Nidec LEROY-SOMER Digistart D5 User manual

24 A -1250 A
200-525 VAC, 380-690 VAC
Reference: 6052 en - 2021.10 / a
Digistart D5
User Guide:
Digital soft starter

Product Compatibility
This user manual issuitable for use with Digistart D5 soft starters version 7 (user interface
software 3.0and motor control code 4.x).
The software versions screen reports the version of each software component in the starter.
For other versions, please contact your local supplier.
Certifications
CE ...................................................................................................... EN 60947-4-2
C-UL ............... CAN/CSA-C22.2 Nº 60947-1-13, CAN/CSA-C22.2 Nº 60947-4-2-14
UL ..................................................................................................... UL 60947-4-2
24B~1250B .......................................................................................... UL Listed
735C~1220C ....................................................................................... UL Listed
RCM .................................................................................................. IEC 60947-4-2

1
Contents
1About this manual ............................................................................................................. 3
1.1 Disclaimer ........................................................................................................................... 3
2Caution statements ........................................................................................................... 4
2.1 Electrical shock risk............................................................................................................. 4
2.2 Unexpected operation ......................................................................................................... 5
2.3 Avertissements à l'attention des clients canadiens .............................................................. 5
3System design................................................................................................................... 8
3.1 Feature list .......................................................................................................................... 8
3.2 Model code.......................................................................................................................... 8
3.3 Model selection ................................................................................................................... 9
3.4 Current ratings................................................................................................................... 10
3.5 Dimensions and weights.................................................................................................... 14
3.6 Physical installation ........................................................................................................... 15
3.7 Accessories....................................................................................................................... 15
3.8 Main contactor or circuit breaker ....................................................................................... 16
3.9 External bypass contactor ................................................................................................. 16
3.10 Power factor correction...................................................................................................... 17
3.11 Short circuit protection devices (SCPD)............................................................................. 17
3.12 IEC coordination with short circuit protection devices ........................................................ 18
3.13 UL coordination with short circuit protection devices ......................................................... 19
3.14 Specifications .................................................................................................................... 26
3.15 Disposal instructions ......................................................................................................... 27
4Installation ....................................................................................................................... 28
4.1 Command source .............................................................................................................. 28
4.2 Setup procedure overview................................................................................................. 28
4.3 Inputs ................................................................................................................................ 29
4.4 Outputs ............................................................................................................................. 30
4.5 Control voltage .................................................................................................................. 32
4.6 Power terminations............................................................................................................ 32
4.7 External bypass contactor ................................................................................................. 34
4.8 Motor connection............................................................................................................... 34
4.9 Earth terminations ............................................................................................................. 36
4.10 Typical installation ............................................................................................................. 36
4.11 Quick setup ....................................................................................................................... 39
5Setup tools....................................................................................................................... 40
5.1 Set date and time .............................................................................................................. 40
5.2 Command source .............................................................................................................. 40
5.3 Commissioning.................................................................................................................. 40
5.4 Run simulation................................................................................................................... 40
5.5 Load/save settings ............................................................................................................ 41
5.6 USB save and load............................................................................................................ 42
5.7 Auto-start/stop................................................................................................................... 43
5.8 Network address ............................................................................................................... 43
5.9 Digital I/O state.................................................................................................................. 44
5.10 Analog I/O state................................................................................................................. 44
5.11 Serial number and rating ................................................................................................... 44
5.12 Software versions.............................................................................................................. 44
5.13 Thermistor reset ................................................................................................................ 45
5.14 Reset thermal model ......................................................................................................... 45

2
6Logs ................................................................................................................................. 46
6.1 Event log ........................................................................................................................... 46
6.2 Counters............................................................................................................................ 46
6.3 QR code............................................................................................................................ 46
7Keypad and feedback...................................................................................................... 47
7.1 The keypad ....................................................................................................................... 47
7.2 Remote keypad ................................................................................................................. 47
7.3 Lighten/darken the display................................................................................................. 48
7.4 Starter status LEDs ........................................................................................................... 48
7.5 Displays............................................................................................................................. 48
8Operation ......................................................................................................................... 50
8.1 Start, stop and reset commands........................................................................................ 50
8.2 Command override............................................................................................................ 50
8.3 Auto-start/stop................................................................................................................... 50
8.4 PowerThrough................................................................................................................... 51
8.5 Emergency mode .............................................................................................................. 51
8.6 Auxiliary trip....................................................................................................................... 51
8.7 Typical control methods..................................................................................................... 52
8.8 Soft start methods ............................................................................................................. 53
8.9 Stop methods .................................................................................................................... 55
8.10 Pump clean ....................................................................................................................... 59
8.11 Reverse direction operation............................................................................................... 59
8.12 Jog operation .................................................................................................................... 60
8.13 Inside delta operation ........................................................................................................ 61
8.14 Secondary motor set ......................................................................................................... 61
9Programmable parameters ............................................................................................. 62
9.1 Main menu ........................................................................................................................ 62
9.2 Altering parameter values.................................................................................................. 62
9.3 Adjustment lock ................................................................................................................. 62
9.4 Parameter list .................................................................................................................... 63
9.5 1 Motor Details .................................................................................................................. 69
9.6 2 Motor Start/Stop ............................................................................................................. 70
9.7 3 Motor Start/Stop-2 .......................................................................................................... 72
9.8 4 Auto-Start/Stop............................................................................................................... 75
9.9 5 Protection Levels............................................................................................................ 77
9.10 6 Protection Action ............................................................................................................
79
9.11 7 Inputs ............................................................................................................................. 83
9.12 8 Relay Outputs................................................................................................................. 85
9.13 9 Analog Output ................................................................................................................ 87
9.14 10 Display ......................................................................................................................... 87
9.15 11 Pump Clean.................................................................................................................. 90
9.16 12 Communications Card .................................................................................................. 91
9.17 20 Advanced ..................................................................................................................... 93
9.18 30 Smart Card Parameters................................................................................................ 95
9.19 40 Ground Fault ................................................................................................................ 95
10 Troubleshooting .............................................................................................................. 96
10.1 Protection responses......................................................................................................... 96
10.2 Trip messages................................................................................................................... 96
10.3 General faults.................................................................................................................. 103

About this manual
3
1 About this manual
WARNING
Indicates a hazard that may cause personal injury or death.
CAUTION
Indicates a hazard that may damage the equipment or installation.
NOTE
Provides helpful information.
1.1 Disclaimer
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.

Caution statements
4
2 Caution statements
Caution statements cannot cover every potential cause of equipment damage but can
highlight common causes of damage. It is the installer's responsibility to read and
understand all instructions in this manual prior to installing, operating or maintaining the
equipment, 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.
NOTE
The soft starter is not user serviceable. The unit should only be serviced by
authorised service personnel. Unauthorised tampering with the unit will void
the product warranty.
FOR YOUR SAFETY
The STOP function of the soft starter does not isolate dangerous voltages from
the output of the starter. The soft starter must be disconnected by an approved
electrical isolation device before accessing electrical connections.
Soft starter protection features apply to motor protection only. It is the user’s
responsibility to ensure safety of personnel operating machinery.
The soft starter is a component designed for integration within an electrical
system; it is therefore the responsibility of the system designer/user to ensure
the system is safe and designed to comply with relevant local safety standards.
2.1 Electrical shock risk
WARNING – ELECTRICAL SHOCK HAZARD
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
SHORT CIRCUIT
The soft starter is 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.
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.

Caution statements
5
2.2 Unexpected operation
WARNING – ACCIDENTAL STARTS
In some installations, accidental starts may pose an increased risk to safety of
personnel or damage to the machines being driven. In such cases, it is
recommended that the power supply to the soft starter is fitted with an isolating
switch and a circuit-breaking device (eg power contactor) controllable through an
external safety system (eg emergency stop, fault detector).
WARNING – STARTER MAY START OR STOP UNEXPECTEDLY
The soft starter will respond to control commands from various sources, and could
start or stop unexpectedly. Always disconnect the soft starter from mains voltage
before accessing the starter or load.
WARNING – DISCONNECT MAINS BEFORE ACCESSING STARTER OR
LOAD
The soft starter has built-in protections which can trip the starter in the event of
faults and thus stop the motor. Voltage fluctuations, power cuts and motor jams
may also cause the motor to trip.
The motor could restart after the causes of shutdown are rectified, which may be
dangerous for personnel. Always disconnect the soft starter from mains voltage
before accessing the starter or load.
CAUTION – MECHANICAL DAMAGE FROM UNEXPECTED RESTART
The motor could restart after the causes of shutdown are rectified, which may be
dangerous for certain machines or installations. In such cases, it is essential that
appropriate arrangements are made against restarting after unscheduled stops of
the motor.
2.3 Avertissements à l'attention des clients canadiens
AVERTISSEMENT
L'icône AVERTISSEMENT ci-contre signale les informations concernant des
risques pouvant entraîner des blessures graves, voire mortelles. Pour votre
sécurité, veuillez consulter les avertissements sur cette page ou demander une
copie du présent manuel en français auprès de votre distributeur local.
AVERTISSEMENT – RISQUE DE CHOC ÉLECTRIQUE
Les zones suivantes sont soumises à des tensions pouvant provoquer des risques
de chocs électriques graves, voire mortels :
•Raccordement et câbles d'alimentation AC
•Câbles et raccordements de sortie
•De nombreuses pièces internes du démarreur

Caution statements
6
PAR SÉCURITÉ
•La fonction STOP du démarreur progressif n'isole pas des tensions
dangereuses de la sortie du démarreur. Le démarreur progressif doit être
déconnecté par un dispositif d'isolement électrique approprié avant d'accéder
aux connexions électriques.
•Les fonctions de protection du démarreur progressif ne concernent que la
protection du moteur. Il relève de la responsabilité de l'utilisateur d'assurer la
sécurité des personnes travaillant sur les machines.
•Le démarreur progressif est un appareil conçu pour s'intégrer dans un système
électrique ; il relève donc de la responsabilité du concepteur ou de l'utilisateur
de veiller à ce que ce système soit sûr et conçu selon les normes de sécurité
locales en vigueur.
AVERTISSEMENT – DÉMARRAGES ACCIDENTELS
Dans certaines installations, des démarrages accidentels peuvent provoquer un
risque supplémentaire pour la sécurité des personnes ou endommager les
machines contrôlées. Dans de tels cas, il est recommandé de doter l'alimentation
du démarreur progressif d'un interrupteur d'isolement et d'un coupe-circuit (par
exemple, un disjoncteur) contrôlable à partir d'un système de sécurité externe (par
exemple, un arrêt d'urgence, un détecteur de défaut).
AVERTISSEMENT – LE DÉMARREUR PEUT DÉMARRER OU S'ARRÊTER À
TOUT MOMENT
Le démarreur progressif répond aux commandes de contrôle de différentes origines
et peut par conséquent démarrer ou s'arrêter à tout moment. Toujours déconnecter
le démarreur de la tension secteur avant d'accéder au démarreur ou à la charge.
AVERTISSEMENT – DÉCONNECTER L'ALIMENTATION PRINCIPALE AVANT
D'ACCÉDER AU DÉMARREUR OU À LA CHARGE
Le démarreur progressif comporte des protections intégrées qui peuvent déclencher
des mises en sécurité dans l'éventualité de défauts et ainsi arrêter le moteur. Des
fluctuations de tension, des coupures d'alimentation et des blocages du moteur
peuvent produire des mises en sécurité de celui-ci.
Le moteur pourrait redémarrer une fois que les causes de l'arrêt ont été résolues,
ce qui pourrait mettre en danger le personnel. Toujours déconnecter le démarreur
de la tension secteur avant d'accéder au démarreur ou à la charge.
AVERTISSEMENT
Ne pas appliquer la tension du secteur au démarreur tant que tout le câblage n'est
pas terminé.
AVERTISSEMENT
Toujours appliquer la tension de commande avant (ou en même temps que) la
tension secteur.
AVERTISSEMENT
Lors du raccordement du soft starter en connexion 6 fils, toujours installer un
contacteur principal ou un disjoncteur magnéto-thermique à bobine de
déclenchement.

Caution statements
7
AVERTISSEMENT
Si l'entrée de démarrage est fermée lorsque la tension de commande est appliquée,
le démarreur tentera d'effectuer un démarrage.
Vérifier que l'entrée de démarrage/arrêt est ouverte avant d'appliquer la tension de
commande.

System design
8
3 System design
3.1 Feature list
Streamlined setup process
•Configuration profiles for common
applications
•Built-in metering and inputs/outputs
Easy to understand interface
•Multi-language menus and displays
•Descriptive option names and feedback
messages
•Real-time performance graphs
Supports energy efficiency
•IE3 compatible
•99% energy efficient when running
•Soft start technology avoids harmonic
distortion
Extensive range of models
•24 A~1250 A (nominal)
•200~525 VAC
•380~690 VAC
•Bypassed or continuous options
•In-line or inside delta connection
Extensive input and output options
•Remote control inputs
(2 x fixed, 2 x programmable)
•Relay outputs
(2 x fixed, 2 x programmable)
•Analog output
Versatile starting and stopping options
•Scheduled start/stop
•Adaptive Control
•Constant Current
•Current Ramp
•Pump Clean
•Timed voltage ramp soft stop
•Coast To Stop
•DC Brake
•Soft Brake
•Reverse Direction
Customisable protection
•Motor overload
•Excess Start Time
•Undercurrent/Overcurrent
•Underpower/Overpower
•Undervoltage/Overvoltage
•Current imbalance
•Input Trip
•Motor thermistor
Optional features for advanced
applications
•Smart cards
•Communication options: DeviceNet,
Ethernet/IP, Modbus RTU, Modbus
TCP, Profibus, Profinet
•Ground fault protection
3.2 Model code
0
0
6
9
–
–
Control voltage
C1 = 110~120 VAC or 220~240 VAC
C2 = 24 VAC/VDC
Mains voltage
V5 = 200~525 VAC
V7 = 380~690 VAC
Bypass
B = internally bypassed
C = non-bypassed (continuous
connection)
Nominal current rating
D5-

System design
9
3.3 Model selection
Starter sizing
The soft starter must be the correct size for the motor and the application.
Select a soft starter that has a current rating at least equal to the motor's full load current
(nameplate) rating, at the start duty.
The soft starter's current rating determines the maximum motor size it can be used with.
The 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 in the conditions specified in the
AC53 code. The current rating may be higher or lower in different operating conditions.
AC53b format (bypassed current rating)
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)
AC53a format (non-bypassed current rating)
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)

System design
10
3.4 Current ratings
Contact your local supplier for ratings under operating conditions not covered by these
ratings charts.
IEC ratings
All ratings are calculated at altitude of 1000 metres and ambient temperature of 40 ºC.
•In-line installation, bypassed
3.0-10:350
3.5-15:345
4.0-10:350
4.0-20:340
5.0-5:355
0024B
24
20
19
16
16
0042B
42
34
34
27
31
0052B
52
41
39
34
34
3.0-10:590
3.5-15:585
4.0-10:590
4.0-20:580
5.0-5:595
0064B
64
62
60
50
53
0069B
69
69
69
62
64
0105B
105
86
84
68
76
0115B
115
107
104
86
95
0135B
135
129
126
103
115
0184B
184
143
139
115
127
0200B
200
170
165
138
150
0229B
229
194
187
157
170
0250B
250
244
230
200
202
0352B
352
285
277
234
257
0397B
397
322
311
262
288
0410B
410
410
410
379
400
0550B
550
526
505
427
462
0580B
580
578
554
469
507
0835B
835
654
630
535
592
0940B
940
736
708
603
663
1070B
1070
950
905
785
834
1230B
1230
1154
1090
959
989
1250B
1250
1250
1250
1155
1250
0735C
835
732
716
593
695
0830C
940
822
803
667
776
1025C
1210
1067
1033
874
1170
1170C
1430
1307
1252
1076
1170
1220C
1620
1620
1616
1309
1620
NOTE
Models 0735C~1220C must be installed with an external bypass contactor to
achieve the bypassed current ratings.

System design
11
•In-line installation, non-bypassed
3.0-10:590
3.5-15:585
4.0-10:590
4.0-20:580
5.0-5:595
0735C
735
590
572
492
542
0830C
830
667
645
557
609
1025C
1025
839
805
710
751
1170C
1170
979
934
838
862
1220C
1220
1134
1109
964
1075
•Inside delta installation, bypassed
3.0-10:350
3.5-15:345
4.0-10:350
4.0-20:340
5.0-5:355
0024B
36
30
29
24
24
0042B
63
51
51
41
47
0052B 78 62 59 51 51
3.0-10:590
3.5-15:585
4.0-10:590
4.0-20:580
5.0-5:595
0064B
96
93
90
75
80
0069B
104
104
104
93
96
0105B
158
129
126
102
114
0115B
173
161
156
129
143
0135B
203
194
189
155
173
0184B
276
215
209
173
191
0200B
300
255
248
207
225
0229B
344
291
281
236
255
0250B
375
366
345
300
303
0352B
528
428
415
351
386
0397B
596
484
466
393
433
0410B
615
615
615
568
600
0550B
825
789
758
640
694
0580B
870
868
832
704
760
0835B
1253
981
945
803
888
0940B
1410
1104
1062
905
995
1070B
1605
1425
1358
1178
1251
1230B
1845
1731
1635
1439
1484
1250B
1875
1875
1875
1733
1875
0735C 1253 1098 1074 890 1043
0830C
1410
1233
1205
1001
1164
1025C
1815
1601
1550
1311
1473
1170C
2145
1961
1878
1614
1755
1220C
2430
2430
2424
1964
2430
NOTE
Models 0735C~1220C must be installed with an external bypass contactor to
achieve the bypassed current ratings.

System design
12
•Inside delta installation, non-bypassed
3.0-10:50-6
3.5-15:50-6
4.0-10:50-6
4.0-20:50-6
5.0-5:50-6
0735C
1103
885
858
738
813
0830C
1245
1001
968
836
914
1025C
1538
1259
1208
1065
1127
1170C
1755
1469
1401
1257
1293
1220C
1830
1701
1664
1446
1613
NEMA motor ratings
All ratings are calculated at altitude of 1000 metres and ambient temperature of 50 ºC.
•In-line installation, bypassed
Normal
350%, 30 s,
4 starts per hour
Heavy
450%, 30 s,
4 starts per hour
A
HP
@240
VAC
HP
@480
VAC
HP
@600
VAC
A
HP
@240
VAC
HP
@480
VAC
HP
@600
VAC
0024B
17
5
10
15
14
3
10
10
0042B
28
10
20
25
22
7.5
15
20
0052B
35
10
25
30
28
10
20
25
0064B
52
15
40
40
40
10
25
30
0069B
59
20
40
50
46
15
30
40
0105B
77
25
60
60
52
15
40
50
0115B
81
30
60
75
65
20
50
60
0135B
99
30
75
100
77
25
60
75
0184B
124
40
100
100
96
30
75
75
0200B
131
50
100
125
104
40
75
100
0229B
156
60
125
150
124
40
100
100
0250B
195
75
150
200
156
60
125
150
0352B
240
75
200
200
180
60
150
150
0397B
261
100
200
250
203
75
150
200
0410B
377
150
300
350
302
100
250
300
0550B
414
150
350
450
321
125
250
300
0580B
477
200
400
500
361
150
300
350
0835B
515
200
450
500
414
150
350
450
0940B
590
200
500
600
480
200
400
500
1070B
797
300
600
800
620
250
500
600
1230B
985
400
800
1000
768
300
600
800
1250B
1180
500
900
1200
904
350
700
900
0735C
551
200
450
500
429
150
350
450
0830C
634
250
500
600
493
200
400
500
1025C
882
350
700
900
686
250
500
700
1170C
1100
450
900
1100
864
350
700
900
1220C
1320
500
1100
1300
1030
450
800
1000

System design
13
•In-line installation, non-bypassed
Normal
350%, 30 s,
4 starts per hour
Heavy
450%, 30 s,
4 starts per hour
A HP
@240
VAC
HP
@480
VAC
HP
@600
VAC
A HP
@240
VAC
HP
@480
VAC
HP
@600
VAC
0735C
480
200
400
500
382
150
300
400
0830C
576
200
450
600
431
150
350
450
1025C
722
300
600
700
590
200
500
600
1170C
864
350
700
900
722
300
600
700
1220C
966
400
800
1000
784
300
600
800

System design
14
3.5 Dimensions and weights
Width
mm (inch)
Height
mm (inch)
Depth
mm (inch)
Weight
kg (lb)
A
B
C
D
E
0024B
4.8
0042B
(10.7)
0052B
4.9
(10.9)
0064B
152
92
336
307
233
0069B
(6.0)
(3.6)
(13.2)
(12.1)
(9.2)
0105B
5.5
(12.1)
0115B
0135B
0184B
0200B
495
12.7
0229B
(19.5)
(28.0)
0250B
216
180
450
245
0352B
(8.5)
(7.1)
523
(20.6)
(17.7)
(9.6)
15.5
(34.2)
0397B
0410B
0550B
19.0
0580B
(41.9)
0835B
51.0
0940B
447
287
618
525
310
(112.4)
1070B
(17.6)
(11.3)
(24.3)
(20.7)
(12.3)
62.0 (136.7)
1230B
63.0 (138.9)
1250B
65.0 (143.3)
0735C
47.0
0830C
447
287
618
525
310
(103.6)
1025C
(17.6)
(11.3)
(24.3)
(20.7)
(12.3)
58.0 (127.9)
1170C
59.0 (130.1)
1220C
61.0 (134.5)
B4 B510 11 12 13 14 15 21 22 33 34 41 42 44 53 54
A3 A1 A2
2/T1 4/ T2 6/T3
1/L 1 3/L 2 5/L3
B4B510 11 12 13 14 15 21 22 33 34 41 42 44 53 54
A
B
C D
E
19115.A
A
B
CD
E

System design
15
3.6 Physical installation
Between starters
Solid surfaces
A
B
C
D
> 100 mm (3.9 inch)
> 10 mm (0.4 inch)
> 100 mm (3.9 inch)
> 10 mm (0.4 inch)
3.7 Accessories
Expansion cards
The soft starter offers expansion cards for users requiring additional inputs and outputs or
advanced functionality. Each soft starter can support a maximum of one expansion card.
•Pumping smart card
The pumping smart card has been designed to support integration with pumping
applications and provides the following additional inputs and outputs:
•3 x digital inputs
•3 x 4-20 mA transducer inputs
•1 x RTD input
•1 x USB-B port
•Remote keypad connector
•Communications expansion cards
The soft starter supports network communication via easy-to-install communications
expansion cards. Each communications card includes a remote keypad connector port.
Available protocols:
DeviceNet, Ethernet/IP, Modbus RTU, Modbus TCP, Profibus, Profinet.
•Ground fault protection
The soft starter can detect ground current and trip before the equipment is damaged.
Ground fault protection requires a 1000:1 or 2000:1 5 VA current transformer (not
supplied). Ground fault protection is available as an option with specific versions of the
Modbus RTU, Modbus TCP, Ethernet/IP and Profinet expansion cards.
Remote keypad
The soft starter can be used with a remote keypad, mounted up to 3 metres away from the
starter. Each expansion card includes a keypad connection port, or a dedicated keypad
connector card is available.
DD
18542. A
C
C
B
A
2/T1 4/T2 6/ T 3
33 34 41 42 44 53 54
2/T1 4/T2 6/ T 3
B4 B5 1011 12 13 14 15 21 22
A3 A1 A2
33 34 41 42 44 53 54
2/T1 4/T2 6/ T 3
B4 B5 1011 12 13 14 15 21 22
A3 A1 A2
33 34 41 42 44 53 54
2/T1 4/ T 2 6/ T 3
B4 B5 1011 12 13 14 15 21 22
A3 A1 A2
33 34 41 42 44 53 54
2/T1 4/ T 2 6/ T 3
B4 B5 1011 12 13 14 15 21 22
A3 A1 A2
33 34 41 42 44 53 54
2/T1 4/ T 2 6/ T 3
B4 B5 1011 12 13 14 15 21 22
A3 A1 A2

System design
16
Finger guard kit
Finger guards may be specified for personnel safety. Finger guards fit over the soft starter
terminals to prevent accidental contact with live terminals. Finger guards provide IP20
protection when used with cable of diameter 22 mm or greater.
Finger guards are available for models 0184B~1250B.
Finger guards must be fitted to all terminals, even if no cable is connected. Contact your
local supplier for assistance selecting the correct finger guard kit.
Soft starter management software
PC software can provide real-time or offline management of soft starters.
•For real-time management in a network of up to 254 starters, the software must
connect to the soft starter via a Modbus TCP or Modbus RTU card. The software
can monitor, control and program the starter across the network.
•The software can be used to program the starter via the USB port on the pumping
smart card.
•For offline management, a configuration file generated in the software can be
loaded into the starter via the USB port.
3.8 Main contactor or circuit breaker
A main contactor or circuit breaker should be installed with the soft starter.
•A main contactor is recommended to protect the soft starter from voltage
disturbances on the network, while stopped. Select a contactor with an AC3 rating
greater than or equal to the full load current rating of the connected motor.
•Use a shunt trip circuit breaker to isolate the motor circuit in the event of a soft
starter trip. The shunt trip mechanism must be powered from the supply side of the
circuit breaker or from a separate control supply.
Use the main contactor output (33, 34) to control the main contactor.
WARNING
When connecting the soft starter in inside delta configuration, always install
a main
contactor or shunt trip circuit breaker.
3.9 External bypass contactor
Models 0735C~1220C can be installed with an external bypass contactor. Bypassing the
soft starter increases the soft starter's maximum current rating, and allows the motor to be
started direct on-line (across the line) if the soft starter is damaged.
•To bypass the soft starter during run, use an external bypass contactor with an AC1
rating.
•To bypass the soft starter completely (to allow direct on-line starting if the starter is
damaged), use an external bypass contactor with an AC3 rating.

System design
17
3.10 Power factor correction
If power factor correction is used, a dedicated contactor should be used to switch in the
capacitors.
To use the soft starter to control power factor correction, connect the PFC contactor to a
programmable relay set to Run. When the motor reaches full speed, the relay will close and
power factor correction will be switched in. Do not use the soft starter relay output to
directly switch in power factor correction.
1
Soft starter
2
Programmable output (set = Run)
3
Power factor correction contactor
4
Power factor correction
CAUTION
Power factor correction capacitors must be connected to the input side of the soft
starter. Connecting power factor correction capacitors to the output side will
damage the soft starter.
3.11 Short circuit protection devices (SCPD)
Fuses may be installed to protect the soft starter or the installation.
Type 1 coordination
Type 1 coordination requires that, in the event of a short circuit on the output side of a soft
starter, the fault must be cleared without risk of injury to personnel. There is no requirement
that the soft starter must remain operational after the fault.
HRC fuses (such as Ferraz/Mersen AJT fuses) can be used for Type 1 coordination
according to IEC 60947-4-2 standard.
Type 2 coordination
Type 2 coordination requires that in the event of a short circuit on the output side of a soft
starter, the fault must be cleared without risk of injury to personnel or damage to the soft
starter.
Semiconductor fuses for Type 2 circuit protection are additional to HRC fuses or MCCBs
that form part of the motor branch circuit protection.
CAUTION
DC Brake: A high brake torque setting can result in peak currents up to motor DOL
being drawn while the motor is stopping. Ensure protection fuses installed in the
motor branch circuit are selected appropriately.
CAUTION
Integral solid state short circuit protection does not provide branch circuit
protection. Branch circuit protection must be provided in accordance with the
National Electrical Code and any additional local codes.
K1
K1
1
2
4
3
20234.A

System design
18
3.12 IEC coordination with short circuit protection devices
HRC fuse codes beginning OFAA are for ABB fuses. All other fuse codes are for Bussmann
fuses.
Models 0024B~0580B
These fuses were selected based on start current of 300% FLC for 10 seconds.
Model
Nominal
Rating (A)
300%, 10 s
SCR I2t (A2s)
Type 1
coordination
480 VAC, 65 kA
Type 2
coordination
690 VAC, 65 kA
0024B
24
1150
40NHG000B
170M3010
0042B
42
7200
63NHG000B
170M3013
0052B
52
80NHG000B
0064B 64 15000 100NHG000B 170M3014
0069B
69
0105B
105
80000 170M3015
0115B
115
160NHG00B
0135B
135
125000
170M3016
0184B
184
320000
250NHG2B
0200B 200 170M3020
0229B
229
315NHG2B
0250B
250
170M3021
0352B
352
202000
355NHG2B
170M6009
0397B
397
400NHG2B
0410B
410
320000
425NHG2B
170M6010
0550B
550
781000 630NHG3B 170M6012
0580B
580
Models 0835B~1250B/0735C~1220C, bypassed installation
These fuses were selected based on start current of 350% FLC for 30 seconds.
Nominal
Rating (A)
350%, 30 s
SCR I2t (A2s)
Type 1
coordination
500 VAC, 100 kA
Type 2
coordination
690 VAC, 100 kA
0835B
565
1000NHG4G
170M6016
0940B
638
2530000
170M6017
1070B
854
1200NHG4G
Not available
1230B
1055
3920000
OFAA5GG1250
1250B
1249
7220000
170M6019
0735C
621
1000NHG4G
170M6016
0830C
699
2530000
170M6017
1025C
945
OFAA5GG1250
Not available
1170C
1178
3920000
OFAA5GG1600
1220C 1403 7220000
170M6021
(at 500 VAC)