AuCom EMX3-1600C, EMX3-0360C, EMX3-0105B, EMX3-0145B, EMX3-0255B User Manual

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USER MANUAL

EMX3 Soft Starter

CONTENTS

Contents

1. About This Manual ....................................................... 2

1.1 Disclaimer .............................................................................. 2

2. Caution Statements .................................................... 3

2.1 Electrical shock risk .............................................................. 3

2.2 Unexpected Operation .......................................................... 3

2.3 Avertissements à l'attention des clients canadiens .......... 4

3. Introduction ................................................................. 6

3.1 Feature List ............................................................................ 6

4. Basic Setup .................................................................. 7

4.1 Setup Procedure Overview ................................................... 7

4.2 Testing the Installation ......................................................... 7

4.3 Simulation Tools .................................................................... 8

5. Installation ................................................................... 9

5.1 Physical Installation .............................................................. 9

5.2 Control Terminals ................................................................. 9

5.3 Control Voltage ...................................................................... 9

5.4 Control Wiring ......................................................................10

5.5 Relay Outputs .......................................................................10

5.6 Motor Thermistors ..............................................................10

5.7 RTD/PT100............................................................................11

5.8 Earth Terminals ...................................................................11

5.9 Power Input and Output Configurations ...........................11

5.10 Power Terminations ............................................................13

5.11 Schematic Diagrams...........................................................14

6. Power Circuits ........................................................... 15

6.1 Motor Connection ................................................................15

6.2 Bypass Contactor.................................................................19

6.3 Main Contactor.....................................................................19

6.4 Circuit Breaker .....................................................................19

6.5 Power Factor Correction ....................................................19

6.6 Short Circuit Protection Devices (SCPD) ..........................19

6.7 UL Short Circuit Ratings .....................................................20

6.8 Fuse Selection for Type 2 Coordination ............................22

10.2 Adjustment Lock ................................................................. 38

10.3 Access Code ........................................................................ 39

10.4 Quick Setup .......................................................................... 39

10.5 Standard Menu ................................................................... 40

10.6 Extended Menu ................................................................... 41

10.7 Load/Save Settings ............................................................. 45

10.8 Parameter Descriptions .................................................... 46

11. Application Examples ................................................ 62

11.1 Installation with Main Contactor ....................................... 62

11.2 Installation with External Bypass Contactor ................... 63

11.3 Emergency Run Operation ................................................ 64

11.4 Auxiliary Trip Circuit ........................................................... 65

11.5 DC Brake with External Zero Speed Sensor ................... 66

11.6 Soft Braking ......................................................................... 67

11.7 Two-Speed Motor ............................................................... 68

11.8 Slip-Ring Motor ................................................................... 69

12. Troubleshooting ........................................................ 71

12.1 Protection Responses ........................................................ 71

12.2 Trip Messages ..................................................................... 71

12.3 General Faults ..................................................................... 75

13. Appendix ..................................................................... 77

13.1 Model code .......................................................................... 77

13.2 IEC ratings ........................................................................... 77

13.3 NEMA motor ratings .......................................................... 80

13.4 Minimum and Maximum Current Settings ..................... 82

13.5 Dimensions and Weights ................................................... 83

13.6 Specifications ...................................................................... 85

13.7 UL Compliant Installation .................................................. 87

13.8 Disposal Instructions ......................................................... 87

13.9 Accessories ......................................................................... 88

13.10 Parameter Values ............................................................... 89

14. Busbar Adjustment Procedure ................................ 93

7. Keypad and Feedback ............................................... 23

7.1 The Keypad ...........................................................................23

7.2 Displays .................................................................................24

8. Maintenance Tools .................................................... 26

8.1 Testing the Installation .......................................................26

8.2 Commissioning Menu (Tools) ............................................26

8.3 Logs Menu ............................................................................29

9. Operation ................................................................... 31

9.1 Priority of Commands .........................................................31

9.2 Start, Stop and Reset Commands .....................................31

9.3 Soft Start Methods ...............................................................32

9.4 Stop Methods .......................................................................34

9.5 Jog Operation .......................................................................37

9.6 Inside Delta Operation ........................................................37

10. Programming Menu .................................................. 38

10.1 Programming Menu ...........................................................38

User Manual (710-04840-00M) | 1

ABOUT THIS MANUAL

WARNING

CAUTION

NOTE

ously improving its products it reserves the right to modify or change the specification of its products at any time

Users may copy some of the material for their personal reference but may not copy or use material for any other purpose

1. About This Manual

Indicates a hazard that may cause personal injury or death.

Indicates a hazard that may damage the equipment or installation.

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.

As AuCom is continu

without notice. The text, diagrams, images and any other literary or artistic works appearing in this document are protected by

without the prior consent of AuCom Electronics Ltd. AuCom endeavours to ensure that the information contained in this document

including images is correct but does not accept any liability for error, omission or differences with the finished product.

2 | User Manual (710-04840-00M)

CAUTION STATEMENTS

NOTE

WARNING – ELECTRICAL SHOCK RISK

WARNING - ELECTRICAL SHOCK HAZARD

SHORT CIRCUIT

GROUNDING AND BRANCH CIRCUIT PROTECTION

FOR YOUR SAFETY

WARNING – ACCIDENTAL STARTS

WARNING – STARTER MAY START OR STOP UNEXPECTEDLY AUTO-START

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.

The EMX3 is not user serviceable. The unit should only be serviced by authorised service personnel. Unauthorised

2.1 Electrical shock risk

tampering with the unit will void the product warranty.

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

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.

Models EMX3-0500B~EMX3-1600C: 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).

The EMX3 is not short circuit proof. After severe overload or short circuit, the operation of the EMX3 should be fully tested by an authorised service agent.

It is the responsibility of the user or person installing the EMX3 to provide proper grounding and branch circuit protection according to local electrical safety codes.

• 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.

2.2 Unexpected Operation

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).

The EMX3 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.

Use the auto-start feature with caution. Read all the notes related to auto-start before operation.

User Manual (710-04840-00M) | 3

CAUTION STATEMENTS

WARNING – DISCONNECT MAINS BEFORE ACCESSING STARTER OR LOAD

CAUTION – MECHANICAL DAMAGE FROM UNEXPECTED RESTART

AVERTISSEMENT

AVERTISSEMENT – RISQUE DE CHOC ÉLECTRIQUE

AVERTISSEMENT - DANGER D'ELECTROCUTION

PAR SECURITE

responsabilité du concepteur ou de l'utilisateur de veiller à ce que ce système soit sûr et conçu selon les normes de

AVERTISSEMENT – DÉMARRAGES ACCIDENTELS

ns de tels cas, il est recommandé de doter l'alimentation du

AVERTISSEMENT – LE DÉMARREUR PEUT DÉMARRER OU S'ARRÊTER À TOUT MOMENT

DEMARRAGE AUTOMATIQUE

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.

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

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.

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 EMX3-0500B à EMX3-1600C : 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).

• 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

sécurité locales en vigueur.

Dans certaines installations, des démarrages accidentels peuvent provoquer un risque supplémentaire pour la sécurité des personnes ou endommager les machines contrôlées. Da 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).

Le EMX3 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.

Utiliser la fonction de démarrage automatique avec précautions. Lire toutes les notes relatives au démarrage automatique avant utilisation.

4 | User Manual (710-04840-00M)

CAUTION STATEMENTS

AVERTISSEMENT

AVERTISSEMENT – DÉCONNECTER L'ALIMENTATION PRINCIPALE AVANT D'ACCÉDER AU DÉMARREUR OU À LA CHARGE

AVERTISSEMENT

Cette fonction ne doit pas être utilisée en association avec la commande à distance 2 fils.

Le démarreur progressif acceptera encore les commandes de démarrage et d'arrêt issues des entrées de commande à distance ou du réseau de communication série. Pour désactiver la commande locale ou à distance, utiliser le parameter 6Q.

Si le démarrage automatique est activé et que l'utilisateur navigue dans le système de menus, ce démarrage ne deviendra actif que si aucune activité du clavier n'est détectée pendant cinq minutes.

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.

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.

Ne pas appliquer la tension du secteur au démarreur tant que tout le câblage n'est pas terminé.

Toujours appliquer la tension de commande avant (ou en même temps que) la tension secteur.

Lors du raccordement du EMX3 en connexion 6 fils, toujours installer un contacteur principal ou un disjoncteur magnéto-thermique à bobine de déclenchement.

User Manual (710-04840-00M) | 5

INTRODUCTION

Selectable soft starting profiles

Selectable soft stopping profiles

Extensive input and output options

Easy-to-read display with comprehensive feedback

Customisable protection

Models for all connection requirements

Optional features for advanced applications

3. Introduction

3.1 Feature List

• Adaptive Control

• Constant Current

• Current Ramp

• Coast To Stop

• Timed voltage ramp soft stop

• Adaptive Control

• Brake

• Remote control inputs

(3 x fixed, 2 x programmable)

• Relay outputs (1 x fixed, 3 x programmable)

• Analog output

• Built-in PT100 RTD input

• Optional expansion cards

• Removable keypad

• Multi-language feedback

• Date and time stamped event logging

• Operational counters (number of starts, hours-run, kWh)

• Performance monitoring (current, voltage, power factor,

kWh)

• User-programmable monitoring screen

• Motor overload

• Excess Start Time

• Undercurrent

• Instantaneous overcurrent

• Current imbalance

• Mains frequency

• Input Trip

• Motor thermistor

• Power circuit

• Phase sequence

• 23 A~1600 A (nominal)

• 200~440 VAC

• 380~690 VAC

• Internally bypassed options

• In-line or inside delta connection

• Input/output expansion

• RTD and Ground fault protection

• Communication modules: Ethernet (Profinet,

Modbus TCP, Ethernet/IP), Profibus, DeviceNet, Modbus RTU, and USB

6 | User Manual (710-04840-00M)

4. Basic Setup

WARNING

NOTE

4.1 Setup Procedure Overview

Do not apply mains voltage to the starter until all wiring is complete.

BASIC SETUP

1. Mount the soft starter (refer to

2. Connect control wiring (refer to

Physical Installation

Control Terminals

on page 9 for details).

3. Apply control voltage to the starter.

4. Set the date and time (refer to

Set Date and Time

on page 26 for details).

5. Configure your application:

1. Press

to open the Menu.

2. Use to scroll to Quick Setup and press to open the Quick Setup menu.

3. Scroll through the list to find your application, then press

to begin the configuration process (refer to

on page 39 for details).

6. If your application is not listed in Quick Setup:

1. Press to return to the Menu.

2. Use

3. Scroll to Motor Data 1 and press , then press again to edit parameter 1A

to scroll to Standard Menu and press .

Motor Full Load Current

4. Set parameter 1A to match the motor's full load current (FLC).

For advanced applications, refer to

7. Close the Menu by pressing

Extended Menu

repeatedly.

on page 41 and

Parameter Descriptions

on page 46.

8. (Optional) Use the built-in simulation tools to check that the control wiring is connected correctly (refer to

on page 27).

9. Connect mains supply cables to starter input terminals 1/L1, 3/L2, 5/L3 (refer to

Power Input and Output Configurations

page 11).

10. Connect the motor cables to starter output terminals 2/T1, 4/T2, 6/T3.

The soft starter is now ready to control the motor.

Quick Setup

Run Simulation

4.2 Testing the Installation

The EMX3 can be connected to a small motor for testing. During this test, the soft starter's control input and relay output protection settings can be tested. This test mode is not suitable for testing soft starting or soft stopping performance.

The FLC of the test motor must be at least 2% of the soft starter's minimum FLC (refer to on page 82).

When testing the soft starter with a small motor, set parameter 1A value.

Motor Full Load Current

Minimum and Maximum Current Settings

to the minimum allowable

User Manual (710-04840-00M) | 7

BASIC SETUP

NOTE

4.3 Simulation Tools

Software simulation functions let you test the soft starter's operation and control circuits without connecting the soft starter to mains voltage.

• The run simulation simulates a motor starting, running and stopping to confirm that the soft starter and associated equipment have been installed correctly. Refer to

Run Simulation

• The protection simulation simulates activation of each protection mechanism to confirm that the soft starter and associated control circuits are responding correctly. Refer to

• The output signal simulation simulates output signalling to confirm that outputs and associated control circuits are operating correctly. Refer to

Output Signal Simulation

on page 28 for details.

The simulations are only available when the soft starter is in Ready state, control voltage is available and the keypad is active.

Access to the simulation tools is protected by the security access code. The default access code is 0000.

on page 27 for details.

Protection Simulation

on page 27 for details.

8 | User Manual (710-04840-00M)

5. Installation

EMX3-0023B ~ EMX3-0220B: Allow 100 mm (3.94 inches) between soft starters.

EMX3-0023B ~ EMX3-0220B: Allow 50 mm (1.97 inches) between the soft starter and solid surfaces.

The soft starter may be mounted on its side. Derate the soft starter's rated current by 15%.

Remote Control Inputs Relay Outputs

Analog Output

5.1 Physical Installation

INSTALLATION

EMX3-0255B ~ EMX3-1000B: Allow 200 mm (7.88 inches) between soft starters. EMX3-0255C: Allow 100 mm (3.94 inches) between soft starters. EMX3-0360C ~ EMX3-1600C: Allow 200 mm (7.88 inches) between soft starters.

EMX3-0255B ~ EMX3-1000B: Allow 200 mm (7.88 inches) between the soft starter and solid surfaces. EMX3-0255C: Allow 100 mm (3.94 inches) between the soft starter and solid surfaces. EMX3-0360C ~ EMX3-1600C: Allow 200 mm (7.88 inches) between the soft starter and solid surfaces.

Soft starters may be mounted side by side with no clearance (that is, if mounted without communications modules).

5.2 Control Terminals

Control terminations use 2.5mm2 plug-in terminal blocks. Unplug each block, complete the wiring, then reinsert the block.

5.3 Control Voltage

Different models require control voltage to different terminals:

• C1 (110~210 VAC) A1, A2

• C1 (220~440 VAC) A2, A3

• C2 (24 VAC/VDC) A1, A3

User Manual (710-04840-00M) | 9

INSTALLATION

A B

C32

C31

C24

C23

C42

C41

03943.D

C32

C31

C24

C23

C42

C41

C32

C31

C24

C23

C42

C41

Two-wire control

Three-wire control

Four-wire control

Start

Stop

Reset

CAUTION CAUTION

NOTE

5.4 Control Wiring

The EMX3 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 control inputs are powered by the soft starter. Do not apply external voltage to the control input terminals.

The reset input can be normally open or normally closed. Use parameter 6M to select the configuration.

Cables to the control inputs must be segregated from mains voltage and motor cabling.

5.5 Relay Outputs

The EMX3 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 parameters 7A~7I.

• If assigned to Main Contactor, the output activates as soon as the soft starter receives a start command and remains active while the soft starter is controlling the motor (until the motor starts a coast to stop, or until the end of a soft stop).

• If assigned to a trip function, the output activates when a trip occurs.

Three additional outputs are available on the input/output expansion card.

• If assigned to a flag, the output activates when the specified flag is active (parameters 7M~7O).

Some electronic contactor coils are not suitable for direct switching with PCB mount relays. Consult the contactor manufacturer/supplier to confirm suitability.

5.6 Motor Thermistors

Motor thermistors can be connected directly to the EMX3. The soft starter will trip when the resistance of the thermistor circuit exceeds approximately 3.6 kΩ or falls below 20 Ω.

If no motor thermistors are connected to the EMX3 thermistor input terminals B4, B5 must be open. If B4, B5 are shorted, the EMX3 will trip.

The thermistor input is disabled by default, but activates automatically when a thermistor is detected. If thermistors have previously been connected to the EMX3 but are no longer required, either:

10 | User Manual (710-04840-00M)

• connect a 1.2 kΩ resistor between B4, B5 or

• reset the starter to factory defaults (refer to

Load/Save Settings

on page 45). If you wish to retain the starter’s configuration, save the starter’s settings to a user set before resetting. Reload the settings after the thermistor input has been reset

The thermistor circuit should be run in screened cable and must be electrically isolated from earth and all other power and control circuits.

INSTALLATION

NOTE

1/L1, 3/L2, 5/ L3

2/T1, 4/T2, 6/T3

1/L1 3/L2 5/L3

2/T1 4/T2 6/T3

1/L1 3/L2 5/L3

2/T1 4/T2 6/T3

1/L1 3/L2 5/L3

2/T1 4/T2 6/T3

1/L1 3/L2 5/L3

2/T1 4/T2 6/T3

15763.A

6/T34/T2 5/L33/L21/L1 2/T 1

5/L33/L21/L1

6/T34/T22/T1 5/L3

3/L21/L1

6/T34/T22/T1 5/L33/L21/L1

5.7 RTD/PT100

RTDs (PT100) can be connected directly to the EMX3. RTD/PT100s B ~ G are only available if the RTD/PT100 and Ground Fault expansion card is fitted.

The soft starter will trip when the temperature exceeds the value specified in parameters 11A~11G (refer to

11 RTD Temperatures

When fitting an RTD/PT100, always review the parameter settings. The default value for each RTD/PT100 input is 50 °C. The RTD/PT100 input is disabled by default, but activates automatically when an RTD/PT100 is detected.

Resistors are required on any unused RTD inputs to avoid trips from electrical fast transient (EFT) noise. When connecting an RTD, remove the resistor and associated jumper wire.

If RTD/PT100s have previously been connected to the EMX3 but are no longer required, either:

• connect a 120Ω~160Ω resistor between Signal + and Return – (B6, B8) to ensure the input remains at a known value, then adjust parameter(s) 11A~11G so that the starter does not trip or

• reset the starter to factory defaults (refer to

Load/Save Settings

on page 45). If you wish to retain the starter’s configuration, save the starter’s settings to a user set before resetting. Reload the settings after the RTD/PT100 input has been reset

5.8 Earth Terminals

Earth terminals are located at the back of the soft starter.

• EMX3-0023B ~ EMX3-0105B have one terminal on the input side (top).

• EMX3-0145B ~ EMX3-1000B and EMX3-0255C ~ EMX3-1600C have two terminals, one on the input side (top) and one

on the output side (bottom).

5.9 Power Input and Output Configurations

Internally Bypassed Models (EMX3-0023B~EMX3-1000B)

Models EMX3-0023B ~ EMX3-0220B have power inputs at the top of the unit and outputs at the bottom of the unit. Internally bypassed models EMX3-0255B ~ EMX3-0425B have output busbars at the bottom of the unit and input busbars at both the

top and bottom of the unit. The AC supply can be connected 'Top in, Bottom out' or 'Bottom in, Bottom out'. Internally bypassed models EMX3-0500B ~ EMX3-1000B have input and output busbars at the top and bottom of the unit. The AC

supply can be connected 'Top in, Bottom out', 'Top in, Top out', 'Bottom in, Bottom out' or 'Bottom in, Top out'.

EMX3-0023B~

EMX3-0105B

EMX3-0145B~EMX3-0220B EMX3-0255B~EMX3-0425B EMX3-0500B~EMX3-1000B

User Manual (710-04840-00M) | 11

INSTALLATION

15764.A

1/L1 3/L2 5/L3

T1B T 2B T3B

2/T1 4/T2 6/T3

(L1B L2 B L3B) 1/L1 3/L2 5/L 3

2/T1 4/T 2 6/T3

1/L1 3/L2 5/L 3

(L1B L2B L3 B)

2/T1 4/T 2 6/T3

(L1B L2B L3 B) 1/L1 3/L2 5/L 3

2/T1 4/T 2 6/T3

1/L1 3/L2 5/L 3 (L1B L2B L3 B)

2/T1 4/T 2 6/T3

Non-bypassed Model - EMX3-0255C

EMX3-0255C has dedicated bypass terminals at the bottom of the unit. The bypass terminals are T1B, T2B, T3B.

Non-bypassed Models (EMX3-0360C~EMX3-1600C)

EMX3-0360C~EMX3-1600C have dedicated bypass terminals, on the input busbars. The bypass terminals are L1B, L2B, L3B. The busbars on non-bypassed models EMX3-0360C ~ EMX3-1600C can be adjusted for top or bottom input and output as required.

Refer to

Busbar Adjustment Procedure

on page 93 for step-by-step instructions. All units are manufactured bottom in/bottom out.

12 | User Manual (710-04840-00M)

5.10 Power Terminations

NOTE

EMX3-0023B~EMX3-0105B

05966

11290.A

EMX3-0145B

EMX3-0170B~EMX3-0220B

EMX3-0255B

6 mm

19 mm

(

)

08351.

08352.B

6 mm

19 mm

10.5 mm (M10)

5 m

8 m

(

)

13181.B

EMX3-0350B~EMX3-0425B

EMX3-0500B~EMX3-1000B

EMX3-0255C

6 m

1 mm

(M1

14543.A

3 mm

2 mm

1 mm

(

M10)

(

08353.B

EMX3-0360C~EMX3-0930C

EMX3-1200C~EMX3-1600C

13 mm

32 mm

.5 mm

10)

16 mm51 mm

12.5 mm (

M12

)

08355.B

For personnel safety, the power terminals on models up to EMX3-0105B are protected by snap-off tabs. When using large cables, it may be necessary to break off these tabs.

Some units use aluminium busbars. When connecting power terminations, we recommend cleaning the surface contact area thoroughly (using an emery or stainless steel brush) and using an appropriate jointing compound to prevent corrosion.

Use only copper stranded or solid conductors, rated for 75 ºC or higher.

INSTALLATION

Cable size: 6-50 mm Torque: 4 Nm (2.9 ft-lb)

(AWG 10-1/0)

14 mm (0.55 inch)

19 Nm (14.0 ft-lb) 38 Nm (28.0 ft-lb) 38 Nm (28.0 ft-lb)

38 Nm (28.0 ft-lb) 38 Nm (28.0 ft-lb) 38 Nm (28.0 ft-lb)

Torx T20 x 150

Flat 7 mm x 150

38 Nm (28.0 ft-lb) 66 Nm (48.7 ft-lb)

User Manual (710-04840-00M) | 13

INSTALLATION

Internally bypassed models

Non-bypassed models

04477.D

6/T3

2/T1

P24

COM

4/T2

B10

B11

C31

C32

C41

C42

C53

C54

C24

C64

C63

B7 Comp

B8 -

B6 +

5/L3

3/L2

C23

1/L1

C BB A

B7 Comp

B8 -

B6 +

B7 Comp

B8 -

B6 +

B7 Comp

B8 -

B6 +

B7 Comp

B8 -

B6 +

B7 Comp

B8 -

B6 +

04480.C

23, 24

NOTE

5.11 Schematic Diagrams

Different models require control voltage to different terminals:

14 | User Manual (710-04840-00M)

Control voltage (model dependent) Remote control inputs Motor thermistor input RTD/PT100 input - 2-wire RTD/PT100 input - 3-wire RTD/PT100 input - 4-wire 24 VDC output Relay outputs 31, 32, 34 Relay output B Analog output 41, 42, 44 Relay output C

• C1 (110~210 VAC) A1, A2

• C1 (220~440 VAC) A2, A3

• C2 (24 VAC/VDC) A1, A3

C23, C24 C31, C32 C41, C42 C53, C54 C63, C64

13, 14

Start Stop Reset Programmable input A Programmable input B Relay output A Run relay output

* EMX3-0255C current transformers are located on the output. Bypass terminals are labelled T1B, T2B and T3B.

POWER CIRCUITS

6/T3

2/T1

5/L3

3/L2

1/L1

4/T2

K1 F1

Main contactor (optional)

Semiconductor fuses (optional)

13, 14

Relay output A (= Main Contactor,

6. Power Circuits

6.1 Motor Connection

The EMX3 can be connected to the motor in-line or inside delta (also called three-wire and six-wire connection). When connecting in inside delta, enter the motor full load current (FLC) for parameter 1A. The EMX3 will automatically detect whether the motor is connected in-line or inside delta and will calculate the correct inside delta current level.

Models which are internally bypassed do not require an external bypass contactor.

Internally bypassed models: EMX3-0023B, EMX3-0043B, EMX3-0050B, EMX3-0053B, EMX3-0076B, EMX3-0097B, EMX3-0100B, EMX3-0105B, EMX3-0145B,

EMX3-0170B, EMX3-0200B, EMX3-0220B, EMX3-0255B, EMX3-0350B, EMX3-0425B, EMX3-0500B, EMX3-0580B, EMX3-0700B, EMX3-0820B, EMX3-0920B, EMX3-1000B

Non-bypassed models: EMX3-0255C, EMX3-0360C, EMX3-0380C, EMX3-0430C, EMX3-0620C, EMX3-0650C, EMX3-0790C, EMX3-0930C, EMX3-1200C,

EMX3-1410C, EMX3-1600C

In-line installation, internally bypassed

default)

User Manual (710-04840-00M) | 15

POWER CIRCUITS

13039.B

6/T3

2/T1

5/L3

3/L2

1/L1

4/T2

T3B

6/T3

2/T1

5/L3

3/L2

1/L1

4/T2

L1B

L2B

L3B

Main contactor

Bypass contactor (external)

Semiconductor fuses (optional)

In-line installation, externally bypassed

Non-bypassed models have dedicated bypass terminals, which allow the EMX3 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 23, 24).

Power connections - in-line installation, externally bypassed (EMX3-0255C)

Power connections - in-line installation, externally bypassed (EMX3-0360C to EMX3-1600C)

16 | User Manual (710-04840-00M)

In-line installation, non-bypassed

6/T3

2/T1

5/L3

3/L2

1/L1

4/T2

K1 F1

6/T3

2/T1

4/T2

U1(1) U2(4)

V1(2)

V2(5)

W1(3) W2(6)

5/L3

3/L2

1/L1

K1 F1

Main contactor (strongly recommended)

Semiconductor fuses (optional)

13, 14

Relay output A (= Main Contactor,

WARNING

NOTE

POWER CIRCUITS

K1 Main contactor (optional) F1 Semiconductor fuses (optional) 13, 14 Relay output A (= Main Contactor,

default)

Inside delta installation, internally bypassed

When connecting the EMX3 in inside delta configuration, always install a main contactor or shunt trip circuit breaker.

When connecting in inside delta, enter the motor full load current (FLC) for parameter 1A. The EMX3 will automatically detect whether the motor is connected in-line or inside delta and will calculate the correct inside delta current level.

default)

User Manual (710-04840-00M) | 17

POWER CIRCUITS

04484.C

6/T3

2/T1

5/L3

3/L2

1/L1

4/T2

K1 F1

U1(1) U2(4)

V1(2)

V2(5)

W1(3) W2(6)

L2B

L1B

L3B

6/T3

2/T1

5/L3

3/L2

1/L1

4/T2

K1 F1

U1(1) U2(4)

V1(2)

V2(5)

W1(3) W2(6)

04483.D

Inside delta installation, externally bypassed

K1 Main contactor (strongly recommended) K2 Bypass contactor (external) F1 Semiconductor fuses (optional) 13, 14 Relay output A (= Main Contactor, default) 23, 24 Run relay output

Inside delta installation, non-bypassed

18 | User Manual (710-04840-00M)

K1 Main contactor (strongly recommended) F1 Semiconductor fuses (optional) 13, 14 Relay output A (= Main Contactor, default)

POWER CIRCUITS

CAUTION

6.2 Bypass Contactor

Some EMX3 soft starters are internally bypassed and do not require an external bypass contactor. Non-bypassed soft starters may be installed with an external bypass contactor. Select a contactor with an AC1 rating greater than

or equal to the full load current rating of the connected motor.

Internally bypassed models: EMX3-0023B, EMX3-0043B, EMX3-0050B, EMX3-0053B, EMX3-0076B, EMX3-0097B, EMX3-0100B, EMX3-0105B, EMX3-0145B,

EMX3-0170B, EMX3-0200B, EMX3-0220B, EMX3-0255B, EMX3-0350B, EMX3-0425B, EMX3-0500B, EMX3-0580B, EMX3-0700B, EMX3-0820B, EMX3-0920B, EMX3-1000B

Non-bypassed models: EMX3-0255C, EMX3-0360C, EMX3-0380C, EMX3-0430C, EMX3-0620C, EMX3-0650C, EMX3-0790C, EMX3-0930C, EMX3-1200C,

EMX3-1410C, EMX3-1600C

6.3 Main Contactor

A main contactor must be installed if the EMX3 is connected to the motor in inside delta format and is optional for in-line connection. Select a contactor with an AC3 rating greater than or equal to the full load current rating of the connected motor.

6.4 Circuit Breaker

A shunt trip circuit breaker may be used instead of a main contactor 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.

6.5 Power Factor Correction

If power factor correction is used, a dedicated contactor should be used to switch in the capacitors. To use the EMX3 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.

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.

6.6 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.

Adaptive Control controls the motor's speed profile, within the programmed time limit. This may result in a higher level of current than traditional control methods.

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.

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.

User Manual (710-04840-00M) | 19

POWER CIRCUITS

480 VAC circuits

600 VAC circuits

@ 480 VAC max.

@ 600 VAC

Model

Short Circuit Rating

Max. Fuse

Rating (A)

(fuse class)

Short Circuit Rating

Ferraz/Mersen fuse,

Listed J, L or RK5 Class

Fuse

Ferraz/Mersen fuse, R/C

semi-conductor fuses

600 V Short cct

rating –

3 cycles †

EMX3-0425B

450 (J)

†

A070URD33XXX0630

30 kA –

EMX3-0500B

600 (J)

30 kA

Any 600 A, Class J

A070URD33XXX0700

For 3 cycles

EMX3-0580B

EMX3-0700B

EMX3-0820B

A070URD33XXX1000

42 kA –

EMX3-0920B

1200 (L)

Any 1200 A, Class L

For 3 cycles

EMX3-1000B

EMX3-0255C

65 kA

350 (RK1/J)

18 kA

AJT300

A070URD30XXX0450

EMX3-0360C

600 (L)

Any 600 A, Class L

A070URD33XXX0630

EMX3-0380C

A070URD33XXX0700

EMX3-0430C

100 kA

800 (L)

100 kA

Any 800 A, Class L

EMX3-0620C

A070URD33XXX1000

Not available

EMX3-0650C

1200 (L)

Any 1200 A, Class L

EMX3-0790C

A070URD33XXX1400

EMX3-0930C

6.7 UL Short Circuit Ratings

Short circuit current ratings (SCCR) are available for 480 VAC and 600 VAC installations.

•

For UL compliant installation, select a fuse that meets the specified fuse class and maximum fuse rating.

•

For UL compliant installation, the starter can be protect by either fuses or a circuit breaker as specified in the following tables.

Fuse selection

EMX3-0023B 25 (J) AJT25 A070URD30XXX0063 EMX3-0043B EMX3-0050B A070URD30XXX0125 EMX3-0053B 60 (J) 10 kA AJT60 EMX3-0076B 80 (J) AJT80 Not available EMX3-0097B EMX3-0100B EMX3-0105B 125 (J) AJT125 EMX3-0145B 150 (J) AJT150 / RK5 200 A070URD30XXX0315 EMX3-0170B 65 kA 175 (J) AJT175 / RK5 200 EMX3-0200B 200 (J) 18 kA AJT200 / RK5 300 EMX3-0220B 250 (J) AJT250 / RK5 300 EMX3-0255B 350 (RK1/J) † EMX3-0350B 400 (J) † For 3 cycles

50 (J)

100 (J)

AJT50

AJT100

A070URD30XXX0200

A070URD30XXX0450

Not available

18 kA –

800 (L)

Any 800 A, Class L Not available

42 kA

EMX3-1200C

85 kA

1600 (L)

A4BQ1600 A065URD33XXX1800

A070URD33XXX1400

EMX3-1410C 65 kA 2000 (L) 85 kA A4BQ2000 A055URD33XXX2250 EMX3-1600C

XXX = blade type. Refer to Ferraz/Mersen catalog for details.

A4BQ2500

† - Models provided with a “3 cycle rating” are suitable for use in a circuit with the prospective current noted, when protected by any UL Listed fuses or UL Listed circuit breakers sized according to the NEC.

20 | User Manual (710-04840-00M)

Circuit breaker selection

Model

Short

Circuit

Rating @

480 VAC

max.

Breaker 1: Eaton

Part Number (rating, A)

Breaker 2: GE

Part Number (rating, A)

Breaker 3: LSIS

Part Number (rating, A)

480 V/ 600 V

standard

short circuit

rating

EMX3-0023B

FXD3050 (50)

SELA36A7030 (50)

UTS125HU (50)

EMX3-0043B

HFD3100 (100)

UTS150HU (100)

EMX3-0050B

UTS150HU/ UTS250HU

EMX3-0105B

HJD3150 (250)

EMX3-0145B

EMX3-0170B

65 kA

EMX3-0200B

EMX3-0220B

UTS400HU/

EMX3-0620C

EMX3-0650C

42 kA

EMX3-0790C

SKLA36AT1200

EMX3-0930C

(1200)

UTS1200 (1200)

EMX3-1200C

EMX3-1410C

85 kA

Siemens:

HPX3R1600 (1600)

85 kA

EMX3-1600C

EMX3-0053B HFD3125 (125) SELA36AT0100 (100) EMX3-0076B EMX3-0097B EMX3-0100B SELA36AT0150 (150)

HJD3250 (250)

POWER CIRCUITS

(150)

10 kA UTS150HU/ UTS250HU (250)

HJD3250 (250) SFLA36AT0250 (250)

UTS250HU/ UTS400HU (400)

18 kA

EMX3-0255B HLD3600 (400) SGLA36AT3600 (400)

UTS600HU (400)

EMX3-0350B HLD3600 (600) SGLA36AT3600 (600) UTS800HU/ EMX3-0425B UTS600HU (800) EMX3-0500B CHLD3600 (600) SKLA3600AT600 (600) UTS800xU (800) 30 kA EMX3-0580B CHLD3800 (800) SKLA3600AT800 (800) EMX3-0700B EMX3-0820B NGH312033E (1200) SKLA36AT1200 (1200) UTS1200xU (1200) 42 kA EMX3-0920B EMX3-1000B UTS800xU (1200)

EMX3-0255C

EMX3-0360C EMX3-0380C

EMX3-0430C 65 kA Not suitable

SGLA36AT600 (400)

SGLA36AT600 (1000) UTS600HU/ 18 kA SGLA36AT800 (1000) UTS800HU (1000)

UTS250HU/ UTS400HU (000)

UTS600HU/ UTS800HU/ UTS1200HU (1200)

30 kA

SGLA36AT800 (1200)

UTS800/ UTS1200 (1200)

User Manual (710-04840-00M) | 21

POWER CIRCUITS

EMX3-0920B

EMX3-1000B

6.8 Fuse Selection for Type 2 Coordination

Type 2 coordination is achieved by using semiconductor fuses. These fuses must be able to carry motor start current and have a total

clearing I

When selecting semiconductor fuses for EMX3, use the I2t values in the table. For further information on selecting semiconductor fuses, contact your local distributor.

I2t values for Type 2 coordination

t less than the I2t of the soft starter SCRs.

Model SCR I2t (A2s) EMX3-0023B 1150 EMX3-0043B 8000 EMX3-0050B 10500 EMX3-0053B EMX3-0076B EMX3-0097B 51200 EMX3-0100B 80000 EMX3-0105B EMX3-0145B EMX3-0170B EMX3-0200B EMX3-0220B EMX3-0255B EMX3-0350B 202000 EMX3-0425B EMX3-0500B EMX3-0580B EMX3-0700B EMX3-0820B 1200000

15000

125000

320000

781000

2530000

EMX3-0255C EMX3-0360C EMX3-0380C

320000

EMX3-0430C EMX3-0620C EMX3-0650C

1200000

EMX3-0790C 2530000 EMX3-0930C EMX3-1200C

4500000

EMX3-1410C 6480000 EMX3-1600C 12500000

22 | User Manual (710-04840-00M)

7. Keypad and Feedback

Run

Trip LocalReady

Exit

Men

tor

Logs

Alt

Tools

Reset

LC L RM T

StopStart

04186.B

1 2

Shortcut buttons for quick access to common

LED name

Flashing

NOTE

7.1 The Keypad

KEYPAD AND FEEDBACK

Four-line display for status and programming details.

Status LEDs Menu navigation buttons: : Exit the menu or parameter, or cancel a

parameter change.

: Enter a menu or parameter, or save a parameter change. / : Scroll to the next or previous menu or parameter, or change the setting of the current parameter.

Soft starter local control buttons

tasks. Alt button. Use with F1 or F2 to open

performance logs or commissioning tools.

Starter Status LEDs

Ready The motor is stopped and the starter is ready to start. The motor is stopped and the starter is waiting for the

Restart Delay Check

(parameter 4M) or

(parameter 4N).

Motor Temperature

Run The motor is in run state (receiving full voltage). The motor is starting or stopping. Trip The starter has tripped. The starter is in warning state. Local The starter is in Local control mode. –

If the starter is in remote control mode, the Local LED will be off. If all LEDs are off, the starter is not receiving control voltage.

Removing and Replacing the Keypad

The keypad can be removed from the soft starter and mounted remotely on a panel using the remote mounting kit.

The keypad can be removed or replaced while the starter is running. It is not necessary to remove mains or control

• Removing the keypad

The keypad is attached to the body of the soft starter by a DB9 serial connector and two screws. The screws are concealed behind a snap-on faceplate.

To remove the keypad:

voltage.

1. Models EMX3-0023B to EMX3-1000B: open the EMX3's door. Models EMX3-0255C to EMX3-1600C: remove the EMX3's front cover.

2. Insert a small screwdriver under the faceplate, at the base of the keypad, and use the screwdriver to lever the faceplate off the keypad.

3. Lift the faceplate off completely.

4. Remove the two screws holding the keypad in place.

5. Lift the keypad gently off the soft starter. Pull the keypad forwards, to avoid damaging the DB9 connector.

User Manual (710-04840-00M) | 23

KEYPAD AND FEEDBACK

STORE

Starter to Display

If any of the settings in the keypad are not valid for the starter, the keypad loads the default

NOTE

M1 000% M2 000%

• Reattaching the keypad

To reattach the keypad:

1. Align the connector on the back of the keypad with the socket on the soft starter and push the keypad firmly into place. The keypad will be held in place by the connector and two locating nibs in the top right and bottom left corners. For temporary installation (eg during commissioning) it is not necessary to screw the keypad in place.

2. Replace the two screws holding the keypad in place.

3. Slide the bottom edge of the faceplate over the body of the keypad, then swing the top edge of the faceplate into place and press onto the keypad. The retaining tabs on the back of the faceplate will snap into place.

• Synchronising the Keypad and the Starter

When a keypad is connected to an EMX3, it synchronises its parameter settings with the settings in the soft starter. Every time a different keypad is plugged into the starter, an acknowledgement is

displayed.

Select the required option using the and buttons. Press

to proceed with

the selection.

values.

New Display Detected

Copy Parameters Display to Starter

7.2 Displays

The keypad displays a wide range of performance information about the soft starter. The top half of the screen shows real-time information on current or motor power (as selected in parameter 8D). Use the shown on the bottom half of the screen.

• Starter status

• Motor temperature

• Current

• Motor power

• Last start information

• Date and time

• SCR conduction

Screens shown here are with the default settings.

Starter Status

The starter status screen shows details of the starter's operating status, motor temperature and motor power.

Ready M1 000% 000.0kW

Programmable screen

and buttons to select the information

The EMX3's user-programmable screen can be configured to show the most important information for the particular application. Use parameters 8E to 8H to select which information to display.

Ready 0000 hrs - - %

Motor Temperature

The temperature screen shows which motor data set is in use, and the temperature of both motors as a percentage of total thermal capacity. If the EMX3 is configured for use on one motor, the temperature for the secondary motor (M2) will always show 0%.

Primary Motor Set

24 | User Manual (710-04840-00M)

KEYPAD AND FEEDBACK

000.0A 000.0A 000.0A

05050.C

000.0 A 0

-40

L3 Cond

Current

The current screen shows real-time line current on each phase. If the RTD/PT100 and ground fault protection card is fitted, the screen will also show ground current.

Phase Currents

Motor Power

The motor power screen shows motor power (kW, HP and kVA) and power factor.

000.0kW 0000HP 0000kVA -. - - pf

The motor power figures are calculated using the Mains Reference Voltage (parameter 8N).

Last Start Information

The last start information screen shows details of the most recent successful start:

• start duration (seconds)

• maximum start current drawn (as a percentage of motor full load current)

Last start 010 s 350 % FLC∆ Temp 5%

• calculated rise in motor temperature

Date and Time

The date/time screen shows the current system date and time (24 hour format). For details on setting the date and time, refer to

Set Date and Time

on page 26.

Performance Graph

The performance graph provides a real-time display of operating performance. Use parameters 8I~8L to select which information to display.

SCR Conduction Bargraph

The SCR conduction bargraph shows the level of conduction on each phase.

L1 Cond

L2 Cond

User Manual (710-04840-00M) | 25

MAINTENANCE TOOLS

NOTE

ALT

TOOLS

ALT

TOOLS

NOTE

8. Maintenance Tools

8.1 Testing the Installation

The FLC of the test motor must be at least 2% of the soft starter's minimum FLC (refer to on page 82).

When testing the soft starter with a small motor, set parameter 1A value.

Motor Full Load Current

8.2 Commissioning Menu (Tools)

The Commissioning Menu provides access to commissioning and testing tools. Press

then

To navigate through the Commissioning Menu:

• to scroll to the next or previous item, press the

• to open an item for viewing, press the

• to return to the previous level, press the

• to close the Commissioning Menu, press

to open the Tools.

or button.

button.

repeatedly.

Minimum and Maximum Current Settings

to the minimum allowable

Set Date and Time

To set the date and time:

1. Press

then

to open the Tools.

2. Scroll to the date/time screen.

3. Press the button to enter edit mode.

4. Press the

and buttons to select which part of the date or time to edit.

5. Use the and buttons to change the value.

6. To save changes, press the To cancel changes, press the

button. The EMX3 will confirm the changes.

button.

Simulation Tools

Software simulation functions let you test the soft starter's operation and control circuits without connecting the soft starter to mains voltage. The EMX3 has three simulation modes:

• The run simulation simulates a motor starting, running and stopping to confirm that the soft starter and associated

equipment have been installed correctly.

• The protection simulation simulates activation of each protection mechanism to confirm that the soft starter and

associated control circuits are responding correctly.

• The output signal simulation simulates output signalling to confirm that outputs and associated control circuits are

operating correctly.

The simulation tools are accessed via the Commissioning Menu. The simulations are only available when the soft starter is in Ready state, control voltage is available and the keypad is active.

Access to the simulation tools is protected by the security access code. The default access code is 0000.

26 | User Manual (710-04840-00M)

Run Simulation

EXIT

ALT

TOOLS

Apply Start Signal

START

STORE to Continue

NOTE

STORE

STOP

STORE

STORE to Continue

ALT

TOOLS

3. Use the and buttons to select the protection you want to simulate.

Selected Protection

NOTE

MAINTENANCE TOOLS

You can end the simulation at any time by pressing

To use the run simulation:

1. Press

then

to open the Tools.

2. Scroll to Run Simulation and press .

3. Press

or activate the start input. The EMX3 simulates its pre-start checks

and closes the main contactor relay. The Run LED flashes.

If mains voltage is connected, an error message is shown. Remove mains voltage and proceed to the next step.

4. Press . The EMX3 simulates starting. The Run LED flashes.

5. Press . The EMX3 simulates running. The Run LED stays on without flashing and the bypass contactor relay closes.

6. Press

or activate the stop input. The EMX3 simulates stopping. The Run

LED flashes and the bypass contactor relay opens.

7. Press . The Ready LED flashes and the main contactor relay opens.

Run Simulation Ready

Run Simulation Pre-Start Checks

Run Simulation ATTENTION! Remove Mains Volts

to Continue

Run Simulation Starting X:XXs

to Continue

Run Simulation Running Apply Stop Signal

Run Simulation Stopping X:XXs

to Continue

Run Simulation Stopped

8. Press to return to the commissioning menu.

Protection Simulation

The protection simulation simulates activation of each protection mechanism to confirm that the soft starter and associated control circuits are responding correctly.

To use the protection simulation:

1. Press

2. Scroll to Protection Simulation and press .

4. Press and hold to simulate the selected protection.

5. The screen is displayed momentarily. The soft starter's response depends on the Protection Action setting (parameter group 16).

6. Use or to select another simulation, or press to exit.

then

to open the Tools.

0.0A Tripped

If the protection trips the soft starter, reset before simulating another protection. If the protection action is set to 'Warn and Log', no reset is required.

If the protection is set to 'Warn and Log', the warning message can be viewed only while the button is pressed.

If the protection is set to 'Log only', nothing appears on the screen but an entry will appear in the log.

User Manual (710-04840-00M) | 27

MAINTENANCE TOOLS

NOTE

ALT

TOOLS

4.0mA

This screen shows the state of the motor thermistors and RTD/PT100s.

Outputs: 0000100

This screen shows the current status of the Analog I/O

Output Signal Simulation

The output signal simulation simulates output signalling to confirm that outputs and associated control circuits are operating correctly.

To test operation of the flags (motor temperature and low/high current), set an output relay to the appropriate function and monitor the relay's behaviour.

To use the output signal simulation:

1. Press

2. Scroll to Output Signalling Simulation and press .

then

to open the Tools.

3. Use the and buttons to select a function to simulate, then press .

4. Use the and buttons to turn the signal on and off. To confirm correct operation, monitor the state of the output.

5. Press to return to the simulation list.

Prog Relay A Off

Analog Output Simulation

The analog output simulation uses the and buttons to change the current at the analog output terminals.

Attach a current measuring device to the analog output terminals. Use the or button to adjust the percentage value on the display. The current measuring device should indicate the same level of current as shown on the display.

If the input/output expansion card is fitted, the simulation can also be used to test the operation of Relays D, E, F and Analog Output B.

Analog Output A 0%

Temperature Sensors State

Temp Sensors State

S = Short H = Hot C = Cold O = Open

RTD/PT100s B ~ G are only available if the RTD/PT100 and Ground Fault expansion card is fitted.

Thermistor: 0 RTD/PT100s:OOOOOOO S = Shrt H=Hot C=Cld O=Opn

Digital I/O State

This screen shows the current status of the digital inputs and outputs.

The top line of the screen shows the start, stop, reset and programmable inputs (A and B, then inputs on the I/O expansion card (if fitted).

The bottom line of the screen shows programmable output A, the fixed Run output, programmable outputs B and C, then the outputs on the expansion card (if fitted).

Analog I/O State

This screen will also show Analog Output B if the expansion card is fitted.

Digital I/O State Inputs: 0110000

Analog I/O State Input: - - - - % Output A: 04.0mA

28 | User Manual (710-04840-00M)

MAINTENANCE TOOLS

1. Press ALT then TOOLS to open the Tools.

to Reset

STORE

CAUTION

ALT

LOGS

ALT

LOGS

ALT

LOGS

Reset Thermal Models

The soft starter's thermal modelling software constantly monitors the motor's performance. This allows the starter to calculate the motor's temperature and ability to start successfully at any time. If the EMX3 is configured for use on two motors, each motor's temperature is modelled separately.

The thermal model for the active motor can be reset if required.

2. Scroll to Reset Thermal Models and press .

3. Use to select Reset and press

to confirm.

4. When the thermal model has been reset, the screen will display a confirmation message then return to the previous screen.

Resetting the motor thermal model will compromise thermal model protection and may compromise motor life. Only reset the thermal model in an emergency.

8.3 Logs Menu

The Logs Menu provides information on events, trips and starter performance. Press

then

to open the Logs.

To navigate through the Logs Menu:

• to open a log, press the

• to scroll through the entries in each log, press the

• to view details of a log entry, press the

• to return to the previous level, press the

The Logs Menu can only be opened while viewing the monitoring screens.

• to close the Logs Menu, press

button.

and buttons.

button.

repeatedly.

Reset Thermal Models M1 X% M2 X%

Do Not Reset Reset

Trip Log

The Trip Log stores details of the eight most recent trips, including the date and time the trip happened. Trip 1 is the most recent and trip 8 is the oldest stored trip.

To open the Trip Log:

1. Press

then

to open the Logs.

2. Scroll to Trip Log and press .

3. Use the

To close the log and return to the main display, press

and buttons to select a trip to view, and press to display details.

repeatedly.

Event Log

The Event Log stores time-stamped details of the starter's 99 most recent events (actions, warnings and trips), including the date and time of the event. Event 1 is the most recent and event 99 is the oldest stored event.

To open the Event Log:

1. Press

2. Scroll to Event Log and press .

3. Use the

To close the log and return to the main display, press

then

to open the Logs.

and buttons to select an event to view, and press to display details.

repeatedly.

User Manual (710-04840-00M) | 29

MAINTENANCE TOOLS

ALT

LOGS

STORE

Performance Counters

The performance counters store statistics on the starter's operation:

• Hours run (lifetime and since counter last reset)

• Number of starts (lifetime and since counter last reset)

• Motor kWh (lifetime and since counter last reset)

• Number of times the thermal model has been reset

The resettable counters (hours run, starts and motor kWh) can only be reset if the Write.

To view the counters:

1. Press

then

to open the Logs.

2. Scroll to counters and press .

3. Use the

and buttons to scroll through the counters. Press to view details.

4. To reset a counter, press then use the and buttons to select Reset/Do Not Reset. Press

the action.

To close the counter and return to the Logs Menu, press .

Adjustment Lock

(parameter 15B) is set to Read &

to confirm

30 | User Manual (710-04840-00M)

OPERATION

LCL/RMT

STOP

START

STOP

RESET

STOP

RESET

9. Operation

9.1 Priority of Commands

Starter Disable overrides any other control command. Refer to parameter 6A Input A Function. Emergency Run overrides normal control commands, including auto-start/stop. Refer to parameter 15C Emergency Run. Auto-start/stop overrides normal control commands (local, remote or via serial communications). Refer to

48.

3 Auto-Start/Stop

9.2 Start, Stop and Reset Commands

The soft starter can be controlled in three ways:

• using the buttons on the keypad

• via remote inputs

• via a serial communication link

The inputs).

Control via the fieldbus communication network is always enabled in local control mode, and can be enabled or disabled in remote control mode (parameter 6R communication module.

The

button controls whether the EMX3 will respond to local control (via the keypad) or remote control (via the remote

• The Local LED on the keypad is on when the soft starter is in local control mode and off when the soft starter is in remote control mode.

• The Remote LED on the EMX3 is on when the soft starter is in Remote mode and off when in Local mode. The Remote LED is located on the main body of the starter (behind the keypad) and is only visible if the keypad is remotely mounted.

Comms in Remote

). Control via the serial communication network requires an optional

button on the keypad is always enabled.

on page

Using the Soft Starter to Control a Motor

To soft start the motor, press the mode selected in parameter 2A.

To stop the motor, press the selected in parameter 2H.

To reset a trip on the soft starter, press the To stop the motor with a coast to stop, regardless of the setting of parameter 2H

at the same time. The soft starter will remove power from the motor and open the main contactor, and the motor will coast to stop.

button on the keypad or activate the Start remote input. The motor will start using the start

button on the keypad or activate the Stop remote input. The motor will stop using the stop mode

button on the keypad or activate the Reset remote input.

Stop Mode

, press the local

and

buttons

Auto-Start/Stop

The EMX3 can also be configured to auto-start or auto-stop. Auto-start/stop operation is only available in Remote mode. In Local mode, the starter will ignore any auto-start/stop setting. To configure auto-start/stop operation, use parameters 3A~3D.

User Manual (710-04840-00M) | 31

OPERATION

Soft Start Method

Parameter Controlled

Performance Parameters Influenced

To Control

Use

Motor Start Current

Constant Current

Motor/Load Acceleration

Adaptive Control

700%

600%

500%

300%

100%

400%

200%

10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

700%

600%

500%

300%

100%

400%

200%

Time

9.3 Soft Start Methods

Soft starters offer a variety of methods to control motor starting. Each soft start method uses a different primary control parameter.

Timed Voltage Ramp Voltage Start current, start torque, acceleration Constant Current Current Start torque, acceleration Torque Control Torque Start current, acceleration Adaptive Control Acceleration Start current, start torque

Best results are obtained by selecting the soft start method that directly controls the parameter of most importance for the application. Typically soft starters are used to limit motor start current or control load acceleration and/or deceleration. The EMX3 can be set to either Constant Current or Adaptive Control.

Constant Current

Constant current is the traditional form of soft starting, which raises the current from zero to a specified level and keeps the current stable at that level until the motor has accelerated.

Constant current starting is ideal for applications where the start current must be kept below a particular level.

Initial Current Current Limit

3: Full voltage current

(parameter 2C) (parameter 2D)

Current

(%motor full load current)

Rotor speed (% full speed)

Current Ramp

Current ramp soft starting raises the current from a specified starting level (1) to a maximum limit (3), over an extended period of time (2).

Current ramp starting can be useful for applications where:

• the load can vary between starts (for example a conveyor which may start loaded or unloaded). Set the initial current (parameter 2C) to a level that will start the motor with a light load, and the current limit (parameter 2D) to a level that will start the motor with a heavy load.

• the load breaks away easily, but starting time needs to be extended (for example a centrifugal pump where pipeline pressure needs to build up slowly).

• the electricity supply is limited (for example a generator set), and a slower application of load will allow greater time for

Current

(%motor full load current)

32 | User Manual (710-04840-00M)

the supply to respond.

Initial Current

Start Ramp Time

Current Limit

(parameter 2C)

(parameter 2B)

(parameter 2D)

4: Full voltage current

OPERATION

CAUTION

20%

30%

40%

50%

60%

80%

90%

100%

048

27.

NOTE

Kickstart

Kickstart provides a short boost of extra torque at the beginning of a start, and can be used in conjunction with current ramp or constant current starting.

Kickstart can be useful to help start loads that require high breakaway torque but then accelerate easily (for example helical rotor pumps).

Kickstart Level

Kickstart Time

Initial Current

Current

Start Ramp Time

Current Limit

(parameter 2G)

(parameter 2F)

(parameter 2C)

(parameter 2B)

(parameter 2D)

6: Full voltage current

(%motor full load current)

Rotor speed (% full speed)

Adaptive Control for Starting

In an adaptive control soft start, the EMX3 adjusts the current in order to start the motor within a specified time and using a selected acceleration profile.

Adaptive Control cannot start the motor faster than a direct on-line (DOL) start. If the start ramp time (parameter 2B) is

Every application has a particular starting profile, based on characteristics of the load and the motor. Adaptive Control offers three different starting profiles, to suit the requirements of different applications. Selecting a profile that matches the inherent profile of the application can help smooth out acceleration across the full start time. Selecting a dramatically different Adaptive Control profile can somewhat neutralise the inherent profile.

The EMX3 monitors the motor's performance during each start, to improve control for future soft starts.

shorter than the motor's DOL start time, starting current may reach DOL levels.

• Adaptive Control

To use Adaptive Control to control starting performance:

1. Select Adaptive Control from the Start Mode menu (parameter 2A)

2. Set the desired Start Ramp Time (parameter 2B)

3. Select the desired Adaptive Start Profile (parameter 2E)

4. Set a start Current Limit (parameter 2D) sufficiently high to allow a successful start. The first Adaptive Control start will be a Constant Current start. This allows the EMX3 to learn the characteristics of the connected motor. This motor data is used by the EMX3 during subsequent Adaptive Control starts.

Speed

Time

Adaptive Control will control the load according to the programmed profile. Start current will vary according to the selected acceleration profile and the programmed start time.

If replacing a motor connected to an EMX3 programmed for Adaptive Control starting or stopping, or if the starter has

Adaptive Start Profile

(parameter 2E):

1. Early Acceleration

2. Constant Acceleration

3. Late Acceleration

Start Ramp Time

(parameter 2B)

User Manual (710-04840-00M) | 33

OPERATION

been tested on a different motor prior to actual installation, the starter will need to learn the characteristics of the new

CAUTION

NOTE

Stop Method

Performance Result

Coast To Stop

Natural load run down

TVR Soft Stop

Extended run down time

Adaptive Control

Extended run down time according to selected deceleration profile

Brake

Reduced run down time

motor. The EMX3 will automatically re-learn the motor's characteristics if parameter 1A parameter 2K

Adaptive Control Gain

is changed.

Motor Full Load Current

• How to Select the Adaptive Control Start Profile

The best profile will depend on the exact details of each application. Some loads, such as submersible pumps, should not be run at slow speeds. An early acceleration profile will raise the speed

quickly, then control acceleration through the rest of the start.

Adaptive Control controls the motor's speed profile, within the programmed time limit. This may result in a higher level of current than traditional control methods.

• Fine-tuning Adaptive Control

If the motor does not start or stop smoothly, adjust the adaptive control gain (parameter 2K). The gain setting determines how much the EMX3 will adjust future adaptive control starts and stops, based on information from the previous start. The gain setting affects both starting and stopping performance.

• If the motor accelerates or decelerates too quickly at the end of a start or stop, increase the gain setting by 5%~10%.

• If the motor speed fluctuates during starting or stopping, decrease the gain setting slightly.

Changing the gain setting resets the starter's adaptive control learning. The first start after changing the gain will use constant current.

9.4 Stop Methods

Soft starters offer a variety of methods for the control of motor stopping.

Soft starters are often used in pumping applications to eliminate the damaging effects of fluid hammer. Adaptive Control should be the preferred stop method for these applications.

Coast to Stop

Coast to stop lets the motor slow at its natural rate, with no control from the soft starter. The time required to stop will depend on the type of load.

TVR Soft Stop

Timed voltage ramp reduces the voltage to the motor gradually over a defined time. The load may continue to run after the stop ramp is complete.

Timed voltage ramp stopping can be useful for applications where the stop time needs to be extended, or to avoid transients on generator set supplies.

Stop Time

(parameter 2I)

Voltage (% full voltage)

Time

34 | User Manual (710-04840-00M)

OPERATION

NOTE

CAUTION

100%

90%

80%

70%

60%

50%

40%

30%

20%

10%

04835.C

2 3

NOTE

Adaptive Stop Profile

Application

Adaptive Control for Stopping

In an adaptive control soft stop, the EMX3 controls the current in order to stop the motor within a specified time and using a selected deceleration profile. Adaptive Control can be useful in extending the stopping time of low inertia loads.

Every application has a particular stopping profile, based on characteristics of the load and the motor. Adaptive Control offers three different stopping profiles. Choose the adaptive control profile that best matches your application requirements.

Adaptive control does not actively slow the motor down and will not stop the motor faster than a coast to stop. To

• Adaptive Control

To use Adaptive Control to control stopping performance:

Speed

shorten the stopping time of high inertia loads, use brake.

Adaptive Control controls the motor's speed profile, within the programmed time limit. This may result in a higher level of current than traditional control methods.

1. Select Adaptive Control from the Stop Mode menu (parameter 2H)

2. Set the desired Stop Time (parameter 2I)

3. Select the required Adaptive Stop Profile (parameter 2J)

Adaptive Stop Profile

(parameter 2J):

1. Early Deceleration

2. Constant Deceleration

3. Late Deceleration

Stop Time

(parameter 2I)

Time

The first Adaptive Control stop will be a normal soft stop. This allows the EMX3 to learn the characteristics of the connected motor. This motor data is used by the EMX3 during subsequent Adaptive Control stops.

• Pump stopping

The hydraulic characteristics of pump systems vary considerably. This variation means the ideal deceleration profile and stop time will vary from application to application. The table provides guidelines on selecting between Adaptive Control deceleration profiles, but we recommend testing the three profiles to identify the best profile for the application.

Late Deceleration High head systems where even a small decrease in motor/pump speed results in a rapid

Constant Deceleration Low to medium head, high flow applications where the fluid has high momentum. Early Deceleration Open pump systems where fluid must drain back through the pump without driving the pump

Adaptive Control will control the load according to the programmed profile. Stopping current will vary according to the selected deceleration profile and stop time.

If replacing a motor connected to an EMX3 programmed for Adaptive Control starting or stopping, or if the starter has been tested on a different motor prior to actual installation, the starter will need to learn the characteristics of the new motor. The EMX3 will automatically re-learn the motor's characteristics if parameter 1A parameter 2K

Adaptive Control Gain

is changed.

Motor Full Load Current

transition between forward flow and reverse flow.

in reverse.

User Manual (710-04840-00M) | 35

OPERATION

CAUTION

100%

75%

50%

25%

Time

CAUTION

NOTE

Brake

Brake reduces the time required to stop the motor. During braking an increased noise level from the motor may be audible. This is a normal part of motor braking.

When brake is selected, the EMX3 uses DC injection to slow the motor. EMX3 braking:

• Does not require the use of a DC brake contactor

• Controls all three phases so that the braking currents and associated heating are evenly distributed through the

Braking has two stages:

To configure the EMX3 for brake operation:

1. Set parameter 2I for the desired stopping time duration (1). This is the total braking time and must be set sufficiently

2. Set Brake Time (parameter 2M) to approximately one quarter of the programmed Stop Time. This sets the time for the Full

3. Adjust the Brake Torque (parameter 2L) so that the desired stopping performance is achieved. If set too low, the motor will

Speed

motor.

If the brake torque is set too high, the motor will stop before the end of the brake time and the motor will suffer unnecessary heating which could result in damage. Careful configuration is required to ensure safe operation of the starter and motor.

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.

Brake operation causes the motor to heat faster than the rate calculated by the motor thermal model. If you are using brake, install a motor thermistor or allow sufficient restart delay (parameter 4M).

• Pre-brake: provides an intermediate level of braking to slow motor speed to a point where full brake can be operated

successfully (approximately 70% speed).

• Full brake: brake provides maximum braking torque but is ineffective at speeds greater than approximately 70%.

longer than the brake time (parameter 2M) to allow the pre-braking stage to reduce motor speed to approximately 70%. If the stop time is too short, braking will not be successful and the motor will coast to stop.

Brake stage (2).

not stop completely and will coast to stop by the end of the braking period.

Stop Time

Brake Time

(parameter 2I)

(parameter 2M)

3: Coast to stop time

When using DC brake, the mains supply must be connected to the soft starter (input terminals L1, L2, L3) in positive phase sequence and parameter 4G

For loads which may vary between braking cycles, install a zero speed sensor to ensure that the soft starter ends DC braking when the motor stops. This avoids unnecessary heating of the motor.

For more information on using the EMX3 with an external speed sensor (eg for applications with variable load during the braking cycle), refer to

36 | User Manual (710-04840-00M)

Phase Sequence

DC Brake with External Zero Speed Sensor

must be set to Positive Only.

on page 66.

OPERATION

CAUTION

Jog operation causes the motor to heat faster than the rate calculated by the motor thermal model. If you are using

NOTE NOTE

100%

90%

80%

20%

40%

10%

50%

60%

05723.D

STOP

Adaptive Control Start

The starter performs a constant current start.

Adaptive Control Stop

The starter performs a TVR soft stop if parameter 2I

Stop Time

is >0 secs. If parameter 2I is set to

Jog

The starter issues a warning with the error message Unsupported Option.

Brake

The starter performs a coast to stop.

PowerThrough

The starter trips with the error message Lx-Tx Shorted.

NOTE

9.5 Jog Operation

Jog runs the motor at reduced speed, to allow alignment of the load or to assist servicing. The motor can be jogged in either forward or reverse direction.

Slow speed running is not intended for continuous operation due to reduced motor cooling.

jog, install a motor thermistor or allow sufficient restart delay (parameter 4M).

Soft start and soft stop are not available during jog operation.

Jog is only available for the primary motor.

The maximum available torque for jog forward is approximately 50%~75% of motor full load torque (FLT) depending on the motor. The torque when the motor is jogged in reverse is approximately 25% to 50% of FLT.

Parameter 15E

Torque settings above 50% may cause increased shaft vibration.

Jog Torque

controls how much of the maximum available jog torque the soft starter will apply to the motor.

1. Motor FLT

2. Jog forward maximum torque

3. Jog reverse maximum torque

Available torque

To activate jog operation, use either a programmable input (refer to parameters 6A and 6F, will operate only in Remote Mode) or a shortcut key (parameters 8B and 8C).

To stop a jog operation, perform one of the following:

• Remove the jog command.

• Press the

button on the keypad.

Jog will recommence at the end of a restart delay if the jog command is still present. All other commands except the above, will be ignored during jog operation.

9.6 Inside Delta Operation

Adaptive Control, Jog, Brake and PowerThrough functions are not supported with inside delta (six-wire) operation. If these functions are programmed when the starter is connected inside delta the behaviour is as given below:

0 secs the starter performs a coast to stop.

When connected in inside delta, current imbalance is the only phase loss protection that is active during run. Do not disable current imbalance protection (parameter 4H) during inside delta operation.

User Manual (710-04840-00M) | 37

PROGRAMMING MENU

Quick Setup

Standard Menu

The Standard Menu provides access to commonly used parameters, allowing you to configure the EMX3

Extended Menu

The Extended Menu provides access to all the EMX3's programmable parameters, allowing experienced

Load/Save Settings

STORE

EXIT

10. Programming Menu

You can access the Programming Menu at any time, including while the soft starter is running. Any changes to the start profile take effect immediately.

The Programming Menu contains four sub-menus:

Quick Setup guides you through the parameters required to configure the EMX3 for common

applications. Quick Setup suggests a value for each parameter, but you can change these as required.

to suit your application.

users to take advantage of advanced features.

Load/Save Settings lets you save the current parameter settings to a file, load parameters from a

10.1 Programming Menu

The Programming Menu lets you view and change programmable parameters that control how the EMX3 operates. To open the Programming Menu, press the To navigate through the Programming Menu:

• to scroll through parameter groups, press the

• to open a submenu, press the

• to view the parameters in a group, press the

• to return to the previous level, press the

• to close the Programming Menu, press

To change a parameter value:

• scroll to the appropriate parameter in the Programming Menu and press

• to alter the parameter setting, use the

value by one unit. If the button is held for longer than five seconds, the value will increase or decrease at a faster rate.

• to save changes, press

parameter list.

• to cancel changes, press

changes.

previously saved file, or reset all parameters to default values.

button while viewing the monitoring screens.

or button.

button.

repeatedly.

and buttons. Pressing or once will increase or decrease the

. The setting shown on the display will be saved and the keypad will return to the

. The keypad will ask for confirmation, then return to the parameter list without saving

to enter edit mode.

10.2 Adjustment Lock

You can lock the Programming Menu to prevent users from altering parameter settings. The adjustment lock can be turned on and off using parameter 15B.

To lock the programming menu:

1. Open the Programming Menu.

2. Open the Extended Menu.

3. Select 'Advanced'.

4. Enter the Access Code.

5. Select parameter 15B

Adjustment Lock

6. Select and store 'Read Only'.

If a user attempts to change a parameter value when the adjustment lock is active, an error message is displayed:

Access Denied Adj Lock is On

38 | User Manual (710-04840-00M)

PROGRAMMING MENU

STORE

Application

Parameter

Suggested value

Pump Centrifugal

Motor Full Load Current

Model dependent

Fan Damped

Motor Full Load Current

Model dependent

Compressor Screw

Motor Full Load Current

Model dependent

10.3 Access Code

Critical parameters (parameter group 15 and higher) are protected by a four-digit security access code, preventing unauthorised users from viewing or modifying parameter settings.

When a user attempts to enter a restricted parameter group, the keypad prompts for an access code. The access code is requested once for the programming session, and authorisation continues until the user closes the menu.

To enter the access code, use the four digits match your access code, press

Enter Access Code 0###

and buttons to select a digit, and the and buttons to change the value. When all

. The keypad will display an acknowledgement message before continuing.

Access Allowed SUPERVISOR

To change the access code, use parameter 15A.

The simulation tools and counter resets are also protected by the security access code. The default access code is 0000.

10.4 Quick Setup

The Quick Setup Menu makes it easy to configure the EMX3 for common applications. The EMX3 selects the parameters relevant to the application and suggests a typical setting, and you can adjust each parameter to suit your exact requirements.

Always set parameter 1A

Motor Full Load Current

starter's minimum full load current. On the display, the highlighted values are suggested values and the values indicated by a are the loaded values.

Start Mode Adaptive Start Profile Start Ramp Time Stop Mode Adaptive Stop Profile Stop Time

Pump Submersible

Motor Full Load Current Start Mode Adaptive Start Profile Start Ramp Time Stop Mode Adaptive Stop Profile Stop Time

to match the motor's nameplate full load current. The suggested value is the

Adaptive Control Early Acceleration 10 seconds Adaptive Control Late Deceleration 15 seconds

Model dependent Adaptive Control Early Acceleration 5 seconds Adaptive Control Late Deceleration 5 seconds

Fan Undamped

Start Mode Current Limit

Motor Full Load Current Start Mode Adaptive Start Profile Start Ramp Time Excess Start Time Locked Rotor Time

Start Mode Start Ramp Time Current Limit

Constant Current 350%

Model dependent Adaptive Control Constant Acceleration 20 seconds 30 seconds 20 seconds

Constant Current 5 seconds 400%

User Manual (710-04840-00M) | 39

PROGRAMMING MENU

Application

Parameter

Suggested value

Crusher Rotary

Motor Full Load Current

Model dependent

Parameter Group

Default Setting

1 Motor Data-1

Motor Full Load Current

Model dependent

2 Start/Stop Modes-1

Stop Mode

Coast To Stop

Stop Time

3 Auto-Start/Stop

4 Protection Settings

Compressor Recip

Conveyor

Crusher Jaw

Motor Full Load Current Start Mode Start Ramp Time Current Limit

Motor Full Load Current Start Mode Start Ramp Time Current Limit Stop Mode Adaptive Stop Profile Stop Time

Start Mode Start Ramp Time Current Limit Excess Start Time Locked Rotor Time

Motor Full Load Current Start Mode Start Ramp Time Current Limit Excess Start Time Locked Rotor Time

Model dependent Constant Current 5 seconds 450%

Model dependent Constant Current 5 seconds 400% Adaptive Control Constant Deceleration 10 seconds

Constant Current 10 seconds 400% 30 seconds 20 seconds

Model dependent Constant Current 10 seconds 450% 40 seconds 30 seconds

10.5 Standard Menu

The standard menu provides access to commonly used parameters, allowing the user to configure the EMX3 as required for the application. For details of individual parameters, refer to

Parameter Descriptions

2A 2B 2C 2D

3A 3B 3C 3D

4A 4C 4D 4E 4F 4G

Start Mode Start Ramp Time Initial Current Current Limit

Auto-Start Type Auto-Start Time Auto-Stop Type Auto-Stop Time

Excess Start Time Undercurrent Undercurrent Delay Instantaneous Overcurrent

Constant Current

10s

350%

Off

20s

20%

400%

Instantaneous Overcurrent Delay Phase Sequence

Any Sequence

on page 46.

40 | User Manual (710-04840-00M)

PROGRAMMING MENU

6 Inputs

7 Outputs

8 Display

Parameter Group

Default Setting

1 Motor Data-1

Motor Full Load Current

Model dependent

Locked Rotor Time

0m:10s

Locked Rotor Current

600%

Motor Service Factor

105%

2 Start/Stop Modes-1

Start Mode

Constant Current

Start Ramp Time

10 s 2C

Initial Current

350%

Current Limit

350%

Adaptive Start Profile

Constant Acceleration

Kickstart Time

0000ms

Kickstart Level

500%

6A 6B 6C 6D 6E 6F 6G 6H 6I 6J

7A 7B 7C 7D 7E 7F 7G 7H 7I 7M 7N 7O

Input A Function Input A Name Input A Trip Input A Trip Delay Input A Initial Delay Input B Function Input B Name Input B Trip Input B Trip Delay Input B Initial Delay

Relay A Function Relay A On Delay Relay A Off Delay Relay B Function Relay B On Delay Relay B Off Delay Relay C Function Relay C On Delay Relay C Off Delay Low Current Flag High Current Flag

Motor Set Select

Input Trip

Always Active

Input Trip (N/O)

Input Trip

Always Active

Main Contactor 0s 0s Run 0s

0s Trip 0s 0s

50%

100%

Motor Temperature Flag

80%

8A 8B 8C 8D 8E 8F 8G 8H

Language F1 Button Action F2 Button Action Display A or kW User Screen - Top Left User Screen - Top Right

English

Auto-Start/Stop Menu None

Current

Starter State

Blank

User Screen - Bottom Left User Screen - Bottom Right

Hours Run

Analog Input

10.6 Extended Menu

The Extended Menu provides access to all the EMX3's programmable parameters.

User Manual (710-04840-00M) | 41

PROGRAMMING MENU

Brake Torque

20% 2M

Brake Time

0m:01s

3 Auto-Start/Stop

4 Protection Settings

Reserved

- 4R

Reserved

- 4S

Reserved

5 Auto-Reset Trips

6 Inputs

2H 2I 2J 2K

3A 3B 3C 3D

4A 4B 4C 4D 4E 4F 4G 4H 4I 4J 4K 4L 4M 4N 4O 4P

Stop Mode Stop Time Adaptive Stop Profile Adaptive Control Gain

Auto-Start Type Auto-Start Time Auto-Stop Type Auto-Stop Time

Excess Start Time Excess Start Time-2 Undercurrent Undercurrent Delay Instantaneous Overcurrent

Coast To Stop

0m:00s

Constant Deceleration

75%

Off

00h:01m

Off

00h:01m

0m:20s

20%

0m:05s

400%

Instantaneous Overcurrent Delay Phase Sequence Current Imbalance Current Imbalance Delay Frequency Check Frequency Variation Frequency Delay Restart Delay Motor Temperature Check Ground Fault Level Ground Fault Delay

Any Sequence

30%

0m:03s

Start/Run

± 5Hz

0m:01s

10s

Do Not Check

100 mA

0m:03s

0m:00s

5A 5B 5C 5D

6A 6B 6C 6D 6E 6F 6G 6H 6I 6J 6K 6L

Auto-Reset Action Maximum Resets Reset Delay Groups A&B Reset Delay Group C

Input A Function Input A Name Input A Trip Input A Trip Delay Input A Initial Delay Input B Function Input B Name Input B Trip Input B Trip Delay Input B Initial Delay Input C Function Input D Function

42 | User Manual (710-04840-00M)

Do Not Auto-Reset

00m:05s

05 m

Motor Set Select

Input Trip

Always Active

0m:00s

Input Trip (N/O)

Input Trip

Always Active

0m:00s

00m:00s

Off

PROGRAMMING MENU

Local/Remote

LCL/RMT Anytime

Comms in Remote

Enable Control in RMT

7 Outputs

Relay F Function

Off 7M

Low Current Flag

50% 7N

High Current Flag

100%

Motor Temperature Flag

80% 7P

Analog Output A

Current (% FLC)

Analog A Scale

4-20 mA

Analog A Maximum Adjustment

100%

Analog A Minimum Adjustment

000%

Analog Output B

Current (% FLC)

Analog B Scale

4-20 mA

Analog B Maximum Adjustment

100%

Analog B Minimum Adjustment

000%

8 Display

Language

English

F1 Button Action

Auto-Start/Stop Menu

F2 Button Action

None

Display A or kW

Current

User Screen - Top Left

Starter State

User Screen - Top Right

Blank

User Screen - Bottom Left

Hours Run

User Screen - Bottom Right

Analog Input

Graph Data

Current (% FLC)

Graph Timebase

10s

Graph Maximum Adjustment

400%

Graph Minimum Adjustment

000%

Current Calibration

100%

6M 6N 6O 6P

7A 7B 7C 7D 7E 7F 7G 7H 7I 7J 7K

Remote Reset Logic Analog Input Trip

Do Not Trip

Analog Input Scale Analog Trip Point

Relay A Function Relay A On Delay Relay A Off Delay Relay B Function Relay B On Delay Relay B Off Delay Relay C Function Relay C On Delay Relay C Off Delay Relay D Function Relay E Function

50%

Main Contactor

0m:00s 0m:00s Run 0m:00s

0m:00s Trip 0m:00s 0m:00s Off

Off

Normally Closed

2-10 V

8N 8O

Mains Reference Voltage Voltage Calibration

400 V

100%

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PROGRAMMING MENU

9 Motor Data-2

10 Start/Stop Modes-2

11 RTD Temperatures

12 Slip-Ring Motors

15 Advanced (Requires Access Code. Default: 0000)

16 Protection Action

16A

Motor Overload

Trip Starter

16B

Excess Start Time

Trip Starter

16C

Undercurrent

Trip Starter

9A 9B 9C 9D 9E

10A 10B 10C 10D 10E 10F 10G 10H 10I 10J 10K 10L 10M

Dual Thermal Model Motor FLC-2 Locked Rotor Time-2

Single

Model dependent

0m:10s

Locked Rotor Current-2 Motor Service Factor-2

Start Mode-2 Start Ramp-2 Initial Current-2 Current Limit-2

Constant Current

0m:10s

350%

Adaptive Start Profile-2 Kickstart Time-2 Kickstart Level-2 Stop Mode-2 Stop Time-2

0000 ms

500%

Coast To Stop

0m:00s

Adaptive Stop Profile-2 Adaptive Control Gain-2 Brake Torque-2 Brake Time-2

20%

0m:01s

600%

105%

Constant Acceleration

Constant Deceleration

75%

11A 11B 11C 11D 11E 11F 11G

12A 12B 12C 12D

15A 15B 15C 15D 15E

RTD/PT100 A °C RTD/PT100 B °C RTD/PT100 C °C RTD/PT100 D °C RTD/PT100 E °C RTD/PT100 F °C RTD/PT100 G °C

50 °C (122 °F) 50 °C (122 °F) 50 °C (122 °F) 50 °C (122 °F) 50 °C (122 °F)

50 °C (122 °F)

Motor Data-1 Ramp Motor Data-2 Ramp Changeover Time Slip Ring Retard

150 ms

50%

Access Code Adjustment Lock Emergency Run

0000

Read & Write

Disable

Shorted SCR Action Jog Torque

50%

Single Ramp Single Ramp

3-Phase Control Only

16D 16E 16F 16G 16H 16I

Instantaneous Overcurrent Current Imbalance Frequency Input A Trip Input B Trip Motor Thermistor

44 | User Manual (710-04840-00M)

Trip Starter

Trip Starter Trip Starter

Trip Starter

PROGRAMMING MENU

16N

Ground Fault

Trip Starter

16O

RTD/PT100 A

Trip Starter

16P

RTD/PT100 B

Trip Starter

16Q

RTD/PT100 C

Trip Starter

16R

RTD/PT100 D

Trip Starter

16S

RTD/PT100 E

Trip Starter

16T

RTD/PT100 F

Trip Starter

16U

RTD/PT100 G

Trip Starter

16V

Reserved

- 16W

Reserved

16X

Low Control Volts

Trip Starter

20 Restricted

1. Open the Programming Menu.

Load User Set 1

4. At the confirmation prompt, select YES to confirm or NO to cancel and then STORE

screen will briefly display a confirmation

NOTE

16J 16K 16L 16M

Starter Communication Network Communication Heatsink Overtemperature Battery/Clock

Trip Starter

Factory Use Only

10.7 Load/Save Settings

The Load/Save Settings menu requires an access code and allows users to:

• Load the EMX3's parameters with default values

• Load parameter settings from an internal file

• Save the current parameter settings to an internal file

In addition to the factory default values file, the EMX3 can store two user-defined parameter files. These files contain default values until a user file is saved.

To load or save parameter settings:

2. Scroll to Load/Save Settings and press the button.

3. Scroll to the required function and press the button.

to load/save the selection.

When the action has been completed, the message, then return to the status screens.

The saved files and current operating settings are stored in both the keypad and in the soft starter. The keypad will prompt you to synchronise the settings whenever it is plugged into a new EMX3.

Load/Save Settings Load Defaults Load Backup

Load Defaults No Yes

User Manual (710-04840-00M) | 45

PROGRAMMING MENU

NOTE

1A – Motor FLC Range: Description:

1B – Locked Rotor Time Range:

Default:

Description:

1C – Locked Rotor Current Range:

Default:

Description:

1D – Motor Service Factor Range:

Default:

Description:

NOTE

2A – Start Mode Options:

Description:

2B – Start Ramp Time Range:

Default:

Description:

2C – Initial Current Range:

Default:

Description:

2D – Current Limit Range:

Default:

Description:

10.8 Parameter Descriptions

1 Motor Data-1

The parameters in Motor Data-1 configure the soft starter to match the connected motor. These parameters describe the motor's operating characteristics and allow the soft starter to model the motor's temperature.

Model dependent Matches the starter to the connected motor's full load current. Set to the full load current (FLC) rating shown on

the motor nameplate.

0:01 - 2:00 (minutes:seconds)

10 seconds

Sets the maximum length of time the motor can sustain locked rotor current from cold before reaching its maximum temperature. Set according to the motor datasheet.

400% - 1200% FLC

600%

Sets the locked rotor current of the connected motor, as a percentage of full load current. Set according to the motor datasheet.

100% - 130%

105%

Sets the motor service factor used by the thermal model. If the motor runs at full load current, it will reach 100%. Set according to the motor datasheet.

Parameters 1B, 1C and 1D determine the trip current for motor overload protection. The default settings of parameters 1B, 1C and 1D provide Motor Overload Protection: Class 10, Trip Current 105% of FLA (full load amperage) or equivalent.

2 Start/Stop Modes-1

Constant Current (default) Adaptive Control

Selects the soft start mode.

1 - 180 (seconds) Sets the total start time for an Adaptive Control start or the ramp time for current ramp starting (from the initial

current to the current limit).

100% - 600% FLC Sets the initial start current level for current ramp starting, as a percentage of motor full load current. Set so

that the motor begins to accelerate immediately after a start is initiated. If current ramp starting is not required, set the initial current equal to the current limit.

100% - 600% FLC Sets the current limit for constant current and current ramp soft starting, as a percentage of motor full load

current.

10 seconds

350%

46 | User Manual (710-04840-00M)

2E – Adaptive Start Profile Options:

Description:

2F – Kickstart Time Range:

Default:

Description:

2G – Kickstart Level Range:

Default:

Description:

CAUTION

2H – Stop Mode Options:

Description:

2I – Stop Time Range:

Default:

Description:

2J – Adaptive Stop Profile Options:

Description:

2K – Adaptive Control Gain Range:

Default:

Description:

NOTE

2L – Brake Torque Range:

Default:

Description:

2M – Brake Time Range:

Default:

Description:

NOTE

Early Acceleration Constant Acceleration (default) Late Acceleration

Selects which profile the EMX3 will use for an Adaptive Control soft start.

0 – 2000 milliseconds Sets the kickstart duration. A setting of 0 disables kickstart.

100% - 700% FLC Sets the level of the kickstart current.

Kickstart subjects the mechanical equipment to increased torque levels. Ensure the motor, load and couplings can handle the additional torque before using this feature.

Coast To Stop (default) TVR Soft Stop Adaptive Control Brake

Selects the stop mode.

0:00 - 4:00 (minutes:seconds) Sets the time for soft stopping the motor using timed voltage ramp or Adaptive Control. This also sets the total

stopping time when using brake. If a main contactor is installed, the contactor must remain closed until the end of the stop time. Use one of the programmable relays to control the main contactor.

Early Deceleration Constant Deceleration (default) Late Deceleration

Selects which profile the EMX3 will use for an Adaptive Control soft stop.

1% - 200% Adjusts the performance of Adaptive Control. This setting affects both starting and stopping control.

We recommend leaving the gain setting at the default level unless performance is not satisfactory. If the motor accelerates or decelerates too quickly at the end of a start or stop, increase the gain setting by 5%~10%. If the motor speed fluctuates during starting or stopping, decrease the gain setting slightly.

20% - 100% Sets the amount of brake torque the EMX3 will use to slow the motor.

1 - 30 (seconds)

Sets the duration for DC injection during a braking stop.

Parameter 2M is used in conjunction with parameter 2I. Refer to

0000 milliseconds

500%

0 seconds

75%

20%

1 second

Brake

for details.

PROGRAMMING MENU

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PROGRAMMING MENU

CAUTION

WARNING

3A – Auto-Start Type

Options:

Off (default)

The soft starter will not auto-start.

Description:

3B – Auto-Start Time Range:

Default:

Description:

3C – Auto-Stop Type

Options:

Timer

The soft starter will auto-stop after a delay from the next start, as specified in

Description:

3D – Auto-Stop Time Range:

Default:

Description:

CAUTION

4A, 4B – Excess Start Time

Range:

Default:

Description:

3 Auto-Start/Stop

The EMX3 can be programmed to start and stop automatically, after a specified delay or at a specified time of day. Auto-start and auto-stop can be set separately.

Auto-start/stop operation is only available in Remote mode. In Local mode, the starter will ignore any auto-start/stop setting.

The auto-start timer overrides any other form of control. The motor may start without warning.

This function should not be used in conjunction with remote two-wire control. The soft starter will still accept start and stop commands from the remote inputs or serial communication network. To disable local or remote control, use parameter 6Q. If auto-start is enabled and the user is in the menu system, auto-start will become active if the menu times out (if no keypad activity is detected for five minutes).

Timer The soft starter will auto-start after a delay from the next stop, as specified in

parameter 3B.

Clock The soft starter will auto-start at the time programmed in parameter 3B.

Selects whether the soft starter will auto-start after a specified delay, or at a time of day.

00:01 - 24:00 (hours:minutes)

1 minute

Sets the time for the soft starter to auto-start, in 24 hour clock format.

Off (default) The soft starter will not auto-stop.

parameter 3D.

Clock The soft starter will auto-stop at the time programmed in parameter 3D.

Selects whether the soft starter will auto-stop after a specified delay, or at a time of day.

00:01 - 24:00 (hours:minutes)

Sets the time for the soft starter to auto-stop, in 24 hour clock format.

1 minute

4 Protection Settings

These parameters determine when the soft starter's protection mechanisms will activate. The activation point for each protection mechanism can be set to suit the installation.

The soft starter responds to protection events by tripping, warning, or writing the event to the event log. The response is determined by the Protection Action settings. The default response is a trip.

The protection settings are vital for safe operation of the soft starter and motor. Defeating the protection may

Excess start time is the maximum time the EMX3 will attempt to start the motor. If the motor does not transition to Run mode within

compromise the installation and should only be done in the case of emergency.

the programmed limit, the starter will trip. Set for a period slightly longer than required for a normal healthy start. A setting of 0 disables excess start time protection.

0:00 - 4:00 (minutes:seconds) Parameter 4A sets the time for the primary motor and parameter 4B (

20 seconds

Excess Start Time-2

) sets the time for the

secondary motor.

48 | User Manual (710-04840-00M)

4C – Undercurrent Range:

Default:

Description:

4D – Undercurrent Delay Range:

Default:

Description:

4E – Instantaneous Overcurrent Range:

Default:

Description:

4F – Instantaneous Overcurrent Delay Range:

Default:

Description:

4G – Phase Sequence Options:

Description:

4H – Current Imbalance Range:

Default:

Description:

4I – Current Imbalance Delay Range:

Default:

Description:

4J – Frequency Check Options:

Description:

4K – Frequency Variation Options:

Description:

4L – Frequency Delay Range:

Default:

Description:

NOTE

CAUTION

0% - 100% Sets the trip point for undercurrent protection, as a percentage of motor full load current. Set to a level between

the motor's normal working range and the motor's magnetising (no load) current (typically 25% to 35% of full load current). A setting of 0% disables undercurrent protection.

0:00 - 4:00 (minutes:seconds) Slows the EMX3's response to undercurrent, avoiding trips due to momentary fluctuations.

80% - 600% FLC Sets the trip point for instantaneous overcurrent protection, as a percentage of motor full load current.

0:00 - 1:00 (minutes:seconds) Slows the EMX3's response to overcurrent, avoiding trips due to momentary overcurrent events.

Any Sequence (default) Positive Only Negative Only

Selects which phase sequences the soft starter will allow at a start. During its pre-start checks, the starter examines the sequence of the phases at its input terminals and trips if the actual sequence does not match the selected option.

10% - 50%

Sets the trip point for current imbalance protection.

0:00 - 4:00 (minutes:seconds) Slows the EMX3's response to current imbalance, avoiding trips due to momentary fluctuations.

Do Not Check Start Only Start/Run (default) Run Only

Determines when and if the starter will monitor for a frequency trip.

± 2 Hz ± 5 Hz (default) ± 10 Hz ± 15 Hz

Selects the soft starter's tolerance for frequency variation.

0:01 - 4:00 (minutes:seconds) Slows the EMX3's response to frequency disturbances, avoiding trips due to momentary fluctuations.

If the mains frequency drops below 35 Hz or rises above 75 Hz, the starter will trip immediately.

Running a motor outside its specified frequency for long periods can cause damage and premature failure.

PROGRAMMING MENU

20%

5 seconds

400%

0 second

30%

3 seconds

1 second

User Manual (710-04840-00M) | 49

PROGRAMMING MENU

4M – Restart Delay Range:

Default:

Description:

NOTE

4N – Motor Temperature Check Options:

Description:

4O – Ground Fault Level Range:

Default: Description:

4P – Ground Fault Delay Range:

Default: Description:

NOTE

4Q – Reserved

4R – Reserved

4S – Reserved

4T – Reserved

Group

Trips

Undercurrent

Motor overload

00:01 - 60:00 (minutes:seconds) The EMX3 can be configured to force a delay between the end of a stop and the beginning of the next start.

During the restart delay period, the display shows the time remaining before another start can be attempted.

The restart delay is measured from the end of each stop. Changes to the restart delay setting take effect after the next stop.

Do Not Check (default) Check

Selects whether the EMX3 will verify the motor has sufficient thermal capacity for a successful start. The soft starter compares the motor's calculated temperature with the temperature rise from the last motor start and only operates if the motor is cool enough to start successfully.

20 mA - 50 A (21 steps) Sets the trip point for ground fault protection.

0:01 - 4:00 (minutes:seconds) Slows the EMX3's response to ground fault variation, avoiding trips due to momentary fluctuations.

Ground fault protection is only available if the RTD/PT100 and ground fault protection card is fitted.

This parameter is reserved for internal use.

10 seconds

100mA

3 seconds

5 Auto-Reset Trips

The EMX3 can be programmed to automatically reset certain trips, which can help minimise operating downtime. Trips are divided into three categories for auto-reset, depending on the risk to the soft starter:

Current imbalance Phase Loss Power loss Frequency

Instantaneous overcurrent Input A trip Input B trip

RTD/PT100 temperature trips Motor thermistor Heatsink overtemperature

Other trips cannot be automatically reset.

50 | User Manual (710-04840-00M)

PROGRAMMING MENU

5A – Auto-Reset Action Options:

Description:

5B – Maximum Resets Range:

Default: Description:

5C – Reset Delay Groups A&B Range:

Default: Description:

5D – Reset Delay Group C Range:

Default: Description:

6A – Input A Function

Options:

Input Trip (N/O)

Input A can be used to trip the soft starter. When parameter 6A is set to

Local/Remote Select

Input A can be used to select between local and remote control, instead of

LCL/RMT

START

LCL/RMT

Jog Forward

Activates jog operation in a forward direction (will operate only in Remote

This function is ideal for remote installations using 2-wire control in Remote mode. If the 2-wire start signal is present after an auto-reset, the EMX3 will restart.

Do Not Auto-Reset (default) Reset Group A Reset Group A & B Reset Group A, B & C

Selects which trips can be auto-reset.

1 - 5

Sets how many times the soft starter will auto-reset, if it continues to trip. The reset counter increases by one each time the soft starter auto-resets, and decreases by one after each successful start/stop cycle.

00:05 - 15:00 (minutes:seconds) Sets the delay before resetting Group A and Group B trips.

5 seconds

5 - 60 (minutes) Sets the delay before resetting Group C trips.

5 minutes

6 Inputs

The EMX3 has two programmable inputs, which allow remote control of the soft starter. If required, two extra inputs are available on the input/output expansion card.

Motor Set Select (default) The EMX3 can be configured with two separate sets of motor data.

To use the secondary motor data, parameter 6A must be set to 'Motor Set Select' and C53, C54 must be closed when a start command is given. The EMX3 checks which motor data to use at a start, and will use that motor data for the entire start/stop cycle.

Input Trip (N/O), a closed circuit across C53, C54 trips the soft starter.

Input Trip (N/C) When parameter 6A is set to Input Trip (N/C), an open circuit across C53, C54

trips the soft starter.

using the is in local mode and can be controlled via the keypad. When the input is closed, the starter is in remote mode. The disabled, and the soft starter will ignore any Local/Remote select command from the serial communications network. To use Input A to select between local and remote control, parameter 6Q must be set to 'LCL/RMT Anytime' or 'LCL/RMT When Off'.

Emergency Run In emergency run the soft starter continues to run until stopped, ignoring all

trips and warnings (refer to parameter 15C for details). Closing the circuit across C53, C54 activates emergency run. Opening the circuit ends emergency run and the EMX3 stops the motor.

Starter Disable The EMX3 can be disabled via the control inputs. An open circuit across C53,

C54 will disable the starter. The EMX3 will not respond to start commands. If running, the soft starter will allow the motor to coast to stop, ignoring the

Jog Reverse Activates jog operation in reverse direction (will operate only in Remote mode).

soft stop mode set in parameter 2H.

mode).

button on the keypad. When the input is open, the starter

and

buttons are

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PROGRAMMING MENU

Description:

6B – Input A Name Options:

Description:

6C – Input A Trip

Options:

Run Only

A trip can only occur while the soft starter is running.

Description:

6D – Input A Trip Delay Range:

Default: Description:

6E – Input A Initial Delay Range:

Default: Description:

6F, 6G, 6H, 6I, 6J – Input B Trip

Default: Default: Default: Default: Default:

6K, 6L – Inputs C and D

Options:

6M – Remote Reset Logic Options:

Description:

Selects the function of Input A.

Input Trip (default) No Flow Low Pressure Starter Disable High Pressure Controller Pump Fault PLC Low Level Vibration High Level

Selects a message for the keypad to display when Input A is active.

Always Active (default) A trip can occur at any time when the soft starter is receiving power.

Operating Only A trip can occur while the soft starter is running, stopping or starting.

Selects when an input trip can occur.

0:00 - 4:00 (minutes:seconds)

0 second

Sets a delay between the input activating and the soft starter tripping.

00:00 - 30:00 (minutes:seconds)

0 second

Sets a delay before an input trip can occur. The initial delay is counted from the time a start signal is received. The state of the input is ignored until the initial delay has elapsed.

Parameters 6F~6J configure the operation of Input B, in the same way as parameters 6A~6E configure Input A. Refer to Input A for

details.

• 6F

Input B Function

• 6G

Input B Name

• 6H

Input B Trip

• 6I

Input B Trip Delay

• 6J

Input B Initial Delay

(

( ( ( (

Input Trip (N/O)) Input Trip) Always Active) 0:00) 0:00)

Parameters 6K and 6L select the function of Inputs C and D. Refer to parameter 6A for details. Inputs C and D are only available if the input/output expansion card has been installed.

Motor Set Select Local/Remote Select Emergency Run Starter Disable (N/C) Off (default)

Normally Closed (default) Normally Open

Selects whether the EMX3's remote reset input (terminals C41, C42) is normally open or normally closed.

52 | User Manual (710-04840-00M)

PROGRAMMING MENU

6N – Analog Input Trip

Options:

Description:

6O – Analog Input Scale Options:

Description:

6P – Analog Trip Point Range:

Default: Description:

6Q – Local/Remote

Options:

LCL/RMT

LCL/RMT When Off

LCL/RMT button is enabled when the starter is off.

START, RESET, LCL/RMT

Description:

LCL/RMT

STOP

WARNING

STOP

6R – Comms in Remote Options:

Description:

7A – Relay A Function

Options:

Off

Relay A is not used.

Main Contactor (default)

The relay closes when the EMX3 receives a start command, and remains Trip

The relay closes when the starter trips (refer to parameter 16A to 16X).

Warning

The relay closes when the starter issues a warning (refer to parameter 16A to

High Current Flag

The relay closes when the high current flag activates while the motor is Input A trip

The relay closes when Input A activates to trip the soft starter.

An analog input can be fitted to the EMX3 if required. An external device can activate the analog input to trip the soft starter in

response to external conditions. Do Not Trip (default)

Trip High Trip Low

Selects the soft starter's response to the analog input signal.

0-10 V (default)

2-10 V Selects the scale of the analog input.

0% - 100%

LCL/RMT Anytime

Sets the signal level at which an analog input trip will occur, as a percentage of the maximum signal on the input.

50%

button is always enabled.

Local Control Only All remote inputs are disabled. Remote Control Only Local control buttons (

Selects when the

button can be used to switch between local and remote control, and enables or

) are disabled.

disables the local control buttons and remote control inputs. The

button on the keypad is always enabled.

The the remote start/stop and reset inputs are still active.

button on the keypad is always enabled. When using two-wire remote control, the soft starter will restart if

Disable Control in RMT Enable Control in RMT (default)

Selects whether the starter will accept Start and Stop commands from the serial communication network when in Remote mode. The Reset and Local/Remote Control commands are always enabled.

7 Outputs

The EMX3 has three programmable outputs, which can be used to signal different operating conditions to associated equipment. Three additional outputs are available on the input/output expansion card.

closed as long as the motor is receiving voltage.

Run The relay closes when the starter changes to run state.

16X).

Low Current Flag The relay closes when the low current flag activates while the motor is

running (refer to parameter 7M

running (refer to parameter 7N

Motor Temperature Flag The relay closes when the motor temperature flag activates (refer to

parameter 7O

Low Current Flag

High Current Flag

Motor Temperature Flag

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PROGRAMMING MENU

Current imbalance

The relay closes when the starter trips on Current Imbalance.

Ground fault

The relay closes when the starter trips on Ground Fault.

Heatsink overtemperature

The relay closes when the starter trips on Heatsink Overtemperature.

Changeover Contactor

The relay closes when the high rotor resistance current ramp has reached full

Description:

7B – Relay A On Delay Range:

Default: Description:

7C – Relay A Off Delay Range:

Default: Description:

7D~7L – Output Relays B, C, D, E, F

Default:

Default: Default: Default:

7M – Low Current Flag

Range:

Default: Description:

7N – High Current Flag Range:

Default: Description:

Input B trip The relay closes when Input B activates to trip the soft starter. Motor overload The relay closes when the starter trips on Motor Overload.

Undercurrent The relay closes when the starter trips on Undercurrent. Instantaneous overcurrent The relay closes when the starter trips on Instantaneous overcurrent. Frequency The relay closes when the starter trips on Frequency.

Phase Loss The relay closes when the starter trips on Phase Loss. Motor thermistor The relay closes when the starter trips on Motor Thermistor.

voltage, allowing use with a slip-ring motor. Undervoltage Not available with EMX3. Ready The relay is closed when the starter is in Ready state.

Selects the function of Relay A (normally open).

0:00 - 5:00 (minutes:seconds) Sets the delay for closing Relay A.

0 second

0:00 - 5:00 (minutes:seconds) Sets the delay for re-opening Relay A.

0 second

Parameters 7D~7L configure the operation of Relays B, C, D, E and F in the same way as parameters 7A~7C configure Relay A.

Refer to

Relay A Function

for details.

Relay B is a changeover relay.

• 7D

Relay B Function

• 7E

Relay B On Delay

• 7F

Relay B Off Delay

Run

Relay C is a changeover relay.

• 7G

Relay C Function

• 7H

Relay C On Delay

• 7I

Relay C Off Delay

Trip

Relays D, E and F are only available if the input/output expansion card has been installed. These relays do not support on or off

delays and do not support 'Changeover Contactor' function. Relay D is normally closed, relays E and F are normally open.

• 7J

Relay D Function

• 7K

Relay E Function

• 7L

Relay F Function

Off Off Off

The EMX3 has low and high current flags to give early warning of abnormal operation. The current flags can be configured to indicate an abnormal current level during operation, between the normal operating level and the undercurrent or instantaneous overcurrent trip levels. The flags can signal the situation to external equipment via one of the programmable outputs.

The flags clear when the current returns within the normal operating range by 10% of the programmed flag value.

1% - 100% FLC

50%

Sets the level at which the low current flag operates, as a percentage of motor full load current.

50% - 600% FLC

100%

Sets the level at which the high current flag operates, as a percentage of motor full load current.

54 | User Manual (710-04840-00M)

PROGRAMMING MENU

7O – Motor Temperature Flag

Range:

Default:

Description:

7P – Analog Output A

Options:

Motor kVA (%)

Measured motor kilovolt amperes, as a percentage of maximum kVA.

Motor pf

Motor power factor, measured by the soft starter.

Measured motor kW:

√3 x average current x mains reference voltage x measured power factor

Description:

7Q – Analog A Scale Range:

Description:

7R – Analog A Maximum Range:

Default:

Description:

7S – Analog A Minimum Range:

Default:

Description:

7T, 7U, 7V, 7W – Analog Output B

8A – Language Options:

Description:

8B, 8C – F1 and F2 Button Action Options:

Description:

The EMX3 has a motor temperature flag to give early warning of abnormal operation. The flag can indicate that the motor is

operating above its normal operating temperature but lower than the overload limit. The flag can signal the situation to external equipment via one of the programmable outputs.

0% - 160%

80%

Sets the level at which the motor temperature flag operates, as a percentage of the motor's thermal capacity.

Current (% FLC) (default) Current as a percentage of motor full load current.

Motor Temp (%) Motor temperature as a percentage of the motor's thermal capacity. Motor kW (%) Measured motor kilowatts, as a percentage of maximum kW.

Maximum motor kW: √3 x motor FLC x mains reference voltage. Power factor is assumed to be 1 Measured motor kVA: √3 x average current x mains reference voltage Maximum motor kVA: √3 x motor FLC x mains reference voltage

Selects which information will be reported via the analog output.

0-20 mA 4-20 mA (default)

Selects the range of the analog output.

0% - 600% Calibrates the upper limit of the analog output to match the signal measured on an external current measuring

device.

0% - 600% Calibrates the lower limit of the analog output to match the signal measured on an external current measuring

device.

Parameters 7T~7W configure the operation of

Refer to

Output B is only available if the input/output expansion card has been installed.

Analog Output A

Analog Output B

for details.

, in the same way as parameters 7P~7S configure analog output A.

8 Display

100%

These parameters allow the keypad to be tailored to individual users' requirements.

English (default) Português Chinese Français Español Italiano Deutsch Russian

Selects which language the keypad will use to display messages and feedback.

None Auto-Start/Stop Menu Jog Forward Jog Reverse

Selects the function of the F1 and F2 buttons on the keypad.

User Manual (710-04840-00M) | 55

PROGRAMMING MENU

NOTE

8D – Display A or kW Options:

Description:

8E, 8F, 8G, 8H – User-Programmable Screen

Options: Motor Current

The average current measured on three phases.

Motor kW

The motor's running power in kilowatts.

Motor HP

The motor's running power in horsepower.

Analog Input

The level of analog input A (refer to parameters 6N~6P). This setting is only

Description:

Default: Default: Default:

Default:

8I – Graph Data

Options:

Motor Temp (%)

Motor temperature as a percentage of the motor's thermal capacity.

Motor kW (%)

Measured motor kilowatts, as a percentage of maximum kW.

Maximum motor kVA:

√3 x motor FLC x mains reference voltage

Description:

8J – Graph Timebase Options:

Description:

8K – Graph Maximum Range:

Default:

Description:

The access code is not required to use the F1 and F2 buttons. Users can access these functions regardless of the setting of parameter 15B

Adjustment Lock

Current (default) Motor kW

Selects whether the EMX3 will display current (amperes) or motor kilowatts on the main monitoring screen.

Blank Displays no data in the selected area, allowing long messages to be shown

Starter State (default) The starter's operating state (starting, running, stopping or tripped). Only

Motor pf The motor's power factor, measured by the soft starter. Mains Frequency The average frequency measured on three phases.

Motor Temp The motor's temperature, calculated by the thermal model. kWh The number of kilowatt hours the motor has run via the soft starter. Hours Run The number of hours the motor has run via the soft starter.

without overlapping.

available for top left and bottom left positions on the screen.

available if the input/output expansion option is installed.

Selects which information will be displayed on the programmable monitoring screen.

• 8E

User Screen - Top Left

• 8F

User Screen - Top Right

• 8G

User Screen - Bottom Left

• 8H

User Screen - Bottom Right

Starter State Blank Hours Run

Analog Input

The EMX3 has a real-time performance graph to report the behaviour of critical operating parameters.

Current (% FLC) (default) Current as a percentage of motor full load current.

Motor kVA (%) Measured motor kilovolt amperes, as a percentage of maximum kVA. Motor pf Motor power factor, measured by the soft starter.

Measured motor kW: √3 x average current x mains reference voltage x measured power factor Maximum motor kW: √3 x motor FLC x mains reference voltage. Power factor is assumed to be 1 Measured motor kVA: √3 x average current x mains reference voltage

Selects which information the graph will display.

10 seconds (default) 10 minutes 30 seconds 30 minutes 1 minute 1 hour 5 minutes

Sets the graph time scale. The graph will progressively replace the old data with new data.

0% – 600% Adjusts the upper limit of the performance graph.

400%

56 | User Manual (710-04840-00M)

8L – Graph Minimum Range:

Default:

Description:

8M – Current Calibration Range:

Default:

Description:

Calibration (%) =

Current shown on EMX3 display

65A

NOTE

8N – Mains Reference Voltage Range:

Default:

Description:

8O Reserved Description:

NOTE

9A – Dual Thermal Model Options:

Description:

9B – Motor FLC-2 Range: Description:

9C – Locked Rotor Time-2 Range:

Default:

Description:

0% – 600% Adjusts the lower limit of the performance graph.

85% - 115% Calibrates the soft starter's current monitoring circuits to match an external current metering device.

Use the following formula to determine the necessary adjustment:

Current measured by external device

eg 102% = 66A

This adjustment affects all current-based functions and protections.

100 – 690 V

Sets the nominal mains voltage for the keypad's monitoring functions. This is used to calculate motor kilowatts and kilovolt amperes (kVA) but does not affect the EMX3's motor control or protection.

This parameter is reserved for future use.

PROGRAMMING MENU

100%

400 V

9 Motor Data-2

The EMX3 can support two different starting and stopping motor data sets.

• To use the EMX3 with two separate motors (such as a duty-standby configuration), use parameter 9A to select dual thermal modelling and configure parameters 9B~9E to suit the second motor.

• To use the EMX3 with two different motor data sets for the same motor (for dual speed motors or applications where starting conditions may vary), use parameter 9A to select a single thermal model, and configure the starting and stopping profiles as required in parameters 10A~10G. The soft starter will ignore parameters 9B~9E and will use settings from the primary motor.

To select the secondary motor data set, a programmable input must be configured to parameter set selection (parameters 6A and 6F) and the input must be active when the soft starter receives a start signal.

You can only choose which motor data set to use while the soft starter is stopped.

Single (default) Dual

Activates dual thermal modelling. The dual thermal model is required only if the EMX3 is controlling two physically separate motors.

Model dependent Sets the secondary motor's full load current.

0:01 - 2:00 (minutes:seconds)

10 seconds

Sets the maximum length of time the motor can sustain locked rotor current from cold before reaching its maximum temperature. Set according to the motor datasheet.

User Manual (710-04840-00M) | 57

PROGRAMMING MENU

9D – Locked Rotor Current-2 Range:

Default:

Description:

9E – Motor Service Factor-2 Range:

Default:

Description:

10A – Start Mode-2 Options:

Description:

10B – Start Ramp Time-2 Range:

Default:

Description:

10C – Initial Current-2 Range:

Default:

Description:

10D – Current Limit-2 Range:

Default:

Description:

10E – Adaptive Start Profile-2 Options:

Description:

10F – Kickstart Time-2 Range:

Default:

Description:

10G – Kickstart Level-2 Range:

Default:

Description:

10H – Stop Mode-2 Options:

Description:

10I – Stop Time-2 Range:

Default:

Description:

400% - 1200% FLC Sets the locked rotor current of the connected motor, as a percentage of full load current. Set according to the

motor datasheet.

100% - 130% FLC Sets the secondary motor's service factor.

10 Start/Stop-2

100% - 600%

Constant Current (default) Adaptive Control

Selects the soft start mode.

1 - 180 (seconds) Sets the total start time for an Adaptive Control start or the ramp time for current ramp starting (from the initial

current to the current limit).

Sets the initial start current level for current ramp starting, as a percentage of motor full load current. Set so that the motor begins to accelerate immediately after a start is initiated. If current ramp starting is not required, set the initial current equal to the current limit.

100% - 600% FLC Sets the current limit for constant current and current ramp soft starting, as a percentage of motor full load

current.

Early Acceleration Constant Acceleration (default) Late Acceleration

Selects which profile the EMX3 will use for an Adaptive Control soft start.

0 - 2000 (milliseconds) Sets the kickstart duration. A setting of 0 disables kickstart.

100% - 700% FLC Sets the level of the kickstart current.

Coast To Stop (default) TVR Soft Stop Adaptive Control Brake

Selects the stop mode.

0:00 - 4:00 (minutes:seconds) Sets the stop time.

600%

105%

10 seconds

350%

0000 milliseconds

500%

0 second

58 | User Manual (710-04840-00M)

PROGRAMMING MENU

10J – Adaptive Stop Profile-2 Options:

Description:

10K – Adaptive Control Gain-2 Range:

Default:

Description:

10L – Brake Torque-2 Range:

Default:

Description:

10M – Brake Time-2 Range:

Default:

Description:

Range:

Default:

Description:

12A, 12B – Motor Data-1 and Motor Data-2 Ramp Options:

Description:

12C – Changeover Time Range:

Default:

Description:

Early Deceleration Constant Deceleration (default) Late Deceleration

Selects which profile the EMX3 will use for an Adaptive Control soft stop.

1% - 200%

Adjusts the performance of Adaptive Control. This setting affects both starting and stopping control.

75%

20% - 100%

20%

Sets the amount of brake torque the EMX3 will use to slow the motor.

1 - 30 (seconds)

Sets the duration for DC injection during a braking stop.

1 second

11 RTD Temperatures

The EMX3 has one RTD/PT100 input and can be fitted with another six PT100 inputs by using the RTD/PT100 and ground fault protection card. The inputs can trip the soft starter when the temperature exceeds a specified point, and different trip temperatures can be set for each input.

PT100 inputs B ~ G are only available if the RTD/PT100 and ground fault protection card has been installed.

0 - 250 ° C Sets the trip points for the RTD/PT100 inputs.

• 11A

• 11B

• 11C

• 11D

• 11E

• 11F

• 11G

RTD A Trip Temp RTD B Trip Temp RTD C Trip Temp RTD D Trip Temp RTD E Trip Temp

RTD F Trip Temp

RTD G Trip Temp

50 ° C

12 Slip-Ring Motors

These parameters allow the soft starter to be configured for use with a slip-ring motor.

100 - 500 (milliseconds)

Single Ramp (default) Dual Ramp

Selects whether to use a single or dual current ramp profile for soft starting. Set to single ramp for non-slip ring induction motors, or dual ramp for slip-ring induction motors. Parameter 12A selects the ramp configuration for the primary motor and parameter 12B selects the ramp configuration for the secondary motor.

Sets the delay between the rotor resistance relay closing and the low resistance current ramp starting. Set so that the contactor has enough time to close, but the motor does not slow down. Parameter 12C only applies if parameter 12A or 12B is set to 'Dual Ramp', and an output relay is set to 'Changeover Contactor'.

150 milliseconds

User Manual (710-04840-00M) | 59

PROGRAMMING MENU

12D – Slip-Ring Retard Range:

Default:

Description:

15A – Access Code Range:

Default:

Description:

NOTE

15B – Adjustment Lock

Options:

Description:

NOTE

15C – Emergency Run Options:

Description:

CAUTION

15D – Shorted SCR Action Options:

Description:

CAUTION

10% - 90%

Sets the level of conduction after the rotor resistance contactor closes, as a percentage of full conduction. Set so that no current pulse occurs, but the motor retains enough speed to start correctly.

15 Advanced

Read & Write (default) Allows users to alter parameter values in the Programming Menu.

0000 - 9999 Sets the access code to control access to restricted sections of the menus.

Use the and buttons to select which digit to alter and use the and buttons to change the value.

In the event of a lost access code, contact your supplier for a master access code that allows you to re-program a new access code.

Read Only Prevents users altering parameter values in the Programming Menu.

Selects whether the keypad will allow parameters to be changed via the Programming Menu.

50%

0000

Parameter values can still be viewed.

Changes to the Adjustment Lock setting take effect only after the Programming Menu has been closed.

Disable (default) Enable

Selects whether the soft starter will permit emergency run operation. In emergency run, the soft starter will start (if not already running) and continue to operate until emergency run ends, ignoring stop commands and trips. Emergency run is controlled using a programmable input.

Continued use of Emergency Run is not recommended. Emergency Run may compromise the starter life as all protections and trips are disabled.

Using the starter in 'Emergency Run' mode will void the product warranty.

3-Phase Control Only (default) PowerThrough

Selects whether the soft starter will allow PowerThrough operation, if the soft starter is damaged on one phase. The soft starter will use two-phase control, allowing the motor to continue operating in critical applications.

• PowerThrough is only available with in-line installations. If the starter is installed inside delta, PowerThrough

will not operate.

• PowerThrough remains active until '3-Phase Control Only' is reselected.

• A shorted SCR or a short within the bypass contactor will trip the starter on ‘Lx-Tx shorted’. If PowerThrough is

enabled, the trip can be reset and subsequent starts will use PowerThrough two-phase control; however not all features will be available. The trip LED will flash and the display will indicate ‘2 Phase - Damaged SCR'.

PowerThrough uses a two-phase soft start technology and additional care is required when sizing circuit breakers and protection. Contact your local supplier for assistance.

The starter will trip on Lx-Tx Shorted on the first start attempt after control power is applied. PowerThrough will not operate if control power is cycled between starts.

60 | User Manual (710-04840-00M)

PROGRAMMING MENU

15E – Jog Torque

Range:

Default:

Description:

CAUTION

16A~16X – Protection Actions Options:

Description:

PowerThrough operation does not support Adaptive Control soft starting or soft stopping. In PowerThrough, the EMX3

will automatically select constant current soft starting and timed voltage ramp soft stopping. If PowerThrough is enabled, parameters 2C and 2D must be set appropriately.

The EMX3 can jog the motor at a reduced speed, which allows precise positioning of belts and flywheels. Jog can be used for either

forward or reverse operation. 20% - 100% Sets the current limit for jog operation.

50%

16 Protection Action

These parameters define how the soft starter will respond to different protection events. The soft starter can trip, issue a warning, or ignore different protection events as required. All protection events are written to the event log. The default action for all protections is to trip the soft starter.

Protections 16N fitted.

Ground Fault

and 16P~16U

RTD/PT100

are only available if the RTD/PT100 and ground fault protection card has been

Defeating the protection may compromise the starter and motor, and should only be done in the case of emergency.

Trip Starter (default) Warn and Log Log Only

Selects the soft starter's response to each protection.

• 16A

• 16B

• 16C

• 16D

• 16E

• 16F

• 16G

• 16H

• 16I

• 16J

• 16K

• 16L

• 16M

• 16N

• 16O~16U

• 16V

• 16W

• 16X

Motor Overload Excess Start Time Undercurrent Instantaneous Overcurrent Current Imbalance

Frequency

Input A Trip Input B Trip

Motor Thermistor

Starter Communication

Network Communication

Heatsink Overtemperature

Battery/Clock Ground Fault

RTD A~G Overtemperature

Reserved

Low Control Volts

20 Restricted

These parameters are restricted for Factory use and are not available to the user.

User Manual (710-04840-00M) | 61

APPLICATION EXAMPLES

6/T3

2/T1

P24

COM

4/T2

B10

B11

C31

C32

C41

C42

C53

C54

C24

C64

C63

5/L3

3/L2

C23

1/L1

05970.E

Control voltage (model

Three-phase supply

Motor terminals

Main contactor

Semiconductor fuses (optional)

Start/stop contact

Reset contact

13, 14

Relay output A

23, 24

Run relay output

31, 32, 34

Relay output B

41, 42, 44

Relay output C

11. Application Examples

11.1 Installation with Main Contactor

The EMX3 is installed with a main contactor (AC3 rated). Control voltage must be supplied from the input side of the contactor. The main contactor is controlled by the EMX3 Main Contactor output, which by default is assigned to Output Relay A (terminals 13, 14).

dependent) Remote control inputs Motor thermistor input RTD/PT100 input 24 VDC output Relay outputs Analog output

Parameter settings:

• Parameter 7A

62 | User Manual (710-04840-00M)

Relay A Function

• Select 'Main Contactor' - assigns the Main Contactor function to Relay Output A (default setting)

11.2 Installation with External Bypass Contactor

8 9

05969.D

6/T3

2/T1

P24

COM

4/T2

B10

B11

C31

C32

C41

C42

C53

C54

C24

C64

C63

5/L3

3/L2

C23

1/L1

L3B

L1B

L2B

1 2

Remote control inputs

Motor thermistor input

RTD/PT100 input

The EMX3 is installed with an external bypass contactor (AC1 rated). The bypass contactor is controlled by the EMX3 Run Output (terminals 23, 24).

APPLICATION EXAMPLES

Control voltage (model dependent)

24 VDC output Relay outputs Analog output Three-phase supply

Motor terminals K1 Bypass contactor (external) F1 Semiconductor fuses (optional) S1 Start contact S2 Stop contact S3 Reset contact

13, 14 Relay output A

23, 24 Run relay output 31, 32, 34 Relay output B 41, 42, 44 Relay output C

Parameter settings:

• No special settings required.

User Manual (710-04840-00M) | 63

APPLICATION EXAMPLES

NOTE

CAUTION

6/T3

2/T1

P24

COM

4/T2

B10

B11

C31

C32

C41

C42

C53

C54

C24

C64

C63

5/L3

3/L2

C23

1/L1

8 9

05971.D

1 Control voltage (model dependent)

Remote control inputs

Motor thermistor input

RTD/PT100 input

24 VDC output

Relay outputs

Analog output

Three-phase supply

Motor terminals

Start/stop contact

11.3 Emergency Run Operation

In normal operation the EMX3 is controlled via a remote two-wire signal (terminals C31, C32). Emergency Run is controlled by a two-wire circuit connected to Input A (terminals C53, C54). Closing Input A causes the EMX3 to run

the motor and ignore certain trip conditions.

Although the Emergency Run satisfies the functionality requirements of Fire Mode, AuCom does not recommend its use in situations that require testing and/or compliance with specific standards as it is not certified.

Continued use of Emergency Run is not recommended. Emergency Run may compromise the starter life as all protections and trips are disabled.

Using the starter in 'Emergency Run' mode will void the product warranty.

S2 Reset contact S3 Emergency Run Contact

F1 Semiconductor fuses (optional) 13, 14 Relay output A 23, 24 Run relay output

31, 32, 34 Relay output B 41, 42, 44 Relay output C

Parameter settings:

• Parameter 6A

• Select 'Emergency Run' - assigns Input A for Emergency Run function.

• Parameter 15C

64 | User Manual (710-04840-00M)

• Select 'Enable' - Enables Emergency Run mode.

Input A Function

Emergency Run

APPLICATION EXAMPLES

6/T3

2/T1

P24

COM

4/T2

B10

B11

C31

C32

C41

C42

C53

C54

C24

C64

C63

5/L3

3/L2

C23

1/L1

05972.D

1 Control voltage (model dependent)

Remote control inputs

Motor thermistor input

RTD/PT100 input

11.4 Auxiliary Trip Circuit

In normal operation the EMX3 is controlled via a remote two-wire signal (terminals C31, C32). Input A (terminals C53, C54) is connected to an external trip circuit (such as a low pressure alarm switch for a pumping system).

When the external circuit activates, the soft starter trips, which stops the motor.

24 VDC output Relay outputs Analog output Three-phase supply

Motor terminals S1 Start/stop contact S2 Reset contact S3 Auxiliary trip contact F1 Semiconductor fuses (optional)

13, 14 Relay output A

23, 24 Run relay output 31, 32, 34 Relay output B 41, 42, 44 Relay output C

Parameter settings:

• Parameter 6A

• Select 'Input Trip (N/O)'. Assigns the Input A to Auxiliary Trip (N/O) function.

• Parameter 6B

• Select a name, eg Low Pressure. Assigns a name to Input A.

• Parameter 6C

• Set as required. For example, 'Run Only' limits the input trip to when the soft starter is running only.

• Parameter 6D

• Set as required. Sets a delay between the input activating and the soft starter tripping.

• Parameter 6E

• Set at around 120 seconds. Limits operation of the input trip to 120 seconds after the start signal. This allows

Input A Function

Input A Name

Input A Trip

Input A Trip Delay

Input A Initial Delay

time for pressure to build up in the piping before the low pressure input becomes active.

User Manual (710-04840-00M) | 65

APPLICATION EXAMPLES

CAUTION

-F1

L3L2L1 N E

-K10

L1 L2 L3 E

T1 T2 T3

A2A3 A1

C23 C24 C31 C32 C41 C42

C53 C54

-K10

-K11

-K10

-K11

T3T2T1

-K11-K10

-A2

06401.E

Control voltage

A Off (Ready)

C23, C24

Start B

Start

C31, C32

Stop C

Run

C41, C42

Reset D

Stop

C53, C54

Programmable input A (Starter Disable)

E Zero speed

Motor terminals

5 Start signal

Three-phase supply

6 Zero speed sensor

Starter Disable (shown on starter display)

CAUTION

11.5 DC Brake with External Zero Speed Sensor

For loads which may vary between braking cycles, there are benefits in using an external zero-speed sensor to interface with the EMX3 for brake shut-off. This control method ensures that the EMX3 braking will always shut off when the motor has reached a standstill, thus avoiding unnecessary motor heating.

The following schematic diagram shows how you can use a zero-speed sensor with the EMX3 to turn the brake function off at motor standstill. The zero-speed sensor (A2) is often referred to as an under-speed detector. Its internal contact is open at zero-speed and closed at any speed above zero-speed. Once the motor has reached a standstill, C53, C54 will open and the starter will be disabled. When the next start command is given (ie next application of K10), C53, C54 closes and the EMX3 is enabled.

The EMX3 must be operated in remote mode and parameter 6A

Input A Function

must be set to 'Starter Disable'.

For details on configuring DC Brake, refer to

When using DC brake, the mains supply must be connected to the soft starter (input terminals L1, L2, L3) in positive phase sequence and parameter 4G

66 | User Manual (710-04840-00M)

Brake

on page 36.

Phase Sequence

must be set to Positive Only.

APPLICATION EXAMPLES

3 4

K10

Run relay S3

Reset contact

K11

Start relay

NOTE

11.6 Soft Braking

For applications with high inertia and/or a variable load, the EMX3 can be configured for soft braking. In this application the EMX3 is employed with forward run and braking contactors. When the EMX3 receives a start signal (pushbutton

S1), it closes the forward run contactor (K1) and controls the motor according to the programmed primary motor settings. When the EMX3 receives a stop signal (pushbutton S2), it opens the forward run contactor (K1) and closes the braking contactor (K2)

after a delay of approximately 2-3 seconds (K1T). K12 is also closed to activate the secondary motor settings, which should be user programmed for the desired stopping performance characteristics.

When motor speed approaches zero, the zero speed sensor (A2) stops the soft starter and opens the braking contactor (K2).

Control voltage (model dependent) K12 Brake relay Remote control inputs K13 Zero speed sensor relay Motor thermistor input K1 Line contactor (Run) RTD/PT100 input K2 Line contactor (Brake) Relay outputs K1T Run delay timer Three-phase supply K2T Brake delay timer Motor terminals K3T Zero speed sensor delay timer*

A2 Zero speed sensor S1 Start contact

F1 Semiconductor fuses (optional) S2 Stop contact

* The K3T timer is only required if the zero speed sensor is the type that performs a self-test upon power-up and momentarily closes the output relay.

Parameter settings:

• Parameter 6A

Input A Function

(terminals C53, C54)

• Select 'Motor Set Select' - assigns Input A for Motor set selection.

• Set starting performance characteristics using the primary motor set.

• Set braking performance characteristics using the secondary motor settings.

• Parameter 7G

• Select 'Trip' - assigns Trip function to Relay Output C.

Relay C Function

If the EMX3 trips on supply frequency (parameter 16F the frequency protection settings.

Frequency

) when the braking contactor K2 opens, modify

User Manual (710-04840-00M) | 67

APPLICATION EXAMPLES

NOTE

C63

C64

2/T1

4/T2

6/T3

1/L1

3/L2

5/L3

C23

C24

C31

C32

C41

C42

C53

C54

K10

K11

K10

K11

K10

K2K 11

K10

8 9

Control voltage

Remote control inputs

Motor thermistor input

RTD/PT100 input

Relay outputs

Three-phase supply

Motor terminals

Remote low speed start input

Remote high speed start input

Semiconductor fuses (optional)

K10

Remote start relay (low speed)

K11

Remote start relay (high speed)

Line contactor (high speed)

Line contactor (low speed)

Star contactor (high speed)

Reset contact

NOTE

11.7 Two-Speed Motor

The EMX3 can be configured for control of dual speed Dahlander type motors, using a high speed contactor (K1), low speed contactor (K2) and a star contactor (K3).

Pole Amplitude Modulated (PAM) motors alter the speed by effectively changing the stator frequency using external winding configuration. Soft starters are not suitable for use with this type of two-speed motor.

When the soft starter receives a high speed start signal, it closes the high speed contactor (K1) and star contactor (K3), then controls the motor according to the primary motor settings.

When the soft starter receives a low speed start signal, it closes the low speed contactor (K2). This closes Input A and the EMX3 controls the motor according to the secondary motor settings.

41, 42, 44 Relay output C

Parameter settings:

Contactors K2 and K3 must be mechanically interlocked.

• Parameter 6A

• Parameter 7G

If the EMX3 trips on supply frequency (parameter 16F the frequency protection settings.

• Select 'Motor Set Select' - assigns Input A for Motor set selection.

• Set high speed performance characteristics using the primary motor settings.

• Set low speed performance characteristics using the secondary motor settings.

• Select 'Trip' - assigns Trip function to Relay Output C

Input A Function

Relay C Function

(terminals C53, C54)

Frequency

) when the high-speed start signal (9) is removed, modify

68 | User Manual (710-04840-00M)

11.8 Slip-Ring Motor

6/T3

2/T1

P24

COM

4/T2

B10

B11

C31

C32

C41

C42

C53

C54

C24

C64

C63

5/L3

3/L2

C23

1/L1

05973.G

Control voltage (model

Remote control inputs

Motor thermistor input

RTD/PT100 input

24 VDC output

Relay outputs

Analog output

Three-phase supply

Slip-ring induction motor

Changeover contactor

Semiconductor fuses

Reset contact

Rotor resistance (external)

The EMX3 can be used to control a slip-ring motor, using rotor resistance.

APPLICATION EXAMPLES

dependent)

(optional)

S1 Start/stop contact

User Manual (710-04840-00M) | 69

APPLICATION EXAMPLES

NOTE

Commissioning

1. Configure the EMX3 as follows:

Parameter settings:

• Parameter 7D

• Select 'Changeover contactor'

• Parameter 7E

• Set this to the maximum time (5m:00s).

• Parameter 12A

• Select 'Dual Ramp' (for slip-ring induction motor control)

• Parameter 12C

• Default setting is 150 milliseconds. Set this to a value just greater than the changeover contactor (K1) pole

closing time.

• Parameter 12D

• Default setting is 50%. Set this parameter to a value which is high enough to cause the motor to instantly

accelerate once the rotor resistance (R1) has been bridged out and low enough to avoid a motor current pulse.

2. Start the motor under normal load conditions and record the time it takes to reach a constant speed with external rotor resistance (R1) in the circuit. Stop the motor soon after a constant speed has been reached. Change parameter 7E to the recorded time value.

3. Start the motor under normal load conditions and monitor the motor speed behaviour and motor current when the changeover contactor (K1) switches in to short-out the rotor resistance (R1). If the motor does not accelerate immediately after changeover, increase the setting of parameter 12D. If there is a pulse in motor current immediately after changeover, reduce the setting of parameter 12D.

Relay B Function

Relay B On Delay

Motor Data-1 Ramp

Changeover Time

Slip Ring Retard

Speed

Time

R1 Constant Speed First ramp Second ramp Run mode (I < 120% FLC)

Parameter 7E K1 closes Parameter 12C

Relay B On Delay

Changeover Time

For this installation to function correctly, only use the primary motor settings with constant current start method (parameter 2A

Start Mode

70 | User Manual (710-04840-00M)

TROUBLESHOOTING

RESET

Display

Possible cause/Suggested solution

12. Troubleshooting

12.1 Protection Responses

When a protection condition is detected, the EMX3 will write this to the event log and may also trip or issue a warning. The soft starter's response depends on the Protection Action setting (parameter group 16).

Some protection responses cannot be adjusted by the user. These trips are usually caused by external events (such as phase loss) or by a fault within the soft starter. These trips do not have associated parameters and cannot be set to Warn or Log.

If the EMX3 trips you will need to identify and clear the condition that triggered the trip, then reset the soft starter before restarting. To reset the starter, press the

If the EMX3 has issued a warning, the soft starter will reset itself once the cause of the warning has been resolved.

12.2 Trip Messages

This table lists soft starter's protection mechanisms and the probable cause of the trip. Some of these can be adjusted using parameter group 4 Protection Settings and parameter group 16 Protection Action, other settings are built-in system protections and cannot be set or adjusted.

button on the keypad or activate the Reset remote input.

2 Phase - Damaged SCR

Battery/clock

Controller

Current imbalance

Current Read Err Lx

Excess start time

Firing Fail Px

This message is displayed if the soft starter tripped on “ Lx-Tx shorted” during the pre-start checks and PowerThrough is enabled. It indicates that the starter now operates in PowerThough mode (2-phase control only). Check for either a shorted SCR or a short within the bypass contactor. Related parameters: 15D

A verification error has occurred on the real time clock, or the backup battery voltage is low. If the battery is low and the power is off, date/time settings will be lost. The EMX3 will continue to soft start and soft stop correctly. Reprogram the date and time. The battery is not removable. In order to replace the battery, the main control PCB must be replaced. Related parameters: 16M

This is a name selected for a programmable input. Refer to Input A trip. Current imbalance can be caused by problems with the motor, the environment or the installation,

such as:

• An imbalance in the incoming mains voltage

• A problem with the motor windings

• A light load on the motor

• A phase loss on input terminals L1, L2 or L3 during Run mode

• An SCR that has failed open circuit. A failed SCR can only be definitely diagnosed by replacing

the SCR and checking the starter's performance.

Related parameters: 4H, 4I, 16E Where 'X' is 1, 2 or 3.

Internal fault (PCB fault). The output from the CT circuit is not close enough to zero when the SCRs are turned off. Contact your local supplier for advice. This trip is not adjustable. Related parameters: None

Excess start time trip can occur in the following conditions:

• parameter 1A

• parameter 2D

• parameter 2B

setting

• parameter 2B Related parameters: 1A, 9B, 2D, 2B, 4A, 10D, 10B, 4B, 16B

Where 'X' is phase 1, 2 or 3. The SCR did not fire as expected. The SCR may be faulty or there may be an internal wiring fault. This trip is not adjustable. Related parameters: None

Motor Full Load Current Current Limit Start Ramp Time

Start Ramp Time

has been set too low

has been set greater than the setting for 4A

is set too short for a high inertia load when using Adaptive Control

is not appropriate for the motor

Excess Start Time

User Manual (710-04840-00M) | 71

TROUBLESHOOTING

Display

Possible cause/Suggested solution

The EMX3 can support higher motor full load current values when connected to the motor using inside The mains frequency has gone beyond the specified range.

NOTE

This is a name selected for a programmable input. Refer to Input A trip.

One of the soft starter's inputs is set to a trip function and has activated. Check the status of the

There has been a sharp rise in motor current, probably caused by a locked rotor condition (shearpin)

During pre-start checks the starter has detected a shorted SCR or a short within the bypass contactor

NOTE

FLC too high

Frequency

Ground Fault

Heatsink overtemperature

delta configuration rather than in-line connection. If the soft starter is connected in-line but the programmed setting for parameter 1A starter will trip at start (see

Minimum and Maximum Current Settings

Motor Full Load Current

is above the in-line maximum, the soft

on page 82). If the soft starter is connected to the motor using inside delta configuration, the soft starter may not be correctly detecting the connection. Contact your local supplier for advice. Related parameters: 1A, 9B

Check for other equipment in the area that could be affecting the mains supply, particularly variable speed drives and switch mode power supplies (SMPS). If the EMX3 is connected to a generator set supply, the generator may be too small or could have a speed regulation problem. Related parameters: 4J, 4K, 4L, 16F

Test the insulation of the output cables and the motor. Identify and resolve the cause of any ground fault.

Ground fault protection is only available if the RTD/PT100 and ground fault protection

card is fitted. Related parameters: 4O, 4P, 16N Check if cooling fans are operating. If mounted in an enclosure, check if ventilation is adequate.

Fans operate during Start, Run and for 10 minutes after the starter exits the Stop state.

Models EMX3-0023B to EMX3-0053B and EMX3-0170B do not have a cooling fan. Models with fans will operate the cooling fans from a Start until 10 minutes after a Stop.

Related parameters: 16L

High Level

High Pressure

Input A trip

inputs to identify which input has activated, then resolve the trigger condition. Related parameters: 6C, 6D, 6E, 6A, 6B, 16G

Instantaneous overcurrent

while running. This may indicate a jammed load. Related parameters: 4E, 4F, 16D

Internal fault X

The EMX3 has tripped on an internal fault. Contact your local supplier with the fault code (X). Related parameters: None

L1 phase loss L2 phase loss L3 phase loss

During pre-start checks the starter has detected a phase loss as indicated. In run state, the starter has detected that the current on the affected phase has dropped below 2% of the programmed motor FLC for more than 1 second, indicating that either the incoming phase or connection to the motor has been lost. Check the supply and the input and output connections at the starter and at the motor end. Related parameters: None

L1-T1 shorted L2-T2 shorted L3-T3 shorted

as indicated. If the starter is connected in-line with the motor, consider using PowerThrough to allow operation until the starter can be repaired.

PowerThrough is only available with in-line installations. If the starter is installed inside delta, PowerThrough will not operate.

72 | User Manual (710-04840-00M)

Related parameters: 15D

The starter will trip on Lx-Tx Shorted on the first start attempt after control power is applied. PowerThrough will not operate if control power is cycled between starts.

TROUBLESHOOTING

Display

Possible cause/Suggested solution

the bypass driver PCB may be faulty (internally bypassed models only). Contact your local supplier

This is a name selected for a programmable input. Refer to Input A trip.

Where 'X' is 1, 2 or 3.

The motor thermistor input has been enabled and:

NOTE

network)

RESET

The phase sequence on the soft starter's input terminals (L1, L2, L3) is not valid.

th a small motor, it must draw at least 2% of

Low Control Volts

Low Level

Low Pressure

Motor Connection Tx

Motor overload Motor 2 overload

Motor thermistor

The EMX3 has detected a drop in the internal control voltage.

• Check the external control supply (A1, A2, A3) and reset the starter. If the external control supply is stable:

• the 24 V supply on the main control PCB may be faulty; or

•

for advice. This protection is not active in Ready state. Related parameters: 16X

The motor is not connected correctly to the soft starter.

• Check individual motor connections to the soft starter for power circuit continuity.

• Check connections at the motor terminal box.

This trip is not adjustable. Related parameters: None

The motor has reached its maximum thermal capacity. Overload can be caused by:

• The soft starter protection settings not matching the motor thermal capacity

• Excessive starts per hour or start duration

• Excessive current

• Damage to the motor windings

Resolve the cause of the overload and allow the motor to cool. Related parameters: 1A, 1B, 9B, 9C, 2A, 2D, 10A, 10D, 16A

• The resistance at the thermistor input has exceeded 3.6 kΩ for more than one second.

• The motor winding has overheated. Identify the cause of the overheating and allow the motor to

cool before restarting.

• The motor thermistor input has been opened.

Related parameters: 16I

Network communication (between device and

No Flow

Parameter out of range

There is a network communication problem, or the network master may have sent a trip command to the starter. Check the network for causes of communication inactivity. Related parameters: 16K

This is a name selected for a programmable input. Refer to Input A trip.

• A parameter value is outside the valid range. The starter will load the default value for all affected parameters. Press invalid parameter and adjust the setting. Related parameters: None

Phase sequence

Check the phase sequence on L1, L2, L3 and ensure the setting in parameter 4G is suitable for the installation. Related parameters: 4G

PLC

Power loss

This is a name selected for a programmable input. Refer to Input A trip. The starter is not receiving mains supply on one or more phases when a Start Command is given.

Check that the main contactor closes when a start command is given, and remains closed until the end of a soft stop. Check the fuses. If testing the soft starter wi its minimum FLC setting on each phase. Related parameters: None

Pump Fault

This is a name selected for a programmable input. Refer to Input A trip.

If a valid motor thermistor is no longer used, a 1.2 kΩ resistor must be fitted across terminals B4, B5.

to go to the first

User Manual (710-04840-00M) | 73

TROUBLESHOOTING

Display

Possible cause/Suggested solution

NOTE Indicates that the indicated RTD/PT100 has short circuited. Check and resolve this condition.

in inside delta)

This is a name selected for a programmable input. Refer to Input A trip.

Where 'X' is 1, 2 or 3.

RTD/PT100 A~ RTD/PT100 G

RTD circuit fail

Starter communication (between device and soft starter)

Starter Disable

Thermistor circuit

Time-overcurrent

Undercurrent

Unsupported option (function not available

The RTD/PT100 set temperature has been exceeded and tripped the soft starter. Identify and resolve the condition which caused the appropriate input to activate.

PT100 B to PT100 G are applicable only if a RTD/PT100 and Ground Fault card is fitted.

Related parameters: 11A~11G, 16O~16U

Related parameters: None

• There is a problem with the connection between the soft starter and the optional communications

module. Remove and reinstall the module. If the problem persists, contact your local

distributor.

• There is an internal communications error within the soft starter. Contact your local distributor. Related parameters: 16J

This is a name selected for a programmable input. Refer to Input A trip. Check that a PT100 (RTD) is not connected to B4, B5.

The thermistor input has been enabled and:

• The resistance at the input has fallen below 20 Ω (the cold resistance of most thermistors will be

over this value) or

• A short circuit has occurred. Check and resolve this condition. Related parameters: None

The EMX3 is internally bypassed and has drawn high current during running. (The 10A protection curve trip has been reached or the motor current has risen to 600% of the motor FLC setting.) Related parameters: None

The motor has experienced a sharp drop in current, caused by loss of load. Causes can include broken components (shafts, belts or couplings), or a pump running dry. Related parameters: 4C, 4D, 16C

The selected function is not available (eg jog is not supported in inside delta configuration). Related parameters: None

Vibration

VZC Fail Px

Internal fault (PCB fault). Contact your local supplier for advice. This trip is not adjustable. Related parameters: None

74 | User Manual (710-04840-00M)

TROUBLESHOOTING

Symptom

Probable Cause

Starter "Not Ready"

• Check Input A (C53, C54). The starter may be disabled via a programmable input. START

RESET

LCL/RMT

NOTE

LCL/RMT

A reset does not occur after an

• The remote 2-wire start signal must be removed and reapplied for a re-start.

Non-resettable Thermistor Cct trip, when

• The thermistor input is enabled once a link is fitted and short circuit protection has The soft starter does not control the

• Start performance may be unstable when using a low

Motor Full Load Current

12.3 General Faults

This table describes situations where the soft starter does not operate as expected but does not trip or give a warning.

If parameter 6A or 6F is set to Starter Disable and there is an open circuit on the corresponding input, the EMX3 will not start.

The soft starter does not respond to the

button on the keypad.

The soft starter does not respond to commands from the control inputs.

The soft starter does not respond to a start command from either the local or remote controls.

• The soft starter may be in Remote control mode. When the soft starter is in Remote control mode, the Local LED on the starter is off. Press the button once to change to Local control.

• The soft starter may be in Local control mode. When the soft starter is in Local control mode, the Local LED on the starter is on. Press the to change to Remote control.

• The control wiring may be incorrect. Check that the remote start, stop and reset inputs are configured correctly (refer to

Control Wiring

on page 10 for details).

• The signals to the remote inputs may be incorrect. Test the signalling by activating each input signal in turn. The appropriate remote control input LED should activate on the starter.

• The soft starter may be waiting for the restart delay to elapse. The length of the restart delay is controlled by parameter 4M

Restart Delay

• The motor may be too hot to permit a start. If parameter 4N

is set to Check, the soft starter will only permit a start when it calculates that

Check

Motor Temperature

the motor has sufficient thermal capacity to complete the start successfully. Wait for the motor to cool before attempting another start.

• The starter may be disabled via a programmable input. If parameter 6A or 6F is set to Starter Disable and there is an open circuit on the corresponding input, the EMX3 will not start. If there is no further need to disable the starter, close the circuit on the input.

Parameter 6Q

Local/Remote

controls when the

button is

enabled.

button once

Auto-Reset, when using a remote two-wire control.

Remote start/stop command is overriding Auto Start/Stop settings when using

• Auto Start/Stop should only be used in remote mode with three-wire or four-wire control.

remote two-wire control.

there is a link between the thermistor input B4, B5 or when the motor thermistor connected between B4, B5 is permanently removed.

activated.

• Remove the link then load the default parameter set. This will disable the

thermistor input and clear the trip.

• Place a 1k2 Ω resistor across the thermistor input.

• Turn thermistor protection to 'Log only' (parameter 16I).

Remote start/stop command is overriding Auto Start/Stop settings when using

• Auto Start/Stop should only be used in remote mode with three-wire or four-wire control.

remote two-wire control.

motor correctly during starting.

setting (parameter 1A).

• Power factor correction (PFC) capacitors must be installed on the supply side of the soft starter and must be disconnected during starting and stopping. To control a dedicated PFC capacitor contactor, connect the contactor to run relay terminals.

User Manual (710-04840-00M) | 75

TROUBLESHOOTING

Symptom

Probable Cause

NOTE

Adaptive Control, brake, jog and

These features are only available with in-line installation. If the EMX3 is installed

Tx Shorted on the first start attempt after control power is

Starter "awaiting data"

• The keypad is not receiving data from the control PCB. Check the cable connection

Corrupted text shown on keypad display.

The keypad may not be screwed down, resulting in an intermittent connection.

STORE

EXIT

ATTENTION! Remove Mains Volts

The soft starter will not activate Run Simulation with three-phase power connected.

Motor does not reach full speed. • If the start current is too low, the motor will not produce enough torque to

accelerate to full speed. The soft starter may trip on excess start time.

Make sure the motor starting parameters are appropriate for the application and that you are using the intended motor starting profile. If a programmable input is set to Motor Set Select, check that the

corresponding input is in the expected state. The load may be jammed. Check the load for severe overloading or a locked rotor situation.

Erratic motor operation. • The SCRs in the EMX3 require at least 5 A of current to latch. If you are testing the

soft starter on a motor with full load current less than 5 A, the SCRs may not latch correctly.

Erratic and noisy motor operation. • If the soft starter is connected to the motor using inside delta configuration, the soft

starter may not be correctly detecting the connection. Contact your local supplier for advice.

Soft stop ends too quickly. • The soft stop settings may not be appropriate for the motor and load. Review the

soft stop settings.

• If the motor is very lightly loaded, soft stop will have limited effect.

•

PowerThrough functions not working. After selecting Adaptive Control the motor

used an ordinary start and/or the second

inside delta, these features will not operate.

• The first Adaptive Control start is actually 'Constant Current' so that the starter can

learn from the motor characteristics. Subsequent starts use Adaptive Control.

start was different to the first. PowerThrough does not operate when

selected.

• The starter will trip on Lx-

applied. PowerThrough will not operate if control power is cycled between starts.

and the fitting of the display on the starter.

•

Screw down the keypad or hold squarely in place.

Display is distorted • Check that the keypad has not been screwed down too tightly. Loosen screws

slightly.

Parameter settings cannot be stored. • Make sure you are saving the new value by pressing the

adjusting a parameter setting. If you press

, the change will not be saved.

• Check that the adjustment lock (parameter 15B) is set to

adjustment lock is set to

Read Only

, settings can be viewed but not changed. You

button after

Read & Write

. If the

need to know the security access code to change the adjustment lock setting.

• The EEPROM may be faulty on the keypad. A faulty EEPROM will also trip the soft

starter, and the keypad will display the message Parameter out of range. Contact your local supplier for advice.

•

This prevents unintentional direct on-line (DOL) start.

76 | User Manual (710-04840-00M)

13. Appendix

EMX3-

– 0 2 5 5 – – –

Mains voltage

V4 = 200~440 VAC Bypass

B = internally bypassed Start time (seconds)

Starter current rating (amperes)

NOTE

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

EMX3-0023B

23 A

20 A

17 A

15 A

EMX3-0043B

43 A

37 A

31 A

26 A

EMX3-0050B

50 A

44 A

37 A

30 A

EMX3-0053B

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

EMX3-0220B

220 A

210 A

178 A

158 A

13.1 Model code

Keypad H = with keypad

X = without keypad

Control voltage C1 = 110~210 VAC & 220~440 VAC

C2 = 24 VAC/VDC

V7 = 380~690 VAC

C = non-bypassed (continuous connection)

APPENDIX

Nominal current rating

13.2 IEC ratings

Current Ratings for Bypass Operation

80 A : AC-53b

Models EMX3-0255C, EMX3-0360C, EMX3-0380C, EMX3-0430C, EMX3-0620C, EMX3-0650C, EMX3-0790C, EMX3-0930C, EMX3-1200C, EMX3-1410C, EMX3-1600C must be externally bypassed.

In-line connection

3.5 - 15 : 345 Off time (seconds)

Start current (multiple of motor full load current)

EMX3-0076B 76 A 64 A 55 A 47 A EMX3-0097B 97 A 82 A 69 A 58 A EMX3-0100B 100 A 88 A 74 A 61 A EMX3-0105B 105 A 105 A 95 A 78 A EMX3-0145B 145 A 123 A 106 A 90 A EMX3-0170B 170 A 145 A 121 A 97 A EMX3-0200B 200 A 189 A 160 A 134 A

User Manual (710-04840-00M) | 77

APPENDIX

EMX3-0380C

380 A

359 A

299 A

EMX3-0425B

425 A

411 A

355 A

305 A

EMX3-0430C

430 A

368 A

309 A

EMX3-0500B

500 A

445 A

383 A

326 A

EMX3-0580B

580 A

492 A

425 A

364 A

EMX3-0620C

620 A

540 A

438 A

EMX3-0650C

650 A

561 A

455 A

EMX3-0700B

700 A

592 A

512 A

438 A

EMX3-0790C

790 A

714 A

579 A

EMX3-0820B

820 A

705 A

606 A

516 A

EMX3-0920B

920 A

804 A

684 A

571 A

EMX3-0930C

930 A

829 A

661 A

EMX3-1000B

1000 A

936 A

796 A

664 A

EMX3-1200C

1200 A

1071 A

EMX3-1410C

1410 A

1319 A

1114 A

EMX3-1600C

1600 A

1353 A

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

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

EMX3-0076B

114 A

96 A

83 A

70 A

EMX3-0097B

145 A

123 A

104 A

87 A

EMX3-0100B

150 A

132 A

112 A

92 A

EMX3-0105B

157 A

158 A

143 A

117 A

EMX3-0145B

218 A

184 A

159 A

136 A

EMX3-0170B

255 A

217 A

181 A

146 A

EMX3-0255B 255 A 231 A 201 A 176 A EMX3-0255C 255 A 231 A 201 A 176 A EMX3-0350B 350 A 329 A 284 A 244 A EMX3-0360C 360 A 360 A 310 A 263 A

Inside delta connection

EMX3-0023B 34 A 30 A 26 A 22 A EMX3-0043B 64 A 59 A 51 A 44 A EMX3-0050B 75 A 66 A 55 A 45 A EMX3-0053B 80 A 80 A 69 A 55 A

EMX3-0200B 300 A 283 A 241 A 213 A EMX3-0220B 330 A 315 A 268 A 238 A EMX3-0255B 382 A 346 A 302 A 264 A EMX3-0255C 382 A 346 A 302 A 264 A EMX3-0350B 525 A 494 A 427 A 366 A EMX3-0360C 540 A 540 A 465 A 395 A EMX3-0380C 570 A 570 A 539 A 449 A EMX3-0425B 638 A 617 A 533 A 458 A EMX3-0430C 645 A 645 A 552 A 464 A EMX3-0500B 750 A 668 A 575 A 490 A EMX3-0580B 870 A 738 A 637 A 546 A EMX3-0620C 930 A 930 A 810 A 651 A EMX3-0650C 975 A 975 A 842 A 683 A EMX3-0700B 1050 A 889 A 768 A 658 A

78 | User Manual (710-04840-00M)

EMX3-0790C 1185 A 1185 A 1075 A 868 A

EMX3-1000B

1500 A

1404 A

1194 A

997 A

EMX3-1200C

1800 A

1606 A

EMX3-1410C

2115 A

1979 A

1671 A

EMX3-1600C

2400 A

2030 A

Start time (seconds)

Starter current rating (amperes)

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

EMX3-0255C

255 A

222 A

195 A

171 A

EMX3-0360C

360 A

351 A

303 A

259 A

EMX3-0380C

380 A

348 A

292 A

EMX3-0430C

430 A

413 A

355 A

301 A

EMX3-0620C

620 A

614 A

515 A

419 A

EMX3-0650C

650 A

629 A

532 A

437 A

EMX3-0790C

790 A

694 A

567 A

EMX3-0930C

930 A

800 A

644 A

EMX3-1200C

1200 A

1135 A

983 A

EMX3-1410C

1410 A

1355 A

1187 A

1023 A

EMX3-1600C

1600 A

1433 A

1227 A

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

EMX3-0820B 1230 A 1058 A 910 A 774 A EMX3-0920B 1380 A 1206 A 1026 A 857 A EMX3-0930C 1395 A 1395 A 1244 A 992 A

Current Ratings for Continuous Operation (Not bypassed)

APPENDIX

351 A : AC-53a

In-line connection

3.5 - 15 : 50 - 6 Starts per hour

On-load duty cycle (%)

Start current (multiple of motor full load current)

Inside delta connection

EMX3-0255C 382 A 334 A 293 A 257 A EMX3-0360C 540 A 527 A 455 A 388 A EMX3-0380C 570 A 570 A 522 A 437 A EMX3-0430C 645 A 620 A 533 A 451 A EMX3-0620C 930 A 920 A 773 A 628 A EMX3-0650C 975 A 943 A 798 A 656 A EMX3-0790C 1185 A 1185 A 1041 A 850 A EMX3-0930C 1395 A 1395 A 1200 A 966 A EMX3-1200C 1800 A 1800 A 1702 A 1474 A EMX3-1410C 2115 A 2033 A 1780 A 1535 A EMX3-1600C 2400 A 2400 A 2149 A 1840 A

User Manual (710-04840-00M) | 79

APPENDIX

Internally bypassed models

Light

300%, 10 seconds

50 ºC <1000 metres

Standard

350%, 30 seconds

50 ºC <1000 metres

Heavy

450%, 30 seconds

50 ºC <1000 metres

EMX3-0920B

920 A

673 A

590 A

EMX3-1000B

1000 A

783 A

720 A

Non-bypassed models

EMX3-0650C

650 A

515 A

414 A

EMX3-0790C

790 A

661 A

527 A

EMX3-0930C

930 A

751 A

597 A

EMX3-1200C

1200 A

1148 A

932 A

EMX3-1410C

1410 A

1200 A

979 A

EMX3-1600C

1600 A

1444 A

1181 A

13.3 NEMA motor ratings

In-line connection

EMX3-0023B 23 A 21 A 16 A EMX3-0043B 43 A 39 A 29 A EMX3-0050B 50 A 46 A 35 A EMX3-0053B 53 A 53 A 45 A EMX3-0076B 76 A 65 A 46 A EMX3-0097B 97 A 79 A 58 A EMX3-0100B 100 A 84 A 65 A EMX3-0105B 105 A 105 A 79 A EMX3-0145B 145 A 124 A 90 A EMX3-0170B 170 A 141 A 110 A EMX3-0200B 200 A 159 A 135 A EMX3-0220B 220 A 180 A 156 A EMX3-0255B 255 A 205 A 180 A EMX3-0350B 360 A 302 A 240 A EMX3-0425B 425 A 360 A 302 A EMX3-0500B 515 A 384 A 324 A EMX3-0580B 590 A 426 A 360 A EMX3-0700B 700 A 515 A 431 A EMX3-0820B 820 A 605 A 509 A

EMX3-0255C 242 A 220 A 160 A EMX3-0360C 360 A 302 A 242 A EMX3-0380C 380 A 341 A 272 A EMX3-0430C 430 A 360 A 302 A EMX3-0620C 620 A 493 A 394 A

80 | User Manual (710-04840-00M)

Inside delta connection

Internally bypassed models

Light

300%, 10 seconds

50 ºC <1000 metres

Standard

350%, 30 seconds

50 ºC <1000 metres

Heavy

450%, 30 seconds

50 ºC <1000 metres

EMX3-0053B

79 A

67 A

EMX3-0076B

114 A

97 A

69 A

EMX3-0097B

145 A

118 A

87 A

EMX3-0100B

150 A

126 A

97 A

EMX3-0105B

157 A

118 A

EMX3-0145B

217 A

186 A

135 A

EMX3-0170B

255 A

211 A

165 A

EMX3-0200B

300 A

238 A

202 A

EMX3-0220B

330 A

270 A

234 A

EMX3-0255B

382 A

307 A

270 A

EMX3-0350B

540 A

453 A

360 A

EMX3-0425B

637 A

540 A

453 A

EMX3-0500B

772 A

576 A

486 A

EMX3-0580B

885 A

639 A

540 A

EMX3-0700B

1050 A

772 A

646 A

EMX3-0820B

1230 A

907 A

763 A

Non-bypassed models

EMX3-0255C

363 A

330 A

240 A

EMX3-0360C

540 A

453 A

363 A

EMX3-0380C

570 A

511 A

408 A

EMX3-0430C

645 A

540 A

453 A

EMX3-0620C

930 A

739 A

591 A

EMX3-0650C

975 A

772 A

621 A

EMX3-0023B 34 A 31 A 24 A EMX3-0043B 64 A 58 A 43 A EMX3-0050B 75 A 69 A 52 A

APPENDIX

EMX3-0920B 1380 A 1009 A 885 A EMX3-1000B 1500 A 1174 A 1080 A

EMX3-0790C 1185 A 991 A 790 A EMX3-0930C 1395 A 1126 A 895 A EMX3-1200C 1800 A 1722 A 1398 A EMX3-1410C 2115 A 1800 A 1468 A EMX3-1600C 2400 A 2166 A 1771 A

User Manual (710-04840-00M) | 81

APPENDIX

In-line connection

Inside delta connection

Model

Minimum

Maximum

Minimum

Maximum

EMX3-0043B

9 A

43 A

9 A

64 A

EMX3-0050B

10 A

50 A

10 A

75 A

EMX3-0076B

15 A

76 A

15 A

114 A

EMX3-1600C

320 A

1600 A

320 A

2400 A

13.4 Minimum and Maximum Current Settings

The EMX3's minimum and maximum full load current settings depend on the model:

EMX3-0023B 5 A 23 A 5 A 34 A

EMX3-0053B 11 A 53 A 11 A 79 A

EMX3-0097B 19 A 97 A 19 A 145 A EMX3-0100B 20 A 100 A 20 A 150 A EMX3-0105B 21 A 105 A 21 A 157 A EMX3-0145B 29 A 145 A 29 A 217 A EMX3-0170B 34 A 170 A 34 A 255 A EMX3-0200B 40 A 200 A 40 A 300 A EMX3-0220B 44 A 220 A 44 A 330 A EMX3-0255B 51 A 255 A 51 A 382 A EMX3-0255C 51 A 255 A 51 A 382 A EMX3-0350B 70 A 350 A 70 A 525 A EMX3-0360C 72 A 360 A 72 A 540 A EMX3-0380C 76 A 380 A 76 A 570 A EMX3-0425B 85 A 425 A 85 A 638 A EMX3-0430C 86 A 430 A 86 A 645 A EMX3-0500B 100 A 500 A 100 A 750 A EMX3-0580B 116 A 580 A 116 A 870 A EMX3-0620C 124 A 620 A 124 A 930 A EMX3-0650C 130 A 650 A 130 A 975 A EMX3-0700B 140 A 700 A 140 A 1050 A EMX3-0790C 158 A 790 A 158 A 1185 A EMX3-0820B 164 A 820 A 164 A 1230 A EMX3-0920B 184 A 920 A 184 A 1380 A EMX3-0930C 186 A 930 A 186 A 1395 A EMX3-1000B 200 A 1000 A 200 A 1500 A EMX3-1200C 240 A 1200 A 240 A 1800 A EMX3-1410C 282 A 1410 A 282 A 2115 A

82 | User Manual (710-04840-00M)

13.5 Dimensions and Weights

EMX3-0023B~EMX3-0105B

EMX3-0145B~EMX3-1000B

C D

14408.A

14409.A

EMX3-0360C~EMX3-1600C

C D

14410.B

APPENDIX

User Manual (710-04840-00M) | 83

APPENDIX

Model

mm (inch)

Weight

kg (lb)

EMX3-0053B

EMX3-0076B

EMX3-0097B

EMX3-0100B

EMX3-0650C

EMX3-0790C

EMX3-0930C

EMX3-1200C

EMX3-1410C

EMX3-1600C

NOTE

EMX3-0023B EMX3-0043B EMX3-0050B

EMX3-0105B EMX3-0145B EMX3-0170B EMX3-0200B EMX3-0220B EMX3-0255B EMX3-0350B EMX3-0425B EMX3-0500B EMX3-0580B EMX3-0700B EMX3-0820B EMX3-0920B EMX3-1000B EMX3-0255C EMX3-0360C EMX3-0380C EMX3-0430C EMX3-0620C

192 (7.6)

156 124 295 278

(6.2) (4.9) (11.7) (11.0)

223 (8.8)

282 250 438 380 250 n/a 14.2 (31.3)

(11.2) (9.9) (17.3) (15.0) (9.9)

424 (16.7) 376 (14.9) 440 (17.4) 392 (15.5) 298 (11.8) n/a 29.4

433 320 640 600 295 n/a 63.5

(17.1) (12.6) (25.2) (23.7) (11.7)

390 (15.4) 320 (12.6) 460 (18.2) 400 (15.8) 279 (11.0) n/a 23 (50.7)

430 320 689 522 300 696

(17.0) (12.6) (27.2) (20.6) (11.9) (27.5) 39.5

574 500 856 727 361 862 128.5 (283.3)

(22.6) (19.7) (33.8) (28.7) (14.3) (34.0) 130 (286.6)

n/a

4.5 (9.9)

14.0 (30.9)

26 (57.3)

(110.2)

(140.0)

(141.1)

51.5 (113.5)

140 (308.6)

Dimension C is the height when input and output busbars are at the same end of the unit (top in/top out or bottom in/bottom out).

4.2

(9.3)

5.0

(11.0)

(33.1)

(64.8)

50.0

64.0

(79.4)

(87.1)

For UL compliant installation, input and output busbars must be at opposite ends of the unit. Dimension F applies for either top in/bottom out or bottom in/top out configuration.

84 | User Manual (710-04840-00M)

13.6 Specifications

• Supply

Mains voltage (L1, L2, L3)

EMX3-xxxx-V4 ................................................................................................................................ 200 VAC ~ 440 VAC (± 10%)

EMX3-xxxx-V7 ................................................................................................................................ 380 VAC ~ 690 VAC (± 10%)

Control voltage (A1, A2, A3)

EMX3-xxxx-xx-C1 (A1, A2) ................................................................................................ 110~210 VAC (+ 10% / -15%), 600 mA

EMX3-xxxx-xx-C1 (A2, A3) ................................................................................................ 220~440 VAC (+ 10% / -15%), 600 mA

• Short circuit capability

EMX3-xxxx-xx-C2 (A1, A3) ............................................................................................................ 24 VAC/VDC (± 20%), 100 VA

Mains frequency ............................................................................................................................................................ 45 Hz ~ 66 Hz

Rated insulation voltage to earth .......................................................................................................................................... 600 VAC

Rated impulse withstand voltage ................................................................................................................................................ 6 kV

Form designation ..................................................................... Bypassed or continuous, semiconductor motor starter form 1

Coordination with semiconductor fuses ..................................................................................................................................... Type 2

Coordination with HRC fuses ....................................................................................................................................................... Type 1

EMX3-0023B ~ EMX3-0220B ......................................................................................................... prospective current 65 kA

EMX3-0255B ~ EMX3-1000B ......................................................................................................... prospective current 85 kA

EMX3-0255C ~ EMX3-0930C ....................................................................................................... prospective current 100 kA

EMX3-1200C ~ EMX3-1600C ......................................................................................................... prospective current 85 kA

APPENDIX

• Electromagnetic capability (compliant with EU Directive 2014/35/EU)

EMC Immunity ............................................................................................................................................................. IEC 60947-4-2

EMC Emissions

EMX3-0023B to EMX3-1000B (Internally bypassed models) ............... IEC 60947-4-2 Class B and Lloyds Marine No 1

Specification EMX3-0255C to EMX3-1600C (Non-bypassed models) IEC 60947-4-2 Class A

This product has been designed as Class A equipment. Use of this product in domestic environments may cause radio

and Lloyds Marine No 1 Specification

interference, in which case the user may be required to employ additional mitigation methods.

• Inputs

Input rating ............................................................................................................................................ Active 24 VDC, 8 mA approx

Start (C23, C24) .......................................................................................................................................................... Normally Open

Stop (C31, C32) ........................................................................................................................................................ Normally Closed

Reset (C41, C42) ...................................................................................................................................................... Normally Closed

Programmable inputs

Input A (C53, C54) .............................................................................................................................................. Normally Open

Input B (C63, C64) .............................................................................................................................................. Normally Open

Motor thermistor (B4, B5) .................................................................................................................... Trip >3.6 kΩ, reset <1.6 kΩ

PT100 RTD (B6, B7, B8) .............................................. Accuracy 0 ~ 100 °C ± 0.5 °C, 100 °C ~ 150 °C ± 2 °C, -20 ~ 0 °C ± 2°C

• Outputs

Relay outputs ................................................................................................ 10 A @ 250 VAC resistive, 5A @ 250 VAC AC15 pf 0.3

Run relay (23, 24) ....................................................................................................................................................... Normally Open

Programmable outputs

Relay A (13, 14) .................................................................................................................................................. Normally Open

Relay B (31, 32, 34) .................................................................................................................................................. Changeover

Relay C (41, 42, 44) ....................................................................................................................................................... Changeover

Analog output (B10, B11) ............................................................................................................ 0-20 mA or 4-20 mA (selectable)

Maximum load ...................................................................................................................................... 600 Ω (12 VDC @ 20 mA)

Accuracy .................................................................................................................................................................................... ± 5%

24 VDC output (P24, COM)

Maximum load ..................................................................................................................................................................... 200 mA

Accuracy ............................................................................................................................................................................. ± 10%

User Manual (710-04840-00M) | 85

APPENDIX

CAUTION

• Environmental

Protection

EMX3-0023B ~ EMX3-0105B ................................................................................................................................................ IP20

EMX3-0145B ~ EMX3-1000B and EMX3-0255C ~ EMX3-1600C .................................................................................... IP00

Keypad (when installed with remote mounting kit) .................................................................................... IP65 & NEMA12

Operating temperature .............................................................................................. -10 ˚C~60 ˚C, above 40 ˚C with derating

Storage temperature ................................................................................................................................................. -25 °C~+ 60 °C

Operating Altitude ............................................................................................................. 0~1000 m, above 1000 m with derating

Humidity .................................................................................................................................................. 5%~95% Relative Humidity

Pollution degree .................................................................................................................................................. Pollution Degree 3

Vibration (EMX3-0023B ~ EMX3-1000B) ............................................................................................................... IEC 60068-2-6

• Heat Dissipation

During Start ...................................................................................................................................................... 4.5 watts per ampere

During Run

EMX3-0023B ~ EMX3-0053B ......................................................................................................................... ≤ 39 watts approx

EMX3-0076B ~ EMX3-0105B ....................................................................................................................... ≤ 51 watts approx

EMX3-0145B ~ EMX3-0220B ..................................................................................................................... ≤ 120 watts approx

EMX3-0255B ~ EMX3-0500B ......................................................................................................................... ≤ 140 watts approx

EMX3-0580B ~ EMX3-1000B ......................................................................................................................... ≤ 357 watts approx

EMX3-0255C ~ EMX3-0930C .................................................................................................... 4.5 watts per ampere approx

EMX3-1200C ~ EMX3-1600C .................................................................................................... 4.5 watts per ampere approx

• Certification

UL / C-UL ...................................................................................................................................................................................... UL 508*

EMX3-0023B ~ EMX3-0425B, EMX3-0255C ~ EMX3-1600C ..................................................................................... UL Listed

EMX3-0500B ~ EMX3-1000B ................................................................................................................................ UL Recognised

EMX3-0023B ~ EMX3-0105B ................................................................................................. IP20 & NEMA1, UL Indoor Type 1

EMX3-0145B ~ EMX3-1600C ........................................................................................................ IP00, UL Indoor Open Type

....................................................................................................................... IP20, when fitted with optional finger guard kit

CE ...................................................................................................................................................................................... EN 60947-4-2

CCC ....................................................................................................................................................................................... GB 14048.6

RCM ............................................................................................................................................................................. IEC 60947-4-2

Marine (EMX3-0023B ~ EMX3-1000B, internally bypassed models only) ............................................................................................

Lloyds ................................................................................................................................... Lloyds Marine No 1 Specification

ABS .................................................................................................................................................... Steel Vessels Rules 2010

RoHS ................................................................................................................................ Compliant with EU Directive 2011/65/EU

* For UL certification additional requirements may apply, depending on the models. For details, refer to

Installation

on page 87.

• Operational life (internal bypass contacts)

EMX3-0023B ~ EMX3-0105B ................................................................................................................................. 1,000,000 operations

EMX3-0145B ~ EMX3-1000B .................................................................................................................................... 100,000 operations

EMX3-0220B~EMX3-1000B: The contacts on the internal bypass contactors should be checked for wear after the stated number of operations. Periodic servicing/replacements may be required.

UL Compliant

86 | User Manual (710-04840-00M)

13.7 UL Compliant Installation

Models

FLC (A)

No. of wires

Recommended lugs part No.

EMX3-0200B

200

OPHD 150-16

EMX3-0220B

220

OPHD 185-16

EMX3-0425B

425

OPHD 185-16

EMX3-0380C

380

EMX3-0790C

790

2 x 600T-2

EMX3-1410C

1410

1 x 750T-4

APPENDIX

This section details additional requirements and configuration settings for the EMX3 to be UL-compliant. Refer to also

Selection and Short Circuit Ratings

on page 19.

UL Fuse

• Models EMX3-0023B ~ EMX3-0105B

There is no additional requirement for these models.

• Models EMX3-0145B ~ EMX3-0425B, EMX3-0255C ~ EMX3-1600C

Use the recommended pressure terminal/connector kit. Refer to

Terminal/Connector Parts

on page 87 for more information.

• Models EMX3-0500B ~ EMX3-1000B

These models are UL recognised components. Separate cable landing busbars may be required within the electrical cabinet when terminating cables sized according to the National Wiring Code (NEC) regulations.

• Terminal/Connector Parts

For models EMX3-0145B~EMX3-0425B and EMX3-0255C~EMX3-1600C to be UL compliant, you must use the recommended pressure terminal/connector as detailed in the table below.

EMX3-0145B 145 1 OPHD 95-16 EMX3-0170B 170 1 OPHD 120-16

EMX3-0255B 255 1 OPHD 240-20 EMX3-0350B 350 1 OPHD 400-16

EMX3-0255C 255 1 OPHD 240-20 EMX3-0360C 360

EMX3-0430C 430

2 1 x 600T-2 EMX3-0620C 620 EMX3-0650C 650

EMX3-0930C 930 3 2 x 600T-2 EMX3-1200C 1200

4 1 x 750T-4

EMX3-1600C 1600 5

13.8 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.

1 x 600T-3

User Manual (710-04840-00M) | 87

APPENDIX

NOTE

13.9 Accessories

Communication Interfaces

EMX3 soft starters support network communication via easy-to-install communications interfaces. Each soft starter can support one communications interface at a time.

Available protocols: Ethernet (Profinet, Modbus TCP, Ethernet/IP), Profibus, DeviceNet, Modbus RTU, and USB.

Expansion Cards

The EMX3 offers expansion cards for users requiring additional inputs and outputs or advanced functionality. Each EMX3 can support a maximum of one expansion card.

• Input/Output

The input/output expansion card provides the following additional inputs and outputs:

• 2 x digital inputs

• 3 x output relays

• 1 x analog input

• 1 x analog output

• RTD/Ground Fault

The RTD/PT100 and ground fault protection card provides the following additional inputs:

• 6 x PT100 RTD inputs

• 1 x ground fault input

To use ground fault protection a 1000:1, 5 VA current transformer is also required.

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 correctly installed.

Finger guards can be used on soft starter models EMX3-0145B~EMX3-1000B (internally bypassed models only).

Different kits are required for different models.

Keypad Mounting Kit

The keypad mounting kit allows remote mounting of the keypad up to 3 m away from the soft starter. Different kits are available with two or three metre cables.

PC Software

WinMaster PC software provides monitoring, programming and control of up to 99 soft starters. A Modbus or USB communication module is required for each starter to use WinMaster.

88 | User Manual (710-04840-00M)

13.10 Parameter Values

Motor Data-1

User Set 1

User Set 2

Locked Rotor Time

Locked Rotor Current

Start/Stop Modes-1

Initial Current

Kickstart Time

Kickstart Level

Adaptive Stop Profile

Adaptive Control Gain

Auto-Start/Stop

Auto-Start Time

Protection Settings

Excess Start Time-2

Undercurrent

Instantaneous Overcurrent Delay

Phase Sequence

Frequency Check

Restart Delay

Motor Temperature Check

Reserved

Auto-Reset Trips

Auto-Reset Action

Maximum Resets

If you require assistance from your supplier or a service technician, please note all parameter settings in the table below.

APPENDIX

2A 2B

2D 2E

2H 2I

2L 2M

Motor Full Load Current

Motor Service Factor

Start Mode Start Ramp Time

Current Limit Adaptive Start Profile

Stop Mode Stop Time

Brake Torque Brake Time

Auto-Start Type

3C 3D

4D 4E

4H 4I

4K 4L

4O 4P

Auto-Stop Type Auto-Stop Time

Excess Start Time

Undercurrent Delay Instantaneous Overcurrent

Current Imbalance Current Imbalance Delay

Frequency Variation Frequency Delay

Ground Fault Level Ground Fault Delay

4S 4T

Reserved Reserved

User Manual (710-04840-00M) | 89

APPENDIX

Inputs

Input A Name

Input A Initial Delay

Input B Function

Input B Trip Delay

Remote Reset Logic

Analog Trip Point

Local/Remote

Outputs

Relay A Off Delay

Relay B Off Delay

Relay C Function

Relay D Function

Relay E Function

High Current Flag

Analog A Scale

Analog A Maximum Adjustment

Analog B Scale

Analog B Maximum Adjustment

Display

F2 Button Action

5C 5D

6C 6D

6G 6H

6J 6K 6L

6N 6O

Reset Delay Groups A&B Reset Delay Group C

Input A Function

Input A Trip Input A Trip Delay

Input B Name Input B Trip

Input B Initial Delay Input C Function Input D Function

Analog Input Trip Analog Input Scale

7A 7B

7D 7E

7H 7I

7L 7M

7O 7P

Comms in Remote

Relay A Function Relay A On Delay

Relay B Function Relay B On Delay

Relay C On Delay Relay C Off Delay

Relay F Function Low Current Flag

Motor Temperature Flag Analog Output A

7S 7T

8A 8B

8D 8E

Analog A Minimum Adjustment Analog Output B

Analog B Minimum Adjustment

Language F1 Button Action

Display A or kW User Screen - Top Left

90 | User Manual (710-04840-00M)

APPENDIX

User Screen - Bottom Right

Graph Minimum Adjustment

Voltage Calibration

9 Motor Data-2

Dual Thermal Model

Motor Service Factor-2

Start/Stop Modes-2

10A

Start Mode-2

10D

Current Limit-2

10E

Adaptive Start Profile-2

10H

Stop Mode-2

10K

Adaptive Control Gain-2

10L

Brake Torque-2

RTD Temperatures

11C

RTD/PT100 C °C

11G

RTD/PT100 G °C

Slip-Ring Motors

12A

Motor Data-1 Ramp

12D

Slip Ring Retard

Advanced

15A

Access Code

15B

Adjustment Lock

Protection Action

16B

Excess Start Time

8F 8G

8I 8J 8K

8M 8N

9B 9C 9D

10B 10C

User Screen - Top Right User Screen - Bottom Left

Graph Data Graph Timebase Graph Maximum Adjustment

Current Calibration Mains Reference Voltage

Motor FLC-2 Locked Rotor Time-2 Locked Rotor Current-2

Start Ramp-2 Initial Current-2

10F 10G

10I 10J

10M

11A 11B

11D 11E 11F

12B 12C

Kickstart Time-2 Kickstart Level-2

Stop Time-2 Adaptive Stop Profile-2

Brake Time-2

RTD/PT100 A °C RTD/PT100 B °C

RTD/PT100 D °C RTD/PT100 E °C RTD/PT100 F °C

Motor Data-2 Ramp Changeover Time

15C 15D

16A

Emergency Run Shorted SCR Action

Motor Overload

User Manual (710-04840-00M) | 91

APPENDIX

16E

Current Imbalance

16I

Motor Thermistor

16L

Heatsink Overtemperature

16M

Battery/Clock

16P

RTD/PT100 B

16T

RTD/PT100 F

16W

Reserved

16X

Low Control Volts

Restricted

16C 16D

16F 16G 16H

16J 16K

16N 16O

16Q 16R 16S

16U 16V

Undercurrent Instantaneous Overcurrent

Frequency Input A Trip Input B Trip

Starter Communication Network Communication

Ground Fault RTD/PT100 A

RTD/PT100 C RTD/PT100 D RTD/PT100 E

RTD/PT100 G Reserved

92 | User Manual (710-04840-00M)

BUSBAR ADJUSTMENT PROCEDURE

NOTE Many electronic components are sensitive to static electricity. Voltages so low that they cannot be felt, seen or heard, can

08604.A

Remove the keypad faceplate, then gently remove the keypad

NOTE

08605.A

08606.A

14. Busbar Adjustment Procedure

The busbars on non-bypassed models EMX3-0360C ~ EMX3-1600C can be adjusted for top or bottom input and output as required.

reduce the life, affect performance, or completely destroy sensitive electronic components. When performing service,

All units are manufactured with input and output busbars at the bottom of the unit as standard. The input and/or output busbars can be moved to the top of the unit if required.

proper ESD equipment should be used to prevent possible damage from occurring.

1. Remove all wiring and links from the soft starter before dismantling the unit.

2. Remove the unit cover (4 screws).

3. (2 screws).

4. Remove the control terminal plugs.

5. Gently fold the main plastic away from the starter (12 screws).

6. Unplug the keypad loom from CON 1 (see note).

7. Label each SCR firing loom with the number of the corresponding terminal on the backplane PCB, then unplug the looms.

8. Unplug the thermistor, fan and current transformer wires from the model board.

9. Remove the plastic tray from the starter (four screws).

Remove the main plastic slowly to avoid damaging the keypad wiring loom which runs between the main plastic and the backplane PCB.

10. Unscrew and remove the magnetic bypass plates (models EMX3-0620C to EMX3-1600C only).

11. Remove the current transformer assembly (three screws).

12. Identify which busbars are to be moved. Remove the bolts holding these busbars in place then slide the busbars out through the bottom of the starter (four bolts per busbar).

13. Slide the busbars in through the top of the starter. For input busbars, the short curved end should be outside the starter. For output busbars, the unthreaded hole should be outside the starter.

14. Replace the dome washers with the flat face towards the busbar, then tighten the bolts holding the busbars in place to 20 Nm.

15. Place the current transformer assembly over the input busbars and screw the assembly to the body of the starter (see note).

16. Run all wiring to the side of the starter and secure with cable ties.

User Manual (710-04840-00M) | 93

BUSBAR ADJUSTMENT PROCEDURE

NOTE

If moving the input busbars, the current transformers (CTs) must also be reconfigured.

1. Label the CTs L1, L2 and L3 (L1 is leftmost when looking from the front of the starter). Remove the cable ties and unscrew the CTs from the bracket.

2. Move the CT bracket to the top of the starter. Position the CTs for the correct phases, then screw the CTs to the bracket. For models EMX3-0360C ~ EMX3-0930C, the CTs must be placed on an angle (the left hand legs of each CT will be on the top row of holes and the right hand legs will be on the bottom tabs).

94 | User Manual (710-04840-00M)

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AuCom EMX3-1600C, EMX3-0360C, EMX3-0105B, EMX3-0145B, EMX3-0255B User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1. About This Manual

1.1 Disclaimer

2. Caution Statements

2.1 Electrical shock risk

2.2 Unexpected Operation

2.3 Avertissements à l'attention des clients canadiens

3. Introduction

3.1 Feature List

4. Basic Setup

4.1 Setup Procedure Overview

4.2 Testing the Installation

4.3 Simulation Tools

5. Installation

5.1 Physical Installation

5.2 Control Terminals

5.3 Control Voltage

5.4 Control Wiring

5.5 Relay Outputs

5.6 Motor Thermistors

5.7 RTD/PT100

5.8 Earth Terminals

5.9 Power Input and Output Configurations

Internally Bypassed Models (EMX3-0023B~EMX3-1000B)

Non-bypassed Model - EMX3-0255C

Non-bypassed Models (EMX3-0360C~EMX3-1600C)

5.10 Power Terminations

5.11 Schematic Diagrams

6. Power Circuits

6.1 Motor Connection

In-line installation, internally bypassed

In-line installation, externally bypassed

In-line installation, non-bypassed

Inside delta installation, internally bypassed

Inside delta installation, externally bypassed

Inside delta installation, non-bypassed

6.2 Bypass Contactor

6.3 Main Contactor

6.4 Circuit Breaker

6.5 Power Factor Correction

6.6 Short Circuit Protection Devices (SCPD)

Type 1 Coordination

Type 2 Coordination

6.7 UL Short Circuit Ratings

Fuse selection

Circuit breaker selection

6.8 Fuse Selection for Type 2 Coordination

7. Keypad and Feedback

7.1 The Keypad

Starter Status LEDs

Removing and Replacing the Keypad

7.2 Displays

Starter Status

Programmable screen

Motor Temperature

Current

Motor Power

Last Start Information

Date and Time

Performance Graph

SCR Conduction Bargraph

8. Maintenance Tools

8.1 Testing the Installation

8.2 Commissioning Menu (Tools)

Set Date and Time

Simulation Tools

Run Simulation

Protection Simulation

Output Signal Simulation

Analog Output Simulation

Temperature Sensors State

Digital I/O State

Analog I/O State

Reset Thermal Models

8.3 Logs Menu

Trip Log

Event Log