Run Performance Test; Bypass Contactor Test; Control Input Test; After Repair Tests - GE ASTAT XL Series Testing, Troubleshooting And Servicing Instructions

Functional Tests
2.3

Run Performance Test

This procedure tests for correct operation of the ASTAT XL during Run mode.
This test is performed using an AC voltmeter.
1. Measure the voltage across each phase (L1-T1, L2-T2, L3-T3). This should be close to the nominal
mains voltage (phase voltage for in-line connection and line voltage for inside delta connection).
• If the voltage is zero, the SCR on that phase may have failed.
• If the voltage is not equivalent to the nominal mains voltage, the bypass contactor may be
damaged and should be replaced (internally bypassed models only).
2. Command the soft starter to start. When the soft starter is starting, measure the voltage across
each phase.
For units which are not bypassed, the voltage should fall to less than 2 VAC just before the soft
starter reaches Run mode. For units with internal bypass contactors, this should be less than 0.5
VAC when the starter reaches Run mode.
• If the voltage remains near nominal mains voltage, the SCR is not firing correctly. Check the
connections between the Main Control PCB and SCRs.
If the voltage starts near nominal mains voltage and then falls to less than 2 VAC just before the ASTAT
XL reaches Run mode, the soft starter is operating correctly and the cause of the starting problem is
not the soft starter.
2.4

Bypass Contactor Test

This procedure tests the operation of the internal bypass contactors. Use this test if the starter trips
with "Bypass Fail", "Time Overcurrent" or "Heatsink Overtemp".
This test is performed using an AC voltmeter.
1. Measure the voltage across each phase (L1-T1, L2-T2, L3-T3). This should be close to the nominal
mains voltage (phase voltage for in-line connection and line voltage for inside delta connection).
• If the voltage is zero, the bypass contactor may be damaged and should be replaced.
2. Command the soft starter to start. When the Run LED stops flashing, you should hear the bypass
contactors close.
• If the bypass contactors do not close, the bypass contactor, Main Control PCB, Model PCB or
Bypass Driver PCB (G2B models only) may be faulty or there may be a faulty connection between
these components.
3. When the soft starter is running, measure the voltage across each phase. This should be less
than 0.5 VAC.
4. Command the soft starter to stop and listen for the bypass contactor to open. If the ASTAT XL is
configured for soft stop, this should occur when the Run LED starts flashing. If the ASTAT XL is not
configured for soft stop, this should occur when the Run LED turns off.
NOTE
The bypass contactors used in the G1B frame size are latching. The ASTAT XL control circuits
are designed to open the bypass contactors even in the event of removal or loss of control
voltage. However it is still possible that the bypass contactor may be closed when there is no
control supply to the soft starter. The bypass contactors will open when control voltage is
next applied.
2.5

Control Input Test

This procedure tests the condition of the soft starter control inputs. This test is performed using a wire
link.
1. Disconnect all external wiring from the soft starter's control inputs.
2. Control voltage must still be connected to the soft starter.
3. Connect a wire link between each input.
• If the corresponding LED lights up, the input is operating correctly.
• If the LED does not light up, the control input is damaged. Replace the Main Control PCB.
2.6

After Repair Tests

NOTE
The servicing technician is responsible for ensuring that all electrical safety tests have been
completed in accordance with local regulations.
To test that the soft starter functions correctly after reassembly:
ASTAT XL Service Manual
DET-813 5