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Santerno ASAB Installation And Programming Instructions

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INSTALLATION AND PROGRAMMING
Issued on 22/05/13
R. 03
•
This manual is integrant and essential to the product. Carefully read the instructions contained herein as
they provide important hints for use and maintenance safety.
•
This device is to be used only for the purposes it has been designed to. Other uses should be considered
improper and dangerous. The manufacturer is not responsible for possible damages caused by improper,
erroneous and irrational uses.
•
Elettronica Santerno is responsible for the device in its original setting.
•
Any changes to the structure or operating cycle of the device must be performed or authorized by the
Engineering Department of Elettronica Santerno.
•
Elettronica Santerno assumes no responsibility for the consequences resulting from the use of non-original
spare parts.
•
Elettronica Santerno reserves the right to make any technical changes to this manual and to the device
without prior notice. If printing errors or similar are detected, corrections will be included in new releases of
the manual.
•
The information contained herein is the property of Elettronica Santerno and cannot be reproduced.
Elettronica Santerno enforces its rights on the drawings and catalogues according to the law.
• 15P0078B1 •
ASAB
ADVANCED SOFT STARTER
INSTRUCTIONS
Elettronica Santerno S.p.A.
S.S. Selice, 47 – 40026 Imola (BO) Italy
Tel. +39 0542 489711
www.santerno.com sales@santerno.com
English
– Fax +39 0542 489722

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  • Page 1 • Elettronica Santerno reserves the right to make any technical changes to this manual and to the device without prior notice. If printing errors or similar are detected, corrections will be included in new releases of the manual.

  • Page 2: Table Of Contents

    Application Examples .............................. 52 Installation with Main Contactor ..............................52 Installation with Bypass Contactor ..............................53 Emergency Run Operation ................................54 Auxiliary Trip Circuit ..................................55 DC Brake with External Zero Speed Sensor ..........................56 Soft Braking ....................................57 Two Speed Motor ..................................58 Troubleshooting ............................... 59 ASAB 1/66...
  • Page 3 Protection Responses .................................59 10.2 Trip Messages .....................................59 10.3 General Faults .....................................62 Accessories ................................64 11.1 Communication Modules ................................64 11.2 Remote Control Panel (RCP) ..............................64 11.3 Finger Guard Kit ..................................64 11.4 PC Software ....................................64 Busbar Adjustment Procedure ..........................65 2/66 ASAB...

  • Page 4: About This Manual

    (including when the starter is tripped or waiting for a command). SHORT CIRCUIT The ASAB is not short circuit proof. After severe overload or short circuit, the operation of the ASAB should be fully tested by an authorised service agent.

  • Page 5: Disposal Instructions

    The STOP function does not remove dangerous voltages from the starter, the motor or any external option units. Disposal Instructions Equipment containing electrical components may not be disposed of together with domestic waste. It must be collected separately as electrical and electronic waste according to local and currently valid legislation. 4/66 ASAB...

  • Page 6: Introduction

    Introduction The ASAB is an advanced digital soft start solution for motors from 11 kW to 850 kW. ASAB soft starters provide a complete range of motor and system protection features and have been designed for reliable performance in the most demanding installation situations.
  • Page 7 AC53b 3.0-10:350 AC53b 3.5-15:345 AC53b 4.0-20:340 AC53b 4.5-30:330 40 ºC <1000 metres 40 ºC <1000 metres 40 ºC <1000 metres 40 ºC <1000 metres ASAB-0023B 23 A 20 A 17 A 15 A ASAB-0043B 43 A 37 A 31 A...
  • Page 8 ASAB-0580B 870 A 738 A 637 A 546 A ASAB-0620C 930 A 930 A 810 A 651 A ASAB-0650C 975 A 975 A 842 A 683 A ASAB-0700B 1050 A 889 A 768 A 658 A ASAB-0790C 1185 A 1185 A...
  • Page 9 Minimum and Maximum Current Settings The ASAB's minimum and maximum full load current settings depend on the model: In-line connection Inside delta connection Model Minimum Maximum Minimum Maximum ASAB-0023B 23 A 34 A ASAB-0043B 43 A 64 A ASAB-0053B 11 A...
  • Page 10 3.2.3 Dimensions and Weights Model Weight mm (inch) mm (inch) mm (inch) mm (inch) mm (inch) kg (lb) ASAB-0023B ASAB-0043B (7.2) (9.5) ASAB-0053B ASAB-0076B (11.6) (10.9) (5.9) (4.9) 4.5 (9.9) ASAB-0097B ASAB-0100B (8.4) (11.0) ASAB-0105B ASAB-0145B ASAB-0170B ASAB-0200B (17.2) (15.0) (10.8)
  • Page 11 GOST ..................................GOST R 50030.4.1-2002 RoHS ............................Compliant with EU Directive 2002/95/EC UL / C-UL ......................................UL 508 ASAB-0023B ~ ASAB-0105B ......................IP20 & NEMA1, UL Indoor Type 1 ASAB-0145B ~ ASAB-1600C ........................IP00, UL Indoor Open Type Marine ..............................Lloyds Marine No 1 Specification...

  • Page 12: Installation

    2 /T 1 4/ T 2 6 / T3 between the soft starter and solid surfaces. ASAB-0255C: Allow 100 mm (3.94 inches) between the soft starter and solid surfaces. ASAB-0380C ~ ASAB-1600C: Allow 200 mm (7.88 inches) 1 / L 1...

  • Page 13: Control Voltage

     14 (24 VAC/VDC) A5, A6 Control Wiring The ASAB has three fixed inputs for remote control. These inputs should be controlled by contacts rated for low voltage, low current operation (gold flash or similar). Two-wire control Three-wire control Four-wire control...

  • Page 14: Power Terminations

    Power Terminations NOTE For personnel safety, the power terminals on models up to ASAB-0105B are protected by snap-off tabs. When using large cables, it may be necessary to break off these tabs. NOTE Some units use aluminium busbars. When connecting power terminations, we recommend cleaning the surface contact area thoroughly (using an emery or stainless steel brush) and using an appropriate jointing compound to prevent corrosion.

  • Page 15: Power Input And Output Configurations

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

  • Page 16: Schematic Diagrams

    Different models require control voltage to different terminals: 12 (110~120 VAC) A5, A6   12 (220~240 VAC) A4, A6  14 (24 VAC/VDC) A5, A6 NOTE * ASAB-0255C current transformers are located on the output. Bypass terminals are labelled T1B, T2B and T3B. ASAB 15/66...

  • Page 17: Power Circuits

    Testing the Installation The ASAB can be connected to a small motor for testing. During this test, the soft starter's control input and relay output protection settings can be tested. This test mode is not suitable for testing soft starting or soft stopping performance.
  • Page 18 5.1.3 In-line installation, externally bypassed Non-bypassed models have dedicated bypass terminals, which allow the ASAB to continue providing protection and monitoring functions even when bypassed via an external bypass contactor. The bypass contactor must be connected to the bypass terminals and controlled by a programmable output configured to Run (refer to parameters 7A~7I).
  • Page 19 6 /T 3 K M 1 CAUTION When connecting the ASAB in inside delta configuration, always install a main contactor or shunt trip circuit breaker. 5.1.6 Inside delta installation, externally bypassed Non-bypassed models have dedicated bypass terminals, which allow the ASAB to continue providing protection and monitoring functions even when bypassed via an external bypass contactor.

  • Page 20: Bypass Contactor

    Main Contactor A main contactor must be installed if the ASAB is connected to the motor in inside delta format and is optional for in-line connection. Select a contactor with an AC3 rating greater than or equal to the full load current rating of the connected motor.
  • Page 21 5.7.2 Bussman Fuses - Square Body (170M) Model SCR I T (A Supply Voltage Supply Voltage Supply Voltage (< 440 VAC) (< 575 VAC) (< 690 VAC) ASAB-0023B 1150 170M1314 170M1314 170M1314 ASAB-0043B 8000 170M1316 170M1316 170M1316 ASAB-0053B 15000...
  • Page 22 ASAB-0380C 320000 400FMM* 400FMM 400FMM* ASAB-0425B 320000 400FMM* –– –– ASAB-0430C 320000 –– –– –– ASAB-0500B 320000 450FMM* –– –– ASAB-0580B 781000 500FMM* 500FMM* 500FMM* ASAB-0620C 1200000 630FMM* 630FMM* –– ASAB-0650C 1200000 630FMM* 630FMM* –– ASAB-0700B 781000 630FMM* –– ––...
  • Page 23 ASAB-0076B 15000 A070URD30XXX0160 A070URD30XXX0160 A070URD30XXX0160 ASAB-0097B 51200 A070URD30XXX0200 A070URD30XXX0200 A070URD30XXX0200 ASAB-0100B 80000 A070URD30XXX0200 A070URD30XXX0200 A070URD30XXX0200 ASAB-0105B 125000 A070URD30XXX0315 A070URD30XXX0315 A070URD30XXX0315 ASAB-0145B 125000 A070URD30XXX0315 A070URD30XXX0315 A070URD30XXX0315 ASAB-0170B 320000 A070URD30XXX0315 A070URD30XXX0315 A070URD30XXX0315 ASAB-0200B 320000 A070URD30XXX0450 A070URD30XXX0450 A070URD30XXX0450 ASAB-0220B 320000 A070URD30XXX0450 A070URD30XXX0450 A070URD30XXX0450...
  • Page 24 ASAB-1000B 2530000 6.9URD33D11A1400 –– –– ASAB-1200C 4500000 6URD233PLAF2200 6URD233PLAF2200 –– ASAB-1410C 6480000 6URD233PLAF2200 6URD233PLAF2200 –– ASAB-1600C 12500000 6URD233PLAF2800 6URD233PLAF2800 –– 5.7.7 Ferraz Fuses - AJT Model SCR I T (A Supply Voltage Supply Voltage Supply Voltage (< 440 VAC) (< 575 VAC) (<...

  • Page 25: Operation

     Starter status  Motor temperature  Current  Motor power  Last start information  Date and time  SCR conduction NOTE Screens shown here are with the default settings. 24/66 ASAB...
  • Page 26 The temperature screen shows which motor data set is in use, and the temperature of both motors as a percentage of total thermal capacity. If the ASAB is configured for use on one motor, the temperature for the secondary motor (M2) will always show 0%.

  • Page 27: Start, Stop And Reset Commands

    The LOCAL/REMOTE button controls whether the ASAB will respond to local control (via the keypad) or remote control (via the remote inputs). The ASAB can also be set to allow local control only or remote control only, using parameter 6A Local/Remote. The Local LED on the keypad is on when the soft starter is in local control mode and off when the soft starter is in remote control mode.
  • Page 28 Time 6.3.3 Adaptive Control for Starting In an adaptive control soft start, the ASAB adjusts the current in order to start the motor within a specified time and using a selected acceleration profile. CAUTION Adaptive Control cannot start the motor faster than a direct on-line (DOL) start. If the start ramp time (parameter 2D) is shorter than the motor's DOL start time, starting current may reach DOL levels.
  • Page 29 Set a start Current Limit (parameter 2B) sufficiently high to allow a successful start. The first Adaptive Control start will be a Constant Current start. This allows the ASAB to learn the characteristics of the connected motor. This motor data is used by the ASAB during subsequent Adaptive Control starts.

  • Page 30: Stop Methods

    Adaptive Control for Stopping In an adaptive control soft stop, the ASAB controls the current in order to stop the motor within a specified time and using a selected deceleration profile. Adaptive Control can be useful in extending the stopping time of low inertia loads.
  • Page 31 Open pump systems where fluid must drain back through the pump without driving the pump in reverse. The first Adaptive Control stop will be a normal soft stop. This allows the ASAB to learn the characteristics of the connected motor. This motor data is used by the ASAB during subsequent Adaptive Control stops.

  • Page 32: Jog Operation

    This avoids unnecessary heating of the motor. For more information on using the ASAB with an external speed sensor (eg for applications with variable load during the braking cycle), refer to DC Brake with External Zero Speed Sensor on page 56.

  • Page 33: Inside Delta Operation

    When connected in inside delta, current imbalance is the only phase loss protection that is active during run. Do not disable current imbalance protection (parameter 4A) during inside delta operation. CAUTION Inside delta operation is only possible with mains voltage  600 VAC. 32/66 ASAB...

  • Page 34: Programming Menu

    Programming Menu The Programming Menu lets you view and change programmable parameters that control how the ASAB operates. To open the Programming Menu, press the MENU/ENTER button while viewing the status or graph screens. To navigate through the Programming Menu: ...

  • Page 35: Quick Setup

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

  • Page 36: Standard Menu

    Standard Menu The standard menu provides access to commonly used parameters, allowing the user to configure the ASAB as required for the application. Default Setting Motor Details 1A Motor Full Load Current Model dependent Primary Start/Stop 2A Start Mode Constant Current...

  • Page 37: Extended Menu

    Extended Menu The Extended Menu provides access to all the ASAB's programmable parameters. Default Setting Motor Details 1A Motor Full Load Current Model dependent 1B Locked Rotor Time 00:10 mm:ss 1C Motor FLC-2 Model dependent 1D Locked Rotor Time-2 00:10 mm:ss...
  • Page 38 Trip Starter 16G Motor Thermistor Trip Starter 16H Excess Start Time Trip Starter 16I Starter Communication Trip Starter 16J Heatsink Overtemperature Trip Starter 16K Battery/Clock Trip Starter 16L Network Communication Trip Starter 16M Low Control Volts Trip Starter ASAB 37/66...

  • Page 39: Parameter Descriptions

    Single (default) Dual Description: Activates dual thermal modelling. The dual thermal model is required only if the ASAB is controlling two physically separate motors. NOTE The second thermal model is only active if parameter 1E Dual Thermal Model is set to 'Dual' and the starter is using the secondary motor set (a programmable input is set to 'Motor Set Select' and the input is active).
  • Page 40 2G – Excess Start Time Excess start time is the maximum time the ASAB will attempt to start the motor. If the motor does not transition to Run mode within the programmed limit, the starter will trip. Set for a period slightly longer than required for a normal healthy start. A setting of 0 disables excess start time protection.
  • Page 41 0:00 - 4:00 (minutes:seconds) Default: 0 second Description: Sets the stop time. 3J – Adaptive Start Profile-2 Options: Early Acceleration Constant Acceleration (default) Late Acceleration Description: Selects which profile the ASAB will use for an Adaptive Control soft start. 40/66 ASAB...
  • Page 42 Check Description: Selects whether the ASAB will verify the motor has sufficient thermal capacity for a successful start. The soft starter compares the motor's calculated temperature with the temperature rise from the last motor start and only operates if the motor is cool enough to start successfully.
  • Page 43 Description: The ASAB can be configured to force a delay between the end of a stop and the beginning of the next start. During the restart delay period, the display shows the time remaining before another start can be attempted.
  • Page 44 Options: Normally Closed (default) Normally Open Description: Selects whether the ASAB's remote reset input (terminals 58, 57) is normally open or normally closed. 6D – Input A Function Options: Motor Set Select (default) The ASAB can be configured with two separate sets of motor data.
  • Page 45 7J, 7K – Low Current Flag and High Current Flag The ASAB has low and high current flags to give early warning of abnormal operation. The current flags can be configured to indicate an abnormal current level during operation, between the normal operating level and the undercurrent or instantaneous overcurrent trip levels.
  • Page 46 Calibrates the lower limit of the analog output to match the signal measured on an external current measuring device. 7.4.9 9 Auto-Reset The ASAB can be programmed to automatically reset certain trips, which can help minimise operating downtime. Trips are divided into three categories for auto-reset, depending on the risk to the soft starter: Group Current imbalance...
  • Page 47 (kVA) but does not affect the ASAB's motor control or protection. 10J – Display A or kW Options: Current (default) Motor kW Description: Selects whether the ASAB will display current (amperes) or motor kilowatts on the main monitoring screen. 46/66 ASAB...
  • Page 48 PowerThrough remains active until '3-Phase Control Only' is reselected. PowerThrough operation does not support Adaptive Control soft starting or soft stopping. In PowerThrough, the ASAB will automatically select constant current soft starting and timed voltage ramp soft stopping. If PowerThrough is enabled, parameters 2C and 2B must be set appropriately.
  • Page 49 15F – Jog Torque The ASAB can jog the motor at a reduced speed, which allows precise positioning of belts and flywheels. Jog can be used for either forward or reverse operation.

  • Page 50: Adjustment Lock

    The default access code is 0000. Setup Tools Setup Tools includes maintenance options to configure the ASAB's date and time, reset the thermal models or load a standard parameter set. To access the Setup Tools, open the Programming Menu then select Setup Tools.
  • Page 51 The ASAB's advanced thermal modelling software constantly monitors the motor's performance. This allows the ASAB to calculate the motor's temperature and ability to start successfully at any time. If the ASAB is configured for use on two motors, each motor's temperature is modelled separately.

  • Page 52: Logs Menu

    To reset a counter, press MENU/ENTER then use the buttons to select Reset/Do Not Reset. Press MENU/ENTER to confirm the action. To close the counter and return to the Logs Menu, press MENU/ENTER. NOTE The reset counters function is protected by the access code. ASAB 51/66...

  • Page 53: Application Examples

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

  • Page 54: Installation With Bypass Contactor

    Installation with Bypass Contactor The ASAB is installed with a bypass contactor (AC1 rated). The bypass contactor is controlled by the ASAB Run Output which by default is assigned to Output Relay B (terminals 21, 22, 24). K M 1...

  • Page 55: Emergency Run Operation

    In normal operation the ASAB is controlled via a remote two-wire signal (terminals 56, 57). Emergency Run is controlled by a two-wire circuit connected to Input A (terminals 53, 55). Closing Input A causes the ASAB to run the motor and ignore certain trip conditions.

  • Page 56: Auxiliary Trip Circuit

    Auxiliary Trip Circuit In normal operation the ASAB is controlled via a remote two-wire signal (terminals 56, 57). Input A (terminals 53, 55) is connected to an external trip circuit (such as a low pressure alarm switch for a pumping system). When the external circuit activates, the soft starter trips, which stops the motor.

  • Page 57: Dc Brake With External Zero Speed Sensor

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

  • Page 58: Soft Braking

    For applications with high inertia and/or a variable load, the ASAB can be configured for soft braking. In this application the ASAB is employed with forward run and braking contactors. When the ASAB receives a start signal (pushbutton S1), it closes the forward run contactor (KM1) and controls the motor according to the programmed primary motor settings.

  • Page 59: Two Speed Motor

    When the soft starter receives a low speed start signal, it closes the low speed contactor (KM2). This closes Input A and the ASAB controls the motor according to the secondary motor settings.

  • Page 60: Troubleshooting

    10.1 Protection Responses When a protection condition is detected, the ASAB will write this to the event log and may also trip or issue a warning. The soft starter's response depends on the Protection Action setting (parameter group 16). Some protection responses cannot be adjusted by the user. These trips are usually caused by external events (such as phase loss) or by a fault within the soft starter.
  • Page 61 This may indicate a jammed load. overcurrent Related parameters: 4D, 5D, 16D The ASAB has tripped on an internal fault. Contact your local supplier with the fault code (X). Internal fault X Related parameters: None L1 phase loss During pre-start checks the starter has detected a phase loss as indicated.
  • Page 62 Related parameters: None Time-overcurrent The ASAB is internally bypassed and has drawn high current during running. (The 10A protection curve trip has been reached or the motor current has risen to 600% of the motor FLC setting.) Related parameters: None The motor has experienced a sharp drop in current, caused by loss of load.

  • Page 63: General Faults

    Check Input A (53, 55). The starter disable function may be active. If parameter 6D  is set to Starter Disable and there is an open circuit on 53, 55, the ASAB will not start. The soft starter does not respond to the The soft starter may be in Remote control mode.
  • Page 64 Parameter out of Range. Contact your local supplier for advice. Remote keypad shows message "awaiting The keypad is not receiving data from the control PCB. Check the cable connection. data" ASAB 63/66...

  • Page 65: Accessories

    11.2 Remote Control Panel (RCP) A remote mounted keypad can be installed with the ASAB. The keypad can be mounted up to 3 metres away from the starter, for control and monitoring. The starter can be controlled and programmed from either the remote keypad or the keypad on the starter.

  • Page 66: Busbar Adjustment Procedure

    Busbar Adjustment Procedure The busbars on non-bypassed models ASAB-0380C ~ ASAB-1600C can be adjusted for top or bottom input and output as required. NOTE Many electronic components are sensitive to static electricity. Voltages so low that they cannot be felt, seen or heard, can reduce the life, affect performance, or completely destroy sensitive electronic components.
  • Page 67 Move the CT bracket to the top of the starter. Position the CTs for the correct phases, then screw the CTs to the bracket. For models ASAB-0380C ~ ASAB-0930C, the CTs must be placed on an angle (the left hand legs of each CT will be on the top row of holes and the right hand legs will be on the bottom tabs).
  • Page 68 15P0078B1...

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