GE ASTAT Plus User manual

GE Power Controls
SOLID STATE
SOFT STARTER
ASTAT Plus
USER MANUAL
REMARKS :
1. Read this manual throughly before using the ASTAT Plus, and store in a safe place for
reference.
2. Make sure that this manual is delivered to the end user
3. CE Marking
When using ASTAT Plus in the EU, compliance with EMC is required.
ASTAT Plus range comply with the generic EN 50081-2 and EN 50082-2
2. The policy of GE Power controls is one of continuous improvement.
The right is reserved to alter the design on any structural details of the products at any
timewithoutgivingnotice.

ASTAT Plus. Soft Starters
WARNINGS
1. Disconnect power before installing or servicing.
2Hazardous voltages are present in the motor circuit even when the starter is OFF. An
isolation contactor is recommended, configured to provide automatic isolation when the
motor is turned OFF.
3. Unit may contain more than one live circuit. Disconnect both control and main circuits
before installing or servicing.
4. Soft stop should not be used as an Emergency stop.
5. Stopping mode must be set to meet applicable standards for operator safety.
6. Separate motor overcurrent protection is required to be provided in accordance with the
Canadian Electrical Code, Part 1. ASTAT Plus provides separate motor protection.
CAUTIONS
1. Semi-conductor fuses specified may not provide branch circuit protection. Refer to local
applicableelectricalcodes.
2. Overload relay setting should be properly coordinated with motor.
3. Slow speed running will affect the motor thermal characteristic due to reduced cooling.
Care must be taken when operating motor under these conditions.
4DC braking - braking current may cause motor overheating. Select the lowest braking
current and time.
5. DC braking must use additional (DC3) in the motor circuit. See wiring diagram page 6-1.
6. Abnormal starting times in excess of 30 seconds, or closely repeated operations of
acceleration ramp/deceleration ramp, slow speed, or DC injection braking may cause
motor damage. Contact motor manufacturer for proper motor selection.
7. If control power is lost between starts, the overload relay protection is reset to cold start
conditions.

ASTAT Plus. Soft Starters
PRECAUTIONS
1. Debranchez l'alimentation en courant électrique avant de raccorder ou d'intervenir.
2. Des tensions dangereuses sort présente dans le circuit moteur même si le soft starter
indiquela position"arrêt". Uncontacteur d'isolementassurant unisolement automatique
quand le moteur est arrête, est recommendé.
3. L'appareilpeutrenfermerplusd'uncircuitsoustensionde'brancherlescircuitsprincipaux
et les circuits de controle avant de raccorder ou d'intervenir.
4. Délestage "soft stop" ne devrait jamais être utilisé en lieu de délestage d'urgence.
5. Procédés de délestage doivent être conforme aux normes de sécurité des utilisateurs.
AVERTISSEMENTS
1. Les fusibles semi-conducteurs specifies ne protégent pas obligatoirement les circuits se
conformer aux codes locaux d'installations électriques.
2. Le relais de courant de surcharge doit être proprement coordonné avec la marche du
moteur.
3. La marche en sous-régime agira sur les caracteristiques thermiques à cause de la
réduction de refroidessement. Opérez le moteur avec précaution dans en ce cas.
4. Ralentissement courant continu peut provoquer la surchauffe de moteur. Choisissez le
plus foible courant de décéleration et la durée de ralentissement la plus courte.
5. Pour freinage courant continu, un contacteur (DC3) additional est nécessaire dans le
circuit moteur, voir le schéma de raccordement page 6-1.
6. Les délais anormaux de mise en service d'une durée supérieure à 30 secondes, ainsi
que les montées/descentes en regime, les exploitations régime lent ou les freinages par
injection de courant continu répétés et rapportes sont suseptibles d'edommager le
moteur. Mettez-vous en rapport avec votre fabricant en ce qui concerne le choix du
moteur adéquat.
7. En cas d'interruption de l'alimentation entre deux dèmarrages, la protection assurée par
démarrage à froid.
8. Le moteur doit être muni d'une protection distincte contre les surintensites, et la
surchauffe conformement au code de l'electricite, premiere partie. ASTAT Plus le relais
de courant de surcharge doit être proprement coordonne avec la marche du moteur.

Section 1. Generalities ................................................................................................................... 1-1
1-1 Comparison of starting systems ......................................................................................... 1-1
1-2 Advantages oftheASTAT Plus Solid State Soft Starters .................................................... 1-2
Section 2. Types and Ratings ....................................................................................................... 2-1
2-1 IEC ratings ........................................................................................................................ 2-1
2-2 UL ratings .......................................................................................................................... 2-2
2-3 Thermalcharacteristics...................................................................................................... 2-2
Section 3. Technical specifications............................................................................................... 3-1
3-1 GeneralSpecifications....................................................................................................... 3-1
3-2 I/O Terminal Board Specification ....................................................................................... 3-2
3-3 I/O Wiring.......................................................................................................................... 3-3
3-4 Operatingmodes ............................................................................................................... 3-4
Section 4. Programming. .............................................................................................................. 4-1
4-1 Keypad and display description ......................................................................................... 4-1
4-2 Parameter configuration .................................................................................................... 4-2
4-3 Monitor block parameters................................................................................................... 4-4
4-4 Calibration block parameters ............................................................................................. 4-5
4-5 Basic block parameters ..................................................................................................... 4-6
4-6 Advanced block parameters............................................................................................... 4-7
Section 5. Installation. ................................................................................................................... 5-1
5-1 Equipmentinstallation ........................................................................................................ 5-1
5-2 Fuses, contactors and supply wiring .................................................................................. 5-2
5-3 Start-up.............................................................................................................................. 5-3
5-4 Troubleshooting.................................................................................................................. 5-3
5-5 Thyristor Check ................................................................................................................. 5-4
Section 6. Appendix....................................................................................................................... 6-1
6-1 ApplicationDiagrams......................................................................................................... 6-1
6-2 Serial Communications ...................................................................................................... 6-4
6-3 Dimensions........................................................................................................................ 6-12
6.4 PCB'sLayout..................................................................................................................... 6-13
i i
INDEX

1-1. Comparison of starting systems
There are numerous applications where soft starting and limited
current peak are needed and thereby making direct starting of
squirrel-cage motors impossible. Traditionally in such cases other
types of starting with reduced stator voltage have been resorted to. The
best-known are star-delta starters, autotransformer starters, stator
resistance starters or using part winding motors.
Any reduced starting voltage imposes a current limitation, and as a
consequence the starting torque is also reduced, but there will always
be peaks during the change from one point or state to another which
can damage the machine being driven. In order to analyse the
performances offered by each of these different types of starters, the
following table shows the special characteristics of each of them,
comparing with the ASTAT system.
Note that in general all reduced voltage starts produce a reduction in
torque in squared proportion to the current in the phases of the motor
(not on the line) and the latter in turn is reduced in linear proportion to
the voltage. From this it can be deduced that any start with reduced
voltage reduces the torque in squared proportion to the voltage per
motor phase. From this point of view soft starting produces, just like any
other reduced voltage start, a reduction in starting torque, according
% of direct start 100% 30 - 40 or 64% 58 - 70% 65% 33% Dependingonadjust,
current (in the line) max. 90%
% of direct start torque 100% 30 - 40 or 64% 33 - 49% 48% 33% Depending on adjust,
max. 90%
Starting steps (1) 1 4, 3 or 2 3 or 2 2 2 Continuous, no steps
Connections to motor 33 3 6 6 3
Line overload 5 In 1,5 - 2,1 or 3,2 In 3 - 3,5 In 3,25 In 1,65 In Depending on adjust,
(approx.) max. 4-7 In
Change or NO NO NO NO YES NO
starting pause
(1) "Steps" mean sharp changes of speed during the time from rest until rated speed is reached.
to the adjusted parameters. The advantage, of course, is the ease with
which this ramp can be controlled to produce a soft start in accordance
with the actual requirement of the machine.
From the comparison table it can be seen that the maximum starting
torque attainable using the soft system is 90% of that which direct
starting tends to. Bearing in mind that the direct starting torque varies
between 1.5 and 2.4 times rated torque, it can be deduced that with the
soft starter, starting torques which are somewhat higher than rated are
obtained.
This area includes the starting of pumps, fans, conveyor belts, etc.,
where a torque in the region of 60% of rated is usually sufficient for
correct starting.
As a general rule it can be guaranteed that soft starter will allow starting
of drives which are currently used in conventional starting systems,
with the advantages outlined, and above all the facility to adjust the
current peaks and torque at the machine, faced with the impossibility
or difficulty of varying the steps in conventional systems.
1. Generalities
1-1
CONVENTIONAL STARTERS SOFT STARTER
Direct Autotransfo Stator Part
resistance winding Star-delta
motor

Increase in productivity and reliability with the use of
static soft starters.
1-2. Advantages of the ASTAT Plus Solid State Soft starter
1
Starting and stopping the motor without steps or transitions lengthens the life of
power-driven machine mechanical elements, greatly reducing stress on trans-
mission and coupling parts.
Consequently,overhaulingtimesare reduced andmachineandfacility lifespans
are lengthened.
1. Generalities
1-2
Improvement in acceleration / deceleration
characteristics
2
Beingabletostartbyusingthevoltageramporalternativelybylimitingcurrentlets
acceleration fit the load characteristics. Application of a pulse start may also be
selected in cases of high static friction load.
Brakingmaybemade by cutting-offpowerorby stop ramp,anditis also possible
to brake more energetically by feeding a DC current to the motor stator, so there
are many ways to obtain the best possible deceleration.
This unit can be used for a wide range of applications.
Adjustments are very easy to make and diverse options may be selected to have
equipment capabilities suited to application needs every time.
Easy to run and adjust
6
The signalling code based on alphanumeric display, makes the equipment
working conditions known at any time and gives a quick diagnosis when
protection security is violated.
7Easy maintanence due to full monitoring
The ASTAT Plus includes advanced functions, like linear acceleration ramp,
forwardand reversejog, programmableI/O or connectionto acomputer byserial
communication (RS 232), all included as standard.
These performances allows the incorporation of the soft starter to a distributed
control net, in automated plant processes, together with other soft starters,
programmable controllers, variable speed drives, etc.
Pump control
The ASTAT Plus includes a Pump Control function which is more effective than
the standard soft stop, reducing fluid surges or hammering in a pipe line system.
This method reduces the motor speed, by controlling internal parameters in the
motor as well as the output voltage in a close-loop system.
9
The soft starter protects the motor from overloads as well as from incorrect
operating conditions such as loss of an input or output phase, blocked rotor,
thyristor short circuit, etc.
Protected motor
3
Digital technology
4
The control system is based on the use of a highly specialized microcontroller by
which signals are treated digitally, thereby avoiding deratings and adjustments
common to analogue circuits and obtaining excellent precision and speed of
execution.
The control board is made with the technology of surface mounting devices
(SMD), which increases equipment reliability.
5High level of immunity
Design of the unit was closely tied to the conditions of supply lines, which handle
more disturbance every day. The control signals are optoelectronically isolated
and various levels of protection have been set up in the circuits to immunize the
equipment against external disturbance and its effects.
Advancedfunctions
8

HEAVY DUTY LIGHT DUTY Degree of TYPE Weight Cooled
Current 220V / 380V/ 440V 480V/ Current 220V / 380V/ 440V 480V/ protection unit
rating (2) 240V 415V 500V rating (3) 240V 415V 500V
A kW(4) kW(4) kW(4) kW(4) A kW(5) kW(5) kW(5) kW(5) Kg. Lbs.
14 3 5.5 7.5 - 17 4 7.5 7.5 - IP-00 QC1FDP 4.3 9.48 Natural
3 5.5 7.5 7.5 4 7.5 7.5 11 IP-00 QC2FDP 4.3 9.48 Natural
17 4 7.5 7.5 - 21 5.5 11 11 - IP-00 QC1GDP 4.3 9.48 Natural
4 7.5 7.5 11 5.5 11 11 13 IP-00 QC2GDP 4.3 9.48 Natural
22 5.5 11 11 - 27 7.5 13 15 - IP-00 QC1HDP 4.6 10.14 Natural
5.5 11 11 15 7.5 13 15 15 IP-00 QC2HDP 4.6 10.14 Natural
32 7.5 15 18.5 - 38 10 18.5 22 - IP-00 QC1IDP 4.6 10.14 Natural
7.5 15 18.5 22 10 18.5 22 25 IP-00 QC2IDP 4.6 10.14 Natural
48 13 22 22 - 58 15 25 30 - IP-00 QC1JDP 12.5 27.56 Byfan
13 22 22 30 15 25 30 37 IP-00 QC2JDP 12.5 27.56 Byfan
63 15 30 37 - 75 22 37 45 - IP-00 QC1KDP 12.5 27.56 Byfan
15 30 37 37 22 37 45 45 IP-00 QC2KDP 12.5 27.56 Byfan
72 20 37 37 - 86 25 45 50 - IP-00 QC1LDP 17.0 37.48 Byfan
20 37 37 45 25 45 50 50 IP-00 QC2LDP 17.0 37.48 Byfan
105 30 55 55 - 126 37 63 75 - IP-00 QC1MDP 17.0 37.48 Byfan
30 55 55 75 37 63 75 80 IP-00 QC2MDP 17.0 37.48 Byfan
156 40 75 90 - 187 55 90 110 - IP-00 QC1NDP 45.0 99.20 Byfan
40 75 90 110 55 90 110 132 IP-00 QC2NDP 45.0 99.20 Byfan
240 63 110 132 - 288 80 150 165 - IP-00 QC1QDP 45.0 99.20 Byfan
63 110 132 160 80 150 165 200 IP-00 QC2QDP 45.0 99.20 Byfan
315 90 160 200 - 378 110 200 220 - IP-00 QC1RDP 55.0 121.3 Byfan
90 160 200 220 110 200 220 250 IP-00 QC2RDP 55.0 121.3 Byfan
370 110 200 220 - 444 132 220 250 - IP-00 QC1SDP 55.0 121.3 Byfan
110 200 220 250 132 220 250 315 IP-00 QC2SDP 55.0 121.3 Byfan
475 150 250 250 - 570 160 300 355 - IP-00 QC1TDP 80.0 176.4 Byfan
150 250 250 335 160 300 355 400 IP-00 QC2TDP 80.0 176.4 Byfan
610 200 315 400 - 732 220 400 450 - IP-00 QC1UDP 105.0 231.5 Byfan
200 315 400 400 220 400 450 500 IP-00 QC2UDP 105.0 231.5 Byfan
850 250 450 530 - 1020 300 560 600 - IP-00 QC1VDP 120.0 264.5 Byfan
250 450 530 600 300 560 600 750 IP-00 QC2VDP 120.0 264.5 Byfan
1075 355 600 670 - 1290 395 715 750 - IP-00 QC1XDP 150.0 330.7 Byfan
355 600 670 750 395 715 750 850 IP-00 QC2XDP 150.0 330.7 Byfan
2. Types and ratings
2-1
2-1. IEC Ratings (1)
Notes: (1) = Ratings in Amps. given for ambient temperature up to 40ªC and 1000m altitude
Derate output current by 1,5% / ºC above 40ºC.
Derate output current by 1% / 100m above 1000m
(2) = Heavy duty ratings, IEC Class 10 and 20 protections allowed
(3) = Light duty ratings, only IEC Class 10 protection allowed.
(4) = Maximumrecommended MotorPowerforIECClass20protection. SetASTAT'sparameters"N"and"o"accordingly
(5) = Maximumrecommended MotorPowerforIECClass10protection. SetASTAT'sparameters"N"and"o"accordingly

2. Types and ratings
2-2
2-2. UL Ratings
Current Max. HEAVY DUTY STANDARD DUTY Degree of TYPE Weight Cooled
rating starting 200V 230V 460V 200V 230V 460V protection (1)
current
A A HP HP HP HP HP HP Kg. Lbs.
14 70 3 3 - 3 3 - IP-00 QC1FDP 4.3 9.48 Natural
- - 7,5 - - 7,5 IP-00 QC2FDP 43 9.48 Natural
17 85 3 3 - 3 3 - IP-00 QC1GDP 4.3 9.48 Natural
- - 10 - - 10 IP-00 QC2GDP 4.3 9.48 Natural
22 110 5 7,5 - 5 7,5 - IP-00 QC1HDP 4.6 10.14 Natural
- - 15 - - 15 IP-00 QC2HDP 4.6 10.14 Natural
34 170 7,5 7,5 - 10 10 - IP-00 QC1IDP 4.6 10.14 Natural
- - 20 - - 25 IP-00 QC2IDP 4.6 10.14 Natural
48 240 10 15 - 15 15 - IP-00 QC1JDP 12.5 27.56 Byfan
- - 30 - - 30 IP-00 QC2JDP 12.5 27.56
63 315 15 20 - 20 20 - IP-00 QC1KDP 12.5 27.56 Byfan
- - 40 - - 40 IP-00 QC2KDP 12.5 27.56 Byfan
72 360 20 20 - 20 25 - IP-00 QC1LDP 17.0 37.48 Byfan
- - 40 - - 50 IP-00 QC2LDP 17.0 37.48 Byfan
105 525 30 30 - 30 30 - IP-00 QC1MDP 17.0 37.48 Byfan
- - 60 - - 75 IP-00 QC2MDP 17.0 37.48 Byfan
156 780 40 50 - 50 60 - IP-00 QC1NDP 45.0 99.20 Byfan
- - 100 - - 125 IP-00 QC2NDP 45.0 99.20 Byfan
240 1200 60 75 - 75 75 - IP-00 QC1QDP 45.0 99.20 Byfan
- - 150 - - 200 IP-00 QC2QDP 45.0 99.20 Byfan
315 1575 75 100 - 100 125 - IP-00 QC1RDP 55.0 121.25 Byfan
- - 200 - - 250 IP-00 QC2RDP 55.0 121.25 Byfan
370 1850 100 125 - 125 150 - IP-00 QC1SDP 55.0 121.25 Byfan
- - 250 - - 300 IP-00 QC2SDP 55.0 121.25 Byfan
500 2500 150 150 - 150 200 - IP-00 QC1TDP 80.0 176.36 Byfan
- - 350 - - 400 IP-00 QC2TDP 80.0 176.36 Byfan
630 3150 200 200 - 200 250 - IP-00 QC1UDP 105.0 231.47 Byfan
- - 400 - - 500 IP-00 QC2UDP 105.0 231.47 Byfan
850 4250 250 300 - 300 350 - IP-00 QC1VDP 120.0 264.54 Byfan
- - 600 - - 700 IP-00 QC2VDP 120.0 264.54 Byfan

2-3. ASTAT Plus, Thermal characteristics
The ASTAT Plus allows motor protection according IEC Class 10 or Class 20 and Nema 10, 20 or 30, free selectable by parameter "o" -overload-
ASTAT-C / CD . Static soft starters
2. Types and ratings
2-3
IEC Class 10 IEC Class 20
Nema 10 Nema 20
Nema 30
Thermal memory:
If the control voltage is not removed, the unit has a cool down charac-
teristic, the time for cool down is 300 sec. after the overload trip.
Ifthecontrolvoltageis removed after tripping,youmustwait, at least, 2
minutes before the unit can be restarted.
Operations per hour:
Supposing a cycle T, with starting time of t1, running time of T-2t1 at
rated current and OFF time of t1 sec. at least, the ASTAT Plus allows
the following operations per hour.
Starting Operations / Hour. Operations / Hour
Current Starting time t1= 10sec. Starting time t1=20 sec.
Sec.
Ir / In
Sec.
Ir / In
Sec.
Ir / In
Sec.
Ir / In
Sec.
Ir / In
2 Ir 180 90
3 Ir 160 60
4 Ir 30 10
COLD
HOT
COLD
HOT
HOT
COLD
HOT
COLD
HOT
COLD

Voltage Ratings 3ph ACSystems Up to 440V, +10%, -15% for QC1xDP ASTAT Plus series
Up to 500V, +10%, -15% for QC2xDP ASTAT Plus series
Freq. Range 50/60 Hz Control range of 45-65 Hz
Control Control system Digital system with microcontroller
Specifications Starting ramp with progressive increase in voltage and current limitation
Initial voltage (pedestal) % 30 - 95 Un
Starting torque % 10 - 90 Mdirect start
Kick start % 95 Un (90% Mdirect start), adjustable 0 to 999 ms
Motor current (Im) 0,4 to 1,2 Ir (rated ASTAT current)
Current limitation 1 to 7 In
Acceleration ramp time s 1 to 99 (types: standard or linear ramp up)
Energysavings Output voltage reduction according to power factor
Override Fixed output voltage permanently equal to supply voltage
Bypass Direct control of a bypass contactor
Brake time by ramp s 1 to 120 (1 to 99 in secondary ramp) adjustable independently of starting ramp time (types: standard,
pump control or linear ramp down)
DC braking 0 to 99 s. ; 0,5 to 2,5In
Slow speed Direct torque: 7% or 14% of nominal speed; reverse torque: 20% of nominal speed
Retry 0 to 4 attemps, and 1 to 99 sec. retry time
Monitoring Motor current, line voltage, power, power factor and elapsed time
Running External control Start - Stop
Acceleration phase Adjustable time
Permanent phase Energy savings / Override choice
Stop phase Power cut-off / Ramp / DC braking/Pump control
Inputs / Outputs Inputs 4 digital optocoupled. Two fixed (Start , Stop) , and 2 programmable (I3, I4)
1 Analog 0-5VDC for Tachogenerator input feedback
Outputs 3 programmable relays, (1r, 2r, 3r)
1 Analog 0-10VDC output for current metering
Protections Current limit Adjustable from 1 In to 7 In
Overload IEC class 10 and 20 ; NEMA class 10,20 and 30 all selectable
Cool-down time after
overload trip s 300 for reset
Loss on input phase s Trip at 3
Thyristor short circuit ms Trip at 200
Heatsink overheating ms Trip at 200
Motor thermistor ms Trip at 200 if thermistor impedance > response value
Loss on output phase s Trip at 3
Stalled rotor ms Trip at 200
Supply frequency error Hz If f < 45 or f > 65, will not start
Overcurrent 100 to 150% In; trip time adjustable from 0 to 99 sec.
Undercurrent 0 to 99% In; trip time adjustable from 0 to 99 sec.
Overvoltage 100 to 130% Un; trip time adjustable from 0 to 99 sec.
Undervoltage 0 to 50% Un; trip time adjustable from 0 to 99 sec.
Error (CPU) ms 60
Memory 4 former errors
Long start time s 2 x ta (ta = acceleration ramp time)
Long slow speed time s 120
Environmental Temperature ºC 0 to +55 (derate output current by 1,5% / ºC above 40ºC)
conditions Relative humidity % 95% without condensation
Maximum altitude m 3000 (derate output current by 1% / 100m above 1000m)
Mounting position Vertical
Protection Degree IP00, UL Open
Standards CE, cUL, UL CE Conforming IEC 947-4-2; UL, cUL conforming to UL508
Conducted & Radiated emissions Conforming IEC 947 -4-2, Class A
Electrostatic discharges Conforming to IEC 1000-4-2, level 3
Radioelectric interference Conforming to IEC 1000-4-6, level 3 and to IEC 1000-4-3, level 3
Immunity to fast trasients Conforming to IEC 1000-4-4, level 3
Immunity to Surge Voltage Conforming to IEC 1000-4-5, level 3
3-1. ASTAT Plus, General specifications
3. Technical specifications
3-1

3. Technical specifications
3-2. I/O terminal board specifications
Power I/O terminals
Terminal Function Description
1L1, 3L2, 5L3 Mains Input 3ph input voltage according ASTAT Plus type.
2T1, 4T2, 6T3 Motor output Output terminals to 3ph AC motor
A1,A2,B1,B2 Input Control Voltage 110/120V AC,+10%,-15%: ; 220/240V AC, +10%, -15%:
Digital Inputs
Terminal Function Description
57 Common for digital inputs This is a common terminal for the digital input terminals specified below.
1 Run Run order. Command signal may be provided by one NO dry momentary contact to terminals 1 and 57.
2 Stop Stop order. Command signal may be provided by one NC dry momentary contact to terminals 2 and 57.
Note: Run/Stop permanent command is allowed linking 1-57 and using one dry NO contact to 2-57
terminals.
3 Programmable input I3 These two inputs are programmable. Can be assigned to the following internal functions
4 Programmable input I4
-softstop -DC brake -Linear Ramp
-pump control -slow speed control -dual ramp selection
-kick start -reverse slow speed -bypass function
-override -local / remote control
Command signal should be provided by one NC dry contact to terminals 57-3 or terminals 57-4. By switching
this contact ON / OFF it is possible to enable or disable the assigned function.
Digital Outputs
Terminal Function Description
11, 12, 14 Programmable relay1r 11-12 = NC, 11-14 = N.O. dry contacts. This relay can be assigned to several internal output functions. (p. 3.6)
As default assigned to function RUN
23, 24 Programmable relay 2r 23-24 = N.O. dry contact. This relay can be assigned to several internal output functions. (page 3-6)
As default assigned to function EOR
33, 34 Programmable relay 3r 33-34 = N.O. dry contact. This relay can be assigned to several internal output functions. (page 3-6)
As default assigned to function DC BRAKE
Common for all relay output contacts Maximum usage voltage: 380VAC(B300-UL)
Thermal current: 8A.
AC-15 use: 220V /3A,380V/ 1A
DC-15 use: 30V max/3.5A
Analog I/O
Terminal Function Description
8 Analog input common (-) This is a common terminal for the analog input terminal number 7, and analog output termnal number 9.
7 TG feedback input (+) 0-5V analog input for speed feedback. It should be provided by a DC tacho-generator coupled to the motor.
This speed feedback signal is required when the "linear ramp" function is used.
9 Current Output (+) 0-10V DC analog Output for current measurement purpose. Ir correspond to 2V DC
Load Impedance 10KΩor higher
Motor thermistor terminals
Terminal Function Description
5 , 6 Motor thermistor input This input allows a motor thermistor with a response value from 2,8 to 3,2KΩ, and a reset value from 0,75 to
1KΩto control motor temperature.
When the motor thermistor is not used, a link must be used in terminals 5-6.
Communications
Terminal Function Description
SG, TD, RD Gr, Tx, Rx data RS232C, 3 wires, half duplex. Maximum cable length 3mts (10 feet)
Asynchronous data transmission, 9600 Bauds, 1 bit start, 8 bits data, 2 bits stop. no parity
ASCII and ModBus RTU protocols selectable from keypad as standard. (Check appendix 6-2)
Profibus DP and DeviceNet by external optional accessory
3-2

3-3. I/O Wiring
3. Technical specifications
ASTAT Plus's terminal layout and wiring configuration is shown in the diagram of below
(1*)
(1*)
(3*)
(2*)
Notes: (1*) Control and Mains wiring recommendations are given in chapter 5.
(2*) The programmable inputs I3, I4 are not assigned to any function as default. Check pages 3-6 prior to using these inputs.
(3*) The programmable relay outputs are assigned to the following functions as default:
Relay (1r): RUN, (RUN status)
Relay (2r): EOR, (End of Ramp)
Relay (3r): DCBR, (DC Braking control)
(4*) Important: Use dry contacts only
3-3
(4*)
(4*)

3. Technical specifications
3-4
3-4. Operating modes
Initialramp
Initialvoltage(pedestal)
Kickstart
Accelerationramp(tramp)
Currentlimit
Permanentstate
Stoppingmodes (Allselectable)
Override
Energy savings
Startingbyvoltageramp Startingby current limitation
5 main frequncy cycles
30 to 95% Un (adjustable)
95% Un. Enabled by parameter "Pxxx" to ON
Voltagerampupfrom1to99s(adjustable).Dualramp possibility
Linear speedrampbytachofeedbackalsopossible
Fastincreaseofoutputvoltagewhenmotorgetsratedspeed
1 to 7 In
Ratedvoltage(Override)
Ratedcurrent
Energy savings. Enabled by "Fxxx" to OFF
Motor power cut-off. "Sxxx" to OFF, "Cxxx" to OFF
Decelerationramp1to120s(adjustable).Secondaryramp1to 99s
Rampdowmmodes availableare:
- Soft Stop -Voltage ramp down-. Enabled by "Sxxx" to ON
- Pump control. Selectable by "Sxxx" to ON and "Cxxx" to ON
-Linearrampdown(Tachofeedbackneeded)
Evolutionofcurrentindecelerationrampmode
DC brake (0 to 99s adjustable). Enabled by "Bxxx" to ON
Starting and Stopping
1
8
7
6
5a
5
4
3a
2
1a
8a
9
3
Override
Energy savings

3. Technical specifications
3-5
Linearaccelerationanddecelerationramp Ramp time adjustable (Selectable by parameter "Dxxx" to ON
Low slow (7%) and High slow (14%) speeds Enabled by parameter "Jxxx" to ON and "jxxx" to LO or HI
Reverse slow speed (20%) Enabled by parameter "Jxxx" to ON and "rxxx" to ON
Slow speed (7% or 14%) Enabled by parameter "Jxxx" to ON
Accelerationramp Ramptimeadjustable
Softstop(decelerationramp) Ramptimeadjustable
Slow speed (7% or 14%) Enabled by parameter "Jxxx" to ON
DC Brake Current and time adjustables, Enabled by parameter Bxxx to ON, and bxx, Ixxx adjustments
1
8
7
6
5
4
3
2
Linearramp withT.G. feedback Slowspeed.Basicdiagram
Slowspeed.Fulldiagram
1a
3a
Jog and linear ramp

ProgrammableInputsandfunctions
3. Technical specifications
The ASTAT Plus functions like Soft stop, kick start, and etc, can be enabled or disabled by setting ON or OFF in their dedicated parameters, using the facilities
provided by the keypad. Most of these functions can be enabled or disabled remotely as well, through the programmable inputs I3 or I4 (terminals board 3-57 and
4-57).
SoftStop
Pump Control
Kick Start
Override
By-pass
DC Brake
Linear Ramp
(Jog). Slow Speed
Reverse Jog
Dual motor
Remote Control
Sxxx
Cxxx
Pxxx
Fxxx
zxxx
Bxxx
Dxxx
Jxxx
rxxx
Axxx
Xxxx
_OFF
_ON
_I3
_I4
Function Parameter
Set Value
The function is permanently disabled
The function is permanently enabled
The status of the function depends on ASTAT's I3 input
The status of the function depends on ASTAT's I4 input
Note: One programmable input may enable or
disable more than one function
<Remarks>
ProgrammableRelayOutputs
The ASTAT Plus includes three programmable relays 1r, 2r and 3r, (dry contacts). ASTAT terminals are 11-12-14, 23-24 and 33-34
These relays can be assigned to several functions, as shown bellow
Relay 1r
Relay 2r
Relay 3r
20
21
22
23
24
25
26
27
28
29
30
EOR Detects end of voltage ramp. -Only can be asigned to relay 2r-
DC Brake DC Brake command -Only can be assigned to relay 3r-
Fault Detects ASTAT's fault status
Undervoltage Detects limit set in parameter UVxx
Overvoltage Detects limit set in parameter OVxx
RUN Detects ASTAT's run status
JOG Detects Jog (slow speed) status
Undercurrent Detects limit set in parameter UCxx
Overcurrent Detects limit set in parameter OCxx
Disables the relay function
Future use
Relay N# Parameter
1r xx
1r xx
3r xx
Set Value <Remarks>
3-6
More than one function can be enabled in the ASTAT Plus, either by the keypad or through the programmable inputs I3 and I4, but there are some functions
which may not work as expected during stopping, when are simultaneously enabled. The priority when two or more of the below functions are simultaneously
enabled is defined in the following table,
DC Brake (B=ON) labc
Linear Ramp (S, D=ON) a laa
Soft Stop (S=ON) b a lc
Pump Control (S, C=ON) c a c l
DC Brake (B=ON)
Linear Ramp (S, D=ON)
Soft Stop (S=ON)
Pump Control (S, C=ON)
a The Unit stops by Linear Ramp
b The unit stops by DC brake after the Soft Stop is completed.
c The unit stops by Pump Control
○○○○○○○○○ ○○○○○○○○○ ○○○○○○○○○
○○○ ○○○○○○○○
○○○○○○○○○○○
○○○○○○○○○○○
Condition Action

4-1. Keypad and Display description
1
2
Display 1
FVVV
F V V V Error code
E010 Frequency out of range
E011 Overloadtrip
E013 Lossofsynchronism
E014 Phase U scr
E015 Phase V scr
E016 PhaseWscr
E017 Heatsinkovertemperature
E018 Motorthermistor
E019 PhaseUlost
E020 PhaseVlost
E021 PhaseWlost
E022 Stalledrotor
E023 Internal error
E025 Longstarttime
E026 Longslowspeedtime
E027 Lock-out
E028 Undervoltage
E029 Overvoltage
E030 Undercurrent
E031 Overcurrent
E032 Retry,attemptsexceeded
F V V V Status code
ON Equipmentisconnected
tomainsupply
(equipmentisON)
STOP Stop
LOCK Remotestop
PULS Kickstart
RAMP Accelerationramp
FULL Fullconductionor
Override
SAVE Energy saving
SOFT Softstop
PUMP Pumpcontrol
DCBK DC braking
INCH Inching / slow speed
TACH Linear ramp(tacho)
Keypad 2
SELECTION
Use with ↑↑
↑↑
↑or ↓↓
↓↓
↓to select the parameter or function code to be
displayed and/or modified
SEARCH / ADJUSTMENT
Increasesthevalueof theselected parameter
ENTER / SAVE
- Introducesthenewparametervalueinto memory
- Updates the selected parameter value with the
displayed value
SEARCH / ADJUSTMENT
Decreasesthevalueof theselected parameter
114
3
2
0
C/V
Data
Functioncode
C/V
4-1
4. Programming
Displays Monitoring, Status indications, error messages and function set values
Allows setting of parameters and functions
F F/V V V function code (*)
Mx x x Motorcurrent
vxxx SoftwareVersion
..
..
PFxx Power Factor
..
..
Lxxx Limitcurrent
Txxx StartingTorque
axxx Rampuptime
dxxx Rampdowntime
Sxxx SoftStopselection
..
..
LKxx Lockout
..
..
(*) These are examples. Full details in
sections 4-2, 4-3, 4-4, 4-5 and 4-6
Display Structure

4-2. Parameter Blocks configuration
4. Programming
ModeSelection
The ASTAT Plus includes a large number of parameters which are divided in four
blocks: Monitor, Calibration, Basic and Advanced. The parameters of each group can be
displayed or skipped according the selection done in parameter "G".
The monitor parameters are always displayed regardless of the mode selected
Settings in parameter "G" Gxxx The Monitor parameters are always displayed,
whichever are the settings in parameter "G".
GCAL The Calibration parameters are displayed
GBAS The Basic parameters are displayed
GADV The Advanced parameters are displayed
GALL All parameters are displayed
Monitoring
Parameters
Calibration
Parameters
Basic
Parameters
Advanced
Parameters
G CAL
G ALL
GBAS
GADV
There is a quick way to search automatically the parameter "G" by pressing and Keys. "Gxxx" will be shown on the display.
Once the parameter "G" is displayed, choose the value desired by pressing or Keys. The display will sequence "GBAS", "GCAL", "GADV" and
"GALL" values repeatedly. The actual value displayed can be stored in a temporal memory buffer by pressing key.
Values stored in the temporal memory are lost upon control power loss, unless these are saved in the permanent E2PROM memory through parameter "W".
Additional indications are given in page 4-4
The above is an example given for parameter "G", but all ASTAT Plus parameters can be modified from its default factory value proceeding in similar way.
SearchingandSettingParameters
The ASTAT Plus displays the parameters sequentially while depresing the key and pushing repeteadly or keys.Proceed in this way untill
the parameter "G" is displayed.
C / V
C / V
Parameter layout
Monitor parameters
ULine Voltage
Voltage Calibration
Unit frame
Current Calibration
t
UF
m
NMotor rated current
Overload Protection
Service Factor
o
GBAS
Motor Current
Software Version
Line Voltage
Line Power
Elapsed time
Fault history Buffer
Password
E2PROM writting
Parameter Block Selector
M
v
V
w
E
e
K
W
G
f
GADV GALL GCAL
100-500
F,G ,H , ... ,X
m
40-120
0, N1, N2, N3,C1,C2
100-130
Calibration parameters
e0, e1, e2, e3
12
Status Shownautomatically ON,STOP,LOCK, PULS,...
(see page 4-4)
C / V
+
4-2
Line Power FactorPF

4. Programming
Ramp up time
Ramp down time
Kick Start
DC Brake time
DC Brake current
Soft Stop switch
Pump Control switch
Kick Start Switch
Override Switch
By-pass Switch
DC Brake Switch
Lock-out
E2PROM Reading
Factory Settings
Retry
Retry time
Undervoltage
Undervoltage trip time
Overvoltage
Overvoltage trip time
Undercurrent
Undercurrent trip time
Overcurrent
Overcurrent trip time
Secondary Ramp up
Secondary Ramp down
Secondary Starting Torque
Tacho control switch
Slow Speed switch
Low / High slow speeds
Reverse slow speed
Dual motor switch
Remote control switch
Output relay 1r
Output relay 2r
Output relay 3r
100-700
010-090
01-99
01-120
000-999
000-099
050-250
OFF, ON, I3, I4
OFF, ON, I3, I4
00-05
OFF, ON, I3, I4
OFF, ON, I3, I4
OFF, ON, I3, I4
PON, PI3, PI4
00-45
ON, OFF
ON, OFF
000-004
001-099
00-50
00-99
00-30
00-99
00-99
00-99
00-50
00-99
01-99
01-99
10-90
ON, OFF, I3, I4
OFF, I3, I4
LO, HI
OFF, ON, I3, I4
OFF, ON, I3, I4
OFF, ON, I3, I4
22-30
20, 22-30
21, 22-30
L
T
a
d
p
b
I
S
C
P
F
z
B
LK
R
Q
Y
y
UV
uv
OV
ov
UC
uc
OC
oc
2a
2d
2t
D
J
j
r
A
X
1r
2r
3r
Basic Parameters Advanced Parameters
12
4-3
Current Limit
Starting Torque
%
%
sec.
sec.
mS.
sec.
%
Range
Unit
minutes
n.attempts
sec.
%
sec.
%
sec.
%
sec.
%
sec.
sec.
sec.
%
Range
Unit
Pump curve selection
starting
Pump curve selection
stopping
00-03
ST
SP
OFF, ON, I3, I4
Comm Protocol selection 00-02
XP
Station number 001-247
s

4-3. Monitor block Parameters
FunctionDisplay
Status
Motor Current
Software Version
Main Source Voltage
Power Factor
Line Power
Elapsed time
Error trace buffer
Password
E2PROM writting
Parameter display
selection
4. Programming
ON
Mxxx
vxxx
Vxxx
PFxx
wxxx
Exxx
exxx
Kxxx
Wxxx
Gxxx
Description
Switch on time. Equipment is connected to main supply
Stop
Remote control through serial port.
Kick start
Acceleration ramp
Full conduction / Override (full voltage)
Energysaving
Softstop
Pump control
DC braking
Inching / slow speed
Linear ramp (tacho feedback needed)
Displays motor current in Amps.
Current higher than 999A is displayed in kA
If parameter UFxx is not calibrated, the motor current is
displayed in %N
xxx = Version number
Displays line voltage in Volts.
Displays line Power Factor
Displays Line Power
Displays RUN time in Hours (x 1000)
Saves the last four errors
e0xx: Fault 1 -Latest fault- xx: Fault code error
e1xx: Fault 2
e2xx: Fault 3
e3xx: Fault 4
= 69 allows E2PROM writing operation
= 10 Key lock enabled
= 20 Key lock disabled
Saves the unit current parameters to the E2PROM
This rewrites the last values saved
CAL: Displays Calibration Parameters
BAS: Displays Basic Parameters
ADV: Displays Advanced Parameters
ALL: Displays All parameters
Note: TheMonitorblockparametersarealways
displayed
4-4
Default Range Unit
ON
STOP
LOCK
PULS
RAMP
FULL
SAVE
SOFT
PUMP
DCBK
INCH
TACH
000-999
1.0-9.9
-
-
00-99
-
-
e0xx-e3xx
000-999
ON, OFF
CAL,BAS,ADV,
ALL
ON
K000
WOFF
GBAS
-
-
-
-
-
-
-
-
-
-
-
-
A
kA
%
-
V
%
kW
Hrs
-
-
-
-

4. Programming
4-5
Function
Display Description
Default Range Unit
4-4. Calibration block Parameteres -CAL-
Line Voltage setting
Voltage Calibration
Unit Frame
Current Calibration
Motor Rated Current
Overload Protection
Service Factor
Uxxx
txxx
UF x
mxxx
Nxxx
oxxx
fxxx
U400
t400
UF 0
m000
N100
oC1
f100
Line Voltage from 100 to 500V. Set rated value
Setting of this parameter allows better accuracy in moni-
toring or voltage protections. (Check the voltage calibra-
tion procedure)
Unit frame rating (F,G,H,...X)
Setting 0 disables calibration
Setting of this parameter allows better accuracy in moni-
toring or current protections. (Check the current calibra-
tion procedure)
100 x I motor/ I unit ratio
When this parameter is adjusted at a value higher than
105% the overload protection curve is automatically ad-
justed to Class 10. "C1", or to Nema 20 "N2"
Selects either the following overload curves
OFF: Overload protection disabled
(external overload relay must be used)
N1: Nema 10
N2: Nema 20
N3: Nema 30
C1: Class 10
C2: Class 20
Allows motor service factor. Applicable for Nema ratings
100-500
000-600
F, G, H, I, J, K, L,
M, N, Q, R, ...X
000-1000
040-120
OFF
N1, N2, N3,
C1, C2
100-130
V
V
-
A
%
-
%
(*) Voltage calibration procedure
When the unit is installed on site or after PCB's replacement the voltage measurements may have accuracy of 10%. To improve the Voltage
measurement accuracy up to 3% proceed as follow.
1. Switch on the ASTAT and measure the RMS voltage on phases 1L1-3L2 using a calibrated voltmeter
2. Search the parameter "txxx", set the voltage measured and save this value by the key. It is not necessary to rewrite the E2PROM
to make permanent the new setting, the ASTAT plus does this automatically.
NOTE: Set real voltage measured while ASTAT is Power ON. DO NOT enter motor nameplate rating
3. Once the ASTAT has been calibrated, this operation does not need to be repeated. Note however that the parameter "txxx" will show
the latest entry, which may differ from the actual voltage value.
(*) Current calibration procedure
When the unit is installed on site or after PCB's replacement the current measurements may have accuracy of 10%. To improve the Current
measurement accuracy up to 3% proceed as follow.
1. Search parameter "UF x" and enter the right ASTAT's frame type letter. ("F", "G", "H", ..etc.)
2. Start the motor, and measure the rms motor current using a calibrated Ammeter.
This measurement must be done after complete the starting, once the motor current has been stabilized.
3. Search the parameter "mxxx", set the current measured and save this value by the enter's keypad key. It is not necessary to rewrite the
E2PROM to make permanent the new setting, the ASTAT Plus do this automatically.
NOTE: Set real current measured while motor is running. DO NOT enter motor nameplate current rating
4. Once the ASTAT has been calibrated, this operation does not need to be repeated. Note however that the parameter "mxxx" will show
the latest entry, which may differ from the actual current value.