GE ASTAT XL Series User guide

GE imagination at work
GE imagination at work
Industrial Solutions
ASTAT XL
GE
Industrial Solutions
GE
Testing, troubleshooting and servicing instructions
Original Instruction
DET-813 ed. 00
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ASTAT XL Service Manual Contents
Contents
1Caution Statements................................................................................................................................. 2
1.1 Electrical Shock Risk ........................................................................................................................................................................................2
1.2 Power-up procedure.......................................................................................................................................................................................3
1.3 Stored charge .....................................................................................................................................................................................................3
1.4 Short circuit..........................................................................................................................................................................................................3
1.5 Disposal Instructions.......................................................................................................................................................................................3
2Functional Tests ....................................................................................................................................... 4
2.1 Power Circuit Test.............................................................................................................................................................................................4
2.2 Start Performance Test..................................................................................................................................................................................4
2.3 Run Performance Test....................................................................................................................................................................................5
2.4 Bypass Contactor Test ...................................................................................................................................................................................5
2.5 Control Input Test .............................................................................................................................................................................................5
2.6 After Repair Tests..............................................................................................................................................................................................5
3Troubleshooting ....................................................................................................................................... 7
3.1 Protection Responses.....................................................................................................................................................................................7
3.2 Trip Messages .....................................................................................................................................................................................................7
3.3 General Faults...................................................................................................................................................................................................11
3.4 SCRs .......................................................................................................................................................................................................................13
4Service Instructions ............................................................................................................................... 14
4.1 QLxxB0023D to QLxxB0053D (G1B).......................................................................................................................................................15
4.2 QLxxB0076D to QLxxB0105D (G1B).......................................................................................................................................................16
4.3 QLxxB0145D to QLxxB0220D (G2B).......................................................................................................................................................17
4.4 QLxxB0255D to QLxxB0425D (G3B).......................................................................................................................................................18
4.5 QLxxX0255D (G3C)..........................................................................................................................................................................................19
4.6 QLxxB0500D to QLxxB1000D (G4B).......................................................................................................................................................20
4.7 QLxxX0360D to QLxxX0930D (G4C).......................................................................................................................................................21
4.8 QLxxX1200D to QLxxX1600D (G5C).......................................................................................................................................................22
5Spare Parts .............................................................................................................................................. 23
5.1 Main Control PCB ............................................................................................................................................................................................23
5.2 Model PCB...........................................................................................................................................................................................................25
5.3 Backplane PCB .................................................................................................................................................................................................26
5.4 Bypass Driver PCB ..........................................................................................................................................................................................27
5.5 SCRs and SCR Connections .......................................................................................................................................................................28
5.6 Power Assemblies...........................................................................................................................................................................................30
5.7 Fans........................................................................................................................................................................................................................31
5.8 Snubber Assemblies ......................................................................................................................................................................................32
5.9 Current Transformers ...................................................................................................................................................................................33
5.10 Bypass Contactors .........................................................................................................................................................................................34
5.11 Plastics..................................................................................................................................................................................................................35
5.12 Busbars ................................................................................................................................................................................................................36
5.13 Other Spare Parts ...........................................................................................................................................................................................38
6Appendix .................................................................................................................................................. 39
6.1 Bolt Tightening Torques...............................................................................................................................................................................39
DET-813 1

ASTAT XL Service Manual Caution Statements
1Caution Statements
WARNING - ELECTRICAL SHOCK HAZARD
The ASTAT XL contains dangerous voltages when connected to mains voltage. Only a
qualified electrician should carry out the electrical installation. Improper installation of the
motor or the ASTAT XL may cause equipment failure, serious injury or death. Follow this
manual and local electrical safety codes.
AVERTISSEMENT - DANGER D'ELECTROCUTION
L’ASTAT XL contient des tensions dangereuses lorsqu'il est raccordé à l'alimentation
secteur. Seul un électricien compétent peut effectuer l'installation électrique. Une
mauvaise installation du moteur ou de l’ASTAT XL peut déclencher une panne
d'équipement, provoquer de graves blessures ou même la mort. Suivre les instructions
de ce manuel et des codes locaux concernant la sécurité électrique.
CAUTION
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. When performing service, proper ESD equipment should be
used to prevent possible damage from occurring.
NOTE
The ASTAT XL soft starter is not user serviceable. The unit should only be serviced by
authorised service personnel. Unauthorised tampering with the unit will void the product
warranty.
GROUNDING AND BRANCH CIRCUIT PROTECTION
It is the responsibility of the user or person installing the ASTAT XL to provide proper grounding
and branch circuit protection according to local electrical safety codes.
The examples and diagrams in this manual are included solely for illustrative purposes. The
information contained in this manual is subject to change at any time and without prior notice. In no
event will responsibility or liability be accepted for direct, indirect or consequential damages resulting
from the use or application of this equipment.
1.1 Electrical Shock Risk
The voltages present in the following locations can cause severe electric shock and may be lethal:
•AC supply cables and connections
•Output cables and connections
•Many internal parts of the starter, and external option units
The AC supply must be disconnected from the starter using an approved isolation device before any
cover is removed from the starter or before any servicing work is performed.
WARNING - ELECTRICAL SHOCK HAZARD
Models QLxxB0500D~QLxxX1600D: The busbar and heatsink must be treated as live whenever
the unit has mains voltage connected (including when the starter is tripped or waiting for a
command).
AVERTISSEMENT - DANGER D'ELECTROCUTION
Modèles QLxxB0500D à QLxxX1600D : Les barres de puissance et le radiateur doivent être traités
comme étant des éléments sous tension si l'appareil est relié au secteur (y compris lorsque le
démarreur s'est mis en sécurité ou s'il attend une commande).
2 DET-813

Caution Statements ASTAT XL Service Manual
1.2 Power-up procedure
Always apply control voltage before (or with) mains voltage.
QLxxB0023D to QLxxB0105D: After transportation, mechanical shock or rough handling there is a
possibility that the bypass contactor may have latched into the on state. To prevent the possibility of
the motor starting immediately, on first commissioning or operation after transportation, always
ensure that the control supply is applied before the power, so that the contactor state is initialised.
1.3 Stored charge
The starter contains capacitors that remain charged to a potentially dangerous voltage after the AC
supply has been disconnected. If the starter has been energised, the AC supply must be isolated at
least two minutes before work may continue.
Normally, the capacitors are discharged by an internal resistor. Under certain, unusual fault conditions,
the capacitors may fail to discharge. Do not assume that the capacitors have discharged. To
protect the user and the equipment, take due care when carrying out any work on the starter.
1.4 Short circuit
The ASTAT XL is not short circuit proof. After severe overload or short circuit, the operation of the ASTAT
XL should be fully tested by an authorised service agent.
1.5 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.
DET-813 3

ASTAT XL Service Manual Functional Tests
2Functional Tests
Use the tests in this section to identify the cause of problems with the soft starter.
NOTE
Before changing any parameter settings, save the current parameter set to a file using GE
ASTAT Setup Tool ed.3 or the soft starter's Save User Set function (see the soft starter user
manual for more information).
2.1 Power Circuit Test
This procedure tests the soft starter's power circuit, including the SCRs, Backplane PCB, Model PCB and
Main Control PCB.
Use a 500 VDC insulation tester on the 200 ohm scale or a standard multimeter (voltmeter).
1. Isolate the soft starter from the incoming mains supply and remove the control voltage.
2. Disconnect the motor cables and any external bypass contactor cables from the soft starter.
3. Allow the soft starter to cool to room ambient temperature.
4. Using a meter, check the resistance across each phase of the soft starter in both directions.
•1/L1 to 2/T1, 2/T1 to 1/L1, 3/L2 to 4/T2, 4/T2 to 3/L2, 5/L3 to 6/T3 and 6/T3 to 5/L3.
5. If any reading is less than 200 ohms, the SCR or internal bypass relay has failed short circuit and
must be replaced.
NOTE
Events that damage SCRs can often damage the Backplane PCB as well, although the Main
Control PCB may be undamaged. Replace the damaged SCR(s) and Backplane PCB, then
check for correct operation, before replacing the Main Control PCB.
SCR damage is almost always caused by external influences.
If the MOVs and/or surrounding circuitry on the Backplane PCB show signs of physical
damage, the most likely cause is overvoltage.
If the MOVs and/or surrounding circuitry on the Backplane PCB do not show signs of
physical damage, the most likely cause is overcurrent.
See SCRs on page 13 for information on typical causes of SCR damage.
2.2 Start Performance Test
This procedure tests for correct operation of the ASTAT XL during start.
1. Connect the ASTAT XL to mains voltage, control voltage and to a motor.
2. Set Motor FLC (parameter 1A) to match that of the motor.
3. Set Start Mode (parameter 2A) to 'Constant Current'.
4. Set Current Limit (parameter 2B) to a level which will supply sufficient start current to enable the
connected motor to produce enough torque to easily accelerate to full speed.
Calculate expected start current by multiplying M o t o r F L C (parameter 1A) by Current L im i t
(parameter 2B). If the secondary parameter set is being tested, multiply M o t o r FL C -2 (parameter 1C)
by Current Limit-2 (parameter 3B) instead.
5. Initiate a start and measure the actual start current. This can be done by viewing the Phase
Currents screen or with a clip-on ammeter.
If the measured current is equal to the actual start current on all three phases, the soft starter is
performing correctly.
NOTE
During Start mode, the Run LED on the keypad should flash.
4 DET-813

Functional Tests ASTAT XL Service Manual
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:
DET-813 5

ASTAT XL Service Manual Functional Tests
1. Apply control power only to the soft starter.
2. Ensure that the welcome screen displays the correct firmware versions.
3. Set the Motor FLC (Parameter 1A) to match the test motor.
NOTE
If the test motor has a current rating which is much lower than that of the soft starter, disable
Undercurrent Trip (Parameter 4C).
4. Connect mains supply and motor. Test that the soft starter functions as expected.
5. Reload the saved parameter set into the ASTAT XL via GE ASTAT Setup Tool ed.3 after servicing
work is complete.
6 DET-813

Troubleshooting ASTAT XL Service Manual
3Troubleshooting
3.1 Protection Responses
When a protection condition is detected, the ASTAT XL 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. These trips do not have
associated parameters and cannot be set to Warn or Log.
If the ASTAT XL trips you will need to identify and clear the condition that triggered the trip, then reset
the soft starter before restarting. To reset the starter, press the RESET button on the keypad or
activate the Reset remote input.
If the ASTAT XL has issued a warning, the soft starter will reset itself once the cause of the warning has
been resolved.
3.2 Trip Messages
This table lists soft starter's protection mechanisms and the probable cause of the trip. Some of these
can be adjusted using parameter group 4 Protection Levels and parameter group 16 Protection Action,
other settings are built-in system protections and cannot be set or adjusted.
Display
Possible cause/Suggested solution
2 Phase - Damaged
SCR
This message is displayed if the soft starter tripped on “ Lx-Tx shorted” during
the pre-start checks and PowerThrough is enabled. It indicates that the starter
now operates in PowerThough mode (2-phase control only).
Check for either a shorted SCR or a short within the bypass contactor.
Related parameters: 15E
Battery/clock
A verification error has occurred on the real time clock, or the backup battery
voltage is low. If the battery is low and the power is off, date/time settings will
be lost. The ASTAT XL will continue to soft start and soft stop correctly.
Reprogram the date and time.
The battery is not removable. In order to replace the battery, the main control
PCB must be replaced.
Related parameters: 16K
Controller
This is a name selected for a programmable input. See Input A trip.
Current imbalance
Current imbalance can be caused by problems with the motor, the
environment or the installation, such as:
•An imbalance in the incoming mains voltage
•A problem with the motor windings
•A light load on the motor
•A phase loss on input terminals L1, L2 or L3 during Run mode
•An SCR that has failed open circuit. A failed SCR can only be definitely
diagnosed by replacing the SCR and checking the starter's performance.
Related parameters: 4A, 5B, 16B
Current Read Err Lx
Where 'X' is 1, 2 or 3.
Internal fault (PCB fault). The output from the CT circuit is not close enough to
zero when the SCRs are turned off. Contact your local supplier for advice.
This trip is not adjustable.
Related parameters: None
Excess start time
Excess start time trip can occur in the following conditions:
•parameter 1A Motor Full Load Current is not appropriate for the motor
•parameter 2B Current Limit has been set too low
•parameter 2D Start Ramp Time has been set greater than the setting for
2G E x c e s s S t a r t T i m e setting
•parameter 2D Start Ramp Time is set too short for a high inertia load when
using Adaptive Control
Related parameters: 1A, 1C, 2B, 2D, 2G, 3B, 3D, 3G, 16H
DET-813 7

ASTAT XL Service Manual Troubleshooting
Display
Possible cause/Suggested solution
Firing Fail Px
Where 'X' is phase 1, 2 or 3.
The SCR did not fire as expected. The SCR may be faulty or there may be an
internal wiring fault.
This trip is not adjustable.
Related parameters: None
FLC too high
The ASTAT XL can support higher motor full load current values when
connected to the motor using inside delta configuration rather than in-line
connection. If the soft starter is connected in-line but the programmed
setting for parameter 1A Motor Full Load Current is above the in-line maximum,
the soft starter will trip at start (see Minimum and Maximum Current Settings).
If the soft starter is connected to the motor using inside delta configuration, the
soft starter may not be correctly detecting the connection. Contact your local
supplier for advice.
Related parameters: 1A, 1C
Frequency
The mains frequency has gone beyond the specified range.
Check for other equipment in the area that could be affecting the mains
supply, particularly variable speed drives and switch mode power supplies
(SMPS).
If the ASTAT XL is connected to a generator set supply, the generator may be
too small or could have a speed regulation problem.
Related parameters: 4G, 4H, 5G, 16F
Heatsink
overtemperature
Check if cooling fans are operating. If mounted in an enclosure, check if
ventilation is adequate.
Fans operate during Start, Run and for 10 minutes after the starter exits the
Stop state.
NOTE
Models QLxxB0023D to QLxxB0053D and QLxxB0170D do not have
a cooling fan. Models with fans will operate the cooling fans from a
Start until 10 minutes after a Stop.
Related parameters: 16J
High Level
This is a name selected for a programmable input. See Input A trip.
High Pressure
This is a name selected for a programmable input. See Input A trip.
Input A trip
The soft starter's programmable input is set to a trip function and has
activated. Resolve the trigger condition.
Related parameters: 4E, 5E, 5F, 6D, 6E, 16E
Instantaneous
overcurrent
There has been a sharp rise in motor current, probably caused by a locked
rotor condition (shearpin) while running. This may indicate a jammed load.
Related parameters: 4D, 5D, 16D
Internal fault X
The ASTAT XL has tripped on an internal fault. Contact your local supplier with
the fault code (X).
Related parameters: None
L1 phase loss
L2 phase loss
L3 phase loss
During pre-start checks the starter has detected a phase loss as indicated.
In run state, the starter has detected that the current on the affected phase
has dropped below 2% of the programmed motor FLC for more than 1 second,
indicating that either the incoming phase or connection to the motor has been
lost.
Check the supply and the input and output connections at the starter and at
the motor end.
Phase loss can also be caused by a failed SCR, particularly an SCR that has
failed open circuit. A failed SCR can only be definitely diagnosed by replacing
the SCR and checking the starter's performance.
Related parameters: None
8 DET-813

Troubleshooting ASTAT XL Service Manual
Display
Possible cause/Suggested solution
L1-T1 shorted
L2-T2 shorted
L3-T3 shorted
During pre-start checks the starter has detected a shorted SCR or a short
within the bypass contactor as indicated. If the starter is connected in-line
with the motor, consider using PowerThrough to allow operation until the
starter can be repaired.
NOTE
PowerThrough is only available with in-line installations. If the
starter is installed inside delta, PowerThrough will not operate.
The starter will trip on Lx-Tx Shorted on the first start attempt after
control power is applied. PowerThrough will not operate if control
power is cycled between starts.
Related parameters: 15E
Low Control Volts
The ASTAT XL has detected a drop in the control voltage.
•Check the external control supply (terminals A4, A5, A6) and reset the
starter.
If the external control supply is stable:
•the 24 V supply on the main control PCB may be faulty; or
•the bypass driver PCB may be faulty (internally bypassed models only).
Contact your local supplier for advice.
This protection is not active in Ready state.
Related parameters: 16M
Low Level
This is a name selected for a programmable input. See Input A trip.
Low Pressure
This is a name selected for a programmable input. See Input A trip.
Motor overload
Motor 2 overload
The motor has reached its maximum thermal capacity. Overload can be
caused by:
•The soft starter protection settings not matching the motor thermal
capacity
•Excessive starts per hour
•Excessive throughput
•Damage to the motor windings
Resolve the cause of the overload and allow the motor to cool.
Related parameters: 1A, 1B, 1C, 1D, 2A, 2B, 3A, 3B, 16A
Motor Connection Tx
Where 'X' is 1, 2 or 3.
The motor is not connected correctly to the soft starter for in-line or inside
delta use.
•Check individual motor connections to the soft starter for power circuit
continuity.
•Check connections at the motor terminal box.
This trip is not adjustable.
Related parameters: None
Motor thermistor
The motor thermistor input has been enabled and:
•The resistance at the thermistor input has exceeded 3.6 kΩfor more than
one second.
•The motor winding has overheated. Identify the cause of the overheating
and allow the motor to cool before restarting.
•The motor thermistor input has been opened.
NOTE
If a valid motor thermistor is no longer used, a 1.2 kΩ resistor must
be fitted across terminals 64, 65.
Related parameters: 16G
Network
communication
(between module and
network)
The network master has sent a trip command to the starter, or there may be a
network communication problem.
Check the network for causes of communication inactivity.
Related parameters: 16L
DET-813 9

ASTAT XL Service Manual Troubleshooting
Display
Possible cause/Suggested solution
No Flow
This is a name selected for a programmable input. See Input A trip.
Parameter out of
range
•
A parameter value is outside the valid range.
The starter will load the default value for all affected parameters. Press
RESET to go to the first invalid parameter and adjust the setting.
Related parameters: None
Phase sequence
The phase sequence on the soft starter's input terminals (L1, L2, L3) is not valid.
Check the phase sequence on L1, L2, L3 and ensure the setting in parameter
4B is suitable for the installation.
Related parameters: 4B
PLC
This is a name selected for a programmable input. See Input A trip.
Power loss
The starter is not receiving mains supply on one or more phases when a Start
Command is given.
Check that the main contactor closes when a start command is given, and
remains closed until the end of a soft stop. Check the fuses. If testing the soft
starter with a small motor, it must draw at least 2% of its minimum FLC setting
on each phase.
Related parameters: None
Pump Fault
This is a name selected for a programmable input. See Input A trip.
Starter
communication
(between module and
soft starter)
•There is a problem with the connection between the soft starter and the
optional communications module. Remove and reinstall the module. If
the problem persists, contact your local distributor.
•There is an internal communications error within the soft starter. Contact
your local distributor.
Related parameters: 16I
Starter Disable
This is a name selected for a programmable input. See Input A trip.
Thermistor circuit
Check that a PT100 (RTD) is not connected to 64, 65.
The thermistor input has been enabled and:
•The resistance at the input has fallen below 20 Ω(the cold resistance of
most thermistors will be over this value) or
•A short circuit has occurred. Check and resolve this condition.
Related parameters: None
Time-overcurrent
The ASTAT XL 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
Undercurrent
The motor has experienced a sharp drop in current, caused by loss of load.
Causes can include broken components (shafts, belts or couplings), or a pump
running dry.
Related parameters: 4C, 5C, 16C
Unsupported option
(function not
available in inside
delta)
The selected function is not available (eg jog is not supported in inside delta
configuration).
Related parameters: None
Vibration Alarm
This is a name selected for a programmable input. See Input A trip.
VZC Fail Px
Where 'X' is 1, 2 or 3.
Internal fault (PCB fault). Contact your local supplier for advice.
This trip is not adjustable.
Related parameters: None
10 DET-813

Troubleshooting ASTAT XL Service Manual
3.3 General Faults
This table describes situations where the soft starter does not operate as expected but does not trip or
give a warning.
Symptom
Probable Cause
Starter "Not Ready"
•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 ASTAT XL will not start.
The soft starter does not respond
to the START or RESET button on
the keypad.
•The soft starter may be in Remote control mode. When the
soft starter is in Remote control mode, the Hand LED on the
starter is off. Press the HAND/AUTO button once to change to
Local control.
The soft starter does not respond
to commands from the control
inputs.
•The soft starter may be in Local control mode. When the soft
starter is in Local control mode, the Hand LED on the starter is
on. Press the HAND/AUTO button once to change to Remote
control.
•The control wiring may be incorrect. Check that the remote
start, stop and reset inputs are configured correctly (see Control
Wiring for details).
•The signals to the remote inputs may be incorrect. Test the
signalling by activating each input signal in turn. The
appropriate remote control input LED should activate on the
starter.
The soft starter does not respond
to a start command from either
the local or remote controls.
•
The soft starter may be waiting for the restart delay to elapse.
The length of the restart delay is controlled by parameter 5A
Restart Delay.
•The motor may be too hot to permit a start. If parameter 4F
Motor Temperature Check is set to Check, the soft starter will
only permit a start when it calculates that the motor has
sufficient thermal capacity to complete the start successfully.
Wait for the motor to cool before attempting another start.
•The starter may be disabled via a programmable input. If
parameter 6D is set to Starter Disable and there is an open
circuit on 53, 55, the ASTAT XL will not start. If there is no
further need to disable the starter, close the circuit on the input.
NOTE
Parameter 6A Local/Remote controls when the
HAND/AUTO button is enabled.
A reset does not occur after an
Auto-Reset, when using a remote
two-wire control.
•The remote 2-wire start signal must be removed and reapplied
for a re-start.
Non-resettable Thermistor Cct
trip, when there is a link between
the thermistor input 64, 65 or
when the motor thermistor
connected between 64, 65 is
permanently removed.
•The thermistor input is enabled once a link is fitted and short
circuit protection has activated.
•Remove the link then load the default parameter set. This
will disable the thermistor input and clear the trip.
•Place a 1k2 Ωresistor across the thermistor input.
•
Turn thermistor protection to 'Log only' (parameter 16G).
The soft starter does not control
the motor correctly during
starting.
•Start performance may be unstable when using a low
M o t o r F u l l
Load Current setting (parameter 1A). This can affect use on a
small test motor with full load current between 5 A and 50 A.
•Power factor correction (PFC) capacitors must be installed on
the supply side of the soft starter. To control a dedicated PFC
capacitor contactor, connect the contactor to run relay
terminals.
DET-813 11

ASTAT XL Service Manual Troubleshooting
Symptom
Probable Cause
Motor does not reach full speed.
•If the start current is too low, the motor will not produce enough
torque to accelerate to full speed. The soft starter may trip on
excess start time.
NOTE
Make sure the motor starting parameters are
appropriate for the application and that you are using
the intended motor starting profile. If parameter 6D is
set to Motor Set Select, check that the corresponding
input is in the expected state.
The load may be jammed. Check the load for severe overloading or
a locked rotor situation.
Erratic motor operation.
•The SCRs in the ASTAT XL require at least 5 A of current to latch.
If you are testing the soft starter on a motor with full load
current less than 5 A, the SCRs may not latch correctly.
Erratic and noisy motor
operation.
•If the soft starter is connected to the motor using inside delta
configuration, the soft starter may not be correctly detecting the
connection. Contact your local supplier for advice.
Soft stop ends too quickly.
•The soft stop settings may not be appropriate for the motor and
load. Review the settings of parameters 2H, 2I, 3H and 3I.
•If the motor is very lightly loaded, soft stop will have limited
effect.
Adaptive Control, brake, jog and
PowerThrough functions not
working.
•These features are only available with in-line installation. If the
ASTAT XL is installed inside delta, these features will not operate.
After selecting Adaptive Control
the motor used an ordinary start
and/or the second start was
different to the first.
•The first Adaptive Control start is actually 'Constant Current' so
that the starter can learn from the motor characteristics.
Subsequent starts use Adaptive Control.
PowerThrough does not operate
when selected.
•The starter will trip on Lx-Tx Shorted on the first start attempt
after control power is applied. PowerThrough will not operate
if control power is cycled between starts.
Parameter settings cannot be
stored.
•Make sure you are saving the new value by pressing the ENTER
button after adjusting a parameter setting. If you press EXIT,
the change will not be saved.
•Check that the adjustment lock (parameter 15B) is set to R e a d &
Write. If the adjustment lock is set to R e a d O n l y , settings can
be viewed but not changed. You need to know the security
access code to change the adjustment lock setting.
•The EEPROM may be faulty on the keypad. A faulty EEPROM
will also trip the soft starter, and the keypad will display the
message Parameter out of range. Contact your local supplier
for advice.
Remote keypad shows message
"awaiting data"
The keypad is not receiving data from the control PCB. Check the
cable connection.
12 DET-813

Troubleshooting ASTAT XL Service Manual
3.4 SCRs
SCR damage is generally caused by overcurrent, overvoltage or overtemperature. To prevent future
damage, check that the soft starter has been installed properly. Common causes of SCR problems
include:
Overcurrent:
•cable fault on soft starter output
•motor fault
•start current and/or start time exceeds the soft starter's rating
•starts per hour exceed the soft starter rating
Overvoltage:
•power supply transient or surge
•lightning strike (direct or indirect) on power supply
•motor fault
•loose connection in power circuit, before or after the starter
•power factor correction connected to the output of the soft starter
•over-corrected bulk power factor correction on a lightly loaded system causing severe ringing
voltages
Overtemperature:
•blocked heatsinks or restricted ventilation
•inadequate ventilation
•excessive ambient temperatures
•bypass relay fails to close during running (internally bypassed starters only)
3.4.2 Protecting SCRs
Modern SCRs are generally rugged and reliable. However, the risk of SCR damage can be reduced by
using semiconductor fuses and/or a main contactor.
3.4.2.1 Semiconductor Fuses
Semiconductor fuses reduce the potential for SCR damage caused by short circuits on the output of the
starter.
Protection systems such as circuit breakers or HRC fuses do not operate quickly enough to protect
SCRs from short circuits.
3.4.2.2 Main Contactors
SCRs are most vulnerable to overvoltage damage when voltage is applied to their input terminal while
they are off. In this condition the SCR is blocking the full line voltage. Using a main contactor to remove
voltage from the SCR input when the starter is off eliminates the risk of SCR damage due to
overvoltage.
DET-813 13

ASTAT XL Service Manual Service Instructions
4Service Instructions
The physical layout and spare parts for ASTAT XL vary according to the size of the starter. ASTAT XL
starters can be grouped into seven "frame sizes" as follows:
Frame Size
ASTAT XL Models
G1B
QLxxB0023D
QLxxB0043D
QLxxB0050D
QLxxB0053D
QLxxB0076D
QLxxB0097D
QLxxB0100D
QLxxB0105D
G2B
QLxxB0145D
QLxxB0170D
QLxxB0200D
QLxxB0220D
G3B
QLxxB0255D
QLxxB0350D
QLxxB0425D
G4B
QLxxB0500D
QLxxB0580D
QLxxB0700D
QLxxB0820D
QLxxB0920D
QLxxB1000D
G3C
QLxxX0255D
G4C
QLxxX0360D
QLxxX0380D
QLxxX0430D
QLxxX0620D
QLxxX0650D
QLxxX0790D
QLxxX0930D
G5C
QLxxX1200D
QLxxX1410D
QLxxX1600D
14 DET-813

Service Instructions ASTAT XL Service Manual
4.1 QLxxB0023D to QLxxB0053D (G1B)
11
1
2
3
4
5
6
7
8
9
10
11629.A
1
Main plastic
2
Keypad
3
Main control PCB
4
Model PCB (including
bypass contactors)
5
Backplane PCB
6
SCRs
7
Current transformers
8
Mounting posts
9
Cage clamps
10
Side plastic
11
Base plastic
DET-813 15

ASTAT XL Service Manual Service Instructions
4.2 QLxxB0076D to QLxxB0105D (G1B)
11630.A
1
2
3
4
5
67
8
9
10
11
12
13
1
Main plastic
2
Keypad
3
Main control PCB
4
Backplane PCB
5
Model PCB
6
Bypass contactors
7
SCRs
8
Current transformers
9
Mounting posts
10
Cage clamps
11
Side plastic
12
Base plastic
13
Fan
16 DET-813

Service Instructions ASTAT XL Service Manual
4.3 QLxxB0145D to QLxxB0220D (G2B)
11631.A
1
2
3
4
5
6
7
8
9
10
1
Main plastic
2
Keypad/Main control PCB
3
Bypass driver PCB
4
Support plastic
5
Model PCB
6
Current transformers
7
SCRs
8
Bypass contactors
9
Main chassis
10
Fan
DET-813 17

ASTAT XL Service Manual Service Instructions
4.4 QLxxB0255D to QLxxB0425D (G3B)
1
2
5
8
9
11 10
14482.A
4
6
3
7
1
Main plastic
2
Keypad
3
Bypass driver PCB
4
Main control PCB
5
Main chassis
6
Bypass contactors
7
Snubber assembly
(QLxxB0350D and
QLxxB0425D only)
8
SCRs
9
Current transformers
10
Heatsink
11
Fan assembly
18 DET-813

Service Instructions ASTAT XL Service Manual
4.5 QLxxX0255D (G3C)
11636.B
1
2
3
4
5
67
8
9
1
Cover
2
Main plastic
3
Keypad/Main
control PCB
4
Support plastic
5
Model PCB
6
Current
transformers
7
SCRs
8
Main chassis
9
Fan assembly
DET-813 19