gemstart 5 - vol 1 - user guide

8/9/2019 Gemstart 5 - Vol 1 - User Guide

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Gemstart 5

Volume 1 - Users

Guide

276192-111 Rev. G

Publication date : October 2011


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Volume 1 Users Guide

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Foreword

This Technical Handbook provides the User with the information necessary to Install,Commission, Operate, Maintain and Test the equipment (as applicable). It is essential thatany Operator(s) reads and understands the content of this Technical Handbook andfollows the instructions contained within.

Every care has been taken to ensure the accuracy of the contents at the date of publication.

If the use of this equipment introduces new technology to your Operators, product training isavailable from COMECA EBT to assist you in complying with relevant Health and SafetyRegulations.

Should you require further guidance or information regarding this equipment, or informationon our After Sales Services available, please contact our Customer Services Department atthe address below who will be pleased to assist:

COMECA Equipements Basse Tension

Route de Givry

ZI La Garenne

F71880 Chtenoy-le-Royal

France

Tel.: +33 (0)3 85 98 22 00

Fax: +33 (0)3 85 98 22 01

Web: www.gemstart.fr

Our policy is one of continuous product development. We reserve the right to supplyequipment that may vary from that described.

The information contained within this Technical Handbook may not be reproduced or passedon to third parties, either wholly or in part, without the express prior written consent ofCOMECA EBT.

Gemstart5 declarations of conformity are available on the internet site or on demand.


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Health and Safety

The User shall ensure that only qualified and authorised Operators, trained in the tasks to beundertaken, are allowed to work on the equipment. All work must be performed inaccordance with local and national Health and Safety Regulations.

All relevant Warnings and Cautions shall be noted and their content strictly adhered toduring the Installation, Commissioning, Operation, Maintenance and Testing (whereapplicable) of this equipment.

This equipment uses, or controls, fatal voltages. It is recommended therefore that Operatorsworking with, or near to, the equipment should be trained in resuscitation techniques.

The User has a duty of care to ensure that the equipment and/or its individual componentsare disposed of in accordance with local and national Environmental Legislation andRegulations. Some components may present a particular hazard to the environment if notdisposed of correctly.

The equipment must not be modified without prior consultation with COMECA EBT.Modification without COMECAs consent may invalidate the warranty and any productliability.

Should the Operator/User require any guidance or advice regarding the equipment, this canbe obtained by contacting COMECA EBT at the address below:


Route de Givry

ZI La Garenne


France

Tel.: +33 (0)3 85 98 22 00

Fax: +33 (0)3 85 98 22 01



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Customer Services

COMECAs Customer Services Department can provide continuous Customer supportthroughout the lifetime of your equipment. A comprehensive range of services is available,including:

Installation and commissioning

Spare parts supply

Service and maintenance

Equipment repair

Refurbishment and modification

Engineering services

Training

COMECAs specialised Customer Service Engineers are available to provide the serviceslisted above, either in our workshop, or alternatively, at your site.

To assist us in providing an efficient and timely service, before contacting COMECA EBT todiscuss existing equipment, please help us by having the following information available:

The original COMECA EBT works order number or the unit serial number and the unit typeand voltage rating.

When you have the information listed above, please contact us at the address below:


Route de Givry

ZI La Garenne


France

Tel.: +33 (0)3 85 98 22 00

Fax: +33 (0)3 85 98 22 01



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Table of Revisions

Issue Description Date

Original issue May 2006

A

Added External Module Protection

Added 2 nd Reset Input

Updated Default table

July 2006

B

Updated Default table

New RTD data Group 11

Information about RTD on Network

Supply Ride-through extension

September2006

C

New profibus profiles

Updated new trending values (group 13)

Added default code on Profibus profiles with NTP tag

New basic schematic diagram

Added PAMM wire color

Environment characteristics revision

Updated parts availability

Instructions for installation, use and maintenance

March 2007

D

Profibus documentation information

Profibus profiles update

Highlighted important points

Note on declaration of conformity

April 2008

E

Corrected CT wiring table. In single phase application, power isonly calculated for CT1

Added information on Installation/MaintenanceCorrected Multi-voltage Input threshold voltage for 230VAC

Added ESD warning message on power connector page

Added RTD Status Word to network

Change about Nowegian language

Corrected ANSI code

New logo

January 2010

FAdded Auto-restart extended function (p34, 55)

Added current/power x100 multiplier (p55, 76)September2010


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G

Information Gemstart5.3 end of life

Information ESD versions end of life

Modbus can be used in 4-wire option (p63, 64, 115)

New Data group 12 (individual currents) (p85)

October 2011


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Acronyms and Abbreviations

Item MeaningA Am eresac Alternatin CurrentALC Actual Load CurrentCT Current Transformerdc Direct CurrentFLC Full Load CurrentI/O In ut / Out utkA Kilo Am erekV Kilo VoltLED Li ht Emittin DiodeLCD Li uid Cr stal Dis lamA Milli Am eremm Milli Metrems Milli SecondMW Me a WattO s O erations

A Micro Am eressec. SecondV VoltVT Volta e Transformer

Symbols used within the Technical Handbook

ADVICE: informationintended to assist inperforming specified tasks

CAUTION: precautions to betaken to avoid damaging theequipment

YOUR ATTENTION ISDRAWN: specific pointsthat should be noted

DANGER, ELECTRICITY:precautions to be taken to avoidinjury to personnel

MECHANICAL DANGER:precautions to be taken toavoid injury to personnel


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About this Guide

This guide provides basic information about Gemstart 5, introducing the user to its mainfeatures, including the various hardware modules; the types of contactor control arrangements;and the protection and control functions that can be used.

It also provides reference to the relevant items where the configuration of settings can becarried out using the Configuration Editor Program; and refers to the basic control using the PCControl Tool. There is also information on the communications links and protocols which can beused to integrate Gemstarts into an intelligent control scheme.

Readership:

The Guide is intended for operating and maintenance staff and general engineers who areresponsible for monitoring Gemstarts system but do not necessarily have responsibility forcommissioning or reconfiguring Gemstarts settings.

Related publications:

Volume 2: Gemstart 5 - Specification Reference Manual

Volume 2 is for use by expert engineers who will be setting up Gemstart systems.

Volume 3: Gemstart 5 - GEMPRO - PC Control & Configuration Software Manual

Volume 3 is for the user and expert engineers, it explains the main features of the GEMPROsoftware, including how to take control of your Gemstart; it also explains the features of theConfiguration Editor, including how the database structure works, and how it is used to enterGemstarts settings.


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6.3.12 Pt100 RTD inputs .................................................... ........................................................... .................... 38

7 DISPLAY MODULES ....................................................... ........................................................... .................... 46

7.1 DISPLAY DATA CONFIGURATION. ................................................................. ....................................... 49

7.2 GEMSTART 5 FAULT MESSAGES ........................................................... ................................................. 50

7.3 GEMSTART FATAL ERRORS ................................................................................................ .................... 59 8 WATCHDOG FUNCTIONS .......................................................................... ................................................. 61

9 EVENT RECORDS ......................................................................................... ................................................. 62

9.1 MOTOR HISTORY ......................................................................................................... .............................. 62

9.2 EVENT HISTORY ........................................................................................................................................ 62

9.3 PLANT ASSOCIATED MEMORY MODULE (PAMM) ......................................................... .................... 62

10 SYSTEM INTEGRATION ................................................................... ........................................................... 63

10.1 MODBUS INTERFACE ............................................................................................................ .................... 63

10.1.1 Configuration of the Serial Link ..................................................................... ....................................... 64 10.1.2 Commands sent to Gemstart via the Serial Link .................................................................................... 65

10.1.3 Data available from Gemstart 5 ........................................................... ................................................. 67

10.1.4 Serial link timeout operation ....................................................... ........................................................... 74

10.1.5 Serial link performance statistics .......................................................... ................................................. 74

10.1.6 Modbus Link Fault Indications ................................................... ........................................................... 74

10.1.7 Modbus Time Synchronisation .................................................... ........................................................... 75

10.2 PROFIBUS INTERFACE ......................................................... ........................................................... .......... 75

10.2.1 Motor Management Starter ......................................................... ........................................................... 76

10.2.2 Motor Management Starter Supported Profiles ....................................................... .............................. 78

10.2.3 Gemstart 5 Profile ................................................... ........................................................... .................... 78

10.2.4 Profile Data Structure Sizes ........................................................ ........................................................... 80

10.2.5 Group Data ..................................................................................................... ....................................... 81

10.3 GEMBUS INTERFACE ......................................................................................... ....................................... 87

10.3.1 Configuration of the Serial Link ..................................................................... ....................................... 87

10.3.2 Serial Link Commands ...................................................... ........................................................... .......... 88

10.3.3 Data Available from Gemstart 5 ........................................................... ................................................. 90

10.3.4 Group Data ..................................................................................................... ....................................... 92

10.3.5 Serial Link Timeout Operation .............................................................................................................. 92

10.3.6 Serial Link Performance Statistics ........................................................ ................................................. 93

10.3.7 Serial Link Compatibility ............................................................ ........................................................... 93

10.3.8 Serial Link Cabling ............................................................................... ................................................. 94

10.3.9 Termination of Serial Links ......................................................... ........................................................... 94

10.4 GEMBUS 3 INTERFACE ...................................................................................... ....................................... 95

10.4.1 Configuration for Gembus 3 ................................................................. ................................................. 95

10.4.2 Gembus 3 Commands ............................................................................................................................ 96 10.4.3 Data available from Gemstart 5 ........................................................... ................................................. 97

10.4.4 Gemstart 3 Fault Codes .................................................... ........................................................... .......... 97


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10.4.5 Gemstart 3 Group Data .................................................... ........................................................... ........ 100

11 GEMSTART 5 ORDERING CODES ............................................................ ............................................... 104

12 GEMPRO PC SOFTWARE TOOL ..................................................... ......................................................... 105

13 INSTRUCTIONS FOR INSTALLATION, USE AND MAINTENANCE ................................................ 106

14 GEMSTART PANEL CUTOUTS AND MOUNTING DETAILS ............................................................. 108 15 GEMSTART 5 CONNECTORS PIN OUTS ........................................................... ..................................... 110

16 TECHNICAL SPECIFICATIONS ............................................................................................................... 113

16.1 GEMSTART 5 BODY UNITS ........................................................... ......................................................... 113

16.2 EXTENSION UNITS ...................................................... ........................................................... .................. 116

16.3 ENVIRONMENTAL ...................................................... ........................................................... .................. 118

16.3.1 EMC .................................................... ............................................................ ..................................... 118

16.3.2 Mechanical .................................................... ........................................................... ............................ 118

16.3.3 Climatic ......................................................... ........................................................... ............................ 118 16.3.4 Fire and smoke ........................................................ ........................................................... .................. 118


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1 IntroductionGemstart 5 is the next generation of the highly successful Gemstart family of intelligentcontroller products brought to you by COMECA. It provides a completely new range of modularunits that enables the user to choose the level of complexity they require for their application.This can range from a stand alone, single unit for status monitoring, to a fully extended controland monitoring solution, integrated into a high level control system.

Its primary purpose it to control, protect and monitor important Medium and Low voltage(MV/LV) loads used in process applications, such as motors, valves, and variable speed driveunits.

The Gemstart 5 can also be easily integrated into electrical distribution installations to monitorand control various electrical supplies, including MV/LV feeders, circuit breakers and othergeneral purpose supplies.

It also has great flexibility in that you can incorporate Gemstart 5 units into a control schemewith relative ease, as multiple devices may be connected on a single communications link withoptions on three communications protocols: Modbus ; Profibus DPV1; and Gembus (proprietaryprotocol);. All three come pre-loaded and are individually selectable.


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2 Main FeaturesThe main features provided by Gemstart 5 comprise:

Motor protection; for example protection against thermal overload, motor startup current andearthing faults.

Application protection; for example protection against under current and instantaneousovercurrent.

Process monitoring; to check for phase current imbalance.

Maintenance prediction; for example the hours run and the number of start/stop operations.

Motor control, for example startup duration time.

User interface; which for example provides fault descriptions and warnings information.

Electrical feeder control and monitoring; allows you to gather information on your loadprofile, highest current, power etc, and allows you to control the load (turn it on or off) from aremote position.


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3 Main Component PartsBy selection of the appropriate hardware module(s) Gemstart 5 can provide the followingcomponent parts:

Analogue inputs to monitor phase currents, phase voltage, thermistor inputs and earth faults.Digital inputs to monitor plant status and local/remote push button controls.

Digital outputs to operate contactors and provide remote signalling.

A Liquid Crystal Display (LCD) to indicate status and mode.

Light Emitting Diodes (LEDs) to highlight status.

RS232 serial port for PC Control, Configuration of settings, and Software upgrades.

RS485 serial port for remote control and condition monitoring.

The component parts that are included are dependent on the type of module(s) selected. Detailsof each module are listed under section 4.0 - Hardware Details.


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4 Hardware DetailsThe hardware modules available on Gemstart 5 comprise the following:

RS485 serial link

8 way inter-connecting leads between units

Figure 1.0 Simplified overview of hardware

RJ45 sockets forcable links betweenunits

Gemstart 5

Body unit

options :-

Version 5.1

Version 5.3 (endof life)

Version 5.4

(optional extensionmodule)

4 x multi - voltageinputs module

or

4 x multi - voltage

inputs + 6 xThermistor inputsmodule

(optional displaymodule)

LED module

or

LCD module

BODY UNIT INPUT MODULE LCD DISPLAY MODULE

Primaryconductora erture

Programming/Configuration port

RS232 PORT


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4.1 Body UnitsA body unit is required in every case where a Gemstart 5 is to be installed and comes in thefollowing versions, ascending in number with increasing functionality.

5.1 BODY UNIT

RS232 PROGRAMMING/CONFIGURATION PORT

RS485 SERIAL COMMUNICATIONS PORT

4 LOCAL 24V DC DIGITAL INPUTS

4 MULTI-VOLTAGE FIELD INPUTS (RANGE 24 110V DC & 24 - 240V AC)

1 MULTI-VOLTAGE INTERLOCK INPUT (RANGE 24 110V DC & 24 - 240V AC)

2 HIGH POWER RELAY OUTPUTS + 2 LOW POWER RELAY OUTPUTS

OPTIONAL PLANT ASSOCIATED MEMORY MODULE (PAMM)

5.3 BODY UNIT, AS 5.1 BUT WITH THE FOLLOWING ADDITIONS (end of life)

2 PHASE CURRENT INPUTS

1 CBCT INPUT FOR EARTH FAULT CURRENT MEASUREMENT

MOTOR VOLTAGE MEASUREMENT

AUTO RESTART FUNCTION

POWER PROTECTION

5.4 BODY UNIT, AS 5.3 BUT WITH THE FOLLOWING ADDITIONS/EXCEPTIONS:

3 PHASE CURRENT INPUTS

1 THERMISTOR / PT100 INPUT

Body unit options Table 1.0


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4.2 Power SuppliesAll body units have an option on two power supply ratings:

110 V 240V ac & 110V dc

24V 48V dc.

4.3 Optional Extension ModulesA range of extension modules are available to increase the functionality of your Gemstartinstallation:

A - 4 x multi-voltage, digital field inputs (range 24 110V dc & 24 - 240V ac).

B - 4 x multi-voltage, digital fields inputs (range 24 110V dc & 24 240V ac) + 6 thermistor /PT100 inputs.

C - LED module, includes 5 LEDs, 1 fixed green for unit healthy, 4 being tri-coloured and freelyassignable + a programming/configuration port.

D - LCD module, includes 5 LEDs , 1 fixed green for unit healthy, 4 being tri-coloured andfreely assignable + a 128 x 64 pixel back lit graphical liquid crystal display + aprogramming/configuration port.

E - Chassis or cubicle mounted Plant Associated Memory Module (PAMM) retainsconfiguration settings, number of operations and trip/alarm log information.

4.4 Interconnections between body units and extensionmodules

All optional extension modules, with the exception of the chassis or cubicle mounted PAMM,which has a separate 3 wire connection to the body unit, are interfaced with the main body unitusing an 8 core inter-connecting cable fitted with an RJ45 plug on either end. This cable plugsinto a RJ45 socket on the body unit and on each module. This cable provides the power supplyfrom the body unit to the extension module(s) and includes the wires for data transfer betweeneach unit. The loss of communication with the extension module (IP or RTD) can be userprotected.


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4.5 Typical arrangement of Gemstart installed in a MCCchassis

Gemstart 5Body Unit

MCCB &Isolator

Contactorwith Aux.s

LCD front panel onchassis above

Mainconductors

interfacewiring

inter-connectingcable to front panel


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4.6 Basic Schematic Diagram

NOTES:

The Earth Fault CT should not be earthed.


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4.7 CT WiringWhen selecting which CT inputs to use there are some restrictions on which phases you canuse. The following tables show which built in CTs must be used.

The number of Motor Phases is configured in the GEMPRO Editor Supply form. The Number of

CTs used is configured in the GEMPRO Editor Phase CTs form.Gemstart 5.3 (end of life)

Number ofMotor Phases

Number of CTs Used

1 2 3

Phase to Neutral Use Phase 1 only Not Valid Not Valid

Phase to Phase Use Phase 1 only Not Valid Not Valid

3 Phase Not Valid Use Phases 1 and 3Phase 2 is residual sum

of phases 1 and 3

Not Valid

3 Phaseplus Neutral

Not Valid Not Valid Not Valid

Gemstart 5.4

Number ofMotor Phases

Number of CTs Used

1 2 3Phase to Neutral Use Phase 1 only Not Valid Not Valid

Phase to Phase Use Phase 1 only Use Phase 1 only Not Valid

3 Phase Not Valid Use Phases 1 and 3

Phase 2 is residual sumof phases 1 and 3

Use Phases 1, 2 and 3

3 Phaseplus Neutral Not Valid Not Valid Use Phases 1, 2 and 3


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5 Protection and Control FunctionsThe Gemstart 5 controller provides a large number of selectable protection and control functionswhich you are able to activate from any of the input sources you have chosen to suit yourcontrol application. These functions cover a wide array of contactor types for motor protectionand control, as well as controls for electrical distribution feeders.

In summary these functions cover:

Contactor type Functions

Input Functions

Protection Functions

Output Functions.

5.1 Contactor type functions

To define the type of control required from a Gemstart 5 unit it must be configured to the specificcontactor type using the Configuration Editor, under the Fuses and Contactors item. Theoptions available are as follows:

Contactor type

DOL-E

MCCB Feeder

VSD Logic

VSD Cut Throat

General Purpose I/O

Star Delta 1 O/P

Star Delta 2 O/P

Star Delta 3 O/P

DOL-L

Forward/Reverse

Motor Operated Valve

Two Speed - Low Start Only

Two Speed

Two Speed - Dahlander

A full description of each contactor function is detailed in Volume 2 Specification ReferenceManual.


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5.2 Input Functions and Configuration OptionsThese are the functions that are available to be activated either by sensing the presence of voltsor the loss of volts at Gemstarts input terminals. (See Digital Inputs section 6.1). You canassign any input number/type to any of these functions. You can also chose the logic typesense you wish the function to have, e.g. N/O or N/C. It is also possible to configure theseverity of fault, that is issued when the input function is activated. All the following inputfunctions can be configured using the Configuration Editor, under items Fuses and Contactors ,Manual Controls and Digital inputs .

Input Function

Configuration Options

Input Type Options Fault Types

Contactor A auxiliaryinput

N/O, N/C None, see contactor typedefinition

Contactor B auxiliary

input

N/O, N/C None, see contactor type

definition Contactor C auxiliaryinput


Contactor D auxiliaryinput


Hard Stop N/O, N/C No Options, always a SCTProcess Stop A N/O, N/C No Options, always a SCTProcess Stop B N/O, N/C No Options, always a SCTManual Start A N/O , N/C No OptionsManual Start B N/O , N/C No OptionsEmergency Start A N/O , N/C No OptionsEmergency Start B N/O , N/C No OptionsTest Mode Start N/O , N/C No OptionsManual Select N/O , N/C No Options, no fault is flaggedINCH Select N/O , N/C No Options, no fault is flaggedRemote Select N/O , N/C No Options, no fault is flaggedInterlock N/O, N/C OFF, SCW, LA, SCT, LTOverload Relay N/O, N/C OFF, SCW, LA, SCT, LT

User text 1 N/O, N/C OFF, SCW, LA, SCT, LTUser text 2 N/O, N/C OFF, SCW, LA, SCT, LTThermistor Relay N/O, N/C OFF, SCW, LA, SCT, LTELCB Relay N/O, N/C OFF, SCW, LA, SCT, LTIsolator N/O, N/C OFF, SCW, LA, SCT, LTDevice Status N/O, N/C OFF, SCW, LA, SCT, LTReset input 1 N/O , N/C NoneReset input 2 N/O , N/C NoneTest Position N/O, N/C OFF, SCW, LA, SCT, LT

Counter 1 N/O , N/C NoneCounter 2 N/O , N/C NoneCounter 3 N/O , N/C None


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Note that if an input is set as N/C the function will become active if the input loses its voltage.Conversely, with the input set as N/O, when the input detects sufficient voltage the function willbecome active. The standard input type option is shown in bold.

Key to abbreviations

Abbreviation Meaning

N/A Not Applicable

N/O Normally Open. Input function active when voltage level is present.

N/C Normally Closed. Input function active when voltage level is lost.

LT Latched trip. The trip flag must be cleared by a reset trips command.

SCT Self Clearing Trip. If the trip input signal clears the trip flag is clearedautomatically

LA Latched Alarm. The alarm flag must be cleared by a reset trips or resetalarms command

SCW Self Clearing Warn. If the warn input signal clears the warn flag iscleared automatically

None No faults are flagged when an input is defined as this


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5.3 Protection FunctionsThis table lists all the Protection type functions that are available on Gemstart 5. They provide awide range of cover for most aspects of motor protection. All these protection functions areselectable, together with additional configuration settings, using the Configuration Editor itemscorresponding to the functions as listed in this table.

ANSI/IEEE No. Protection Function Configuration Editor item

79 Fail/Recovery Voltages Supply

50S Startup Current Motor Protection

48, 51LR Startup Time/locked rotor Motor Protection

49 Thermal Overload Thermal Protection

Thermal Reset Delay Thermal Protection

Restart Inhibit Thermal Protection

Temperature threshold Thermal Protection

46 Single Phasing Motor Protection

46 Imbalance Motor Protection

66 Starts in Hour Motor Protection

14 Speed sense Digital Inputs & Motor Protection

27, 59 Voltage protection Supply

50N, 51N Earth Fault Protection Earth Fault Protection

46 Phase Reversal Supply

37 Under Current Application Protection

50 Instant ALC Application Protection

51 Constant ALC Application Protection

Under Power Power Protection

Over Power Power Protection

55 Power Factor High Power Protection

55 Power Factor Low Power Protection

79 AutoRestart Supply

74 Alarm Relay86 Lockout

An explanation of the protection function and the settings parameters applicable to each of theabove can be found in volume 2 - Specification Reference.

NB: Current based protection is only applicable to Gemstart versions 5.3 & 5.4.

Voltage, Power and Auto-Restart protection is only applicable to Gemstart versions 5.3 & 5.4.


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6 Inputs and Outputs

6.1 Digital inputs

6.1.1 Local inputsThere are four local digital inputs, numbered 1 to 4, available on all Gemstart body units. Theseare powered from the internal 24V dc supply in the Gemstart 5 body unit. A common positive24Volts is fed through the local chassis contacts and returned to the desired local input. Theyare configurable to any of the input functions, but are typically used for contact position sensing.e.g.

local/ remote switch position,

isolator opened/closed,

contactor opened/closed,

chassis test position.

It is only permissible for wiring associated with these inputs to be carried out locally within amotor starter chassis or a feeder cubicle.

6.1.2 Multi Voltage Field inputsThere are four multi-voltage field inputs which are numbered 5 to 8 and are included inGemstart body units 5.1 to 5.4. They are rated in the range of 24 110V dc & 24 240V ac.They are also configurable to any of the input functions, but are typically used for manual controlfunctions. e.g.

Field Start, Emergency Start

Field Stop, Hard Stop

Manual Select, Auto/Manual Select

The user must set the correct voltage rating for each of these inputs using the ConfigurationEditor, under the Multi- voltage inputs item. The settings are either High Range (110/230v) orLow Range (24/48v) The default is set to High Range. Please note that an input with lowvolts applied will not become active if it has been set to sense the high voltage level.

In addition, a supply Ride Through Time setting of 0 to 200ms, in 10ms steps is alsoconfigurable on these inputs. This is useful to prevent false input readings for momentary dips in

the input voltage. The default is set at 20ms. The switching on of the inputs is not delayed.Warning! If input 8 is used for the Emergency Shut Down (ESD) option to controloutput 4, the voltage applied to this input must be limited to 24V dc, otherwise theoutput may be damaged.

Note : ESD version = end of life

A further four additional Multi voltage inputs, numbered 9 12, are available on both theoptional Input and the RTD/INPUT extension modules and these are connected to the body

units using the 8 way connection lead fitted with RJ45 plugs.


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6.1.3 Multi Voltage Interlock inputThis input has the same voltage rating as the multi voltage field inputs and must also be set tothe correct rating using the Configuration Editor. It is also freely assignable to any of theGemstart input functions, but it is usually reserved specifically for the Interlock function as thedefault. The supply for this input is fed through the contacts of the two high power rated relayslocated within the Gemstart body unit on versions 5.1, 5.3 & 5.4, and is typically used for directcontrol of motor contactors. Therefore, the loss of this input will cause the contactors to dropout.

The interlock input is monitored to detect the loss of the Interlock supply. e.g. When the inputopens this can be due to the operation of a Stop button or from the loss of the Interlock supplysource.

A configurable Ride Through Time of up to 200ms will allow the contactor(s) to be automaticallypulled back in if the interlock supply returns within this time setting. The default ride through timeis set to 200ms.

NB: A Stop signal of less than the Ride Through Time will be ignored by the Interlock input and

the contactor will be pulled back in as the Gemstart output will remain closed.

6.1.4 Default mapping of Inputs.Across all the contactor types there is a common default setup for using the inputs. This is thesuggested use for each input, although Gemstart 5 allows you to use any input for any of theinput functions available.

Input Number/Type Default input Function

Interlock (multi-voltage input) Interlock. A self clearing TRIP (N/C Sense)

1 (24V local input) Contactor A auxiliary contact (N/C Sense)

2 (24V local input) Contactor B auxiliary contact (N/C Sense)

3 (24V local input) Contactor C auxiliary contact (N/C Sense)

4 (24V local input) Contactor D auxiliary contact (N/C Sense)

5* (multi-voltage input) Process Stop A (N/C Sense)

6* (multi-voltage input) Manual Start A (N/O Sense)

7*(multi-voltage input) Not assigned

8*(multi-voltage input) Manual Select (N/C Sense)

9**(multi-voltage input) Not assigned

10** (multi-voltage input) Not assigned

11* *(multi-voltage input) Not assigned

12** (multi-voltage input) Not assigned

Output 4 Not assigned

Table 3.0 Default mapping of inputs

Inputs 1 4 inclusive are available on all versions of Gemstart 5 body units.

* Inputs 5 8 inclusive are available on all body units.

** Inputs 9 12 inclusive are only available with the optional input extension modules.


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Example:

Take the case of single contactor motors typical of direct on line starting; both Start A and StartB functions can be used to start the motor. Start A could be for local control and Start B forremote control. Assign Start A to input 6 and Start B to input 7.

It is also possible to set an output based on the level of an Input. This is available on a limitednumber of inputs (Interlock, Local I/P 4, Multi-voltage I/P 7, and Extension module I/P 12). e.g.For chassis test position, you could use the local input 4 to set output 3 to signal remotely thatthe chassis is in test position.

Additionally, the status of output 4 can also be used to activate any input function.

A full description of all the input functions is detailed in Volume 2 Specification ReferenceManual.

6.2 Digital outputs

Gemstart versions 5.1, 5.3 & 5.4 include four digital outputs in the form of electro mechanicalrelays that each have a pair of volt free, normally open, SPST contacts. Two of the relays arehigh power rated (outputs 1&2) and are typically used to switch the supply to contactor coils formotor control. These outputs are used for all contactor control configurations. The supply forthese outputs is fed from the Interlock input, so if the interlock supply is lost or isolated themotor will stop.

Contact data high power relays

Configuration : 1 N/O contact

Type of contact : single contact

Rated current :12 A

Rated voltage / max. breaking voltage: AC 250 Vac /

Maximum breaking capacity : AC 4000 VA

Make current (max. 4 s at duty cycle 10%) 30 A

peak inrush current (20 ms) 80 A

Contact material AgSnO2

There are also two low power rated output relays (outputs 3&4) that are typically used for

remote status indication or additional contactor control when using the interlock supply.

Contact data low power relays

Configuration : 1 N/O contact

Type of contact : single contact

Rated current : 6 A

Rated voltage / max. breaking voltage : AC 250 Vac /

Maximum breaking capacity : AC 1500 VA

Make current (max. 4 s at duty cycle 10%) 15 A

Contact material AgCdO


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Gemstart 5 also has an option to replace output 4 with an Emergency Shut Down (ESD) relay.This option allows a 24VDC input signal from an ESD system to operate an embedded relaywithin the Gemstart unit. Note : this version is declared end of life

All output contacts will drop out if the power supply to Gemstart is lost either momentarily orpermanently. However, see also sections 6.3.4 & 6.3.5 for details on Voltage Monitoring andAuto-Restart features.The output contacts will also drop out if the Gemstart 5 system watchdog detects a hardware orfatal error software failure.

All relay contacts should be protected from large transient voltages caused byswitching external inductive loads. Either RC networks for AC voltage or Free-wheeling diodes for DC voltage should be used in parallel with the externalloads.

6.2.1 Hardware Outputs 1 to 4 Configuration OptionsThe configuration options available to the hardware outputs 1 - 4 are defined below and can becarried out using the Configuration Editor under item Fuses and Contactors.

Option Description

Disabled The output is Off all the time.

Active The output source is On all the time.

Contactor Output A This Function varies with contactor type but is generally the mainoutput drive

Contactor Output B This Function varies with contactor type but is generally thesecondary output drive. If contactor B does not exist this output isOff all the time.

Contactor Output C This Function varies with contactor type. If contactor C does notexist then this output defaults to the Trip Present status bit.

Contactor Output D This Function varies with contactor type. If contactor D does notexist then this output defaults to the No Trips Present status bit.

GP Output A A GP Output bit supplied by the Host via the serial link. Used forremote outputs

GP Output B A GP Output bit supplied by the Host via the serial link. Used for

remote outputsGP Output C A GP Output bit supplied by the Host via the serial link. Used for

remote outputs

GP Output D A GP Output bit supplied by the Host via the serial link. Used forremote outputs

Motor Stopped The contactors are open and there is no current flowing.

Running One of the contactors is closed.

Running A Contactor A is, or should be, closed.

Running B Contactor B is, or should be, closed.

In Startup Gemstart is in the startup phase.

Available to Auto The motor is available for serial link commands. I.e. Gemstart is in


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Option Description

Auto or Priority Mode, there are no trips present, there are volts onthe interlock input and the contactor is not in the test position.

Any Fault Present A Warn, Alarm, Trip or LTrip (Latched trip) is present. I.e. there is a

non zero fault code.No Trips Present There are no Trips or LTrips present.

Warn Present There is a Warning present.

Alarm Present There is an Alarm present.

Self Clearing TripPresent

There is a (self clearing) Trip present.

Latched Trip present There is a (latching) LTrip present.

Available to Priority A priority command can start the motor. I.e. there are no tripspresent, the contactor is not in the test position, there are volts onthe interlock input and the Hard Stop input is not active.

Available to Manual A manual command can start the motor. I.e. Gemstart is in ManualMode, there are no trips present, the contactor is not in the testposition, there are volts on the interlock input and the Hard Stopand Process Stop inputs are not active.

Interlock Input If this input is active it will act directly upon any one of the outputs ithas been assigned to.

Inputs 4, 7 or 12 If any one of these inputs is active it will act directly upon any oneof the outputs it has been assigned to.

6.2.2 Hardware Outputs 1 to 4 senseThe sense of the output signal Normally open or Normally closed is configurable. The defaultis Normally Open. Selecting Normally Closed will invert the sense of the status bit. e.g. a N/Csense will cause the output contact to open when the output function is active, and conversely,a N/O sense will close the output contact when the output function is active.

Please note that when the unit is not powered these output relays will be openregardless of configuration.

6.3 Analogue inputs6.3.1 Phase current inputsGemstart unit version 5.3 has 2 phase current inputs (end of life).

Gemstart unit version 5.4 has 3 phase current inputs.

Phase current measurement is provided for motors/feeders in the range of 0.5 to 30 ampsnominal, using CTs integral to the body unit. The phase conductors are routed through theapertures in the body unit to provide the primary winding for the integral CT.

Higher current ratings in the range of 30 to 1000 amps nominal are catered for using externalinterposing CTs mounted in the motor chassis or feeder cubicle. These interposing CTs canhave either 1 amp or 5 amp secondaries with the secondary windings, likewise being routing


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through the appropriate apertures in the Gemstart body unit.

The Gemstart body unit with the integral CTs has a current measuring error limit of 2%across the nominal range of 0.5 30 amps, and within 5% across the range of 31 250amps.

All external interposing phase CTs specified by COMECA comply with Class 5P10 Protectioncategory of IEC 60044-1, thereby providing exceptional total accuracy for all currentmeasurements.

Phase CT selection :CT1 = INTEGRAL CT (NOT OPTIONAL) EXTENDED NOMINAL CURRENT RANGE 0.5A 30A = INTEGRAL CT

CT2 = (100/1A) EXTENDED NOMINAL CURRENT RANGE 25A 160A = CHASSIS

MOUNTED INTERPOSING 3CT BLOCK WITH 3 CTS FITTED.

CT2a = (100/1A)

(end of life)

EXTENDED NOMINAL CURRENT RANGE 25A 160A = CHASSIS

MOUNTED INTERPOSING 3CT BLOCK WITH 2 CTS FITTED.

Phase CT table 4.0

6.3.2 FLC SettingPhase current settings are applied to the load to be protected based on the motor/feeder fullload current (FLC) and this is set up as follows using the Configuration Editor in the GEMPROPC program:

First select the Gemstart unit type, i.e. 5.1, 5.3, etc, then select Phase CTs item and finallyselect the CT input type, e.g. Primary, 1 amp or 5 amp. Primary refers to the integral CT for use

up to 30 amps, whereas 1 amp and 5 amp refers to the secondary winding current rating of theexternal interposing CTs. Then select the number of CTs.

Now close the Phase CT item and then select the Motor item to configure the FLC range andthe actual FLC value.

e.g. Using a Gemstart 5.3 on a motor with an FLC of 16 amps, the Primary CT would beselected first, followed by the number of CTs as 2, then the FLC range entered as 10-100A,then the FLC value entered as 16 amps.

For FLC values which result in a current of less than 0.5Amp through the integral CT, themultiple turns option must be used. e.g. Using an interposing CT with a 100/1Amp ratio, thislimits the low current measurement range to 50Amps using 1 turn through Gemstart. However,using multiple turns would allow Gemstart to measure lower currents with the same CT. Forexample, 25Amps would require 2 turns and 10Amps would require 5 turns. The maximumnumber of turns that can be passed through Gemstart comfortably using 1.0 mm PVC covered,switchgear type cable is 5.

6.3.3 ALC SettingThe ALC (Actual Load Current) setting is set in a similar manner, but under the Application item of the Configuration Editor. However, this may be left the same as the FLC setting as this isits default setting.

6.3.4 Motor Starting CurrentMotor starting currents can be set under the Motor item in the range of 100% 1000% of theFLC, noting that this may be limited by the maximum current rating of the CT. The integral CT is


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limited to a maximum current of 250Amps for 30 seconds, and all Gemstart specifiedinterposing CTs are limited to10x their nominal primary current rating for 30 seconds. Thestandard default starting current setting is 800%.

6.3.5 Contactor RatingSet to protect the contactor under heavy fault condition, allowing upstream fuse / MCCBprotection to operate first. Gemstart will keep the contactor closed for currents greater than thissetting value until the fuse blow time has elapsed. The default settings are 1000% of the FLCvalue for the contactor rating and 1s for the fuse blow time. These may be changed under theFuses and Contactors item.

6.3.6 Thermal Overload Curves Up to 31 Gemstart overload curves are available to choose from for the thermal protection ofyour motor. They are typically selected based on the I t withstand of the motor. This is usuallyobtained from the maximum stall current and its withstand time from cold. You would typicallyselect a curve that would cause the overload protection to trip if these time/current parameterswere exceeded. Selection can be made under the Thermal item in the Configuration Editor.

Thermal overload protection is ATEX certified (Certification available on the internet site or ondemand).


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Gemstart Curves

Gemstart Curves

0.1

1

10

100

1000

10000

100000

0 1 2 3 4 5 6 7 8 9

Fault Level (xFLC)


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6.3.7 Earth fault current input (CBCT)The earth fault current input is available on Gemstart 5.3 & 5.4.

Selected by setting Earth Fault Method to EF Input within the Earth Faultconfiguration page of GEMPRO

Earth fault current measurement/protection can be provided when the three phaseconductors are routed through a core balanced current transformer (CBCT). Anyresidual current is picked up by the secondary winding which is fed to an analogueinput within the Gemstart body unit where it is measured and compared to the earthfault trip threshold setting.

Gemstarts earth fault input is nominally rated at 20mA and has a maximummeasurement limit of 120mA. The burden for the CBCT is 38 . Various proprietaryCBCTs may be used but this upper limit of 120 mA must be borne in mind. TheCBCT wiring should not be earthed.

Tested types include Socomec W2-S70 (EF CT rating = 12A) and Socomec W4-S140 (EF CT Rating = 12A)

You can set the Earth Fault level in the Configuration Editor. The 20mA nominalrating of the input is assumed in the configuration.

E.g. for a 800 turn CBCT as below, the primary rating would be 800 x 20mA = 16A.Therefore, set the CT primary rating Range = 10 -100A and the Earth fault CTprimary rating Value = 16 A.

You can then set the Earth Fault Trip Current to the desired value.

If the earth fault trip setting is selected above the input limit a Config Error faultmessage will be reported on the LCD display.

The overall accuracy for earth fault current measurement is 2% for the Gemstartinput, plus the error contributed by the CBCT that is used. Please be sure that theCBCT chosen has sufficient dynamic range to ensure an accurate result.

Gemstart specified CBCT:

CBCT (16/0.02A) CLASS 10P10 EARTH FAULT CURRENT DETECTION

RANGE 1.0A 96A

CBCT table 5.0

6.3.8 Residual Earth Fault (5.4 only)

Residual earth fault is available on Gemstart 5.4Residual Earth Fault is selected by setting Earth Fault Method to Residual CT withinthe Earth Fault configuration page of GEMPRO.

Gemstart 5.4 uses 3 Current transformers to measure the individual phase currents.If these three currents are summed together the resultant value is equivalent to theearth fault current flowing. This value is then treated in the same way as the EarthFault Current Input (CBCT).

This method is inherently less accurate than the CBCT method as the currentreading is dependant on the individual phase CTs. This gives a larger scope forintroducing errors, particularly when using interposing CTs for large current motors

(>30A) or MV motors. Care should be taken to ensure that these interposing CTs arematched or that any errors introduced by such CTs are accounted for.


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Earth Fault setting below 10% of the FLC rating should not use this method.

The overall accuracy using this method of Earth Fault detection is +/- 5% in range 0.1- 30A.

EF Limit must be between 10% and 100% of FLC. This accuracy does not includeany additional errors introduced by external CTs.

6.3.9 Thermistor (PTC) input (Gemstart 5.4 only)Gemstart 5.4 has a built in positive temperature coefficient (PTC) input. This inputuses a standard PTC thermistor to detect an over temperature condition within themotor.

Typically a PTC will have a low temperature resistance of up to 150 ohms at atemperature defined by the supplier the PTC will experience a sudden change inresistance resulting in values of over 10K ohms.

The Gemstart 5.4 unit measures these values and provides a fault condition if thereis an increase in resistance.

To allow up to three of these devices to be placed in series the following thresholdsare used

Trip at 1600 to 2000

Reset at 1000 to 1400

Gemstart can be configured to perform a LTRIP, TRIP, ALARM or WARN should thethreshold be exceeded

This protection is available in addition to the overload protection and is ideal for useon motors that are in a raised ambient temperature or within a hazardousenvironment.

6.3.10 Motor supply monitoringOn Gemstart versions 5.3 & 5.4 the body unit incorporates a voltage transformerwhich is used to directly measure the motor supply voltage up to a maximum of 240Vac. Higher voltage monitoring is possible by using an external interposing, step downtransformer. The motor supply can be monitored to detect motor supply loss or dipsdown to 10 ms. The Monitored Voltage level, which must be set to the correct valueunder the Supply item in the Configuration Editor, is used for both the Auto-Restartfeature and the Under/Over Voltage protection. The under voltage level is set by thevalue selected from the Supply Fail level in the Auto-Restart feature and the Overvoltage level is pre-set at 110% of the monitored voltage value. The severity of thefault issued for voltage protection is also selectable from the configuration settings.

Gemstart versions 5.3 & 5.4 can be powered independently to the motor supply,however if the control supply is derived from the same source as the motor voltagethen this can be linked across to the motor supply input terminals to monitor thissource.


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6.3.11 Auto - RestartWhen motor supply monitoring is included, as it is in Gemstart versions 5.3 & 5.4, theAuto-Restart feature is available to carry out automatic re-starting of the motor uponrestoration of supply. The re-start is carried out either immediately or after a set timedelayed period.

The Auto-Restart feature has five settings to be entered using the Supply item underthe Configuration Editor:

1. Supply Fail and Recovery voltage levels entered as percentages of themonitored voltage value.

2. Ride through will ride through a motor supply failure of up to 5s. This will enablean immediate auto-restart of the motor should the motor supply return within this timeperiod.

3. Maximum Dip Time will sense if the monitored voltage has returned within this settime period. Auto-restart is aborted if the supply does not return within the MaximumDip Time period.

4. Delay to Restart is the next timing phase, following a return of the supply withinthe Maximum Dip Time, before an Auto-restart is initiated.

See also fig 2 below for further explanation of the Auto-Restart feature.

Note that the Auto-Restart feature can be disabled if the Maximum Dip Time is set toOFF.

5. Inputs Supply Volatile allows Gemstart5 to know if Multi-Voltage inputs are wiredon the busbar or backup. In the first case, Gemstart5 knows that it has not to readthe opening of Normally Closed inputs during a voltage dip and go on autorestart.

Warning : a system with volatile Multi-Voltage inputs (that lose supply during asupply dip) cannot be used with Supply Ride-Through set to No Limit.


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Motor supply voltage monitoring for Auto-Restart

Immediate Auto-Restart ifsupply returns withinconfigurable Ride Through time 40ms 5s

Configurable Delay to Restart

0 99m59s for Auto-Restart.Only enabled if supply returnswithin configurable Max DipTime 0.5 60 seconds.


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6.3.12 Pt100 RTD inputsAn RTD input unit (Resistance Thermometry Device) is available to complement theprotection of all Gemstart units. This input module provides 6 channels of inputssuitable for 2 or 3 wire Pt100 temperature sensors. In addition there are 4 multivoltage digital inputs.

Each RTD channel measures the resistance of an IEC 60751 standard platinumresistance element that has a nominal resistance of 100 ohms at 0 degreesCentigrade. Temperatures between 0 degrees Centigrade and +250 degreescentigrade can be measured. If three wire connections are used, lead compensationis automatically performed up to 30 ohms.

The Gemstart unit reports the temperature in Degrees Centigrade of each Pt100.

Protection levels and actions can be configured for each individual element. The faultlevel is set in degrees centigrade with a fault severity of LTRIP, TRIP, ALARM orWARN. In addition a pre warning level can be set to indicate if the motor temperatureis close to tripping.

It is possible to group three sensors together. This allows all three to have identicalsettings and they can be used for protecting stator windings, low speed windings,high speed windings or bearings.

The inputs will also perform diagnostics and report any open circuit or short circuitcondition.

Suitable shielded cable must be used and earthed, preferably at the switchboard.

A protection can be configured in case of the loss of communication between theIP/RTD module and the Body Unit (no protection, warn, alarm, trip, latched trip).

A typical wiring scheme for the RTD unit is shown below.

Please note it is recommended that 3 wire connections are always used as leadresistance can cause significant errors in the measurement of the temperature. If 2wire connections are used then the RTD + and RTD + Sense terminals should belinked together at the device


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10111213

1415161718192021222324252627

RTD 1 +

RTD 1 + SenseRTD 1 -

RTD 2 +


RTD 3 +


RTD 4 +


RTD 5 +


RTD 6 +


10111213

1415161718192021222324252627

RTD 1 +


RTD 2 +

RTD 2 + Sense

RTD 2 -

RTD 3 +


RTD 4 +


RTD 5 +


RTD 6 +


3 wire connections (recommended) 2 wire connections

6.3.12.1 Installation

It is important to ensure a clean installation of the RTD sensors as the signal levelsinvolved are very low.

Each PT100 element should be screened with either a braid screen or foil screen.Earthing of the screen should be applied both at the Pt100 element and at the


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switchboard.

Ideally the plant wiring should also be enclosed in earthed, armoured cable.

Connections within the switchboard should ensure that unshielded connections arekept to a minimum and that all wiring is shielded even within the switchboard. It ispermissible to earth the shield locally within a chassis, separately to the RTD element

The wiring connecting to the PT100 sensor should be sized to ensure that the DCresistance is kept below 30 ohms in each cable. This is to ensure that the RTD unitcan compensate for the additional cable resistance.

6.3.12.2 RTD Configuration

The RTD can measure a range of temperatures and each temperature input requiresa pre warn and fault level. It will be possible to group three RTDs together to allow acommon configuration setting for all three (i.e. bearings). The group settings will beheld in RTD 1 or RTD 4. When RTDs are grouped the highest RTD temperature willbe used to perform the protection.

The Fault must be configurable from 105 C to 180 C in steps of 5 C (16 options)

The pre warn can be Off or provide a warning at a temperature of 5, 10 or 15 C lowerthan the fault level.It will also be possible to disable each RTD (no error reporting).


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The loss of link between the RTD module and the input module can be protected (noprotection, warn, alarm, trip, latched trip). Select module type in Fuses andContactor and the protection severity. Note : Select carefully the right module; ifRTD module is selected and IP is fitted, protection will be engaged.


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6.3.12.3 RTD Status Reporting (GEMPRO)

The status is displayed on GEMPRO. Access is via the temperature sensors button.

For these three cases, protection will work:If the RTD measures > 264 then the warning message RTD x Open

circuit is displayed.

If the RTD measures = 194 < 264 then the warning message RTD xHigh Temp.(>250 C) is displayed.

For these two cases, input channel will be ignored:

If the RTD is not connected when starting the application then the warningmessage RTD x Not connected is displayed.

If the RTD measures >88


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Working connection

Short circuit

100250ohms

Not Connected (1)

Open circuit

88< R


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6.3.12.4 RTD Status Reporting (Network)

Information previously explained is also available in a data word over the network. Itis the Word 5 of Group 11 (dedicated to RTD). This word is called RTD Status and isdecoded using the following table :

6.3.12.5 RTD Fault Reporting (Fault log and serial link)

This is the information available via the Fault log

Fault reporting is enabled on each channel individually (unless groups are used)using the active box. In normal operation the only reports will be an Over temperaturefault. The severity of this is configurable.

RTD # Over Temp. Trip # is the RTD input number (1 to 6). The severity can beconfigured.

If the temperature is over the fault limit then an Over Temperature fault is indicated.Six new fault codes will be created.

If there is a fault with the external wiring then a Warning will be reported. One of thefollowing is applicable

RTD # Open Circuit # is the RTD input number (1 to 6). The severity can beconfigured.

Open Circuit is indicated if the resistance goes very high or there is no connection.

RTD # Short Circuit # is the RTD input number (1 to 6). The severity can beconfigured.

Short Circuit is indicated if the resistance goes very low.

RTDs 1, 2 and 3 and/or 4, 5 and 6 can be grouped together. When they are grouped


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then the individual channel protection is disabled and a group fault code is generatedif the temperature for any of the RTDs in the group is over the configured level.

NB When group protection is enabled Open or Short Circuit faults are generated forany of the RTDs in the group.

Between the 2 groups there are 6 fault codes that can be generated. The severity ofthese faults is configurable.

Group 1 RTD Trip

Group 2 RTD Trip

Bearings RTD Trip

Stator RTD Trip

Low Speed RTD Trip

High Speed RTD Trip

These faults will be generated instead of an RTD fault if the RTDs are grouped.

On the network, RTD values are on one byte and correspond to:

0 = low temperature (250C)

252 = group value not available (e.g. all probes in this group are short-circuit)

253 = open circuit (e.g. a probe has been deplugged during functionning)

254 = probe short-circuit

255 = not connected (at gemstart startup, no probe has been detected)


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7 Display ModulesThere are two display modules, the LED module and the LCD module. These unitsare mounted on the front panel of the chassis and fit a standard 68mm square, metersize cut-out. They are wired to the body unit using an 8 core cable with RJ45connectors. This cable supplies the power from the body unit to the display moduleand transfers data between them.

LCD Module. LED Module.

Common Features:

LED 1 = Green Healthy/Watchdog LED. This turns off if there is a hardware/softwarefault and the contactor opens. It is advised to proceed to the remplacement of thedrawer in this case.

LEDs 2 to 5 = 4 x tri-coloured, Red/Green/Yellow LEDs.

LEDs 2 -5 are pre-assigned to the following status conditions:

LED 2 = Running - LED red = contactor closed, LED off = contactor open

LED 3 = Stopped - LED green = contactors open and no current flowing, LED off =contactor closed or current flowing.

LED 4 = Tripped/Alarm

LED red = Tripped or LED red flashing = Latched trip.LED yellow = Warn or LED yellow flashing = Alarm


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LED OFF = no fault.

Note: A Latched Trip or an Alarm needs to be reset (see section 7.2 for ways toreset), whereas a Trip or a Warn are self clearing. The resetting or self clearing of afault is only possible once the source of the fault has been cleared. However, anAlarm caused by a protection trip will reset automatically once the source of the faulthas been cleared and a successful start has been achieved. If both a Trip and Alarmare present simultaneously, the Trip will take precedence.

LED 5 = Serial Link - LED yellow = Link active but not in control or LED green = Linkactive and in control or LED off = no link.

However, LEDs 2 to 5 can be freely assigned to any one of the different functionoptions which are available. In addition, all four LEDs are user configurable to anyone of the three colour states. The LEDs can be configured to be On or Off forfunction on or function off indication.

e.g. LED Off/Green = Function Off/Function On and LED Green/Off = FunctionOff/Function On.

The following table lists all the functions available and their auto (default) colourconfiguration.

Function LED with Auto colour selected Function Status

Serial Mode Off = No link

Yellow = Link active but not in serial link control

Green = In serial link control

OFF

OFF

ON

Manual Mode Off = Manual not activeYellow = Manual active but not in control

Green = In manual control

OFFOFF

ON

Local Manual Mode Off = Local not active

Yellow = Local active but not in control

Green = In local control

OFF

OFF

ON

Remote Manual Mode Off = Remote not active

Yellow = Remote active but not in control

Green = In Remote control

OFF

OFF

ONStopped Off = Current flowing or contactor closed

Green = Contactor(s) open and no current flowing

OFF

ON

Running (A or B) Off = Contactor A or B open

Red = Contactor A or B closed

OFF

ON

Running A

(fwd, low, star, close)

Off = Contactor A open

Red = Contactor A closed

OFF

ON

Running B

(rev, hi, delta, open)

Off = Contactor B open

Red = Contactor B closed

OFF

ON


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Function LED with Auto colour selected Function Status

Avail to Manual Off = Test position, interlock, hard stop, emergencystart, Not in manual.

Green = A manual start/stop will start/stop the motor

OFF

ON

Avail to Host Off = Test position, interlock, hard stop, emergencystart, not in link control

Green = An auto start/stop will start/stop the motor

OFF

ON

Avail to Priority Off = Test position, interlock, hard stop, emergencystart

Green = A priority start/stop will start/stop the motor

OFF

ON

Fault Off = No fault

Yellow = Warn

Yellow flashing = Alarm

Red = Trip

Red Flashing = LTrip

OFF

ON

ON

ON

ON

Test Off = Not in test position

Yellow = In test position

OFF

ON

Current Off = Stopped

Yellow (On) = i < undercurrent level

Green (On) = i < 100%FLC

Red (On) = i > 100%FLC

OFF

ON

ON

ON

Auto LED 2. Running, as above

LED 3. Stopped, as above

LED 4. Tripped, as above

LED 5. Serial Mode, as above

See Display item under the Configuration Editor for full settings options.

There is also the option to display current on a single LED as None (Off), Low(Yellow), Normal (Green), and High (Red).

Easy knockout plugs are provided as standard for the option to fit 16mm diameterpush buttons. One can be fitted on the LCD module or up to three on the LEDmodule.

The display modules are designed to allow self-adhesive labels to be affixed toidentify customised LED and push button configurations.

The RS232 programming port allows Flash Memory updates of Gemstart 5software and configuration changes, both using the PC Programming

Tool/Configuration Editor.


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7.1 Display data configuration.The LCD module also includes a 128 x 64 pixel, back lit graphical display, to providelocal display of Gemstart 5 information. The display can be in English (UK), French,German or a User Defined language (Norwegian has been deleted from baselanguages but can be reintegrated as User Defined Language). The requiredlanguage required can be selected from the Configuration Editor.

The data and format displayed is configurable using the Configuration Editor.

Running A415V, 123.4kW, 0.66

90%, 90%, 90%FLC

Thermal Overload Tri3 ALC Warn.3/3 Imbal

101: 12-GM-3456

StatusVoltage and Power

FLC Currents

Scrolling Primary faultRotating list of other faults

Link address and Tag Number

LINE 1

2

3

4

5

6

7

L1-2= 415V123.4A,123.4A,123.4A

235Hr, 612 Ops

No Faults

101: 12-GM-3456

VoltageAMPS

Hours and Operations

SCROLLING PRIMARY FAULT

Rotating list of other faults


LINE 1

2

3

4

5

6

7

L1^100%FLC

415V, 123.4kW, 0.66

No Faults

101: 12-GM-3456

Highest Percentage

Voltage and Power

Scrolling Primary fault

Rotating list of other faults


LINE 1

2

3

45

6

7

Typical example of Gemstart 5 data on graphical display.


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7.2 Gemstart 5 Fault MessagesAll fault messages are displayed on both the LCD display and in the FAULTS itemwindow in the GEMPRO control tool. Refer to the list below for the full meaning of themessage.

The ~ symbol indicates where the severity text (Warn, Alarm Trip, LTrip) is placed.Warn is a self clearing message

Alarm is a latched message. Reset Faults to clear.

Trip is a self clearing trip. The motor is stopped and cannot be started until the tripsource is cleared.

LTrip is a latched trip. The motor is stopped and cannot be started. Reset Faults toclear the fault. If the fault is still present the fault message cannot be reset.

The reset groups are:

T: Thermal Protection

M: Motor Protection

A: Application Protection

I: Interlocks

E: Earth Protection

There are a number of ways that the Resets can be carried out, namely:

Reset Faults using PC Control tool in Monitor Mode

See Configuration Editor, GEMPRO item for configuration options.

Reset Faults using PC Control tool in Control Mode - Resets all Faults as well asindividual Statistics with Reset buttons shown beside certain items displayed byGEMPRO. e.g. maintenance data.

Reset Faults using the Reset Input function

See Configuration Editor, Digital Inputs item for configuration options.

Reset Faults from release of Stop button

See Configuration Editor, Manual Controls item for configuration options.

Reset Faults using the Communications Host Operator

See Configuration Editor, Communications item for configuration options.

Reset Faults using the Communications Host Supervisor

See Configuration Editor, Communications item for configuration options.


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Gemstart 5 Fault Messages list

FAULT MESSAGE

FAULTCODE SENT

DOWNSERIAL LINK

S E V E R I T Y

R E S

E T

G R O

U P

MEANING

Unknown Fault Code ~. 1 An unknown fault code is present. UseGEMPRO see what the fault code is

Config. Conflict ~. 2 TripThe configuration in GEMSTART doesnot match the configuration passed viathe serial link

Isolator Fault ~. 3 Config. I The isolator is off

Undefined Fault ~. 4Undefined fault. This is a general faultmessage provided for futurecompatibility

Earth Fault ~. 5 Config. E The configured mode of earth faultdetection has detected an earth fault

Thermistor Relay ~. 6 Config. T The thermistor relay input toGEMSTART is active

Overload Relay ~. 7 Config. T The external thermal overload relay isactive

Thermal Overload ~. 8 Config. T The estimated thermal content of the

motor is over 100%9 Not Used

Manual Stop ~. 10 TripThe manual Hard Stop input is activeand GEMSTART is NOT in Manualmode. The Fault is self clearing

11 Not Used

Interlock ~. 12 Config. IAn external emergency stop orinterlock has removed the supply forthe contactors

Failed to Close A ~. 13 Trip &Alarm IGEMSTART could not close contactorA. The state of contactor A is derivedfrom the Auxiliary input

Failed to Close B ~. 14 Trip &Alarm IGEMSTART could not close contactorB. The state of contactor B is derivedfrom the Auxiliary input

Failed to Open A ~. 15 Trip &Alarm IGEMSTART could not open contactorA. The state of contactor A is derivedfrom the Auxiliary input

Failed to Open B ~. 16 Trip &

AlarmI

GEMSTART could not open contactorB. The state of contactor B is derivedfrom the Auxiliary input


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FAULT MESSAGE

FAULTCODE SENT

DOWNSERIAL LINK

S E V E R I T Y

R E S E T

G R O U P

MEANING

PAMM Read/Write ~. 17 Config.

The unit has failed to read or write tothe PAMM. This fault occurs whilstpower is valid and no data has yetbeen lost

Release Manual Start~. 18 Warn

One of the manual start inputs isactive but the relevant contactor isopen

Current Flow WhileOpen ~. 19

Trip &Alarm A

Both contactors are open but currentflow to the motor has been detected

Fwd/Rev ~. 20 WarnA request to close has been receivedwhile the opposite contactor is closed

Release Host Start ~. 21 Warn

A host close command is beingreceived in Auto or Priority mode andthe contactor is open. A Start edgemust be seen to generate a startcommand

Under Current ~. 22 Config. AThe motor current has been below theconfigured under current level for theconfigured time

Start Current ~. 23 Config. MThe current during startup exceededthe configured limit

Start Time ~. 24 Config. M The start time has exceeded theconfigured limit

Continuous ALC ~. 25 Config. AThe current was above the continuousALC level for longer than theconfigured time

Instant ALC ~. 26 Config. A The current reached the instant ALClimit

Restart Inhibit ~. 27 Trip &Alarm T

Restart inhibit. The motor can berestarted in xxxxs. This is theestimated time to reach the pointwhere a successful start can becompleted. GEMPRO displays"Restart Inhibit", Gemstart displaysAvailable xxxxs

28 Not Used

ELCB Fault ~. 29 Config. I The input assigned as ELCB fault hasdetected a fault condition


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FAULT MESSAGE

FAULTCODE SENT

DOWNSERIAL LINK

S E V E R I T Y

R E S E T

G R O U P

MEANING

AutoRestart ~.30 Warn

Contactor will be closed by the autorestart function in xxxx seconds.GEMPRO displays "Auto RestartWarn". Gemstart displays Restartxxxxs

Imbalance ~. 31 Config. M The configured imbalance level hasbeen detected

Single Phasing ~. 32 Config. M An imbalance of 80% has beenpresent for the configured time

Power Factor High ~. 33 Config. AThe power factor is above the powerfactor high level

Power Factor Low ~. 34 Config. A The power factor is below the powerfactor low level

Overload Reset Delay~. 35 Trip T

Time remaining after an overloadcondition before GEMSTARTbecomes available

Device Fault ~. 36 Config. I The device connected has reported afault (i.e. breaker, VSD etc.)

User Text Message 1 37 Config. I User defined text input 1 has become

invalidUser Text Message 2 38 Config. I User defined text input 2 has becomeinvalid

Chassis SettingsChanged ~. 39 Warn

One of the Chassis Definitionconfiguration items has changedduring a power down. This means thechassis has been moved to a newPAMM. Check the chassis settingsbefore resetting the fault

Failed to Close C ~. 40 Trip &

AlarmI

GEMSTART could not close contactorC. The state of Contactor C is derivedfrom the auxiliary input

Failed to Open C ~. 41 Trip &Alarm IGEMSTART could not open contactorC. The state of Contactor C is derivedfrom the auxiliary input

Unexpected Open A ~. 42 Trip &Alarm IContactor A opened when it was notexpected. The state of Contactor A isderived from the auxiliary input

Unexpected Open B ~. 43 Trip &Alarm IContactor B opened when it was notexpected. The state of Contactor B isderived from the auxiliary input


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FAULT MESSAGE

FAULTCODE SENT

DOWNSERIAL LINK

S E V E R I T Y

R E S E T

G R O U P

MEANING

Unexpected Open C ~. 44 Trip &Alarm IContactor C opened when it was notexpected. The state of Contactor C isderived from the auxiliary input

Unexpected Close A ~. 45 Trip &Alarm IContactor A closed when it was notexpected. The state of Contactor A isderived from the auxiliary input

Unexpected Close B ~. 46 Trip &Alarm IContactor B closed when it was notexpected. The state of Contactor B isderived from the auxiliary input

Unexpected Close C ~. 47 Trip &Alarm IContactor C closed when it was notexpected. The state of Contactor C isderived from the auxiliary input

Changeover Timeout ~. 48 Trip &Alarm I

The requested change from FWD toREV or STAR to DELTA has faileddue to current still flowing or thecontactor not opening

Phase Reversal ~. 49 Config. A The phases are not rotating or notrotating in the correct order

Starts/Hr ~. 50 Config. M The number of starts per hour hasbeen exceeded. A warn is issued

Unknown ContactorType ~. 51 Alarm

The configured contactor type is notavailable to this unit

Over Voltage ~. 52 Config. M The supply voltage is above 110% ofthe nominal voltage

Under Voltage ~. 53 Config. M The supply voltage is below 90% ofthe nominal voltage

Test Mode ~. 54 Config. I GEMSTART has been withdrawn tothe test position

Host Link Lost ~. 55 Warn orTrip

The serial link has timed out but bytes

are still being received. The timeouttime varies with the link speed.GEMSTART will cycle through thebaud rates in an attempt to find a validmessage

No GS RX ~. 56 Warn No Bytes received from Host (Link fail)

GS RX Crossed ~. 57 WarnFailed CRC checks at all baud rates(Link fail). Suspect that the RX lineshave been crossed

Baud Rate Scan ~. 58 Warn

All baud rates are being scanned to

find a valid link speed. If all rates failmessage changes to GS RX Crossed


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FAULT MESSAGE

FAULTCODE SENT

DOWNSERIAL LINK

S E V E R I T Y

R E S E T

G R O U P

MEANING

Address in use ~. 59 WarnSequence bit toggling before replysent by this unit so another unit isusing this address

TX RX Lines Crossed~. 60 Warn

Primed by previous message butfailed CRC to this address

Speed Sense ~. 61 Config. M The Speed Sense input has not beenactivated within the required time

Wrong Host Link ~. 62 Warn The number of the link does not matchthe configured link

GS TX Fault ~. 63 Warn

Gemstart is not receivingacknowledgements from the Host thatit has received a message fromGemstart. (The sequence bit is notchanging.)

Stop Delayed.

(Contactor Protection)64 Alarm I

The current flowing is too high to openthe contactor. The stop command isnot actioned until the current drops orthe fuse delay has been exceeded

65 Not Used

66 Not Used67 Not Used

68 Not Used

69 Not Used

PAMM Config Invalid ~. 70 Alarm

One or more of the 16 configurationblocks could not be read from thePAMM. Default configuration has beenused. The default configuration shouldbe overwritten by GEMPRO when thelink is established. CHECK ALL

CONFIGURATION VALUES BEFORERESETTING THIS TRIP

71 Not Used

PAMM Motor Data Lost~. 72 Alarm

The motor data in the PAMM could notbe read. All or some motor data hasbeen lost

73 Not Used

74 Not Used

75 Not Used


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FAULT MESSAGE

FAULTCODE SENT

DOWNSERIAL LINK

S E V E R I T Y

R E S E T

G R O U P

MEANING

Host TX Range ~. 76 Warn This Gemstart is not in the addressrange addressed by the host

Config Area XSUM ~. 77 LTrip

The configuration data in Gemstarthas been corrupted. CHECK ALLCONFIGURATION VALUES BEFORERESETTING THIS TRIP

78 Not Used

Wrong PAMM ~-Resetto Clear.

New PAMM ~-ResetTrips to Initialise

79 LTrip

The PAMM is not a Gemstart 5 PAMMor is new. Default configuration data isloaded into GEMSTART. ResettingTRIPS will load the PAMM with thedefault configuration data

Manual Start and StopActive ~. 80 Warn

The START command will not functionwhile the STOP input is active

81 Not Used

82 Not Used

Unknown FunctionEnabled ~. 83 Alarm

The PAMM has been configured witha feature which is unknown to thisGemstart. Update Gemstart Firmware

or replace with a more up to date unitUnder Power ~. 84 Config. A Under Power Protection has beenactivated

Over Power ~. 85 Config. A Over Power Protection has beenactivated

CRC Failed ~. 86 Alarm Program code CRC failed

Config Error ### Warn~. 87 Warn

This fault is generated if there is aproblem with the configuration data.The number in the message indicatesthe first configuration error that

occurred. The codes are:

10 - The FLC level is too high for theconfigured CT.

11 - The primary CT rating isunknown.

12 - Contactor rating level too high forthe configured CT.

13 - FLC Set too low for the CT ( FLC.


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FAULT MESSAGE

FAULTCODE SENT

DOWNSERIAL LINK

S E V E R I T Y

R E S E T

G R O U P

MEANING

15 - Start Current limit level too highfor the configured CT.

20 - The difference between EF CTrange and Fault range is toomuch.

21 - The EF CT must be definedbefore EF fault can be enabled

22 - The ratio of the fault to the EF CTis too big.

23 - The ratio of the startup fault to theEF CT is too big.

24 - The EF Fault level is too big forthe EF CT input.

25 - The Residual CT EF Fault level istoo low (below 100mA)

30 - Power set too high.

31 - Power set too low.

32 - Power protection enabled but kWcannot be calculated

40 Ride-through > Max Dip Time

41 3 CTs configuration onGemstart5.3

42 Profibus Ampsx100 not valid withexternal CT

43 Profibus Powerx100 not valid forthis range

44 Ride-Through = No Limitincompatible with Volatile Supply

Inputs100-199 The above faults are

increased by 100 if the error onlyexists in the Speed 2configuration

The fault clears itself once theconfiguration problem is resolved.

HV on LV input ~. 88 Alarm Input wrongly configured or volts toohigh for configured voltage level


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FAULT MESSAGE

FAULTCODE SENT

DOWNSERIAL LINK

S E V E R I T Y

R E S E T

G R O U P

MEANING

Chassis Input OverloadWarn ~. 89 Warn

Common 24v short circuited.

PTC Over Temperature 90 Config. T The temperature measurementthermistor has rea

gemstart 5 - vol 1 - user guide

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