaging, 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 Getting Started Guide 3
Issue: B www.leroy-somer.com
Contents
1.Safety Information ............................................................................................................................................4
1.1Warnings, cautions and notes....................................................................................................................................................4
1.2Electrical safety - general warning.............................................................................................................................................4
1.3System design and safety of personnel.....................................................................................................................................4
1.4Environmental limits...................................................................................................................................................................4
1.5Compliance with regulations......................................................................................................................................................4
1.6Motor..........................................................................................................................................................................................4
1.7Adjusting parameters.................................................................................................................................................................4
1.8Electrical installation...................................................................................................................................................................5
2.Rating Data........................................................................................................................................................6
2.1Model code.................................................................................................................................................................................6
2.2Current ratings ...........................................................................................................................................................................6
3.Mechanical Installation.....................................................................................................................................9
3.1Dimensions and weights..........................................................................................................................................................10
3.2Physical installation..................................................................................................................................................................12
4.Electrical Installation......................................................................................................................................13
4.1Terminal layout.........................................................................................................................................................................13
4.2Control connections .................................................................................................................................................................17
4.3Power connections...................................................................................................................................................................18
4.4Fuse information ......................................................................................................................................................................21
4.5Bypass contactor......................................................................................................................................................................24
4.6Main contactor..........................................................................................................................................................................24
4.7Circuit breaker..........................................................................................................................................................................24
4.8EMC (electromagnetic compatibility)........................................................................................................................................24
5.Keypad and Status..........................................................................................................................................25
5.1Keypad.....................................................................................................................................................................................25
5.2Displays....................................................................................................................................................................................25
6.Quick Start Commissioning...........................................................................................................................27
6.1Control wiring...........................................................................................................................................................................27
6.2Setup procedure.......................................................................................................................................................................28
7.Operation.........................................................................................................................................................29
7.1Start, stop and reset commands..............................................................................................................................................29
7.2Using the soft starter to control a motor...................................................................................................................................29
7.3Soft start methods....................................................................................................................................................................29
7.4Stop methods...........................................................................................................................................................................30
7.5Jog ...........................................................................................................................................................................................31
7.6Inside delta operation...............................................................................................................................................................31
8.Programming...................................................................................................................................................32
8.1Programming menu..................................................................................................................................................................32
8.2Access code.............................................................................................................................................................................32
8.3Adjustment lock........................................................................................................................................................................33
8.4Load defaults............................................................................................................................................................................33
8.5Quick setup details...................................................................................................................................................................34
8.6Standard menu.........................................................................................................................................................................35
8.7Advanced menu.......................................................................................................................................................................36
8.8Parameter descriptions............................................................................................................................................................36
9.Diagnostics......................................................................................................................................................42
9.1Protection responses ...............................................................................................................................................................42
9.2Trip messages..........................................................................................................................................................................42
9.3General faults...........................................................................................................................................................................45
10.Technical Data.................................................................................................................................................47
11.Maintenance....................................................................................................................................................49
11.1Care .........................................................................................................................................................................................49
11.2Measuring the motor current....................................................................................................................................................49
11.3Measuring the input and output power.....................................................................................................................................49
11.4Exchanging products................................................................................................................................................................49
12.Options ............................................................................................................................................................50

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1. Safety Information
1.1 Warnings, cautions and notes
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.
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, i.e. 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:
98/37/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.
WARNING
CAUTION
NOTE

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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:
xAC supply cables and connections
xOutput cables and connections
xMany 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 perf
ormed.
Models D3-1x-0350-B to D3-1x-1000-B, D3-1x-0360-N to D3-16-1600-N: The busbar and heatsink are live while the unit is operating
(starting, running or stopping). If the starter is installed without a main contactor, the busbar and heatsink are live whenever mains
voltage is connected (including when the starter is ready or tripped).
1.8.2 Power-up procedure
Always apply control voltage before (or with) mains voltage.
D3-1x-0023-B to D3-1x-0220-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.

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2. Rating Data
2.1 Model code
Figure 2-1 Model code explanation
D3 – 1 4 – 0 2 5 5 – N
Bypass
B = Internal
N = Non-bypassed
Nominal current rating
Mains voltage
14 = 200 to 440 Vac
16 = 380 to 600 Vac (± 10%)
16 = 380 to 690 Vac (± 10%) (grounded star supply system
only)
Digistart D3 can only be used on 690V IT supply equipped with surge protectors.
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, the length and current level of the start, and the amount of time the soft starter will be off (not passing
current) between starts.
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.
For models D3-1x-0255-N, 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 these ratings are valid only when externally bypassed using a suitable contactor.
NOTE
NOTE

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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-N 255 A 231 A 201 A 176 A
D3-1x-0350-B 350 A 306 A 266 A 230 A
D3-1x-0360-N 360 A 360 A 310 A 263 A
D3-1x-0425-B 425 A 371 A 321 A 276 A
D3-1x-0430-N 430 A 430 A 368 A 309 A
D3-1x-0500-B 500 A 445 A 383 A 326 A
D3-1x-0650-N 650 A 650 A 561 A 455 A
D3-1x-0700-B 700 A 592 A 512 A 438 A
D3-1x-0790-N 790 A 790 A 714 A 579 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-0930-N 930 A 930 A 829 A 661 A
D3-1x-1000-B 1000 A 936 A 796 A 664 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
Table 2-2 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 35 A 30 A 26 A 22 A
D3-1x-0043-B 65 A 59 A 51 A 44 A
D3-1x-0053-B 80 A 80 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 146 A 123 A 104 A 87 A
D3-1x-0105-B 158 A 158 A 143 A 117 A
D3-1x-0145-B 218 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-N 383 A 346 A 302 A 264 A
D3-1x-0350-B 525 A 459 A 399 A 345 A
D3-1x-0360-N 540 A 540 A 465 A 395 A
D3-1x-0425-B 638 A 557 A 482 A 414 A
D3-1x-0430-N 645 A 645 A 552 A 464 A
D3-1x-0500-B 750 A 668 A 575 A 490 A
D3-1x-0650-N 975 A 975 A 842 A 683 A
D3-1x-0700-B 1050 A 889 A 768 A 658 A
D3-1x-0790-N 1185 A 1185 A 1071 A 868 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-0930-N 1395 A 1395 A 1244 A 992 A
D3-1x-1000-B 1500 A 1404 A 1194 A 997 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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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 2-3 Current ratings - in-line 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 2-4 Current ratings - inside delta 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 383 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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3. Mechanical Installation
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.
Models D3-1x-0145-B 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
D3-16-1600-N while the product is energized, provides protection against contact and ingress requirements of IP20.
Models D3-1x-0145-B to D3-1x-0220-B can be installed with optional finger guards, in which case they do not need to be
mounted in an enclosure.
WARNING
WARNING

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3.1 Dimensions and weights
For further details on Digistart D3 dimensions and corresponding CAD drawings please visit www.leroy-somer.com.
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)
Weight
kg
(lb)
D3-1x-0023-B
G1B 156.4
(6.16) 124.0 (4.88) 294.6 (11.60) 278.0 (10.94)
196.2
(7.72) n/a n/a n/a
3.2
(7.05)
D3-1x-0043-B
D3-1x-0053-B
D3-1x-0076-B 226.7
(8.92) 3.5 (7.22)
D3-1x-0097-B 4.8
(10.58)
D3-1x-0105-B
D3-1x-0145-B
G2B 282
(11.10) 250 (9.84) 438 (17.24) 380 (14.96) 254 (10.00) n/a n/a n/a 16 (35.27)
D3-1x-0170-B
D3-1x-0200-B
D3-1x-0220-B
D3-1x-0255-N G3N 394
(15.51) 320 (12.60) 460 (18.11) 400 (15.75) 284 (11.18) n/a n/a n/a 25 (55.12)
D3-1x-0350-B
G4B 438
(17.24) 320 (12.60) 640 (25.20) 600 (23.62) 300 (11.81) n/a n/a n/a 60.0 (132.3)
D3-1x-0425-B
D3-1x-0500-B
D3-1x-0700-B
D3-1x-0820-B
D3-1x-0920-B
D3-1x-1000-B
D3-1x-0360-N
G4N 430
(16.93) 320 (12.60) 556 (21.89) 522 (20.55) 302 (11.89) 104.5 (4.11) 104.5 (4.11) 5.5 (0.22)
50.5
(111.33)
D3-1x-0430-N
D3-1x-0650-N 53.5
(117.95)
D3-1x-0790-N
D3-1x-0930-N
D3-16-1200-N G5N 574
(22.60) 500 (19.69) 750 (29.53) 727 (28.62) 364 (14.33) 132.5 (5.22) 129 (5.08) 5 (0.20) 140 (308.65)
D3-16-1410-N
D3-16-1600-N
Dimensions F, G and H are the additional space required for the output and input busbars, in addition to the overall
chassis measurement (C).
NOTE
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Figure 3-1 Unit dimensions
08 3 37 .C
F
A
BG
C CD
E
H
A
B
C D
EE
CD
A
B
E
C D
B
A
A
BE
C D
G1B G2B
G3N G4B
G4N - G5N

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3.2 Physical installation
Figure 3-2 Mounting clearances
1D3-1x-0023-B to D3-1x-0255-N: Allow 100 mm (3.94 in) between soft starters.
D3-1x-0350-B to D3-1x-1000-B: Allow 200 mm (7.88 in) between soft starters.
D3-1x-0360-N to D3-16-1600-N: Allow 200 mm (7.88 in) between soft starters.
2D3-1x-0023-B to D3-1x-0220-B: Allow 50 mm (1.97 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-0350-B to D3-1x-1000-B: Allow 200 mm (7.88 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.
3Soft starters may be mounted side by side with no clearance.
4The soft starter may be mounted on its side. Derate the soft starter's rated current by 15%.
1
3 4
2
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4. Electrical Installation
Always apply control voltage before (or with) mains voltage.
Always follow the specified tightening torque for all power and ground terminal connections.
For specifications and detailed technical data, see Technical Data on page 47.
4.1 Terminal layout
4.1.1 Power terminations
Use only copper stranded or solid conductors, rated for 75 ºC.
Some units use aluminium bus bars. 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.
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.
Models which are internally bypassed do not require an external bypass contactor.
WARNING
WARNING
NOTE
NOTE

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Figure 4-1 Cable sizes, busbar dimensions and maximum torque settings (D3-1x-0023-B to D3-16-1600-N)
D3-1x-0023-B to D3-1x-0105-B
Power (L1/T1, L2/T2, L3/T3)
14 (0.55)
mm (in)
5-60 (10-1/0)
mm2 (AWG)
Torx
T20 x 150 Torque = 4 Nm 2.9 Ft-lb
Flat
7mm x 150 Torque = 4 Nm 2.9 Ft-lb
D3-1x-0145-B D3-1x-0170-B to D3-1x-0220-B
8.5 Nm (6.3 ft-lb) 8.5 Nm (6.3 ft-lb)
D3-1x-0255-N 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
17 Nm (12.5 ft-lb) 38 Nm (28.5 ft-lb)
D3-1x-0360-N, D3-1x-0430-N, D3-1x-0650-N,
D3-1x-0790-N, D3-1x-0930-N D3-16-1200-N to D3-16-1600-N
38 Nm (28.5 ft-lb) 58 Nm (42.7 ft-lb)
4.1.2 Ground terminals
Ground terminals are located at the back of the soft starter.
xD3-1x-0023-B to D3-1x-0105-B have one terminal on the input side (top).
xD3-1x-0145-B 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.
11290.A
11291.A
6 mm
32 mm
10.5 mm
08353. A
6mm
32 mm
11 mm
09866.A
13 mm32 mm
10.5 mm
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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-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 4-2 Ground terminal locations
D3-1x-0023-B to D3-1x-0105-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
D3-1x-0145-B to D3-16-1600-N
4.1.3 Control terminals
Always connect control voltage to the correct terminals:
x110 to 210 Vac: CSL-CSR or
x220 to 440 Vac: CSH-CSR
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 4-3 Control terminal layout
CAUTION
WARNING
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220~440 VAC
110~21 0 VAC

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4.1.4 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 4-4 Control wiring options
1Two-wire control
2Three-wire control
3Four-wire control
For comprehensive information on control connection, see Control connections on page 17.
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.
You can set the Reset input to either NO or NC (default). See Pr 3N Remote Reset Logic.
4.1.5 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.
xIf 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).
xIf assigned to a trip function, the output activates when a trip occurs.
xIf assigned to a flag, the output activates when the specified flag is active (Pr 7A to 7C).
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.
4.1.6 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 60 :.
Figure 4-5 Motor thermistor connection
No motor thermistors
Motor thermistors
Thermistor input
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
NOTE
CAUTION
NOTE
CAUTION
TH2
TH1
TH2
TH1
08528.A
E

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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.
4.2 Control connections
Figure 4-6 Digistart D3 electrical schematic
1Control voltage DI1, +24V Start
2Remote control inputs DI2, +24V Stop
3Motor thermistor input DI3, +24V Reset
4A RTD/PT100 input - 2-wire DI4, +24V Programmable input A
4B RTD/PT100 input - 3-wire DI5, +24V Programmable input B
4C RTD/PT100 input - 4-wire COM1, RLO1 Relay output A
524 Vdc output COM2, RLO2 Run relay output
6Relay outputs COM3, RLC3, RLO3 Relay output B
7Analog output COM4, RLC4, RLO4 Relay output C
The Digistart D3 can be commanded to emergency stop the motor, ignoring the soft stop mode set in Pr 2H.
When the circuit across DI4, +24V is opened, the soft starter allows the motor to coast to stop.
To use the emergency stop function, set Pr 3A to 'Emergency Stop' (this is the default setting).
If emergency stop is not required, change the setting of Pr 3A or connect a link across DI4, +24V.
NOTE
08347.A
5
4
3
2
1
RLC3
COM3
COM1
RLO1
+24V
0V
RLO2
COM2
RLO3
AO1
0V
COM4
RLC4
RLO4
TH2
TH1
DI2
+24V
DI3
+24V
DI4
+24V
+24V
+24V
DI5
PT4
PT5
PT3
CSR
CSL
CSH
DI1
110-210 VAC +10%
-15%
220-440 VAC +10%
-15%
A
PT4
PT5
PT3
C
PT4
PT5
PT3
BB E
7
6

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For keypad control, the soft starter requires:
xcontrol supply connections (terminals CSH, CSL, CSR depending on the control voltage)
xprogrammable input A (DI4, +24V) must be closed or Pr 3A Input A Function must be changed from Emergency Stop
4.3 Power connections
4.3.1 Motor connection
Digistart D3 soft starters can be connected to the motor in-line or inside delta (also called three-wire and six-wire connection). The
Digistart D3 will automatically detect the motor connection and perform the necessary calculations internally, so it is only necessary to
program the motor full load current (Pr 1A).
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.
Models which are internally bypassed do not require an external bypass contactor.
Internally 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, 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
Non-bypassed models:
D3-1x-0255-N, 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
4.3.2 In-line installation
xIn-line installation, internally bypassed
Figure 4-7 Power connections - in-line installation, internally bypassed
KM1 Main contactor (optional)
F1 Semiconductor fuses (optional)
Main contactor is the default setting for Pr 4A Relay A Action (COM1, RLO1).
NOTE
6/T3
2/T1
5/L3
3/L2
1/L1
COM1
RLO1
4/T2
E
KM1
KM1 F1
M
3
08341.A
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xIn-line installation, externally bypassed
Non-bypassed models have dedicated bypass terminals, which allow the Digistart D3 to continue providing protection and monitoring
functions even when bypassed via an external bypass contactor. The bypass contactor must be connected to the bypass terminals
and controlled by the soft starter's run output (terminals COM2, RLO2).
Figure 4-8 Power connections - in-line installation, externally bypassed
KM1 Main contactor (optional) F1 Semiconductor fuses (optional)
KM2 Bypass contactor (external)
The bypass terminals on D3-1x-0255-N are T1B, T2B, T3B. The bypass terminals on D3-1x-0360-N to D3-16-1600-N are
L1B, L2B, L3B.
The fuses can be installed on the input side if required.
Main contactor is the default setting for Pr 4A Relay A Action (COM1, RLO1). Output relay COM2, RLO2 is dedicated to
Run output operation and is ideal for managing an external bypass contactor.
xIn-line installation, non-bypassed
Figure 4-9 Power connections - in-line installation, non-bypassed
KM1 Main contactor (optional)
F1 Semiconductor fuses (optional)
NOTE
NOTE

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4.3.3 Inside delta installation
When connecting the Digistart D3 in inside delta configuration, always install a main contactor or shunt trip circuit breaker.
xInside delta installation, internally bypassed
Figure 4-10 Power connections - inside delta installation, internally bypassed
KM1 Main contactor
F1 Semiconductor fuses (optional)
xInside delta installation, externally bypassed
Non-bypassed models have dedicated bypass terminals, which allow the Digistart D3 to continue providing protection and monitoring
functions even when bypassed via an external bypass contactor. The bypass contactor must be connected to the bypass terminals
and controlled by the soft starter's run output (terminals COM2, RLO2).
Figure 4-11 Power connections - inside delta installation, externally bypassed
KM1 Main contactor F1 Semiconductor fuses (optional)
KM2 Bypass contactor (external)
CAUTION
08344.A
M
3
6/T3
2/T1
COM1
RLO1
4/T2
KM1
U1(1) U2(4)
V1(2) V2(5)
W1(3) W2(6)
5/L3
3/L2
1/L1
E
KM1 F1