Nidec Digistart D4 User Manual
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Nidec Digistart D4 User Manual

Digital soft starter 24 a - 580 a 200-525 vac, 380-600 vac
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User Guide:
Digital soft starter
Digistart D4
24 A - 580 A
200-525 VAC, 380-600 VAC
Reference: 6051 en - 2021.10 / a

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Summary of Contents for Nidec Digistart D4

  • Page 1 User Guide: Digital soft starter Digistart D4 24 A - 580 A 200-525 VAC, 380-600 VAC Reference: 6051 en - 2021.10 / a...
  • Page 2 Product Compatibility This user manual is suitable for use with Digistart D4 soft starters version 7 (user interface software 3.x and motor control code 3.x). The software versions screen reports the version of each software component in the starter. For other versions, please contact your local supplier.

  • Page 3: Table Of Contents

    Contents About This Manual ......................3 Disclaimer ........................... 3 Caution Statements ......................4 Electrical shock risk ......................4 Unexpected Operation ......................4 Avertissements à l'attention des clients canadiens .............. 5 System Design ........................7 Feature List ......................... 7 Model Code ......................... 7 Model Selection ........................
  • Page 4 Counters..........................32 QR Code ........................... 32 Keypad and Feedback ..................... 33 The Keypad ........................33 Remote Keypad ......................... 33 Lighten/Darken the Display ....................34 Starter status LEDs ......................34 Displays..........................34 Operation ......................... 36 Start, Stop and Reset Commands ..................36 Command Override ......................

  • Page 5: About This Manual

    About This Manual About This Manual WARNING Indicates a hazard that may cause personal injury or death. CAUTION Indicates a hazard that may damage the equipment or installation. NOTE Provides helpful information. 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.

  • Page 6: Caution Statements

    Caution Statements 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.

  • Page 7: Avertissements À L'attention Des Clients Canadiens

    Caution Statements WARNING – STARTER MAY START OR STOP UNEXPECTEDLY The soft starter will respond to control commands from various sources, and could start or stop unexpectedly. Always disconnect the soft starter from mains voltage before accessing the starter or load. WARNING –...
  • Page 8 Caution Statements AVERTISSEMENT – DÉMARRAGES ACCIDENTELS Dans certaines installations, des démarrages accidentels peuvent provoquer un risque supplémentaire pour la sécurité des personnes ou endommager les machines contrôlées. Dans de tels cas, il est recommandé de doter l'alimentation du démarreur progressif d'un interrupteur d'isolement et d'un coupe-circuit (par exemple, un disjoncteur) contrôlable à...

  • Page 9: System Design

    System Design System Design Feature List Streamlined setup process Customisable protection • Configuration profiles for common • Motor overload applications • Excess Start Time • Built-in metering and inputs/outputs • Undercurrent • Overcurrent Easy to understand interface • Current imbalance •...

  • Page 10: Model Selection

    System Design Model Selection Starter sizing The soft starter must be the correct size for the motor and the application. Select a soft starter that has a current rating at least equal to the motor's full load current (nameplate) rating, at the start duty. The soft starter's current rating determines the maximum motor size it can be used with.
  • Page 11 System Design NEMA motor ratings All ratings are calculated at altitude of 1000 metres and ambient temperature of 50 ºC. Light Normal Heavy 300%, 10 s, 350%, 30 s, 450%, 30 s, 6 starts per hour 4 starts per hour 4 starts per hour @240 @480...

  • Page 12: Dimensions And Weights

    System Design Dimensions and Weights B4 B5 10 11 12 13 14 15 21 22 33 34 41 42 44 53 54 B4 B5 10 B4 B5 10 11 12 13 14 15 21 22 11 12 13 14 15 21 22 33 34 41 42 44 53 54 33 34 41 42 44 53 54 A3 A1 A2...

  • Page 13: Physical Installation

    System Design Physical Installation 2/T1 4/T2 6/T3 B4 B5 10 1 1 12 13 14 15 21 22 33 34 41 42 44 53 54 B4 B5 10 1 1 12 13 14 15 21 22 33 34 41 42 44 53 54 B4 B5 10 1 1 12 13 14 15 21 22 33 34 41 42 44 53 54 B4 B5 10 1 1 12 13 14 15 21 22...

  • Page 14: Main Contactor Or Circuit Breaker

    System Design Soft Starter Management Software PC software can provide real-time or offline management of soft starters. • For real-time management in a network of up to 254 starters, the software must connect to the soft starter via a Modbus TCP or Modbus RTU card. The software can monitor, control and program the starter across the network.

  • Page 15: Short Circuit Protection Devices (Scpd)

    System Design 3.10 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.

  • Page 16: Ul Coordination With Short Circuit Protection Devices

    System Design 3.12 UL Coordination with Short Circuit Protection Devices Standard Fault Short Circuit Current Ratings Suitable for use on a circuit capable of delivering not more than the stated level of amperes (symmetrical rms, refer ##1 in table), 600 VAC maximum. Maximum fuse rating (A) –...
  • Page 17 System Design Listed fuse rating Short Circuit Fuse class Nominal Rating @ 480 Model Rating (A) VAC max. 0184B 0200B J, T 0229B 0250B 0352B 65 kA 0397B 0410B (J, T, K-1, 0550B RK1, RK5) 0580B • Circuit breakers – High fault short circuit current Suitable for use on a circuit capable of delivering not more than 65,000 rms symmetrical amperes, 480 VAC maximum, when protected by circuit breaker models noted in ##4, ##5 or ##6.

  • Page 18: Fuse Selection For Type 2 Coordination

    System Design 3.13 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 t less than the I t of the soft starter SCRs.

  • Page 19: Disposal Instructions

    System Design Inputs Input rating ................Active 24 VDC, 8 mA approx Motor thermistor (B4, B5) ............Trip >3.6 kΩ, reset <1.6 kΩ Outputs Relay outputs ......10 A @ 250 VAC resistive, 5A @ 250 VAC AC15 pf 0.3 Main contactor/Shunt relay (33, 34) ...........

  • Page 20: Installation

    Installation Installation WARNING Do not apply mains voltage to the starter until all wiring is complete. WARNING Always apply control voltage before (or with) mains voltage. Command Source The soft starter can be started and stopped via the digital inputs, remote keypad, communication network or smart card.

  • Page 21: Inputs

    Installation Inputs CAUTION The control inputs are powered by the soft starter. Do not apply external voltage to the control input terminals. NOTE Cables to the control inputs must be segregated from mains voltage and motor cabling. Input terminals B4 B5 10 11 12 13 14 15 21 22 B4 B5 10 11 12 13 14 15 21 22 33 34 41 42 44 53 54...
  • Page 22 Installation Reset/Starter Disable The reset input (10, 11) is normally closed by default. The soft starter will not perform a start if the reset input is open. The display will show "Not Ready". If the reset input opens while the soft starter is running, the starter will remove power and allow the motor to coast to stop.

  • Page 23: Outputs

    Installation Outputs Output terminals B4 B5 10 11 12 13 14 15 21 22 B4 B5 10 11 12 13 14 15 21 22 33 34 41 42 44 53 54 33 34 41 42 44 53 54 A3 A1 A2 1/L1 3/L2 5/L3...

  • Page 24: Control Voltage

    Installation Soft starter installed with main contactor Soft starter installed with a shunt relay and circuit breaker 1/L1 2/T1 1/L1 2/T1 3/L2 4/T2 3/L2 4/T2 5/L3 6/T3 5/L3 6/T3 F1 Fuses Q1 Circuit breaker K1 Main contactor CAUTION Some electronic contactor coils are not suitable for direct switching with PCB mount relays.

  • Page 25: Power Terminations

    Installation Power Terminations The power input and output terminals are at the bottom of the unit. • Models 0024B~0135B use cage clamps. Use only copper stranded or solid conductors, rated for 75 ºC or higher. • Models 0184B~0580B use busbars. Use copper or aluminium conductors, stranded or solid, rated for 60 ºC/75 ºC.
  • Page 26 Installation Motor Connection The soft starter must be connected to the motor in-line (also called three-wire connection). 1/L1 2/T1 3/L2 4/T2 5/L3 6/T3 Main contactor (strongly recommended) Fuses or circuit breaker 33, 34 Main contactor output...

  • Page 27: Typical Installation

    Installation Typical installation The soft starter 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 main contactor output (33, 34). 1/L1 2/T1 3/L2 4/T2 5/L3...

  • Page 28: Quick Setup

    Installation Quick Setup The Quick Setup Menu makes it easy to configure the soft starter for common applications. The soft starter guides you through the most common installation parameters, and suggests a typical setting for the application. You can adjust each parameter to suit your exact requirements.

  • Page 29: Setup Tools

    Setup Tools Setup Tools Setup Tools includes options to load or save parameters to a backup file, set the starter's network address, check the status of the inputs and outputs, reset the thermal models or test operation using the Run Simulation. To access the Setup Tools, press MENU to open the Menu then select Setup Tools.

  • Page 30: Load/Save Settings

    Setup Tools Run Simulation 6. Apply a stop command from the selected command Stopping X:XXs source. The soft starter simulates stopping. The Run MENU to Continue LED flashes. Run Simulation 7. Press . The Ready LED flashes and the main Stopped contactor relay opens.

  • Page 31: Network Address

    Setup Tools USB Save & Load 3. Scroll to USB Save & Load and press the button. Save Params and Logs 4. Scroll to the required function and press the button. Save Master Params Load Master Params Save Params and Logs 5.

  • Page 32: Digital I/O State

    Setup Tools When the action has been completed, the screen will briefly display a confirmation message, then return to the previous menu level. NOTE The network address can also be set using parameters 12H~12S. NOTE To configure the soft starter for use with other communication protocols, use parameters 12A~12G.

  • Page 33: Software Versions

    Setup Tools 5.10 Software Versions The software versions screen reports the version of each software component in the starter: • user interface • motor control • remote keypad (if connected) • parameter list • bootloader • expansion card (if fitted) NOTE Updated software, including alternative languages, can be loaded into the starter via the USB port if required.

  • Page 34: Logs

    Logs Logs The Logs Menu provides information on events, trips and starter performance. To access the Logs Menu on the local keypad, press MENU to open the Menu then select Logs. On the remote keypad, press LOGS. Event Log The Event Log stores details of the starter's most recent trips, warnings, and operations (including starts, stops and configuration changes).

  • Page 35: Keypad And Feedback

    Keypad and Feedback Keypad and Feedback The Keypad Local keypad Remote keypad (if installed) Ready Trip Local Four-line display for status and programming details. Status LEDs Menu navigation buttons: : Exit the menu or parameter, or cancel a parameter change. On the local keypad, this button also resets a trip.

  • Page 36: Lighten/Darken The Display

    Keypad and Feedback NOTE If parameter 1A Command Source is set to Remote Keypad, removing the remote keypad will cause a trip. Lighten/Darken the Display The backlight on the display can be adjusted: • to lighten the display, hold down the button and press the •...
  • Page 37 Keypad and Feedback Starter status screen 69.0 A Motor running current Running Starter status 69.0 A 415 V Parameter 10H User Parameter 1 and parameter 10I User Parameter 2 Current The current screen shows real-time line current on each phase. Phase Currents 000.0A 000.0A...

  • Page 38: Operation

    Operation Operation Start, Stop and Reset Commands The soft starter can be started and stopped via the digital inputs, remote keypad, communication network or smart card. The command source can be set via the Setup Tools, or using parameter 1A Command Source. •...

  • Page 39: Typical Control Methods

    Operation • Parameter 7D Input A Initial Delay: sets a delay before the soft starter monitors the state of the input, after the start signal. For example, a delay may be required to allow time for pipeline pressure to build up. •...

  • Page 40: Soft Start Methods

    Operation Application Start Mode Stop Mode Constant Fan - high pressure Coast To Stop Current Constant Mill - ball Coast To Stop Current Constant Mill - hammer Coast To Stop Current Adaptive Adaptive Pump - bore Control Control (Const. accel.) (Const.
  • Page 41 Operation Constant Current with 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: •...

  • Page 42: Stop Methods

    Operation 1: Initial Current (parameter 2C) 2: Current Limit (parameter 2D) 3: Start Ramp Time (parameter 2B) 4: Full voltage 5: Motor 1 current 6: Motor 2 current Time Adaptive Control for Starting In an adaptive control soft start, the soft starter adjusts the current in order to start the motor within a specified time.
  • Page 43 Operation Timed Voltage Ramp Soft Stop Timed voltage ramp stopping reduces the voltage to the motor gradually over a defined time. This can extend the stopping time of the motor and may avoid transients on generator set supplies. NOTE The load may continue to run after the stop ramp is complete. 1: Stop Time (parameter 2G) Time Adaptive Control for Stopping...

  • Page 44: Programmable Parameters

    Programmable Parameters Programmable Parameters Main Menu The main menu lets you view and change programmable parameters that control how the soft starter operates. To open the main menu, press the MENU/ENTER button then scroll to Main Menu and press MENU/ENTER again. NOTE Parameters for smart card functions are only visible in the parameter list if the smart card is installed.
  • Page 45 Programmable Parameters Parameter Group Default Setting Stop Time 00:00 (mm:ss) Constant Deceleration Adaptive Stop Profile Adaptive Control Gain Multi Pump Single Pump Start Delay 00:00 (mm:ss) Protection Levels Current Imbalance Current Imbalance Delay 00:03 (mm:ss) Undercurrent Undercurrent Delay 00:05 (mm:ss) 400% Overcurrent Overcurrent Delay...
  • Page 46 Programmable Parameters Parameter Group Default Setting Input A Name Input A Trip Input B Trip Input B Name Relay Outputs Relay A Function Relay A On Delay 00:00 (mm:ss) Relay A Off Delay 00:00 (mm:ss) Relay B Function Relay B On Delay 00:00 (mm:ss) Relay B Off Delay 00:00 (mm:ss)
  • Page 47 Programmable Parameters Parameter Group Default Setting Gateway Address 2 Gateway Address 3 Gateway Address 4 IP Address IP Address 2 IP Address 3 IP Address 4 Subnet Mask Subnet Mask 2 Subnet Mask 3 Subnet Mask 4 DHCP Disable Location ID Advanced Tracking Gain Pedestal Detect...
  • Page 48 Programmable Parameters Parameter Group Default Setting Flow Response Delay 00:00:500 (mm:ss:ms) Pressure Protection High Pressure Trip Level High Pressure Start Delay 00:00:500 (mm:ss:ms) High Pressure Response Delay 00:00:500 (mm:ss:ms) Low Pressure Trip Level Low Pressure Start Delay 00:00:500 (mm:ss:ms) Low Pressure Response Delay 00:00:500 (mm:ss:ms) Pressure Control Pressure Control Mode...

  • Page 49: Motor Details

    Programmable Parameters 1 Motor Details 1A – Command Source Digital Input (default) The soft starter will accept start and stop commands Options: from the digital inputs. Network The soft starter will accept start and stop commands from the communication expansion card. Remote Keypad The soft starter will accept start and stop commands from the Remote Keypad.
  • Page 50 Programmable Parameters 2B – Start Ramp Time Range: 0:01 - 3:00 (minutes:seconds) Default: 10 seconds Description: 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). 2C –...

  • Page 51: Protection Levels

    Programmable Parameters 2J – Multi Pump Options: Single Pump (default) Manifold Pump Description: Adjusts the performance of adaptive control to suit installations with multiple pumps connected to a common outlet manifold. 2K – Start Delay Range: 0:00 - 60:00 (minutes:seconds) Default: 0 second Description: Sets a delay after the starter receives a start command, before it starts the...

  • Page 52: Protection Action

    Programmable Parameters 5H – Restart Delay Range: 00:01 - 60:00 (minutes:seconds) Default: 10 seconds Description: The soft starter 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.
  • Page 53 Programmable Parameters Log Only The protection will be written to the event log but the soft starter will continue to operate. Trip + Shunt Relay The soft starter will remove power and the motor will coast to stop. The shunt trip relay (33, 34) will activate and the circuit breaker will disconnect mains voltage from the soft starter.
  • Page 54 Programmable Parameters 6I – Network Communications Options: Soft Trip and Log (default) Warn and Log Soft Trip and Reset Log Only Trip Starter Stop Trip and Reset Trip + Shunt Relay Description: Selects the soft starter's response to the protection event. If set to Stop, the soft starter will perform a soft stop, then can be restarted without a reset.

  • Page 55: Inputs

    Programmable Parameters 7 Inputs 7A – Input A Function Command Override: Overrides the setting of 1A and sets the command Options: Network source to the communications network. Command Override: Overrides the setting of 1A and sets the command Digital source to the digital inputs. Command Override: Overrides the setting of 1A and sets the command Keypad...
  • Page 56 Programmable Parameters 7G – Input B Trip Delay Range: 0:00 - 4:00 (minutes:seconds) Default: 0 second Description: Sets a delay between the input activating and the soft starter tripping. 7H – Input B Initial Delay Range: 00:00 - 30:00 (minutes:seconds) Default: 0 second Description: Sets a delay before an input trip can occur.

  • Page 57: Relay Outputs

    Programmable Parameters 9.10 8 Relay Outputs 8A – Relay A Function Options: Relay A is not used. Ready The relay is closed when the starter is in Ready state. Run (default) 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...

  • Page 58: Analog Output

    Programmable Parameters 8G – Low Current Flag The soft starter 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.

  • Page 59: Display

    Programmable Parameters 9C – Analog A Maximum Adjustment Range: 0% - 600% Default: 100% Description: Calibrates the upper limit of the analog output to match the signal measured on an external current measuring device. 9D – Analog A Minimum Adjustment Range: Default: 0% - 600%...
  • Page 60 Programmable Parameters 10G – Adjustment Lock Read & Write Allows users to alter parameter values in the main Options: (default) menu. Read Only Prevents users altering parameter values in the main menu. Parameter values can still be viewed. Description: Selects whether the keypad will allow parameters to be changed via the main menu.

  • Page 61: Communications Card

    Programmable Parameters 10J – User Parameter 3 Options: See parameter 10H User Parameter 1 for details. Default: Motor pf Description: Selects which information will be displayed on the programmable monitoring screen. See parameter 10H User Parameter 1 for details. 10K – User Parameter 4 Options: See parameter 10H User Parameter 1 for details.
  • Page 62 Programmable Parameters 12E – Devicenet Address Range: 0 - 63 Default: Description: Sets the DeviceNet network address for the soft starter. 12F – Devicenet Baud Rate Options: 125 kB (default) 250 kB 500 kB Description: Selects the baud rate for DeviceNet communications. 12G –...
  • Page 63 Programmable Parameters 12O – IP Address 4 Range: 0 - 255 Default: Description: Sets the fourth component of the soft starter's IP address, for Ethernet communications. NOTE The network address can also be set via the Network Address options in the Setup Tools.

  • Page 64: Advanced

    Programmable Parameters 9.14 20 Advanced 20A – Tracking Gain Range: 1% - 200% Default: Description: Fine-tunes the behaviour of the adaptive control algorithm. 20B – Pedestal Detect Range: 0% - 200% Default: Description: Adjusts the behaviour of the adaptive control algorithm for soft stop. 20C –...

  • Page 65: Smart Card Parameters

    Programmable Parameters 20G – Shunt Trip Mode Options: Disable (default) Enable Description: Reconfigures the soft starter's main contactor output (33, 34) for use as a shunt trip relay. When the soft starter trips on selected conditions, the relay will activate and the shunt trip will trigger the circuit breaker and disconnect mains voltage from the soft starter.

  • Page 66: Troubleshooting

    Troubleshooting Troubleshooting 10.1 Protection Responses When a protection condition is detected, the soft starter 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 6). Some protection responses cannot be adjusted by the user.
  • Page 67 Troubleshooting Display Possible cause/Suggested solution Excess start time Excess start time trip can occur in the following conditions: • parameter 1B Motor Full Load Current is not appropriate for the motor • parameter 2D Current Limit has been set too low •...
  • Page 68 Troubleshooting Display Possible cause/Suggested solution Internal fault x Where 'X' is a number. This trip is not adjustable. The soft starter has tripped on an internal fault. Contact your local supplier with the fault code (X). Internal fault 88 The soft starter firmware does not match the hardware. Keypad Parameter 1A Command Source is set to Remote Keypad but the disconnected...
  • Page 69 Troubleshooting Display Possible cause/Suggested solution Motor connection This trip is not adjustable. • Ensure the motor is connected to terminals T1, T2, T3 using in-line (three wire) connection. The soft starter does not support inside delta (six wire) connection. • If the soft starter is connected to a grounded delta mains supply, the starter may incorrectly detect the motor configuration.
  • Page 70 Troubleshooting Display Possible cause/Suggested solution Not ready The reset input may be active. If the reset input is active, the • starter will not operate. • The soft starter may be waiting for the restart delay to elapse. The length of the restart delay is controlled by parameter 5H Restart Delay.

  • Page 71: General Faults

    Troubleshooting Display Possible cause/Suggested solution The temperature of the SCRs, calculated by the thermal model, is too overtemperature high to allow further operation. Wait for the starter to cool. Related parameters: None Starter There is a problem with the connection between the soft starter and communication the optional expansion card.
  • Page 72 Troubleshooting Symptom Probable Cause The soft starter does not The soft starter will only accept commands from the inputs • respond to commands from if parameter 1A Command Source is set to Digital Input. the control inputs. Check the setting of 1A. •...
  • Page 73 Troubleshooting Symptom Probable Cause 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.
  • Page 76 È710-23084-00A5ËÍ 7 1 0 - 2 3 0 8 4 - 0 0 A...

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