Pel004 1071 004

Publication date April 03
Gemstart 4
Volume 3 - Specification Reference
Technical Handbook 15G0012(E)
Gemstart 4
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
that any Operator(s) reads and understands the content of this Technical
Handbook and follows 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 is
available from ALSTOM T&D Ltd to assist you in complying with relevant Health and Safety
Regulations.
Should you require further guidance or information regarding this equipment, or information
on our After Sales Services available, please contact our Customer Services Department at the
address below who will be pleased to assist:
ALSTOM T&D Ltd - Services

Frederick Road, Salford
M6 6QH, England
Tel.: +44 (0)161 745 9090

Fax: +44 (0)161 745 4482
E-mail: tom.lavin@tde.alstom.com
Our policy is one of continuous product development. We reserve the right to supply
equipment that may vary from that described.
The information contained within this Technical Handbook may not be reproduced or passed
on to third parties, either wholly or in part, without the express prior written consent of
ALSTOM T&D Ltd.
15G0012(E)
Page 3
Gemstart 4
Health and Safety

The User shall ensure that only qualified and authorised Operators, trained in the tasks to be
undertaken, are allowed to work on the equipment. All work must be performed in
accordance with local and national Health and Safety Regulations.
All relevant Warnings and Cautions shall be noted and their content strictly adhered to during
the Installation, Commissioning, Operation, Maintenance and Testing (where applicable) of
this equipment.
This equipment uses, or controls, fatal voltages. It is recommended therefore that Operators
working 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 components
are disposed of in accordance with local and national Environmental Legislation and
Regulations. Some components may present a particular hazard to the environment if not
disposed of correctly.
The equipment must not be modified without prior consultation with ALSTOM T&D Ltd.
Modification without ALSTOM’s consent may invalidate the warranty and any product liability.
Should the Operator/User require any guidance or advice regarding the equipment, this can
be obtained by contacting ALSTOM at the address below:

M6 6QH, England
Tel.: +44 (0)161 745 9090

Fax: +44 (0)161 745 4482
15G0012(E)
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Gemstart 4
Customer Services
ALSTOM’s Customer Services Department can provide continuous Customer support
throughout 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
ALSTOM’s specialised Customer Service Engineers are available to provide the services listed
above, either in our Salford workshop, or alternatively, at your site.
To assist us in providing an efficient and timely service, before contacting ALSTOM to discuss
existing equipment, please help us by having the following information available:
The original ALSTOM works order number or
The unit serial number and the unit type and voltage
When you have the information listed above, please contact us at the address below:

M6 6QH, England
Tel.: +44 (0)161 745 9090

Fax: +44 (0)161 745 4482
15G0012(E)
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Gemstart 4
Table of Revisions
Edition Description
A Original issue
B Completely revised
C Updated in line with Gemstart version F8
D Updated Gemstart 3 Fault Codes.

Added User Text application note.
E Fixed error in GS4 Time to Trip equation
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Gemstart 4
Acronyms and Abbreviations

Item Meaning
A Amperes
ac Alternating Current
ALC Actual Load Current
CT Current Transformer
dc Direct Current
FLC Full Load Current
I/O Input / Output
kA Kilo Ampere
kV Kilo Volt
LED Light Emitting Diode
LCD Liquid Crystal Display
mA Milli Ampere
mm Milli Metre
ms Milli Second
MW Mega Watt
Ops Operations
mA Micro Amperes
sec. Second
V Volt
VT Voltage Transformer
Symbols used within the Technical Handbook
ADVICE: information
CAUTION: precautions to
intended to assist in
be taken to avoid
performing specified
damaging the equipment
tasks
YOUR ATTENTION IS DANGER, ELECTRICITY:
DRAWN: specific precautions to be taken
points that should be to avoid injury to
noted. personnel.
MECHANICAL
DANGER: precautions
to be taken to avoid
injury to personnel.
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Gemstart 4
Contents
1 About this manual ..................................................................................................... 10

2 Introduction .............................................................................................................. 11
2.1 Definitions .......................................................................................................... 11
2.1.1 Contactor types............................................................................................. 11
2.1.2 Input functions .............................................................................................. 11
2.1.3 Input Configuration summary ........................................................................ 12
2.1.4 Protection functions ....................................................................................... 14
3 Functional specifications ............................................................................................ 15
3.1 Contactor type .................................................................................................... 15
3.1.1 Two Speed Dahlander Starter [Start in High or Low] (Gemstart 4.3 only) ......... 16
3.1.2 Two Speed Starter [Start in High or Low] (Gemstart 4.3 only) .......................... 18
3.1.3 Two Speed Starter [Start in Low Only] (Gemstart 4.3 only) .............................. 20
3.1.4 DOL-E.......................................................................................................... 22
3.1.5 Latching Contactor DOL-L (Gemstart 4.3 only) .............................................. 24
3.1.6 Forward/Reverse (Gemstart 4.3 only) ............................................................ 26
3.1.7 General Purpose I/O Unit.............................................................................. 28
3.1.8 MCCB Feeder ............................................................................................... 30
3.1.9 Motor Operated Valve (Gemstart 4.3 only) .................................................... 32
3.1.10 Star Delta using 1 Output .............................................................................. 34
3.1.11 Star Delta using 2 Outputs (Gemstart 4.3 only).............................................. 36
3.1.12 Star Delta using 3 Outputs (Gemstart 4.3 only).............................................. 38
3.1.13 Variable Speed Drive (Cut Throat Control)...................................................... 40
3.1.14 Variable Speed Drive [Logic Control] (Gemstart 4.3 only) ............................... 42
3.2 Contactor type/advanced settings ........................................................................ 44
3.2.1 Contactor rating ........................................................................................... 44
3.2.2 Fuse Time ..................................................................................................... 44
3.2.3 Contactor input A source. .............................................................................. 44
3.2.4 Contactor input B source. .............................................................................. 44
3.2.5 Contactor input C source............................................................................... 45
3.2.6 Contactor input D source............................................................................... 45
3.2.7 Contactor input A, B, C & D sense. ................................................................ 45
3.2.8 Hardware Outputs 1 to 4 Source ................................................................... 45
3.2.9 Hardware Outputs 1 to 4 sense. .................................................................... 47
3.2.10 Check Auxiliaries........................................................................................... 47
3.2.11 Changeover Allowed (Gemstart 4.3 only) ....................................................... 47
3.2.12 Follower Contactor........................................................................................ 47
3.2.13 Minimum Start Time ...................................................................................... 47
3.2.14 Maximum STAR Time (4.3 only) ..................................................................... 47
3.2.15 Slow Down Time (4.3 only) ............................................................................ 48
3.2.16 Level Triggered Start ..................................................................................... 48
3.2.17 Analogue Input Type ..................................................................................... 48
3.3 Input functions .................................................................................................... 49
3.3.1 Counter 1 / Counter 2 / Counter 3 ................................................................ 50
3.3.2 Device Status ................................................................................................ 51
3.3.3 ELCB Relay ................................................................................................... 52
3.3.4 Emergency Start A / Emergency Start B........................................................... 53
3.3.5 Hard STOP ................................................................................................... 54
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3.3.6 INCH Select .................................................................................................. 55

3.3.7 Interlock ....................................................................................................... 56
3.3.8 Isolator......................................................................................................... 57
3.3.9 Manual Select ............................................................................................... 58
3.3.10 Manual Start A / Manual Start B..................................................................... 59
3.3.11 Overload Relay ............................................................................................. 61
3.3.12 Process Stop A / Process Stop B...................................................................... 62
3.3.13 Remote Select ............................................................................................... 63
3.3.14 Reset Input.................................................................................................... 65
3.3.15 Test Mode Start ............................................................................................. 66
3.3.16 Test Position.................................................................................................. 67
3.3.17 Thermistor Relay ........................................................................................... 68
3.3.18 User Text 1 / User Text 2 ............................................................................... 69
3.4 Protection functions ............................................................................................. 70
3.4.1 CFG / Contactor / Fail/Recover Voltages........................................................ 71
3.4.2 CFG / Motor Protection / FLC Setting ............................................................. 72
3.4.3 CFG / Motor Protection / Startup Current ....................................................... 73
3.4.4 CFG / Motor Protection / Startup Time ........................................................... 75
3.4.5 CFG / Motor Protection / Thermal Overload .................................................. 77
3.4.6 CFG / Motor Protection / Thermal Reset Delay................................................ 83
3.4.7 CFG / Motor Protection / Restart Inhibit.......................................................... 84
3.4.8 CFG / Motor Protection / Single Phasing ........................................................ 85
3.4.9 CFG / Motor Protection / Imbalance .............................................................. 86
3.4.10 CFG / Motor Protection / Starts in Hour.......................................................... 87
3.4.11 CFG / Motor Protection / Speed Sense ........................................................... 88
3.4.12 CFG / Motor Protection / Voltage Protection (4.3 only) .................................... 89
3.4.13 CFG / Motor Protection / Earth Fault Protection .............................................. 91
3.4.14 CFG / Contactor / Advanced Settings / Contactor Protection ........................... 94
3.4.15 CFG / Measurements / Power Rating (4.3 only) .............................................. 95
3.4.16 CFG / Application Protection / Set ALC .......................................................... 96
3.4.17 CFG / Application Protection / Phase Reversal ................................................ 97
3.4.18 CFG / Application Protection / Under Current ................................................ 98
3.4.19 CFG / Application Protection / Instant ALC ..................................................... 99
3.4.20 CFG / Application Protection / Constant ALC ............................................... 100
3.4.21 CFG / Application Protection / Under Power (4.3 only).................................. 101
3.4.22 CFG / Application Protection / Over Power (4.3 only) ................................... 103
3.4.23 CFG / Application Protection / Power Factor High (4.3 only) ........................ 105
3.4.24 CFG / Application Protection / Power Factor Low (4.3 only).......................... 106
3.4.25 CFG / Application Protection / AutoRestart (4.3) ........................................... 107
List of Figures
Figure 1 Gemstart 3 curves ............................................................................................ 81
Figure 2 - Gemstart 4 curves ............................................................................................ 82
List of Tables
Table 1 - Key to abbreviations .......................................................................................... 12

Table 2 - Input Configuration Options .............................................................................. 13
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Gemstart 4
1 About this manual

This reference manual contains the specifications of the contactor types, input and output
functions which are relevant to Gemstart 4.
Readership
The publication is a reference for engineers who are responsible for setting up and
configuring Gemstart 4.
Related publications
n Volume 1: Gemstart 4 User Guide
Volume 1 is for the general engineer and user who will install, commission,
use and maintain Gemstart 4
n Volume 2: Gemstart 4 Design guide
Volume 2 is for the expert engineer who needs to exploit the advanced
facilities provided by Gemstart 4
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Gemstart 4
2 Introduction
2.1 Definitions
This reference manual specifies the detail of the functions of Gemstart 4
q Contactor types
q Input functions
q Protection functions
Each of the items is defined individually. The information for each set of items
follows the same layout which is briefly described in the following sections.
2.1.1 Contactor types

Specifications of the Gemstart 4 contactor types are given under the following
headings:
n Description
A description of the type of contactor
n Options
Any variations on the contactor connection are given
n Connections
A diagram of the contactor inputs and outputs and their open or closed
status is shown
n Configuration
A list is given of the contactor settings including configuration options
n Special settings
Any special settings of the contactor type are described
2.1.2 Input functions

Specifications of the Gemstart 4 input functions are given under the following
headings:
n Menu location:
The Hand held programmer keystrokes to configure this item.
n Source:
The source from which the signal which activates this function is derived
from.
n Advanced settings:
SENSE OPTIONS: Type of contact applied to source (normally closed or
normally open)
REPORTING OPTIONS: The action the Gemstart unit takes when the input is
activated
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Gemstart 4
n Fault codes:
GEMSTART 4 LINK: The fault code sent on the GS4 link when the input is
activated
GEMSTART 3 LINK:
Trip: Fault code sent on GS3 compatible link if Tripped
Alarm: Fault code sent on GS3 compatible link if in Alarm
Warn: Fault code sent on GS3 compatible link if in Warn
n Description:
A description of the input function and the expected device which activates
it
n Application notes:
Any comments which may help in applying the input function. This could
include methods of applying the function and any special circumstances
2.1.3 Input Configuration summary

Gemstart 4 allows for flexible function definitions. Every input functions can be
assigned to any of the inputs offered by the product. A key to the abbreviations
is given in Table 1.
A Summary of functions available is shown in Table 2. A full description of the
input functions can be found in the appropriate function description.
The table shows the function type, the options available for polarity and the
type of fault that can be initiated when the input event occurs.
Table 1 - Key to abbreviations
Abbreviation Meaning
N/A Not Applicable
N/O Normally Open. The input closes when active
N/C Normally Closed. The input opens when active
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
cleared automatically
LA Latched Alarm. The alarm flag must be cleared by a reset trips
or reset alarms command
SCW Self Clearing Warn. If the warn input signal clears the warn flag
is cleared automatically
None No faults are flagged when an input is defined as this
The standard input type option is shown in bold.
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Gemstart 4
Table 2 - Input Configuration Options
Configuration Options Input Type Fault Types

Options
Contactor A input N/O, N/C None, see contactor type definition
Contactor B input N/O, N/C None, see contactor type definition
Contactor C input N/O, N/C None, see contactor type definition
Contactor D input N/O, N/C None, see contactor type definition
Hard Stop N/O ,N/C No Options, always a SCT
Process Stop A N/O, N/C No Options, always a SCT
Process Stop B N/O, N/C No Options, always a SCT
Manual Start A N/O, N/C No Options
Manual Start B N/O, N/C No Options
Emergency Start A N/O, N/C No Options
Emergency Start B N/O, N/C No Options
Test Mode Start N/O, N/C No Options
Manual Select N/O, N/C No Options, no fault is flagged
INCH Select N/O, N/C No Options, no fault is flagged
Remote Select N/O, N/C No Options, no fault is flagged
Interlock N/O, N/C OFF, SCW, LA, SCT, LT
Overload Relay N/O, N/C OFF, SCW, LA, SCT, LT
User text 1 N/O, N/C OFF, SCW, LA, SCT, LT
User text 2 N/O, N/C OFF, SCW, LA, SCT, LT
Thermistor Relay N/O, N/C OFF, SCW, LA, SCT, LT
ELCB Relay N/O, N/C OFF, SCW, LA, SCT, LT
Isolator N/O, N/C OFF, SCW, LA, SCT, LT
Device Trip N/O, N/C OFF, SCW, LA, SCT, LT
Trip reset N/O, N/C None
Test Position N/O, N/C OFF, SCW, LA, SCT, LT
Counter 1 N/O, N/C None
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Gemstart 4
2.1.4 Protection functions

Specifications of the Gemstart 4 protection functions are given under the
following headings:
n Item title and description
The item title indicates the menu position on the Hand Held Programmer.
Features of the item are then described
n Pre-requisites
Other configuration items that need to be defined before this item
n Configuration items
The configuration items and options for this item are listed.
The new system (default) settings are shown in bold.
Guidance is given on selecting the best option
n Protection wizard
Any changes to the configuration items by the protection Wizards are
defined here
n Additional information
Information is given about this item which may be useful
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Gemstart 4
3 Functional specifications
3.1 Contactor type
To define the type of control required from a Gemstart 4 unit the contact type
must be configured. Various styles of automation are provided each of which is
described in the following datasheets:
Contactor type Section Gemstart Page

type number
2 Speed Dahlander 3.1.1 4.3 16
2 Speed High/Low 3.1.2 4.3 18
2 Speed Low Start 3.1.3 4.3 20
DOL-E 3.1.4 4.2, 4.3 22
DOL-L 3.1.5 4.3 24
Forward / Reverse 3.1.6 4.3 26
General Purpose 3.1.7 4.2, 4.3 28
I/O
MCCB Feeder 3.1.8 4.2, 4.3 30
MOV 3.1.9 4.3 32
Star Delta 1 O/P 3.1.10 4.2, 4.3 34
Star Delta 2 O/P 3.1.11 4.3 36
Star Delta 3 O/P 3.1.12 4.3 38
VSD Cut Throat 3.1.13 4.2, 4.3 40
VSD Logic 3.1.14 4.3 42
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Gemstart 4
3.1.1 Two Speed Dahlander Starter [Start in High or Low]

(Gemstart 4.3 only)
Description
This two speed starter allows a motor with two sets of windings to be
controlled. The two windings have two different sets of protection settings. The
only link between the two protection sets is the thermal content mimic of the
motor. The Dahlander motor uses tapped windings to provide the two winding
connection methods.
A close A command closes the Low Speed contactor and close B closes the
High speed contactor. In Manual and Local modes this contactor must go
through stop to change speed. A change of speed from the Host is taken
through stop automatically.
Low Speed Û Stopped Û High Speed

Options
The Line contactor for the High speed connection may be omitted. The Low
speed contactor and High speed star contactor must be wired in to prevent
these contactors being closed at the same time and creating a short across the
3 phases.
Connections
The software contactor control block is defined as:
Inputs Outputs
Low Speed Aux A A Low Speed contactor
High Speed Line Aux (Opt) B B High Speed Line cont.
High speed star Aux C C High speed Star cont.
D D No Trips
Dahlander
(Low or High
Start)
All inputs are Normally Closed.
All outputs are Normally Open.
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Gemstart 4
Configuration
The contactor control is configured and connected as follows:
Configuration Item Configuration Option

Auxiliary Testing On
Follower Contactor No
Changeover Allowed in Manual No
Minimum Start Time 1s
Contactor Rating 1000% of CT
Fuse Time to Blow at Contactor Rating 1s
Contactor Input A Hardware Input 1
Contactor Input B Hardware Input 5
Contactor Input C Hardware Input 7
Contactor Input D Closed
Hardware Output 1 Contactor Output A
Hardware Output 2 Contactor Output B
Hardware Output 3 Contactor Output C
Hardware Output 4 Contactor Output D
Analogue input type 25mA a.c.
Level start at power on Off
Slow down delay 0.0s
Special Settings
This contactor type can be used as a follower contactor if the A and B Aux are
wired in. The contactor will followed Low Speed Start if the A Aux is closed with
B and C Open. A High speed start is followed if the B Aux is closed with the A
Aux open.
Application notes
The configuration item ‘slow down delay’ provides a minimum time the motor
must remain in the stopped condition when moving from high speed to low
speed. There is no delay when moving from low to high speed.
Example. A Two Speed motor is running in high speed with a 30s Slow
Down Time.
Case 1: The stop button is pressed and the motor stops. The Low Start
button is pressed 10s later. Gemstart displays “Slow Down Delay.” for 20s then
the low speed contactor is closed.
Case 2: The Low Start button is pressed while in High Speed. Gemstart
displays “Slow Down Delay.” for 30s then the low speed contactor is closed.
The slow down delay will not be maintained though a power down. Therefore
a long delay can be reset by power cycling Gemstart.
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Gemstart 4
3.1.2 Two Speed Starter [Start in High or Low]

(Gemstart 4.3 only)
Description
A two speed starter allows a motor with two sets of windings to be controlled.
The two windings have two different sets of protection settings. The only link
between the two protection sets is the thermal content mimic of the motor. This
version of Two Speed will allow the motor to be started in High or Low .
High speed contactor. A change of speed is allowed in all control modes.
Stopped Û Low Speed Û High Speed Û Stopped
Options
There are no options to wiring these contactors as Gemstart must know the
state of contactors. By knowing both contactor positions Gemstart can ensure
that a 3 phase short is not generated by having both contactors closed at the
same time.
Connections
Inputs Outputs
Low Speed Aux (Optional) A A Low Speed
High Speed Aux (Optional) B B High Speed
C C Trip active
D D No Trips
Two Speed
(Low or High Start)

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Gemstart 4
Configuration

Changeover Allowed in Manual Yes
Contactor Input C Closed
Special Settings
wired in.
Application notes
Down Time.
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Gemstart 4
3.1.3 Two Speed Starter [Start in Low Only]

(Gemstart 4.3 only)
Description
A two speed starter allows a motor with two sets of windings to be controlled.
The two windings have two different sets of protection settings. The only link
between the two protection sets is the thermal content mimic of the motor. This
version of Two Speed will not allow the motor to be started in High Speed.
High Speed can only be started if Low Speed has completed the Startup phase.
A high speed start from the stop condition will automatically cycle through a
low speed start first before moving to high speed.
High speed contactor. A change of speed is allowed in all control modes.
Stopped Û Low Speed Û High Speed Þ Stopped
Options
same time.
Connections
Inputs Outputs
Low Speed Aux (Optional) A A Low Speed
High Speed Aux (Optional) B B High Speed
C C Trip active
D D No Trips
Two Speed (Low Start)
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Gemstart 4
Configuration:

Please refer to Contactor type/advanced settings later in this chapter
Special Settings:
wired in.
Application notes:
Down Time.
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Gemstart 4
3.1.4 DOL-E
Description:
The Direct On Line Electrically Held (DOL-E) contactor is the simplest and most
common contactor type. The contactor is held closed while the Output to the
contactor is on.
Options:
The auxiliary connection from the contactor can be fed back to Gemstart to
allow the status of the contactor to be reported to the user. If the auxiliary is not
connected and the Contactor Input is configured to Closed then the position of
the contactor is assumed from the intended contactor status.
Connections:
Inputs Outputs
Contactor Aux (Optional) A A Contactor
B B Off
C C Trip active
D D No Trips
DOL-E
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Gemstart 4
Configuration:
The contactor settings for DOL-E are configured as follows:
Configuration item Configuration option

Fuse Time to Blow at Contactor 1s
Rating
Contactor Input B Closed
Slow down delay Not Applicable
Special Settings:
This contactor type can be used as a follower contactor if the A Aux is wired in.
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Gemstart 4
3.1.5 Latching Contactor DOL-L

(Gemstart 4.3 only)
Description:
The latching contactor is a mechanically latched contactor which uses two coils
to latch the contactor closed or delatch the contactor. Output A is used to latch
(close) the contactor. Output B is used to delatch (open) the contactor.
Options:
None
Connections:
Inputs Outputs
Line Aux A A Latch
B B Delatch
C C Trip active
D D No Trips
DOL-L
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Gemstart 4
Configuration:

Slow down Delay Not applicable
Special Settings:
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Gemstart 4
3.1.6 Forward/Reverse
(Gemstart 4.3 only)
Description:
The forward reverse contactor allows a motor to be driven in either direction.

Before closing one of the contactors a test is performed to ensure that the
opposite contactor is open and that there is no current flowing. The current
check ensures that there is no arcing.
A close A command closes the forward contactor. A close B command closes

the Reverse contactor. In Manual and Local modes this contactor must go
through stop to change direction. A change of direction from the Host is taken
Options:
same time.
Connections:
Inputs Outputs
Forward Contactor Aux A A Forward Contactor
Reverse Contactor Aux B B Reverse Contactor
C C Trip active
D D No Trips
Forward/Reverse
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Gemstart 4
Configuration:

Special settings:
This contactor type can be used as a follower contactor.
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Gemstart 4
3.1.7 General Purpose I/O Unit
Description:
This allows Gemstart to be used for simple I/O. Minimal error checking is
performed on the outputs. The only change to outputs is that Outputs A and B
are turned Off if the Link has failed and Gemstart is configured to Link Fail
Trip.
The 4 bit Host Command is used as the source for the 4 off GP outputs. These
4 bits can be modified by the HHP if the HHP is in control. On returning the
HHP to Monitor the GP Outputs are updated with the Host command again
and could therefore resume their original state.
NOTE: There is no edge detection on these commands.
Options:
No options.
Connections:
Inputs Outputs
A A Command bit 0
B B Command bit 1
C C Command bit 2
D D Command bit 3
GP I/O
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Gemstart 4
Configuration:

Auxiliary Testing No
Contactor Input A Closed
Analogue input type 4-20mA d.c.
Slow down Delay Not Applicable
Special Settings:
No special settings.
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Gemstart 4
3.1.8 MCCB Feeder
Description:
This contactor type allows easy control of a latching device which is normally
manually controlled rather than via Gemstart.
NOTE: This option should only be used on Gemstarts which do

not have a front panel switch, as activation of the STOP switch
would prevent the TRIP output being activated.
Control via Gemstart
Opening this contactor type will activate the Trip Output for a fixed duration.
Closing will activate the Close Output for a fixed duration. The Running Aux is
fed to Input A as the Open Aux may not report Open when the drive is tripped.
Manual control
Once the contactor driver has come out of the latching or tripping state it will
follow any changes on the auxiliary input.
Options:
The Closing coil does not have to be used on this contactor type. This allows
units with only one output to be used to monitor and trip an MCCB.
Connections:
Inputs Outputs
Running Aux A A Trip coil
B B Closing Coil (Optional)
C C Trip active
D D No Trips
MCCB
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Gemstart 4
Configuration:

Follower Contactor Yes
Special Settings:
This contactor type defaults to a follower contactor. The A Aux must be wired
in.
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Gemstart 4
3.1.9 Motor Operated Valve

(Gemstart 4.3 only)
Description:
Motor operated valves use a motor to open or close a valve. Limit switches at
either end of the valve travel indicate when the motor has reached the fully
closed or fully open position.
A close A command Opens the valve for maximum flow. A close B command
Closes the valve for no flow. When the relevant limit switch is activated the
contactor is opened. In Manual and Local modes this contactor must go
through stop to change direction. A change of direction from the Host is taken
Open Value = Start A = Software Output A = Hardware Output 1
Valve fully Open = “Open Limit Switch” Open Circuit = Input 7 Open
Options:
same time.
Connections:
Inputs Outputs
Opening Contactor Aux A A Open Valve Contactor
Closing Contactor Aux B B Close Valve Contactor
Fully Open Limit Switch C C Trip active
Fully Closed Limit Switch D D No Trips
Forward/Reverse
15G0012(E)
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Gemstart 4
Configuration:
The software contactor control block is configured and connected as follows:

Auxiliary Testing Off
Contactor Input D Hardware Input 8
Slow down Delay 0.0s
Special Settings:
This contactor type can be used as a follower contactor.
Application Notes:
The limit travel switches must be placed in line with the forward and reverse
contactors. To implement this slave open and close relays are required see
example circuits in Volume 1.
To provide remote positional indication status bit 11 and status bit 13 must be
configured to inputs 7 and 8.
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Gemstart 4
3.1.10 Star Delta using 1 Output
Description:
For units with a single output for the line contactor. Used to drive a Star Delta
changeover relay. After the minimum start time has expired Gemstart will wait
for the Star contactor to open and then the current to drop below 100% FLC
before ending startup.
Options:
The Delta Auxiliary does not have to be connected.
Connections:
Inputs Outputs
Line Aux A A Line Cont. (and timer relay)
Delta Aux (Optional) B B Off
Star Aux C C Trip active
D D No Trips
Star/Delta (1)
15G0012(E)
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Gemstart 4
Configuration:

Special Settings:
The minimum start time can be set to a fixed time roughly equal to the time to
delta of the star/delta relay.
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Gemstart 4
3.1.11 Star Delta using 2 Outputs

(Gemstart 4.3 only)
Description:
This is the same two output method of Gemstart 3. Output A drives the star
contactor and Output B drives the Delta contactor. Both outputs are slaved
from the interlock circuit.
The Line contactor is slaved from the auxiliaries of the Star or Delta contactors.
The statistics for Contactor C are maintained for the Line Contactor.
When a start command is actioned, the Star contactor (and therefore the line
contactor) is pulled in. The starter will remain in this state until the line current
decays to FLC. The star contact will then open and the Gemstart will wait until
the line current decays to zero. The Delta contactor will then be closed. The
Start period will then finish when the line current again falls below FLC.
Options:
same time.
Connections:
Inputs Outputs
Star Aux A A Star Contactor
Delta Aux B B Delta Contactor
C C Trip active
D D No Trips
Star/Delta (2)
15G0012(E)
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Gemstart 4
Configuration:

Auxiliary Testing Yes
Special Settings:
Closing the Star contactor will put Gemstart in to the Star startup condition.
15G0012(E)
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Gemstart 4
3.1.12 Star Delta using 3 Outputs

(Gemstart 4.3 only)
Description:
Three outputs are provided to drive each contactor individually. This improves
the control of the line contactor and improves fault reporting of contactor
faults.
The star contactor is on Output C and not Output A to ensure that an interlock
will remove all volts from the motor. i.e. Opening the Line and Delta
contactors removes volts from the star so the need for an interlock to the star
contactor is reduced.
With the above connections the star and line contactors are closed together,
and then the line contactor is held through the changeover and opens at the
same time as the delta contactor.
When a start command is actioned, the Star contactor and the line contactor
are pulled in. The starter will remain in this state until the line current decays to
FLC. The star contact will then open and the Gemstart will wait until the line
current decays to zero. The Delta contactor will then be closed. The Start
period will then finish when the line current again falls below FLC.
Options:
The Line Auxiliary is optional.
The auxiliary connection from the contactor can be fed back to Gemstart to
allow the status of the contactor to be reported to the user. If the auxiliary is not
connected and the Contactor Input is configured to Closed then the position of
the contactor is assumed from the intended contactor status.
The Delta and star must be wired in.
same time.
15G0012(E)
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Gemstart 4
Connections:
Inputs Outputs
Line Aux (Optional) A A Line Contactor
Delta Aux B B Delta Contactor
Star Aux C C Star Contactor
D D No Trips
Star/Delta (3)
Configuration:

Auxiliary Testing Yes
Special Settings:
This contactor type can be used as a follower contactor if the A Aux is wired in
15G0012(E)
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Gemstart 4
3.1.13 Variable Speed Drive (Cut Throat Control)
Description:
A Variable Speed Drive (VSD) can be controlled from Gemstart for simple
control tasks. This driver operates with in built delays to wait for the VSD to
power on after a start command.
Start A will generate a Run Forward command to the VSD.
Options:
If reversing is not required the reverse connections do not need to be used.
Connections:
Inputs Outputs
Running A A Line Contactor
Reversing (Optional) B B Off
C C Reverse (Optional)
D D No Trips
VSD (Logic)
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Gemstart 4
Configuration:

Special Settings:
This contactor can be defined as a follower. If the Running in goes active a

Start A is generated. If the Reversing input and Running input become active a
Start B is generated.
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Gemstart 4
3.1.14 Variable Speed Drive [Logic Control]

(Gemstart 4.3 only)
Description:
A Variable Speed Drive can be controlled from Gemstart for simple control
tasks.
Start A will generate a Run Forward command to the VSD.
Options:
If reversing is not required the reverse connections do not need to be used.
RUN/stop is provided as a Mains and a Volt Free output. The Mains output will
require an interposing relay. The volt free output can be used to feed the VSD
directly.
Connections:
Inputs Outputs
Running A A RUN/stop
Reversing (Optional) B B Off
C C Reverse (Optional)
D D RUN/stop (Optional)
VSD (Logic)
15G0012(E)
Page 42
Gemstart 4
Configuration:

Contactor Input A Hardware I/P 1
Contactor Input B Hardware I/P 5
Hardware Output 2 Off
Special Settings:
This contactor can be defined as a follower. If the Running input goes active a
Start A is generated. If the Reversing input and Running input become active a
Start B is generated.
Output 2 can be used to control a line contactor which is placed before the
VSD. This ensures that an Interlock fault will isolate the VSD and the motor. To
operate with a line contactor output 2 should be configured to be ON.
15G0012(E)
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Gemstart 4
3.2 Contactor type/advanced settings

Each contactor type has a set of advanced settings that allow modification of
the standard function. These items are explained below:
3.2.1 Contactor rating

Used to define the highest phase current the contactor can safely break. This,
together with the fuse time, allows Gemstart to co-ordinate the opening of the
contactor with the fuse. When a fault current of less than the contactor rating is
flowing Gemstart will open the contactor. When a current of greater than the
rating of the breaker is flowing Gemstart will wait for the fuse to blow before
opening the contactor.
This item is configured in percent FLC with a limit of 1000% of the CT rating.
The default value is 1000% FLC
3.2.2 Fuse Time

The time that the motor fuses (or MCB) take to break at the contactor rating
current. This is used in conjunction with the contactor rating and defines the
length of time Gemstart waits after detecting a fault current of greater than the
contactor rating before opening the contactor.
This item is configured in seconds.
The default value is 1s.
3.2.3 Contactor input A source.

The location of the feedback contact of output A. This is generally used to
determine the state of the contactor driven by output A and will generate a
fault condition if it is in the wrong condition (exceptions occur when Auxiliary
testing and Follower contactor are used – see below). The state of contactor A
is assumed to be correct if this source is configured as Closed or Open.
The actual function of this input is contactor type dependent – consult relevant
contactor type data sheet for further information.
If contactor A exists the default value is Input 1.
3.2.4 Contactor input B source.

The location of the feedback contact of output B. This is generally used to
determine the state of the contactor driven by output B and will generate a
testing and Follower contactor are used – see below). The state of contactor B
If contactor B exists the default value is Input 5.
15G0012(E)
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Gemstart 4
3.2.5 Contactor input C source.

The location of the feedback contact of output C. This is generally used to
determine the state of the contactor driven by output C and will generate a
testing and Follower contactor are used – see below). The state of contactor C
If contactor C exists the default value is Input 7.
3.2.6 Contactor input D source.

The location of the feedback contact of output D. This is generally used to
determine the state of the contactor driven by output D and will generate a
testing and Follower contactor are used – see below). The state of contactor D
If contactor D exists the default value is Input 8.
3.2.7 Contactor input A, B, C & D sense.

The polarity of the input signal – Normally open or Normally closed. The
default is Normally Closed i.e. opposite to the contactor state.
3.2.8 Hardware Outputs 1 to 4 Source

The Hardware Output sources 1 to 4 default to Contactor Outputs A to D.
Hardware output 4 does not physically exist on Gemstart 4 and Hardware

outputs 2 and 4 do not physically exist on Gemstart 4.2 but the state of the
output can be passed to any of the input functions. In particular the serial link
status bits 11 and 13 can be fed from the outputs which in turn can be
configured to one of the status bits below.
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Gemstart 4
The status options available to the hardware outputs are defined below:
Option Description
Off The output is Off all the time.
On The output source is on all the time.
Contactor Output A This output is generally used to control contactor A.
Contactor Output B This output is generally used to control contactor B.
If contactor B does not exist this output is Off all the
time.
Contactor Output C This output is generally used to control contactor C.
If contactor C does not exist then this output
defaults to the “Trip Present” status bit.
Contactor Output D This output is generally used to control contactor D.
If contactor D does not exist 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.
GP Output B A GP Output bit supplied by the Host via the serial
link.
GP Output C A GP Output bit supplied by the Host via the serial
link.
GP Output D A GP Output bit supplied by the Host via the serial
link.
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. (4.3 only)
In Startup Gemstart is in the startup phase.
Motor Available to Host The motor is available for serial link commands.
I.e. Gemstart is in Auto or Priority Mode, there are
no trips present, 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 Trip There is a (self clearing) Trip present.
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 trips present, the contactor is not in the test
position and the Hard Stop input is not active.
Available to Manual A priority command can start the motor. I.e.
Gemstart is in Manual Mode, there are no trips
present, the contactor is not in the test position and
the Hard Stop and Process Stop inputs are not
active.
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Gemstart 4
3.2.9 Hardware Outputs 1 to 4 sense

The polarity of the output signal – Normally open or Normally closed. The
default is Normally Open. Selecting Normally Closed will invert the sense of
the status bit.
3.2.10 Check Auxiliaries

On changing the state of a contactor 0.5s is allowed for the contactor to settle.
During this settling time the auxiliaries status is not checked.
If the auxiliary status does not match the intended contactor status a number of
faults can be reported. If the contactor has just changed state a “Failed to
Open” or ”Failed to Close” fault is reported. If the contactor has been in the
correct state then an “Unexpected Close” or Unexpected Open” fault is
reported.
Checking of an auxiliary can also be disabled by selecting the Open or Closed

configuration option for the Contactor Input Source.
3.2.11 Changeover Allowed (Gemstart 4.3 only)

Selecting Yes for this item allows the motor to change direction in Manual or
HHP mode without going through a stop.
Selecting No with force the user to issue a Manual Mode Stop or HHP stop
before sending the opposite direction command.
3.2.12 Follower Contactor

Selecting Yes for this item instructs Gemstart to follow the action of the
contactor. This is particularly useful if the user can change the state of the
contactor without going through Gemstart. For example a MCCB or a directly
controlled contactor.
3.2.13 Minimum Start Time

Gemstart remains in startup until the highest phase current drops below
100%FLC. The startup time can be extended by selecting a Minimum Start
Time. This may be useful in a number of situations where you wish to delay the
start of the more sensitive ALC protection items. This time is also used as the
minimum time that the Star contactor is held in before changing over to delta.
3.2.14 Maximum STAR Time (4.3 only)

This item is only used by Star/Delta contactor types. Normally a Star/Delta
contactor will changeover from Star to Delta once the current drops to
100%FLC. However on some starters the current never drops that low with the
star contactor. This item defines the maximum time that Gemstart will keep the
star contactor closed before changing to the delta contactor.
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Gemstart 4
3.2.15 Slow Down Time (4.3 only)

The Slow Down Time will delay a low speed start for a configured time after
running in high speed. This delay is not affected by going through stop. If a
low speed start is received at any time from any source it is accepted. However
the low speed start is delayed in the Stopped condition until the Slow Down
timer has elapsed. The low speed contactor is then closed.
Similar functionality is provided for all 3 Star/Delta contactor types. I.e. the Star
contactor will not be closed within a configured time of the Delta contactor
being closed.
Forward/Reverse and MOV contactors implement the Slow Down Time delay
when changing direction.
Contactor Type Contactor A -> B Contactor B -> A

DOL-E Not Applicable Not Applicable
DOL-L, MCCB Not Applicable Not Applicable
Star / Delta No Delay Slow Down Delay
Two Speed & Dahlander No Delay Slow Down Delay
Fwd/Rev & MOV Slow Down Delay Slow Down Delay
VSD No Delay No Delay
3.2.16 Level Triggered Start

Defaults to No. When set to Yes a Manual Start signal that is present at power
on is actioned. This is particularly useful for automatic start signals such as
level detectors.
3.2.17 Analogue Input Type

The 3 analogue current inputs can be used as 25mA ac or 4-20mA dc inputs.
This configuration items selects the input type.
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Gemstart 4
3.3 Input functions

The following input functions are available on Gemstart 4:
Counters 1, 2 and 3 Section 3.3.1 on page 50

Device Status Section 3.3.2 on page 51
ELCB Relay Section 3.3.3 on page 52
Emergency Start A and Start B Section 3.3.4 on page 53
Hard Stop Section 3.3.5 on page 54
INCH Select Section 3.3.6 on page 55
Interlock Section 3.3.7 on page 56
Isolator Section 3.3.8 on page 57
Manual Select Section 3.3.9 on page 58
Manual Start A and Start B Section 3.3.10 on page 59
Overload Relay Section 3.3.11 on page 61
Process Stop A and Stop B Section 3.3.12 on page 62
Remote Select Section 3.3.13 on page 63
Reset Input Section 3.3.14 on page 65
Test Mode Start Section 3.3.15 on page 66
Test Position Section 3.3.16 on page 67
Thermistor Relay Section 3.3.17 on page 68
User Text 1 and Text 2 Section 3.3.18 on page 69
15G0012(E)
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Gemstart 4
3.3.1 Counter 1 / Counter 2 / Counter 3
Menu location:
CFG/Protection Inputs/Counter 1 (2 or 3) source.
Source:
Open, Closed, Interlock, Input 1,2,3,4(,5,6,7,8,9).
Advanced settings:
SENSE OPTIONS: Normally Closed (negative edge), Normally Open (positive
edge)
REPORTING OPTIONS: None
Fault codes:
GEMSTART 4 LINK: N/A
GEMSTART 3 LINK:
TRIP: N/A
Alarm: N/A
Warn: N/A
Description:
The Counters indicate the pulsed input from a transducer.

This function counts pulses from an external source. Counts up to 65,535,999
can be made before the counter rolls over back to 0.
Application notes:
Defaults to a Normally Open, positive edge signal.
Used for counting Kilowatt hour pulses, rotary transducer pulses etc. The
maximum counting frequency is 15 Hz.
15G0012(E)
Page 50
Gemstart 4
3.3.2 Device Status
Menu location:
CFG/Protection Inputs/Device Trip source.
Source:
Advanced settings:
SENSE OPTIONS: Normally Closed, Normally Open
REPORTING OPTIONS: Off, Warn, Alarm, Trip, LTrip
Fault codes:
GEMSTART 4 LINK: 36
GEMSTART 3 LINK:
TRIP: 61
Alarm: 62
Warn: 63
Description:
Any auxiliary volt free contact indicating an error condition from third party
equipment.
An active signal applied to this input will cause a device fault. The Gemstart
action will depend on the configured reporting option and a fault code will be
sent on the serial link.
Application notes:
Defaults to a normally Closed, Self clearing Warn. Typical devices which could
use this function are:
q Miniature Circuit Breakers
q Moulded Case Circuit Breakers
q Air Circuit Breakers
q Variable Speed Drive
15G0012(E)
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Gemstart 4
3.3.3 ELCB Relay
Menu location:
CFG/Protection Inputs/ELCB Relay source.
Source:
Advanced settings:
Fault codes:
GEMSTART 4 LINK: 29
GEMSTART 3 LINK:
TRIP: 29
Alarm: 29
Warn: 29
Description:
Output from an Earth leakage Circuit breaker.
An active signal applied to this input will cause an ELCB Fault. The Gemstart
action will depend on the configured reporting option and a fault code will be
sent on the serial link.
Application notes:
Defaults to a Normally closed, Latching trip. This function may complement the
Earth fault protection available by the unit by providing personnel protection
levels. If this is required then, to ensure health and safety compliance, the
interlock input must be used.
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Gemstart 4
3.3.4 Emergency Start A / Emergency Start B
Menu location:
CFG/Protection Inputs/Emergency Start A (B) source.
Source:
Advanced settings:
Fault codes:
GEMSTART 3 LINK:
TRIP: N/A
Alarm: N/A
Warn: N/A
Description:
The Emergency Start functions ignore all trip conditions and close the
contactor.
The Emergency Start functions are level triggered functions that force
Emergency Manual Mode while they are active. Emergency Manual Mode
M
(LCD displays E ) is the highest priority mode. I.e. it will override HHP and
Priority modes.
While in Emergency Manual Mode all LTrips and Trips are reported on the link
as Alarms and Warns respectively. As soon as the Emergency Start is removed
any LTrips that have occurred or Trips that are still active are automatically
actioned. While Emergency Start is active Gemstart will display a status
message “Emergency Start”.
Application notes:
These functions are for a very specific function and should not be used for
normal operation. They should only be used to start the motor in circumstances
where it is better for the motor to be damaged rather than tripped. E.g. for a
fire pump or gas extractor.
The only way to stop or prevent a start command being actioned is to open the
Interlock input. Restoring volts to the interlock input with the Emergency Start
still active will re-close the contactor.
Due to the urgent need for action in an emergency state, if Emergency Start A
and Emergency Start B, are both active then the A input will be actioned and
the B input ignored.
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Gemstart 4
3.3.5 Hard STOP
Menu location:
CFG/Manual Controls/Hard Stop source.
Source:
Advanced settings:
REPORTING OPTIONS: Self clearing Trip (except in manual mode where no fault is
flagged)
Fault codes:
GEMSTART 4 LINK: 10
GEMSTART 3 LINK:
TRIP: 11
Alarm: 11
Warn: 11
Description:
Hard Stop is a signal from field push button.

It is a microprocessor based STOP signal. This signal causes the contactor(s) to
open in any mode. A trip will not be reported if the unit is in manual mode or
manual mode can be forced.
Application notes:
Defaults to a Normally Closed, Latched trip (see above for trip reporting).
The Hard Stop will attempt to put the unit in manual mode. This will be
successful if no higher priority modes are active (i.e. Priority or HHP modes).
Useful where a Stop in any mode is required from a remote push button.
From the Gemstart 2 Wizard menu, this function can be configured to

generate a trip report when in Manual mode. See UTIL / Wizards / GS 2
Wizard / Local Stop.
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Gemstart 4
3.3.6 INCH Select
Menu location:
CFG/Manual controls/Inch select source.
Source:
Advanced settings:
REPORTING OPTIONS: N/A
Fault codes:
GEMSTART 3 LINK:
TRIP: N/A
Alarm: N/A
Warn: N/A
Description:
The signal determining how remote push-buttons are acted upon.

This signal determines whether manual mode start signals are latching or
momentary.
Run (inactive signal)
A start signal is latched by the unit. Release of Start signal will not open the
contactor. A separate signal is needed.
Inch (active signal)
A start signal is not latched. Release of the start signal will open the contactor.
Application notes:
Defaults to a Normally Open signal.

Manual Run is for standard three wire control of a motor from separate Start &
Stop push-buttons.
Manual Inch is for two wire control using a single push-button for jogging or
inching the motor.
If Start B and INCH select are configured to the same input then Start B will act
as an INCH input. Start A will operate as a Run input.
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Gemstart 4
3.3.7 Interlock
Menu location:
CFG/Protection Inputs/Interlock source.
Source:
Advanced settings:
SENSE OPTIONS: Normally Closed
Fault codes:
GEMSTART 4 LINK: 12
GEMSTART 3 LINK:
TRIP: 12
Alarm: 12
Warn: 12
Description:
An active signal from a field switch will cause an INTERLOCK trip.
Application notes:
Usually a normally closed self clearing trip. Used to indicate that an unsafe
condition has occurred and the contactor requires opening.
Usually applied to the Interlock input where it directly removes the feed to the
contactor.
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Gemstart 4
3.3.8 Isolator
Menu location:
CFG/Protection Inputs/Isolator source.
Source:
Advanced settings:
Fault codes:
GEMSTART 4 LINK: 03
GEMSTART 3 LINK:
TRIP: 03
Alarm: 03
Warn: 03
Description:
A signal from chassis indicating isolator position.

This signal indicates that the chassis isolator has been opened and triggers an
update of the PAMM.
Application notes:
Defaults to a Normally Open, Warn.
The default input sense is opposite to the isolator condition.
Only useful if the Gemstart is not isolated by isolator.
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Gemstart 4
3.3.9 Manual Select
Menu location:
CFG/Manual controls/Manual select source.
Source:
Advanced settings:
Fault codes:
GEMSTART 3 LINK:
TRIP: N/A
Alarm: N/A
Warn: N/A
Description:
A signal from remote switch indicating running mode.

This signal selects Manual mode, allowing control from Manual start and
process stop pushbuttons.
Application notes:
Defaults to a Normally Closed input. Opening the signal will select manual
mode. Ideal for Manual / Auto selection.
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Gemstart 4
3.3.10 Manual Start A / Manual Start B
Menu location:
CFG/Manual controls/Manual Start A (or B) source.
Source:
Advanced settings:
Fault codes:
GEMSTART 4 LINK: 18 Release manual start Warn
80 Manual start and stop active warn
20 Fwd/Rev Warn
GEMSTART 3 LINK:
TRIP: N/A
Alarm: N/A
Warn: 57 Release manual start Warn
63 Gemstart 4 Warn
20 Fwd/Rev Warn
Description:
A signal from Push-button requesting the motor to be started.
An active signal will cause a start request for contactor A (or B). If the unit is in
manual mode and available then the unit will close the relevant contactor.
If a single contactor type (such as DOLE) is selected then Manual Input B acts
as a second source of start for that contactor
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Gemstart 4
Application notes:
This function has three configurable Trigger settings found in

Contactor/advanced settings:
q Edge: (Default setting)
An ‘edge’ is required from the signal i.e. a change from inactive to active
states. Thus if a stop signal occurs and the start remains active, release of
the stop will not restart the motor. If this occurs a Release Manual Start
Warn is flagged. A Release Manual Start Warn would also occur if the unit
were powered up with an active start signal present.
q Mode Change:
If a Start is present on entering manual mode then the signal will be
actioned. Changing from Manual Local to Manual Remote or vice versa
will also action the relevant Start input if it is present.
q Level:
If a Start is present at any time in manual mode then it will be actioned
(assuming there are no trips).
When used with Remote Select, Start A and Start B can be used as start signals
from different sources. Start A is the Local Start and Start B is the Remote Start.
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Gemstart 4
3.3.11 Overload Relay
Menu location:
CFG/Protection Inputs/Overload relay source.
Source:
Advanced settings:
Fault codes:
GEMSTART 4 LINK: 07
GEMSTART 3 LINK:
TRIP: 30
Alarm: 30
Warn: 30
Description:
The signal is output from a conventional Thermal Overload relay.
An active signal applied to this input will cause an Overload Relay Fault.
This will cause a fault code on the Serial Link. A fault on the Hand Held
Programmer and a condition as defined when configured.
Application notes:
Defaults to a Normally Closed, Latching Trip. This function is needed if current

measurement is not available or practical and motor protection is required.
Can be fed into Interlock input for direct action upon contactor.
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Gemstart 4
3.3.12 Process Stop A / Process Stop B
Menu location:
CFG/Manual controls/Process Stop A (or B) source.
Source:
Advanced settings:
Fault codes:
GEMSTART 4 LINK: 80 Manual start and stop active warn
GEMSTART 3 LINK:
TRIP: N/A
Alarm: N/A
Warn: 63 Gemstart 4 Warn
Description:
A signal from field push button.

A microprocessor based STOP signal. This signal causes the contactor(s) to
open only if Gemstart is in manual mode. The contactor will not open if
manual mode has not been selected.
Application notes:
Defaults to a Normally Closed input. No trip is generated.
Useful if manual START/STOP pushbuttons require de-selecting.
When used with Remote Select, Stop A and Stop B can be used as stop signals
from different sources. Stop A is the Local Stop and Stop B is the Remote Stop.
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Gemstart 4
3.3.13 Remote Select
Menu location:
CFG/Manual controls/Remote Select source.
Source:
Advanced settings:
Fault codes:
GEMSTART 3 LINK:
TRIP: N/A
Alarm: N/A
Warn: N/A
Description:
When Manual Mode is enabled, Remote Select allows the source of Manual
Commands to be switched between a local start and stop (Manual Start A and
Process Stop A) and a remote start and stop (Manual Start B and Process Stop
B).
When Remote Select is enabled it will enable the Remote inputs and disable
the Local inputs. When Remote Select is disabled the Local Inputs are enabled
and Remote inputs disabled.
If the source of Remote Select is Open or Closed then all 4 Process Start A/B
and Process Stop A/B inputs are all enabled in Manual mode.
The following table summarises the influence of Remote Select:
Manual Remote Select Local Remote LCD
Mode Mode
Manual Start A Manual Start B
Process Stop A Process Stop B
Disabled Ignored Ignored Ignored A,P or H
Enabled Source = Open or Closed Active Active M
Enabled Input is Inactive “Local” Active Ignored M
L
Enabled Input is Active “Remote” Ignored Active M

R
15G0012(E)
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Gemstart 4
Application notes:
This function can be used to monitor a Local / Remote selector switch. In this
context Local and Remote are both sources of Manual Control. This function
cannot be used with two direction contactors. It can only be used with DOL-E,
Star/Delta, MCCB, VSD or DOL-L.
NB The INCH function is not affected by Remote Select and is therefore always
active. This means the INCH function cannot be used for one start source but
not the other. However if Inch mode is needed in one mode but not the other,
then use Manual Start x and Process Stop x to look at the same input.
A change in the Remote Select input will generate an edge on the start input if
the start input is configured to “Mode Change”.
E a r th F a u lt CT3 C T2 C T1
N e u tr a l
L iv e
L iv e
O /P 1
N e u tr a l
D e la tc h
E a r th
N e u tr a l
In te r lo c k
O /P 2
I/ P 1
C o n t. F ie ld S T O P
S ta tu s
I/ P 2
S ta r t A F ie ld S T A R T
I/ P 3
S to p A R L
I/ P 4
R e m o te
I/ P 5
PA M M
I/ P 6
S ta r t B &
S to p B P L C -1
I/ P 7
I/ P 8
S e r ia l
L in k
I/ P 9 PLC
To PLC
O /P 3
In this example Manual Mode is permanently enable.

With the switch in the ‘R’ (Remote) position control is by the PLC via input 6.
Start A and Stop A on inputs 2 and 3 are ignored.
When the switch is changed to ‘L’ (Local) position the Start A and Stop A inputs
control Gemstart. In this case the PLC input is ignored.
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Gemstart 4
3.3.14 Reset Input
Menu location:
CFG/User IF/Reset Input Source.
Source:
Advanced settings:
Fault codes:
GEMSTART 3 LINK:
TRIP: N/A
Alarm: N/A
Warn: N/A
Description:
An active edge will allow the pre-defined set of trips and counters to be reset
from the field device.
Application notes:
This function would typically be used to reset overload trips although a wide
range of reset options are available. Note that other reset options are
available (HHP, serial link and Front panel stop switch).
The reset options are defined in CFG/User IF/Reset Input. The reset input
standard settings will reset:
q Alarms
q Overloads
q Motor protection
q Application protection
q Interlocks
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Gemstart 4
3.3.15 Test Mode Start
Menu location:
CFG/Manual controls/Test Mode Start source.
Source:
Advanced settings:
Fault codes:
GEMSTART 3 LINK:
TRIP: N/A
Alarm: N/A
Warn: N/A
Description:
A signal from Push-button requesting the contactor to be tested.

The Test Mode Start input is only active while in Test position. The input, when
activated in test position, will enable Manual Mode and generate a momentary
manual start command. If there are no trips present the contactor will be
closed. Any errors will be reported. Releasing the Test Mode Start will generate
a momentary Manual Stop command and remove the Manual Mode enable.
On “two contactor” types, pressing Test Mode Start again will operate the B
contactor. Subsequent operations will toggle between A and B. The first
operation in Test mode will always be to Contactor A.
The config item “Test Mode Start”, “Source (N/O) = Open” will be added to
the Manual Controls menu. Advanced setting for this function will also be
added. The standard options are Open and Normally Open.
This feature has not been added to the old (single output) GS4.2.
Application notes:
Use a push button on the chassis casing to test that the contactors can be
operated. The function only operates when the chassis is in test position and no
trips are present.
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Gemstart 4
3.3.16 Test Position
Menu location:
CFG/Protection Inputs/Test position source.
Source:
Advanced settings:
Fault codes:
GEMSTART 4 LINK: 54
GEMSTART 3 LINK:
TRIP: 61 & Status word bit 7
Alarm: 62 & Status word bit 7
Warn: 63 & Status word bit 7
Description:
A signal from chassis indicating physical position.
This signal indicates that the motor starter has been withdrawn to the Test
Position. Whilst In this mode the following items of protection are disabled:
q Undercurrent
q Number of operations (of the contactor)
q Hours Run
q Trip counters
Application notes:
Defaults to a Normally Closed, Warn.
This function allows for the chassis to be tested off load without affecting the
chassis wear statistics.
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Gemstart 4
3.3.17 Thermistor Relay
Menu location:
CFG/Protection Inputs/Thermistor relay source.
Source:
Advanced settings:
Fault codes:
GEMSTART 4 LINK: 06
GEMSTART 3 LINK:
TRIP: 06
Alarm: 06
Warn: 06
Description:
The signal is output from Thermistor protection relay.
An active signal applied to this input will cause a Thermistor relay fault
300ms later. The time delay allows time for the relay to pick up after power
cycling.
Application notes:
A Normally closed, Latched trip. This function is used for measuring motor
winding temperatures on motors equipped with PTC probes enabling the
motor to be tripped at a threshold temperature.
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Gemstart 4
3.3.18 User Text 1 / User Text 2
Menu location:
CFG/Protection Inputs/User Text 1 (or 2) source.
Source:
Advanced settings:
Fault codes:
GEMSTART 4 LINK: 37 (38 for user text 2)
GEMSTART 3 LINK:
TRIP: 09 (10 for user text 2)
Alarm: 09 (10 for user text 2)
Warn: 36 (37 for user text 2)
Description:
A signal from user defined device.

When active a message of up to 30 characters is displayed and the action
defined is performed.
Application notes:
Defaults to a Normally Closed, Latched trip reporting User text 1 (or User Text
2)
With the reporting options set to OFF, the User Text message is still displayed
on the LCD while the source input is active. This allows an active “Stop” input
to be reported locally, without generating a fault report on the serial link.
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Gemstart 4
3.4 Protection functions

The following protection functions are applicable on Gemstart 4:
CFG/Contactor/Fail/Recover Voltages p 71
CFG/Motor Protection/FLC Setting p 72
CFG/Motor Protection/Startup Current p 73
CFG/Motor Protection/Startup Time p 75
CFG/Motor Protection/Thermal Overload p 77
CFG/Motor Protection/Thermal Reset Delay p 83
CFG/Motor Protection/Restart Inhibit p 84
CFG/Motor Protection/Single Phasing p 85
CFG/Motor Protection/Imbalance p 86
CFG/Motor Protection/Starts in Hour p 87
CFG/Motor Protection/Speed sense p 88
CFG/Motor Protection/Voltage protection p 89
CFG/Motor Protection/Earth Fault Protection p 91
CFG/Contactor/Advanced settings/Contactor protection p 94
CFG/Measurements/Power rating p 95
CFG/Application Protection/Set ALC p 96
CFG/Application Protection/Phase Reversal p 97
CFG/Application Protection/Under Current p 98
CFG/Application Protection/Instant ALC p 99
CFG/Application Protection/Constant ALC p 100
CFG/Application Protection/Under Power p 101
CFG/Application Protection/Over Power p 103
CFG/Application Protection/Power Factor High p 105
CFG/Application Protection/Power Factor Low p 106
CFG/Application Protection/AutoRestart p 107
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Gemstart 4
3.4.1 CFG / Contactor / Fail/Recover Voltages

These voltages are used for the auto restart function and vary dependant on
the type of Gemstart.
At the Low Threshold the Auto restart function will initiate and the Gemstart will
enter and display ‘Low motor Volts’.
At the High threshold the Gemstart will recover from the ‘Low motor Volts’
condition.
Gemstart type Configuration item Configuration option

4.3 Low Threshold 65%,70%,75%,80%
High Threshold 80%, 85%, 90%
4.2 Low Threshold 65%,75%
High Threshold 80%, 90%
NOTE: The Gemstart 4.2 only offers a limited range of voltages

due to the accuracy of the voltage sensing
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Gemstart 4
3.4.2 CFG / Motor Protection / FLC Setting

FLC is the Full Load Current of the motor as defined on the Motor Rating Plate.
It is defined as a percentage of the Nominal CT Rating. When configuring FLC
the user is presented with the configuration as a percentage and as Amps.
This item is configured in terms of the Nominal CT Value.

All of the current based Motor Protection features are configured in terms of
FLC. The HHP will display the equivalent Amps setting where possible.
Pre-requisites
Before the HHP can display FLC as percentage and Amps, the CT Rating and
CT Turns must be configured.
Configuration items
FLC Setting
25% to 150% of the Nominal CT value in 1% steps. Standard 100%.
Select the option that is the first below the FLC value named on the Motor
Rating Plate. Remember that the HHP will display the equivalent Amps reading
if possible.
Protection wizard
The FLC setting is changed by the Motor Setup Wizard. The suggested
option is the first option below the Motor FLC rating.
Additional information
None.
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Gemstart 4
3.4.3 CFG / Motor Protection / Startup Current

Startup Current protection is used to detect a fault current which is greater than
the expected start current. The maximum current for a motor is generally the
current flowing when the motor is started. This is normally around 600% FLC.
Start delta starters can limit this peak current to around 350%.
This protection feature trips Gemstart if the highest phase current rises above
the trip limit.
This item is configured in terms of FLC. The equivalent Amps value is also
displayed.
Prerequisites
To correctly configure this item in Amps the CT Rating, CT Turns and FLC
Setting must be configured.
Configuration items
Start Current Limit
Off, 100% to 2000%FLC in 10% steps. Standard 800% (Maximum
is 1000% Nominal CT)
Advanced Settings
Protection Active No, Yes
Severity Warn, Alarm, Trip, Trip & Alarm, LTrip
Pre Warn Level Off, 70, 80, 90, 100%
Disabled in Startup No, Yes
Select a Start Current Limit which is greater than the Inrush current of the
motor. Allow a margin of about 15% to avoid false trips.
The Start Current Limit cannot exceed 10 times the Nominal CT value due to
limits on the output from a CT. If the limit is configured to be too high,
Gemstart will repair the limit to the maximum value.
Protection wizard
The Motor Setup Wizard will offer a configuration of this item which is the
highest of the following options:
q The next value greater than the start inrush current
q The next value greater than the average of the start inrush current and stall
current
For example: if Inrush Current is 550% and the stall current is 600%, the
Motor Setup Wizard will suggest the first option above 600 i.e. 610%
The Motor Protection Wizard offers a Start Current configuration which is

the Startup Peak Current plus the Wizard Margin.
For example: if Startup Peak Current was 630% and the Wizard Margin is
15%, the option offer is the first option above 1.15*630%=724% i.e. the
option 730% is offered.
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Gemstart 4
If the Wizard Setting is accepted the Advanced Settings / Protection Active Item
is forced to Yes.
For very high instantaneous currents the Contactor Protection feature may hold
the contactor closed for a short time until the fuse blows. During such a delay
Gemstart will display “Stop Delayed.”
Information about the peak current is available from two statistics available on
the HHP.
n Currents / Peak Current
This displays the peak of the highest phase since the last startup. This
variable is continuously updated and is not limited to the startup phase
n Start / Startup Peak
This displays the peak of the highest phase current which was reached
during the last successful start. Note that this value is only updated when
the startup becomes successful, i.e. when the current drops to 100%FLC. If
the motor is stopped or trips during startup then the start was not successful
and this statistic is not updated
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Gemstart 4
3.4.4 CFG / Motor Protection / Startup Time

This Protection Item will protect the motor should it take longer than expected
to reach a reasonable running current. This will protect the motor in a locked
rotor condition.
Once a motor reaches its running speed the current drops to the application
running current. If, at the end of the Startup Time, the motor current is greater
than 125% FLC then a fault will be generated.
The Startup Time Protection Feature stops once the current drops below 100%
FLC or the Startup time has elapsed.
Pre-requisites
The FLC figure must be configured before this feature will work. The FLC value
is required to allow the end of the startup phase to be detected.
Configuration items
Start Time Limit
Off, 00m01s to 99m59s, Standard 60s
Advanced Settings
Select a Start Time Limit which is greater than the motor acceleration time and
less than the stall withstand time.
Protection wizard
The Motor Setup Wizard will offer a configuration of this item which is the
highest of the following options:
q The next value greater than the acceleration time
q The next value greater than the average of the acceleration time and stall
withstand time from hot
For example: if Acceleration time is 6s and the stall withstand time from hot
is 9s, the Motor Setup Wizard will suggest the first option above (6+9)/2=7.5s
i.e. 8s
The Motor Protection Wizard offers a Start Current configuration which is

the Startup Time plus the Wizard Margin.
For example: if Startup Time was 7s and the Wizard Margin is 15%, the
option offered is the first option above 1.15*7=8.05s i.e. the option 9s is
offered.
If the Wizard Setting is accepted the Advanced Settings / Protection Active Item
is forced to Yes.
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Gemstart 4
Information about the startup time is available from the statistics available on
the HHP.
n Start / Startup Time
This displays the time taken for the current to drop to 100%FLC. Note that
this value is only updated when the startup becomes successful, i.e. when
the current drops to 100%FLC. If the motor is stopped or trips during
startup then the start was not successful and this statistic is not updated
n When setting the Startup time remember to take into account the
Minimum Start Time. Minimum Start time is defined in the contactor
advanced settings and defaults to 10s for the star delta contactors and 1 s
for all other contactor types. The Start Time limit must be greater than the
Minimum Startup time.
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Gemstart 4
3.4.5 CFG / Motor Protection / Thermal Overload

Overload protection protects the motor from overheating by maintaining a
thermal model of the motor. The model is based on IEC 255-8.
Two sets of curves are available, Gemstart 3 and Gemstart 4. The Gemstart 3
curves are provided to allow you to provide exactly the same protection and
thermal information as you could with Gemstart 3. The Gemstart 4 curves offer
a larger range of curves and provide the thermal information in a slightly
easier way.
An Auto option is also available which will select a GS4 curve based on the
configured Start Time Limit and Start Current Limit. The resultant “curve” will
lie somewhere between curve 1 and curve 31 although not exactly on a
numbered curve. The Auto Curve will trip after running for the Start Time Limit
at the Start Current Limit.
Gemstart 3 Curve
This curve is the same as the Gemstart 3 curve. Gemstart trips when the
thermal content reaches 110%. The 100% level is the Hot condition, i.e. after
extended running at 100%FLC.
GS3 Curves Summary:
Trip at 110% Thermal Content

Overload pickup current 105% FLC
Thermal Content at 100% FLC = 100%
Gemstart 4 Curve
There are 31 new curves for Gemstart 4. The thermal content is reported as a
percentage of the trip level.
Gemstart 4 curves can be configured with the ratio of the “hot stall withstand
time” to the “cold stall withstand time”. This allows a better model of the
thermal content to be maintained during normal (<= FLC) running.
GS4 Curves Summary:

Trip at 100% Thermal Content
Overload pickup current 107% FLC
Thermal Content at 100% FLC = 100%- %Hot Cold ratio
As part of the configuration display on the HHP the time to trip at 600% FLC is
shown along with the curve number. On PC based configuration tools the time
to trip for other currents may be calculated for the user.
Pre-requisites
For this protection feature to operate correctly the FLC Setting must be correctly
configured.
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Gemstart 4
Configuration items
Overload Curve Type
Off, Gemstart 3, Gemstart 4, Auto (GS4)
Gemstart 3 Curve (Only Displayed if Gemstart 3 Curve Type)
Off, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14
Gemstart 4 Curve (Only Displayed if Gemstart 4 Curve Type)
Off, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19,
20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31
Hot/Cold Ratio (Only Displayed if Gemstart 4 Curve Type)
Unknown, 1 to 100% in 1% steps
Advanced Settings
The process of selecting the best overload curve for Gemstart 4 is described in
Chapter 2 Volume 1 - User Guide.
Protection wizard
The Motor Setup Wizard will force the Curve Type to Gemstart 4 and setup
the curve number and Hot Cold Ratio based on the Stall Withstand Times. The
offered curve will trip the motor after running at the Stall current for the Stall
Withstand time from cold. The Hot Cold Ratio is set to the Hot over Cold Stall
Withstand Times.
The Motor Protection Wizard forces Thermal Overload into the Auto
setting. This will trip the motor after the motor has been running for the Start
Time Limit at the Start Current Limit. The Hot/Cold Ratio is forced to Unknown.
Hot/Cold Ratio
The Hot/Cold Ratio setting modifies the thermal model to allow a Hot Start to
use the full Stall Withstand Time From Hot as well as limiting cold starts to the
Stall Withstand Time From Cold.
The Hot/Cold Ratio modification works by derating the heating effect during
normal running. Normal running is when the current is below the pickup level
(107%). This means that even after extended running at 100%FLC there is still
enough thermal content left to allow a start duration equal to the Hot
Withstand Time.
When Hot/Cold Ratio is not used (Gemstart 3 Curves) or is set to Unknown the
normal heating effect is not derated. (This is equivalent to a Hot/Cold Ratio of
about 13%.)
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Gemstart 4
Related statistics
Information about the thermal content is available from the statistics available
on the HHP.
n Start / Therm Used by Start
This displays the thermal content used by the last successful start. Note that
this value is only updated when the startup becomes successful, i.e. when
the current drops to 100%FLC. If the motor is stopped or trips during
startup then the start was not successful and this statistic is not updated
n Therm / Thermal Content
This is the estimated thermal content of the motor. For Gemstart 4 Curves
the percentage is a percentage of the Trip Level
n Therm / Time to Trip/Avail
If the motor is running this is the estimated time to reach the Trip Level. If
the motor is stopped this is the estimated time for the motor to become
available
Thermal Content Equations

The following equations are given for Gemstart 3 and Gemstart 4 curves. They
are slightly different due to the following differences:
Gemstart 3 Gemstart 4
Trip Level 110% 100%
Overload Pickup Level 105% 107%
In the following equations the variables are:
k This is a curve specific number as given below

TS The starting thermal content. Usually quoted as a percentage but
should be entered to the equations as a number. i.e. 80% should be
entered as 0.8
TA The available thermal content level. i.e. 100% - %Thermal Content
Used by Last Successful Start - 1%.
I The fault current in terms of %FLC. Usually quoted as a percentage
but should be entered to the equations as a number. i.e. 80% should
be entered as 0.8
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Gemstart 4
Curve k(GS3) K(GS4)

1 24 9.36
2 32 12.17
3 48 14.98
4 72 18.72
5 96 23.41
6 128 29.96
7 176 37.45
8 256 46.81
9 360 58.98
10 512 73.96
11 768 93.62
12 1152 121.7
13 1728 149.8
14 2560 187.2
15 234.1
16 300
17 375
18 468
19 590
20 740
21 936
22 1217
23 1498
24 1872
25 2341
26 2996
27 3745
28 4681
29 5898
30 7396
31 9362
The following equations allow the effect of fault currents to be predicted. The
time to trip and time to available times can be calculated or read from the
charts shown in Figures 1 and 2.
Gemstart 3 Gemstart 4
Time to Trip æ 1.1 - TS ö æ 1 - TS ö
= - k * lnçç1 - 2 ÷ = -k * lnçç1 - ÷
è I - TS ÷ø è [ I 1 . 07 ]2
- T ÷
S ø
Time to available æ TS - TA ö æ T - TA ö
= - k * lnçç1 - ÷ = -k * lnçç1 - S ÷
è TS ÷ø è TS ÷ø
Normal running =I 2
= I 2 * (1 - Hot _ Cold _ Ratio)
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Gemstart 4
Gemstart 3 Curves
10000
1000
Curve 14
Curve 13
Curve 12
Curve 11
100 Curve 10
Time to Trip (s)
Curve 9
Curve 8
Curve 7
10 Curve 6
Curve 5
Curve 4
Curve 3
Curve 2
1
Curve 1
0.1
0 1 2 3 4 5 6 7 8 9 10 11
Fault Level (xFLC)
Figure 1 Gemstart 3 curves
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Gemstart 4
Gemstart 4 Curves
Curve 31
100000 Curve 30
Curve 29
Curve 28
Curve 27
Curve 26
10000
Curve 25
Curve 24
Curve 23
Curve 22
1000 Curve 21
Curve 20
Curve 19
Time to Trip (s)
Curve 18
100 Curve 17
Curve 16
Curve 15
Curve 14
Curve 13
10 Curve 12
Curve 11
Curve 10
Curve 9
1 Curve 8
Curve 7
Curve 6
Curve 5
Curve 4
0.1
Curve 3
0 1 2 3 4 5 6 7 8 9 10 11 Curve 2
Fault Level (xFLC) Curve 1
Figure 2 - Gemstart 4 curves
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Gemstart 4
3.4.6 CFG / Motor Protection / Thermal Reset Delay

This feature will generate a Thermal Reset Delay fault immediately after a
Thermal Overload fault is detected. This prevents a start within a user
configured time after a thermal overload fault. Thermal Reset Delay may not
be required if Restart Inhibit protection is enabled.
Thermal Reset Delay gives a fixed delay after, and only after, a Thermal
Overload fault occurs. Restart Inhibit will always prevent a start if there is not
enough thermal headroom to start the motor.
Pre-requisites
None.
Configuration items
Thermal Reset Delay Time
Off,1, 2, 5, 10, 15, 20, 30 minutes
Advanced Settings
Set to OFF unless you wish to have a fixed delay after every Thermal Overload
Trip.
Protection wizard
The protection wizards do not modify this item.
Information about the Thermal Reset Delay is available from the statistics
available on the HHP.
Therm / Therm Reset Delay

The time left before Thermal Reset Delay clears itself.
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Gemstart 4
3.4.7 CFG / Motor Protection / Restart Inhibit

This feature will generate a Trip on stopping the motor if another start cannot
be performed. The trip remains until there is enough thermal headroom to
complete a start without incurring a Thermal Overload fault.
Restart Inhibit works by adding the thermal content used by the last successful
start to the present thermal content. Once the total is less than 100% the
Restart Inhibit fault is removed.
Pre-requisites
None.
Configuration items
Restart Inhibit Enable
Off, On
Advanced Settings
There is no advantage in turning Restart Inhibit off unless it is causing

problems with motors which do not have a repeating startup characteristic.
Protection wizard
The Protection Wizards do not modify Restart Inhibit.
Information about Reset Inhibit is available from the statistics available on the
HHP.
n Therm / Therm to Trip/Avail
If the motor is stopped this is the estimated time for the motor to become
available
See Thermal Overload for the Time to Available Equation and Chart.
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Gemstart 4
3.4.8 CFG / Motor Protection / Single Phasing

Single Phasing Protection is provided to detect extreme imbalance conditions
such as a missing phase. Single Phasing can be configured with a Time Delay
to avoid nuisance tripping.
A single phasing fault is the same as an Imbalance fault of 80% present for a
user configured time. Note that this means that a single phasing fault cannot
occur unless the highest phase is at least 80%FLC.
Pre-requisites
None.
Configuration items
Single Phasing Time
Off, 0.1s to 25.5s in 0.1s steps
Advanced Settings
Select the shortest time unless you are experiencing nuisance trips.
Protection wizard
Single Phasing is not modified by the Protection Wizards.
See Imbalance.
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Gemstart 4
3.4.9 CFG / Motor Protection / Imbalance

Imbalance Protection allows imbalances in the motor to be detected and acted
upon. By having separate Single Phasing and Imbalance protection it is
possible to trip on a full Single Phasing Fault but to perhaps Alarm on a lesser
imbalance. This would allow maintenance to be performed on the next
appropriate occasion.
Imbalance monitors the highest and lowest average phase currents. The
Imbalance current is calculated by subtracting the lowest from the highest
phase. The fault level is calculated as a ratio of the Imbalance Current to the
Highest Phase or 100%FLC current, whichever is highest.
Highest _ Phase - LowestPhase
Imbalance =
Highest _ of ( Highest _ Phase,100% FLC )
Pre-requisites
None.
Configuration items
Imbalance Limit
Off, 5% to 100% of highest current in 5% steps
Imbalance Time
0, 0.1 to 25.5s in 0.1s steps, Standard 0.5s
Advanced Settings
Protection wizard
The Application Protection Wizard will offer a configuration option that is

a percentage above the highest imbalance measured since the last motor start.
The margin percentage is defined by the Wizard Tolerance configuration.
For example: the highest imbalance since the last start is 10%. The Tolerance
level is set to 15%. The Wizard will offer a new configuration above
10%*1.15=11.5% i.e. 15%.
Information about the Imbalance Current is available from the statistics

n Currents / Imbalance
This item displays the imbalance current as a percentage of the highest
phase (or as a percentage of 100%FLC if the highest phase current is less
than 100%FLC)
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Gemstart 4
3.4.10 CFG / Motor Protection / Starts in Hour

The Starts in Hour Protection feature is designed to protect the number of
operation limit specified for some motors. This feature will generate a Self
Clearing Trip when the motor is stopped if another start cannot be performed.
A rolling total of the number of starts in the last hour is maintained. As the
oldest starts drop out of the count the Starts in Hour Trip is removed to allow
further starts to be actioned.
Pre-requisites
None.
Configuration items
Start in Hour Limit
Off, 1, 2, 3, 5, 8, 12, 30
Advanced Settings
If the motor has a maximum starts in an Hour then set the Limit to match.
Otherwise set the Limit to Off.
Protection wizard
The Motor Setup Wizards selects the value equal to or below the actual Motor
Limit.
Information about the number of Starts in the Last Hour is available from the
statistics available on the HHP.
n Counters / Starts in Hour
The total number of starts in the last hour
The history of when starts occurred is held in 4 counters. Therefore each start
operation is held in one of the counters for between 45 and 60 minutes.
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3.4.11 CFG / Motor Protection / Speed Sense

The Speed Sense protection is for use with motors with a centrifugal switch.
This switch is used to indicate that the motor has started turning and has not
stalled. This is useful in situations where the stall withstand time is shorter than
the acceleration time.
The Speed Sense timer is started when the contactor is closed. Once the timer
elapses and while the motor is running, Speed Sense will trip the motor if the
Speed Sense input is, or becomes, inactive.
Pre-requisites
None.
Configuration items
Speed Sense Limit
Off, 1 to 255s in 1s steps
Speed Sense Source
Off, On, Interlock, Input 1, ..., Input 4
Speed Sense I/P Sense
N/O, N/C
Advanced Settings
Leave the Speed Sense Limit Off if the motor does not have a Centrifugal
Switch.
If the motor has a centrifugal switch set the Speed Sense Limit to the first setting
below the lowest of the following:
n Stall withstand time from hot
n Acceleration time
Protection Wizard
The Chassis Setup Wizard will define the Speed Sense Source.
If the speed sense source is not set to Off or On the Motor Setup Wizard will
offer a Speed Sense Limit which is the first value below the lowest of the
following:
n Stall withstand time from hot
n Acceleration time
Additional Information
None.
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3.4.12 CFG / Motor Protection / Voltage Protection (4.3 only)
Voltage Protection Configuration is provided to give the user some indication

of the voltage condition. You can configure the severity of fault generated by
Gemstart. If all Gemstarts are configured to generate a fault on a voltage
failure then the Control System is likely to be swamped by a fault report from
each Gemstart when the voltage does dip. A useful system scheme is to
configure one Gemstart in each Motor Control Centre (MCC) to report the
voltage condition for that MCC. All other Gemstarts should have Voltage
Protection left in the default condition.
The fault levels for Voltage Protection are variable and defined as:
Low Voltage Fault 65% of 110/220V = 71.5/143V

High Voltage Fault 110% of 120/240V = 132/264V
If PreWarn is enabled the warn level is calculated as a percentage of the

configured Control Voltage. e.g. If the control voltage is configured to be 110V
and the PreWarn level is set to 70% then a Warn is generated at 70% of 110V.
PreWarn has no effect on High Voltage Monitoring.
As Gemstart does not transmit to the Host while in a Supply Fail condition
(<65%) an “Under Voltage Warn” condition will not been seen by the Host.
However there are two configurations of Voltage Protection which may be
useful:
If you wish to latch a supply dip condition set the severity to Alarm.
If you wish to receive a warning when the supply voltage drops below 70, 80,
90 or 100% of the control supply voltage then set the PreWarn level to the
appropriate level.
Pre Requisites
For the PreWarn level to work correctly the Control Voltage must be correctly
configured.
Configuration Items
Voltage Protection Enabled
No, Yes
Advanced Protection Settings
For one Gemstart on each MCC (or Control Supply circuit if different) enable
the protection and set the PreWarn level to 90%.
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Protection Wizard
The protection Wizards do not change this configuration.
A Gemstart with Voltage Protection disabled will report “Supply Fail Warn” on
the LCD if a supply dip of longer than 12ms occurs or the average voltage
drops below 65% of 110V/220V. The fault is not reported to the Host.
A Supply Fail condition is defined as starting when the average voltage drops
below 65% of 110/220V or if the instantaneous voltage has not been above
92/184V (the peak of 65Vrms) for 12ms. A Supply Fail ends when the average
climbs above 90% of 110/220V
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3.4.13 CFG / Motor Protection / Earth Fault Protection

Earth Fault Protection monitors the amount of current that does not return via
the phase conductors. The fault level can be configured to cover a wide range
of fault levels.
Two fault levels are provided. A Start EFC active during the startup phase
(Until the highest phase falls below 100% FLC) and a standard EFC active
during normal running. The Start EFC allows for an increase in the protection
and Warn levels during start up to avoid nuisance tripping due to CT
mismatches which are accentuated during the high current start phase. In
addition if nuisance tripping continues to be a problem then EF Ignore at Start
can be used
In addition to the two fault levels two timers are used to provide comprehensive
control in event of an earth fault.
The first Earth Fault Timer, Delay to Detect, is used to prevent nuisance trips or
in the case of layered protection to allow protection devices lower in the chain
to trip first. If an earth fault is present for the duration of this timer’s setting
then Gemstart will trip - but not immediately. This is where the second timer,
Delay to Trip, comes in.
The second timer, Delay to Trip, holds the contactor closed to allow the fuses
to break the Earth Fault. The contactor is then opened and although the fault
has cleared, Gemstart will still flag an Earth Fault LTrip. The Delay to Trip timer
is required in 3 phase systems with 2 CT's and a CBCT. In 3 CT systems
Contactor Protection will ensure that the contactor is held closed while the fault
current is above the contactor break rating.
The advantage of having two delays is that an earth fault condition will still be
detected and flagged even if the fault is removed by a fuse blowing.
NOTE: The additional Delay to Trip is only required when all 3
phases are not being measured, or contactor protection is not
configured.
Explanation: The additional earth fault delay is implemented to allow the
fuse to blow before opening the contactor when very high fault currents are
flowing to earth. This is the aim of type 2 co-ordination.
All contactors are only rated to break currents up to a limit. Therefore if
Gemstart can guarantee not to open the contactor while the instantaneous
current is above that limit, no delay needs to be calculated or configured.
However for this to work correctly, Gemstart must be reading from 3 CT's.
As Earth Faults have serious safety implications this fault can only be cleared
with a HHP in Control (i.e. with the Key in the active position).
Pre-requisites
There are 2 hardware methods of Earth Fault Detection. The first method, by
CBCT, uses a CBCT with a load resistor to generate enough voltage at the
Earth Fault input to trip Gemstart.
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The second method, by CT, sums the 3 phase CT’s externally and passes the
residual current through a resistor across the Earth Fault input.
Both methods protect in exactly the same way.
The Hardware settings, CT Residual Resistor or Nominal EF Current, must be

defined if you wish to configure Earth Fault in Amps. If the Hardware settings
have been defined the HHP shows the configuration in percentage and Amps.
The configuration is held as a percentage so if you later change the Hardware
Settings it will affect the Amps fault level.
Configuration items
Earth Fault Current (EFC)
25% to 150% of EF Rating in 1% steps, Standard 100%
Start EFC
EFC + 0% to 100% in 1% steps
EF Ignore at Start
0.0, 0.4, 0.7, 1.0s
EF Delay to Detect
Off, 0, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 1.0, 1.2, 1.5, 1.8, 2.2,
2.7, 3.3, 3.9, 4.7, 5.6, 6.8, 8.2, 10s
Additional Delay to Trip

0, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 1.0, 1.2, 1.5, 1.8, 2.2, 2.7,
3.3, 3.9, 4.7, 5.6, 6.8, 8.2, 10s
Advanced Settings
Earth Fault Current
Set this value to the required fault level.
Earth Fault Ignore at start
Should only be used if residually connected CT’s are measuring the earth fault
Earth Fault Delay to Detect
Start with 0.1s. This time can be increase to improve rejection of nuisance trips.
If downstream protection is present this time should be set to be longer than
the downstream protections trip time.
Earth Fault Additional Delay to Trip
The next table summaries how to set up the Earth Fault Timers.
System Type Delay to Trip

2 CT’s & CBCT Set to ensure the sum of the Delay to Detect Time and the
Delay to Trip Time is longer than the Time to Blow for the
fuse when the Contactor Rating Current is flowing
3 CT’s Set to 0
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Protection wizard
The Application Protection Wizard offers an Earth Fault Current option

which is a percentage above the highest Earth Fault Current detected since the
last startup.
For example: if the Earth Fault Current has reached 35% of the Nominal
Earth Fault Current since the last startup and the Wizard Tolerance level is set
to 15%, the new option offered is 35%*1.15=40.25, i.e. 41% will be offered
as the new configuration.
The Delay to Detect and Delay to Trip times are not affected.
Information about the number of Starts in the Last Hour is available from the
statistics available on the HHP.
n Currents. / Earth Crnt(%Fault)
This item displays the Earth Fault Current as a percentage of the Fault Level
and in Amps
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3.4.14 CFG / Contactor / Advanced Settings / Contactor

Protection
Type 2 co-ordination requires that the contactor and fuse are co-ordinated
such that the fuse will be allowed to break currents which are too large for the
contactor to break.
To allow this to be fully implemented the following details about the contactor
and fuse must be configured.
q The maximum breaking current of the contactor
q The time for the fuse to blow at the above current
Maximum Contactor Rating
To provide full co-ordination Gemstart needs to know the maximum breaking

capacity of the contactor. Gemstart will delay opening a contactor while the
current is above this rating. This delay gives time for the fuses to blow.
Fuse Time
The Fuse Time is the maximum time that Gemstart will wait for the fuse to blow
while the current is above the Maximum Contactor Rating. If the contactor has
not opened by the end of the Fuse Time Gemstart will open the contactor even
if the currents are still high.
Pre-requisites
The Contactor Type should be set up first.
To see the Contactor Rating in Amps as well as percent the CT Rating and
number of turns must first be defined.
Configuration items
Contactor Rating Break Current
100% to 2000% in 10% steps. Standard 1000%
Fuse Time
0, 0.1, 0.15, 0.22, 0.33, 0.47, 0.68, 1, 1.5, 2.2, 3.3, 4.7, 6.8, 10,
15, 22s
Select the first Contactor Rating below the contactor Maximum (RMS) Break
Current.
To select the Fuse Time value:
1. From the Time to Blow chart for the in line fuses, read off the time to
blow at the Contactor Rating Current
2. Use the next highest value for the Time to Blow configuration
Protection wizard
The Protection Wizards do not modify this Contactor Protection.
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q While Contactor Protection is active and preventing a trip, Gemstart
displays “Stop Delayed.”
3.4.15 CFG / Measurements / Power Rating (4.3 only)

The Power Rating of the motor is configured here. This is the power of the
motor as defined on the motor rating plate.
This item is used as the basis for:
Under Power Protection
the calculation of power as a percentage for display and the serial link.
Pre Requisites
None.
Configuration Items
Power Rating
Unknown
0.10 to 0.99 in 0.01 steps,
1.0 to 9.9 in 0.1 steps,
10 to 99 in 1 steps,
100 to 990 in 10 steps (kW)
Protection Wizard
Power rating is not affected.
Additional Information - Power and Power Factor Calculation
Real Power in Gemstart 4.3 is calculated by multiplying the control supply

instantaneous voltage by an instantaneous current which is in phase with the
voltage. The result is then averaged and scaled to give a reading in 0.1kW
units. The current used will be (I1) for 1 and 2 phase systems; (I1 -I2 - I3) for
phase voltage V1n; and (I1 -I2) for line voltage V12.
Apparent power is calculated (but not displayed) by multiplying the average

voltage by the average of the current used in the power calculation above.
Power Factor is calculated by dividing the Real Power by the Apparent Power.
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3.4.16 CFG / Application Protection / Set ALC

The ALC level is the Actual Load Current for the Application. The Application
protection items are all configured relative to this setting. The ALC setting
cannot be configured to a value greater than FLC. If the FLC level is set below
the ALC setting, Gemstart will “repair” the ALC figure to be equal to FLC.
Pre-requisites
This item is configured as a percentage of the CT rating. If you wish to see the
Amps rating as you are configuring this item then you must configure the CT
rating and CT turns first.
Configuration items
ALC Setting
25% to 150% of CT Rating in 1% steps
Protection wizard
The Application Protection Wizard offers an ALC setting equal to the

current flowing when the wizard was entered (if the motor is running) or equal
to the current just before the motor was last stopped.
The percentage values displayed on Gemstart and the HHP are displayed as a
percentage of the FLC Setting during the startup phase. At all other times
currents are displayed as a percentage of the ALC Setting.
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3.4.17 CFG / Application Protection / Phase Reversal

Phase Reversal protection monitors the phase rotation of the currents on a 3
phase system. If the application is rotating in the wrong direction then a fault is
flagged. Phase Reversal protection becomes active once the contactor has
been allowed to settle (about 500ms).
Pre-requisites
This protection only works in 3 phase systems. It is also disabled if Gemstart is

in Test Position.
Configuration items
Phase Reversal Enable
Off, On
Advanced Settings
Turn this feature On if Gemstart is controlling a motor. Switch if Off if a

Variable Speed Drive is controlling the motor.
Protection wizard
The protection wizard does not change this item.
None.
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3.4.18 CFG / Application Protection / Under Current

Undercurrent protection monitors the lowest phase current. Gemstart trips if
the current remains below the fault limit for the configured time.
Under Current protection can be used to detect loss of load or changes in the
load characteristics.
Pre-requisites
This protection item is disabled if Gemstart is in the Test Position.
Configuration items
Under Current Limit
Off, 5% to 100%ALC in 5% steps
Under Current Time
0 to 6000s in 1s steps (only expect 9m99s to be configurable),
Standard 10s
Advanced Settings
If Under Current Protection is required set the Under Current Limit to a value
above the no load current.
The Under Current Time should be set to ensure that gaps in the load are
ignored. At the same time the time should be short enough to prevent damage
from continuous dry running.
Protection wizard
The Application Protection Wizard offers a new undercurrent limit that is a

percentage below the lowest current since the end of startup.
For example: if the lowest current was 50% and the Wizard Margin is set to
15% then the new option offered is the first option below 50*(100-
15)%=42.5% i.e. 40% option is offered.
The configuration wizard does not modify the Under Current Time.
Information about the minimum phase current is available from the statistics
n Currents / Min&MaxALC
This item displays the minimum (and maximum) value for the highest
phase current since the end of the last startup phase. The current is
displayed as a percentage of the ALC Setting
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NOTE: Undercurrent protects against the lowest phase current

where as MinALC records the lowest value for the Highest
Phase Current.
3.4.19 CFG / Application Protection / Instant ALC

Instant ALC monitors the highest phase current and LTrips if the current
exceeds the configured limit. Typically used for stalled or locked rotor detection
after startup has finished.
Pre-requisites
This protection item is disabled during startup.
Configuration items
Instant ALC Limit
Off, 100% to 1000%ALC in 10% steps
Advanced Settings
Set the Instant ALC Limit to a value above the peak running current of the
motor but below the Locked Rotor Current.
Protection wizard
The Application Protection Wizard monitors the highest current since the
end of the last startup. The new option offered is the first option above the
highest current plus the Wizard Margin.
For example: if the highest current since the end of startup is 132%ALC and
the Wizard Margin is set to 15%. The new option offered is 132*1.15=152. So
option 160% is offered.
Information about the peak ALC current is available from the statistics
n Currents / Min&MaxALC
This item displays the maximum (and minimum) phase current since the
end of the last startup phase. The current is displayed as a percentage of
the ALC Setting
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3.4.20 CFG / Application Protection / Constant ALC

Constant ALC monitors the highest phase current and provides time delayed
protection.
This protection is useful for detecting partial blockages or other events which
cause a higher than normal load to be present for an extended time.
Pre-requisites
The protection item is disabled during startup.
Configuration items
Continuous ALC Limit
Off, 100% to 2000%ALC in 10% steps. Standard 800% (Maximum
is 1000% Nominal CT)
Continuous ALC time
00m00s to 99m59s in 1s steps. Standard 00m10s
Advanced Settings
Set the Continuous ALC Limit to a value less than the Instant ALC limit.
Select a time which will not cause nuisance trips under normal operational
conditions.
Protection wizard
The Application Protection Wizard offers a new value which is half way
between the ALC and the Instantaneous ALC fault limit.
None.
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3.4.21 CFG / Application Protection / Under Power (4.3 only)

Under Power protection is provided to protect motors or applications where the
power drops but where there is no discernible change in the current. For
example when a motor runs with no load.
Under Power has a delay to trip time to allow short drops in power to be
ignored.
See also Power Factor High, and Power Factor Low.
Pre Requisites
Under Power protection is enabled if:
Gemstart is Gemstart 4.3 or higher;
Motor Power Rating, Motor Voltage, CT Rating, and Control Supply Phase have
been configured;
Gemstart is NOT in Test Position.
Power can be calculated as long as the CT rating, motor voltage and control
supply phase have been defined. However as Under Power is configured as a
percentage of the Power Rating then that also must be configured to allow
Under Power Protection to operate.
Configuration Items
The new system and default settings are shown in bold.
Under Power Limit

Off, 1 to 100% in 1% steps
Note: The HHP display will show the kW setting
Under Power Time
0 to 25.5s in 0.1s steps, Standard 1s
Advanced Settings

The Under Power limit is configured as a percentage of the Power Rating.
If a pre warn level of 70, 80 or 90% is selected, the warn level is calculated as
a percentage of the difference from 100% to the fault level.
For example if the fault level is 60% and the pre warn is set to 90% then the
pre warn level is 90% of the way from 100% to 60% i.e. 64%.
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Protection Wizard
The Application Protection Wizard will offer a configuration of this item

which is a percentage below the minimum power level since the end of the last
startup.
For example if the minimum power level since the end of the last startup is
20kW and the Protection Wizard is setup with a 15% tolerance then the new
option offered for Under Power will be the first option below (100%-
15%)*20kW = 17kW.
The Wizard will not change Under Power Time.
If the Wizard settings for Under Power Limit are accepted, the Advanced
Setting/Protection Active item is forced to Yes.
None.
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3.4.22 CFG / Application Protection / Over Power (4.3 only)

Over Power protection is provided to protect motors or applications where the
power increases but where there is no discernible change in the current.
Over Power has a delay to trip time to allow short increases in power to be
ignored.
See also Under Power, Power Factor High, and Power Factor Low.
Pre Requisites
Over Power protection is enabled if:
Motor Power Rating, Motor Voltage, CT Rating, and Control Supply Phase have
been configured;
Power can be calculated as long as the CT rating, motor voltage and control
supply phase have been defined. However as Over Power is configured as a
percentage of the Power Rating then that also must be configured to allow
Over Power Protection to operate.
Configuration Items
Over Power Limit

Off, 1 to 100% in 1% steps
Note: The HHP display will show the kW setting
Over Power Time
0 to 25.5s in 0.1s steps, Standard 1s
Advanced Settings

The Over Power limit is configured as a percentage of the Power Rating.
If a pre warn level of 70, 80 or 90% is selected, the warn level is calculated as
a percentage of the difference from 100% to the fault level.
For example if the fault level is 60% and the pre warn is set to 90% then the
pre warn level is 90% of the way from 100% to 60% i.e. 64%.
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Protection Wizard

which is a percentage above the maximum power level since the end of the
last startup.
For example if the maximum power level since the end of the last startup is
20kW and the Protection Wizard is setup with a 15% tolerance then the new
option offered for Over Power will be the first option above
(100%+15%)*20kW = 23kW.
The Wizard will not change Over Power Time.
If the Wizard settings for Over Power Limit are accepted, the Advanced
None.
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3.4.23 CFG / Application Protection / Power Factor High

(4.3 only)
Power Factor protection is provided to protect motors or applications where the
power factor changes but where there is no discernible change in the current.
For example when the viscosity of the product changes. There are two Power
Factor protection functions to allow a high and a low fault condition to be
defined. Both features have identical protection options.
Power Factor is an instantaneous fault condition.
See also Under Power, and Power Factor Low.
Pre Requisites
Power Factor High protection is enabled if:
Control Supply Phase has been configured;
Configuration Items

Power Factor High Limit
Off, 0.05 to 1.00 in 5% steps
Advanced Settings
For Power Factor High the pre warn levels 70, 80, and 90% correspond to 0.3,
0.2 and 0.1 below the configured fault limit.
Protection Wizard

which is a value above the maximum power factor since the end of the last
startup. The headroom value is equal to the Wizard Headroom percentage.
For example if the maximum power factor since the end of the last startup is
0.72 and the Protection Wizard is setup with a 15% tolerance then the new
option offered for Power Factor High will be the first option above
0.72+0.15=-0.87 i.e. 0.90
If the Wizard settings for Power Factor High Limit are accepted, the Advanced
None.
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3.4.24 CFG / Application Protection / Power Factor Low

(4.3 only)
Power Factor protection is provided to protect motors or applications where the
power factor changes but where there is no discernible change in the current.
For example when the viscosity of the product changes. There are two Power
Factor protection functions to allow a high and a low fault condition to be
defined. Both features have identical protection options.
Power Factor is an instantaneous fault condition.
See also Under Power, and Power Factor High.
Pre Requisites
Power Factor Low protection is enabled if:
Control Supply Phase has been configured;
Configuration Items

Power Factor low Limit
Off, 0.05 to 1.00 in 5% steps
Advanced Settings
For Power Factor Low the pre warn levels 70, 80, and 90% correspond to 0.3,
0.2 and 0.1 above the configured fault limit.
Protection Wizard

which is a value below the minimum power factor since the end of the last
startup. The headroom value is equal to the Wizard Headroom percentage.
For example if the minimum power factor since the end of the last startup is
0.35 and the Protection Wizard is setup with a 25% tolerance then the new
option offered for Power Factor Low will be the first option below 0.35-0.25=-
0.10 i.e. 0.10
If the Wizard settings for Power Factor Low Limit are accepted, the Advanced
None.
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3.4.25 CFG / Application Protection / AutoRestart (4.3)

AutoRestart provides you with the ability to restart you application after a short
loss or dip in the supply. With AutoRestart there are 3 configurable phases of
operation.
The three phases are shown below and are described as

Ride Through This is the initial phase and is the period of time immediately
following the loss of supply and represents the time that
Gemstart will continue to operate as normal. This time is
configurable between 0s and 200ms plus and additional
setting of Max.
NOTE Gemstart 4.3 has a guaranteed ride through time of 200ms at 65%
control supply. Gemstart 4.2 has a guaranteed ride through
time of 200ms at 75% control supply. The higher the voltage
prior to loss the longer the ride through. At 100% volts the
Gemstart 4.3 can ride through for over 1 second hence the
Max configuration option
Hold Off This immediately follows the Ride through period and
represents the time period between Ride through and power
restoration.
Max DIP time This is the sum of Ride through and Hold off and represents
the time the supply has been lost for.
Delay to restart This is the time that Gemstart waits after power has been
restored before automatically closing the contactor and is
used to provide a staged restart of the plant based on
process or supply conditions.
Control Supply
Present
Lost
Contactor Status
Closed
Open
<-- Ride Through --> <-- Hold Off --> <---- Delay to Restart ---->
<-- Up to 200ms --> <---- (Up to 99m59s) ---->
<---- Up to 30s (Max Dip Time) ---->
The first phase of AutoRestart is the Ride Through Phase. Ride Through
starts when the control supply is lost. During this phase the close command to
the contactor is maintained. The status of the contactor is unknown while there
are no volts present. If the supply is restored within the “Ride Through” period
Gemstart will automatically and immediately re-close the contactor. This will
allow your plant to continue running for short breaks of the control supply.
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NOTE: Any close which occurs during the Ride through period will not
be recorded in any statistics nor will it update the Starts/hour
counter.
If the supply is not restored within the Ride Through time, or a
second dip occurs within 1 second of the first dip, the contactor is
opened and AutoRestart moves into the Hold Off phase.
If the Ride Through time is set to Off the contactor will be opened when a
Supply Fail condition is detected. (A supply fail is when there are no volts for
10ms or the average drops to the Voltage Fail Level). A Max option is also
offered which will try to hold the contactor closed for as long as Gemstart has
enough power to run.
Turning Ride Through OFF puts Gemstart straight into the hold off phase.
Setting Ride Through = OFF does not disable auto restart.
The second phase of AutoRestart is the Hold Off Phase. During this time
Gemstart is waiting for the control supply to be restored. Gemstart may power
down during this phase. The end of Hold Off is when the average voltage rises
above the Voltage Recovery level. The configuration options for the recovery
levels vary dependant on the type of Gemstart as shown below.
Gemstart type Configuration item Configuration option

4.3 Low Threshold 65%,70%,75%,80%
High Threshold 80%, 85%, 90%
4.2 Low Threshold 65%,75%
High Threshold 80%, 90%
NOTE: The Gemstart 4.2 only offers a limited range of voltages

due to the accuracy of the voltage sensing
If the supply is restored within the Dip Time then AutoRestart moves into the
Delay to Start phase.
If the Dip Time is exceeded without the supply being restored then AutoRestart
is aborted.
During the third phase, the Delay to Start Phase, Gemstart will wait for the
configured time before re-closing the contactor. After the Delay to Start time
has elapsed the contactor is then re-closed.
Turning Max Dip Time to OFF will disable Auto Restart. Setting Max Dip Time
to OFF does not disable the Ride through facility
If a command to stop is received at any stage then Auto Restart is aborted.
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Pre Requisites
AutoRestart is available on both Gemstart 4.2 and 4.3
Configuration Items
Ride Through
Off, 40, 80, 120, 160, 200ms, Max
Max Dip Time
Off, 0.5 to 10s in 0.5s steps, 11, 12, 13, 14, 15, 17, 20, 25, 30s
Delay to Restart
00m00s to 99m59s
Select a ride through time which is longer than the hold in time for the
contactor. If your application can be restarted after stopping for 200ms then
pick the 200ms option. Selecting Max will attempt to hold the contactor closed
for as long as Gemstart keeps running. This can be up to 1s (or longer for
brown outs) depending on the voltage before the supply failed.
Select a Dip Time that matches the time your application or process can stand
without requiring a controlled startup.
The control supply to several Gemstart is likely to return at the same time.
Delay to Restart allows you to configure the order in which your process
restarts.
Protection Wizard
The Protection Wizards do not modify AutoRestart.
If a second supply fail condition occurs after some motors have restarted but
others are waiting for the Delay to Restart, it is very likely that only the motors
which have already started will go through another AutoRestart. This is
because the later motors are still measuring the dip time from the original loss
of supply. In this situation the control system will need to perform a controlled
restart.
The Gemstart 4.2 measures voltage to +/- 10% and hence the voltage
thresholds for triggering auto restart are limited. There is also more
possibilities for thresholds to vary between Gemstart units. In the case where
volts dip to 70% before restoring it is likely that some units will enter auto
restart whilst others will not. Loss of supply to 60% or less will guarantee all
units enter the restart condition. Similarly restoration of power can occur at a
spread of voltages
15G0012(E)
Page 109
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Publication date April 03

ALSTOM T&D Ltd - Services

Tel.: +44 (0)161 745 9090

Health and Safety

ALSTOM T&D Ltd - Services

Tel.: +44 (0)161 745 9090

Installation and commissioning

ALSTOM T&D Ltd - Services

Tel.: +44 (0)161 745 9090

C Updated in line with Gemstart version F8

D Updated Gemstart 3 Fault Codes.

Acronyms and Abbreviations

1 About this manual ..................................................................................................... 10

3.3.6 INCH Select .................................................................................................. 55

Table 1 - Key to abbreviations .......................................................................................... 12

1 About this manual

2.1.1 Contactor types

2.1.2 Input functions

2.1.3 Input Configuration summary

Table 1 - Key to abbreviations

The standard input type option is shown in bold.

Table 2 - Input Configuration Options

Configuration Options Input Type Fault Types

2.1.4 Protection functions

Contactor type Section Gemstart Page

3.1.1 Two Speed Dahlander Starter [Start in High or Low]

Low Speed Û Stopped Û High Speed

All inputs are Normally Closed.

All outputs are Normally Open.

The contactor control is configured and connected as follows:

Configuration Item Configuration Option

3.1.2 Two Speed Starter [Start in High or Low]

Stopped Û Low Speed Û High Speed Û Stopped

The software contactor control block is defined as:

All inputs are Normally Closed.

The contactor control is configured and connected as follows:

Configuration Item Configuration Option

3.1.3 Two Speed Starter [Start in Low Only]

Stopped Û Low Speed Û High Speed Þ Stopped

The software contactor control block is defined as:

All outputs are Normally Open.

The contactor control is configured and connected as follows:

Configuration Item Configuration Option

Please refer to Contactor type/advanced settings later in this chapter

The software contactor control block is defined as:

All inputs are Normally Closed.

All outputs are Normally Open.

The contactor settings for DOL-E are configured as follows:

Configuration item Configuration option

Please refer to Contactor type/advanced settings later in this chapter

3.1.5 Latching Contactor DOL-L

The software contactor control block is defined as:

All inputs are Normally Closed.

All outputs are Normally Open.

The contactor control is configured and connected as follows:

Configuration Item Configuration Option

Please refer to Contactor type/advanced settings later in this chapter

The forward reverse contactor allows a motor to be driven in either direction.

A close A command closes the forward contactor. A close B command closes