Peter electronic VersiStart i III Training manual

electronic
Quality is our Drive.
Commissioning Instructions
VS i III ... - 23 ... 1600

User Manual
VersiStart i III Quality is our Drive. Qualität ist unser Antrieb.
Contents
1. About This Manual...............................................................................................................................3
2. Caution Statements .............................................................................................................................4
2.1 Electrical shock risk.......................................................................................................................................................................4
2.2 System Design and Safety of Personnel.......................................................................................................................................4
2.3 Disposal Instructions.....................................................................................................................................................................4
3. Avertissements à l'attention des clients canadiens..........................................................................5
4. Declaration of conformity....................................................................................................................6
5. Introduction..........................................................................................................................................7
5.1 Feature List ...................................................................................................................................................................................7
5.2 Specifications................................................................................................................................................................................7
6. Installation..........................................................................................................................................14
6.1 Physical Installation.....................................................................................................................................................................14
6.2 Control Terminals........................................................................................................................................................................14
6.3 Control Voltage............................................................................................................................................................................15
6.4 Control Wiring..............................................................................................................................................................................15
6.5 Relay Outputs..............................................................................................................................................................................15
6.6 Motor Thermistors.......................................................................................................................................................................15
6.7 Power Terminations....................................................................................................................................................................16
6.8 Power Input and Output Configurations......................................................................................................................................17
6.9 Schematic Diagrams...................................................................................................................................................................18
7. Power Circuits....................................................................................................................................19
7.1 Motor Connection........................................................................................................................................................................19
7.2 Bypass Contactor........................................................................................................................................................................22
7.3 Main Contactor............................................................................................................................................................................22
7.4 Circuit Breaker.............................................................................................................................................................................22
7.5 Earth Terminals...........................................................................................................................................................................22
7.6 Power Factor Correction.............................................................................................................................................................22
7.7 Power Supply Fuses...................................................................................................................................................................23
8. Operation............................................................................................................................................29
8.1 The Keypad.................................................................................................................................................................................29
8.2 Starter Status LEDs ....................................................................................................................................................................29
8.3 Displays.......................................................................................................................................................................................29
8.4 Start, Stop and Reset Commands..............................................................................................................................................31
8.5 Soft Start Methods.......................................................................................................................................................................31
8.6 Stop Methods..............................................................................................................................................................................34
8.7 Jog Operation..............................................................................................................................................................................36
8.8 Inside Delta Operation ................................................................................................................................................................37
9. Programming Menu ...........................................................................................................................38
9.1 Quick Setup.................................................................................................................................................................................39
9.2 Standard Menu............................................................................................................................................................................40

VersiStart i III 2
9.3 Extended Menu...........................................................................................................................................................................41
9.4 Parameter Descriptions...............................................................................................................................................................43
9.5 Adjustment Lock..........................................................................................................................................................................55
9.6 Access Code...............................................................................................................................................................................55
9.7 Setup Tools.................................................................................................................................................................................56
10. Logs Menu..........................................................................................................................................57
10.1 Trip Log.......................................................................................................................................................................................57
10.2 Event Log....................................................................................................................................................................................57
10.3 Performance Counters................................................................................................................................................................57
11. Application Examples........................................................................................................................58
11.1 Installation with Main Contactor..................................................................................................................................................58
11.2 Installation with Bypass Contactor..............................................................................................................................................59
11.3 Emergency Run Operation..........................................................................................................................................................60
11.4 Auxiliary Trip Circuit....................................................................................................................................................................61
11.5 DC Brake with External Zero Speed Sensor...............................................................................................................................62
11.6 Soft Braking.................................................................................................................................................................................63
11.7 Two Speed Motor........................................................................................................................................................................64
12. Troubleshooting.................................................................................................................................65
12.1 Protection Responses.................................................................................................................................................................65
12.2 Trip Messages.............................................................................................................................................................................65
12.3 General Faults.............................................................................................................................................................................68
13. Accessories........................................................................................................................................70
13.1 Communication Modules.............................................................................................................................................................70
13.2 Remote Control Panel (RCP)......................................................................................................................................................70
13.3 Finger Guard Kit..........................................................................................................................................................................70
13.4 PC Software................................................................................................................................................................................70
14. Busbar Adjustment Procedure .........................................................................................................71

3 VersiStart i III
1. About This Manual
The examples and diagrams in this manual are included solely for illustrative purposes. The information contained in this manual is
subject to change at any time and without prior notice. In no event will responsibility or liability be accepted for direct, indirect or
consequential damages resulting from the use or application of this equipment.
WARNING
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.

VersiStart i III 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 VersiStart i III 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.
2.1 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 performed.
WARNING - ELECTRICAL SHOCK HAZARD
Models VS i III 500~VS i III 1600N: 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).
SHORT CIRCUIT
The VersiStart i III is not short circuit proof. After severe overload or short circuit, the operation of the VersiStart i III 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 VersiStart i III to provide proper grounding and branch circuit
protection according to local electrical safety codes.
2.2 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 havethe
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.
2.2.1 STOP function
The STOP function does not remove dangerous voltages from the starter, the motor or any external option units.
2.3 Disposal Instructions
Equipment containing electrical components may not be disposed of together with domestic waste.
It must be collected separately as electrical and electronic waste according to local and currently valid
legislation.

5 VersiStart i III
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
L'alimentation AC doit être déconnectée du démarreur au moyen d'un dispositif d'isolation agréé avant de retirer des
capots ou avant de procéder à des travaux d'entretien.
Modèles VS i III 500 à VS i III 1600N : Les barres de puissance et le radiateur doivent être traités comme étant des
éléments sous tension si l'appareil est relié au secteur (y compris lorsque le démarreur s'est mis en sécurité ou s'il attend
une commande).
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
Le bouton STOP (ARRET) du clavier est toujours actif. Lors de l'utilisation d'une commande à distance 2 fils, le démarreur
progressif redémarrera si les entrées de démarrage/arrêt et de reset sont toujours actives.
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 VersiStart i III en connexion 6 fils, toujours installer un contacteur principal ou un disjoncteur
magnéto-thermique à bobine de déclenchement.

VersiStart i III 6
4. Declaration of conformity
In industrial linguistic usage the drive controllers of the type series VersiStart i III are called "devices", however, in the sense of the "law
on the safety of equipment", the "EMC-law" or the "EC-machinery directive" they are not devices or machines ready for use or
connection but they are components. It is only possible to define their final function, when these components are integrated into the
design and construction of the user.
To be able to use the devices to their intended purpose, it requires power supply networks according to DIN EN 50160 (IEC
60038).
The user takes the responsibility that the user's design and construction comply with the applicable legal provisions.
The commissioning is strictly forbidden as long as the conformity of the final system with the guidelines 2006/42/EC (Machinery
directive) and 2014/35/EU (Low voltage directive) is not proved.
The devices of the VersiStart i III series are electrical equipment that is used in industrial electrical power installations. They are
designed for application in machines, in order to reduce the starting torque and starting current peaks as well as the tripping torque of
drives with three-phase induction motors. With due regard to the installation guidelines they meet the following requirements:
Emitted interference: Continuous duty EN 61000-6-3:2005
Acceleration, decel. EN 60947-4-2
Immunity to interference: EN 61000-6-2:2005
VersiStart i III has been designed to meet the standards specified in EN 60947-4-2: Ed2.2 2007-02 Low voltage switchgear – Part 4-2
Contactors and motor-starters – AC Semiconductor motor controllers and starters, for low voltage safety, operation and EMC.
This product has been designed as Class A equipment. Use of this product in domestic environments may cause radio interference, in
which case the user may be required to employ additional mitigation methods.
Dr. Thomas Stiller
Managing director

7 VersiStart i III
5. Introduction
5.1 Feature List
Extensive starting and stopping options
xAdaptive Control
xConstant Current
xCurrent Ramp
xTimed voltage ramp soft stop
xBrake
Models for allconnection requirements
x23 A to 1600 A (nominal)
x200 VAC to 525 VAC
x380 VAC to 690 VAC
xInternally bypassed options
xIn-line or inside delta connection (auto-detect)
Inputs and outputs
xRemote control inputs
(3 x fixed, 1 x programmable)
xRelay outputs
(3 x programmable)
xAnalog output
xCommunication modules: Ethernet (Profinet, Modbus TCP,
Ethernet/IP), Profibus, DeviceNet, Modbus RTU, and USB
Easy-to-read display with comprehensive feedback
xMulti-language feedback
xMultiple status screens and performance graphs
xDate and time stamped event logging
xOperational counters (number of starts, hours-run, kWh)
xPerformance monitoring (current, voltage, power factor, kWh)
xUser-programmable monitoring screen
Customisable protection
xMotor overload
xExcess Start Time
xUndercurrent
xInstantaneous overcurrent
xCurrent imbalance
xMains frequency
xInput Trip
xMotor thermistor
xPower circuit
xPhase sequence
5.2 Specifications
5.2.1 Model Code
VS i III – –
Control voltage
C1 = 110~120 VAC or 220~240 VAC
C2 = 24 VAC/VDC
Bypass
" " = internally bypassed
N = non-bypassed
Nominal current rating
Mains voltage
525 = 200 ~ 525 VAC
690 = 380 ~ 690 VAC
5.2.2 Current Ratings
Contact your local supplier for ratings under operating conditions not covered by these ratings charts.
Current Ratings for Bypass Operation
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)
NOTE
Models VS i III 255N~VS i III 1600N must be externally bypassed.

VersiStart i III 8
In-line connection
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
VS i III 23 23 A 20 A 17 A 15 A
VS i III 43 43 A 37 A 31 A 26 A
VS i III 50 50 A 44 A 37 A 30 A
VS i III 53 53 A 53 A 46 A 37 A
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
VS i III 76 76 A 64 A 55 A 47 A
VS i III 97 97 A 82 A 69 A 58 A
VS i III 100 100 A 88 A 74 A 61 A
VS i III 105 105 A 105 A 95 A 78 A
VS i III 145 145 A 123 A 106 A 90 A
VS i III 170 170 A 145 A 121 A 97 A
VS i III 200 200 A 189 A 160 A 134 A
VS i III 220 220 A 210 A 178 A 158 A
VS i III 255 255 A 231 A 201 A 176 A
VS i III 255N 255 A 231 A 201 A 176 A
VS i III 350 350 A 329 A 284 A 244 A
VS i III 360N 360 A 360 A 310 A 263 A
VS i III 380N 380 A 380 A 359 A 299 A
VS i III 425 425 A 411 A 355 A 305 A
VS i III 430N 430 A 430 A 368 A 309 A
VS i III 500 500 A 445 A 383 A 326 A
VS i III 580 580 A 492 A 425 A 364 A
VS i III 620N 620 A 620 A 540 A 438 A
VS i III 650N 650 A 650 A 561 A 455 A
VS i III 700 700 A 592 A 512 A 438 A
VS i III 790N 790 A 790 A 714 A 579 A
VS i III 820 820 A 705 A 606 A 516 A
VS i III 920 920 A 804 A 684 A 571 A
VS i III 930N 930 A 930 A 829 A 661 A
VS i III 1000 1000 A 936 A 796 A 664 A
VS i III 1200N 1200 A 1200 A 1200 A 1071 A
VS i III 1410N 1410 A 1410 A 1319 A 1114 A
VS i III 1600N 1600 A 1600 A 1600 A 1353 A
Inside delta connection
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
VS i III 23 34 A 30 A 26 A 22 A
VS i III 43 64 A 59 A 51 A 44 A
VS i III 50 75 A 66 A 55 A 45 A
VS i III 53 80 A 80 A 69 A 55 A
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
VS i III 76 114 A 96 A 83 A 70 A
VS i III 97 145 A 123 A 104 A 87 A
VS i III 100 150 A 132 A 112 A 92 A
VS i III 105 157 A 158 A 143 A 117 A
VS i III 145 218 A 184 A 159 A 136 A
VS i III 170 255 A 217 A 181 A 146 A
VS i III 200 300 A 283 A 241 A 213 A
VS i III 220 330 A 315 A 268 A 238 A
VS i III 255 382 A 346 A 302 A 264 A
VS i III 255N 382 A 346 A 302 A 264 A
VS i III 350 525 A 494 A 427 A 366 A
VS i III 360N 540 A 540 A 465 A 395 A

9 VersiStart i III
VS i III 380N 570 A 570 A 539 A 449 A
VS i III 425 638 A 617 A 533 A 458 A
VS i III 430N 645 A 645 A 552 A 464 A
VS i III 500 750 A 668 A 575 A 490 A
VS i III 580 870 A 738 A 637 A 546 A
VS i III 620N 930 A 930 A 810 A 651 A
VS i III 650N 975 A 975 A 842 A 683 A
VS i III 700 1050 A 889 A 768 A 658 A
VS i III 790N 1185 A 1185 A 1075 A 868 A
VS i III 820 1230 A 1058 A 910 A 774 A
VS i III 920 1380 A 1206 A 1026 A 857 A
VS i III 930N 1395 A 1395 A 1244 A 992 A
VS i III 1000 1500 A 1404 A 1194 A 997 A
VS i III 1200N 1800 A 1800 A 1800 A 1606 A
VS i III 1410N 2115 A 2115 A 1979 A 1671 A
VS i III 1600N 2400 A 2400 A 2400 A 2030 A
Current Ratings for Continuous Operation (Not bypassed)
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)
In-line connection
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
VS i III 255N 255 A 222 A 195 A 171 A
VS i III 360N 360 A 351 A 303 A 259 A
VS i III 380N 380 A 380 A 348 A 292 A
VS i III 430N 430 A 413 A 355 A 301 A
VS i III 620N 620 A 614 A 515 A 419 A
VS i III 650N 650 A 629 A 532 A 437 A
VS i III 790N 790 A 790 A 694 A 567 A
VS i III 930N 930 A 930 A 800 A 644 A
VS i III 1200N 1200 A 1200 A 1135 A 983 A
VS i III 1410N 1410 A 1355 A 1187 A 1023 A
VS i III 1600N 1600 A 1600 A 1433 A 1227 A
Inside delta connection
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
VS i III 255N 382 A 334 A 293 A 257 A
VS i III 360N 540 A 527 A 455 A 388 A
VS i III 380N 570 A 570 A 522 A 437 A
VS i III 430N 645 A 620 A 533 A 451 A
VS i III 620N 930 A 920 A 773 A 628 A
VS i III 650N 975 A 943 A 798 A 656 A
VS i III 790N 1185 A 1185 A 1041 A 850 A
VS i III 930N 1395 A 1395 A 1200 A 966 A
VS i III 1200N 1800 A 1800 A 1702 A 1474 A
VS i III 1410N 2115 A 2033 A 1780 A 1535 A
VS i III 1600N 2400 A 2400 A 2149 A 1840 A