GE ASTAT XL User manual

ASTAT XL User Manual
Contents
DET-812
1
Contents
1!About This Manual ...................................................................................................................................3!
2!Caution Statements .................................................................................................................................4!
2.1!Electrical Shock Risk...................................................................................................................................................................................4!
2.2!System Design and Safety of Personnel ..........................................................................................................................................4!
2.3!Disposal Instructions..................................................................................................................................................................................5!
3!Introduction...............................................................................................................................................6!
3.1!Feature List.....................................................................................................................................................................................................6!
4!Specifications ............................................................................................................................................7!
4.1!Model Code.....................................................................................................................................................................................................7!
4.2!Current Ratings.............................................................................................................................................................................................7!
4.3!Dimensions and Weights......................................................................................................................................................................12!
4.4!Specifications .............................................................................................................................................................................................13!
4.5!UL Compliant Installation .....................................................................................................................................................................14!
5!Installation.............................................................................................................................................. 16!
5.1!Physical Installation ................................................................................................................................................................................16!
5.2!Control Terminals .....................................................................................................................................................................................16!
5.3!Control Wiring ............................................................................................................................................................................................17!
5.4!Relay Outputs............................................................................................................................................................................................. 17!
5.5!Motor Thermistors....................................................................................................................................................................................17!
5.6!Power Terminations ................................................................................................................................................................................18!
5.7!Power Input and Output Configurations .......................................................................................................................................19!
5.8!Schematic Diagrams...............................................................................................................................................................................20!
6!Power Circuits ........................................................................................................................................ 22!
6.1!Motor Connection..................................................................................................................................................................................... 22!
6.2!Bypass Contactor..................................................................................................................................................................................... 25!
6.3!Main Contactor..........................................................................................................................................................................................25!
6.4!Circuit Breaker............................................................................................................................................................................................25!
6.5!Power Factor Correction....................................................................................................................................................................... 25!
6.6!Earth Terminals..........................................................................................................................................................................................25!
6.7!Power Supply Fuses ................................................................................................................................................................................25!
7!Operation................................................................................................................................................ 27!
7.1!The Keypad..................................................................................................................................................................................................27!
7.2!Starter Status LEDs.................................................................................................................................................................................. 27!
7.3!Displays.........................................................................................................................................................................................................27!
7.4!Start, Stop and Reset Commands.....................................................................................................................................................29!
7.5!Soft Start Methods ................................................................................................................................................................................... 29!
7.6!Stop Methods..............................................................................................................................................................................................31!
7.7!Jog Operation.............................................................................................................................................................................................34!
7.8!Inside Delta Operation ...........................................................................................................................................................................35!
8!Programming Menu .............................................................................................................................. 36!
8.1!Quick Setup ................................................................................................................................................................................................. 36!
8.2!Standard Menu..........................................................................................................................................................................................38!
8.3!Extended Menu..........................................................................................................................................................................................39!
8.4!Parameter Descriptions......................................................................................................................................................................... 41!
8.5!Adjustment Lock .......................................................................................................................................................................................54!
8.6!Access Code................................................................................................................................................................................................ 56!
8.7!Setup Tools ..................................................................................................................................................................................................56!
9!Logs Menu............................................................................................................................................... 58!
9.1!Trip Log.......................................................................................................................................................................................................... 58!
9.2!Event Log......................................................................................................................................................................................................58!

ASTAT XL User Manual
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DET-812
9.3!Performance Counters...........................................................................................................................................................................58!
10!Application Examples ........................................................................................................................... 59!
10.1!Installation with Main Contactor....................................................................................................................................................... 59!
10.2!Installation with Bypass Contactor..................................................................................................................................................60!
10.3!Emergency Run Operation...................................................................................................................................................................61!
10.4!Auxiliary Trip Circuit................................................................................................................................................................................. 62!
10.5!DC Brake with External Zero Speed Sensor..................................................................................................................................63!
10.6!Soft Braking.................................................................................................................................................................................................64!
10.7!Two Speed Motor...................................................................................................................................................................................... 65!
11!Troubleshooting..................................................................................................................................... 67!
11.1!Protection Responses............................................................................................................................................................................. 67!
11.2!Trip Messages............................................................................................................................................................................................. 67!
11.3!General Faults............................................................................................................................................................................................71!
12!Accessories............................................................................................................................................. 73!
12.1!Communication Modules......................................................................................................................................................................73!
12.2!Remote Control Panel (RCP)................................................................................................................................................................. 73!
12.3!Finger Guard Kit ........................................................................................................................................................................................73!
12.4!PC Software................................................................................................................................................................................................. 73!
13!Appendix 1: Fuse Selection Tables...................................................................................................... 74!
13.1!Bussman Fuses - Square Body (170M)........................................................................................................................................... 74!
13.2!Bussman Fuses - British Style (BS88) .............................................................................................................................................. 75!
13.3!Ferraz/Mersen Fuses - HSJ ..................................................................................................................................................................76!
13.4!Ferraz/Mersen Fuses - North American Style (PSC 690) ........................................................................................................77!
13.5!Ferraz/Mersen Fuses - European Style (PSC 690) .....................................................................................................................78!
13.6!Ferraz/Mersen Fuses - AJT...................................................................................................................................................................79!
13.7!UL Fuse Selection and Short Circuit Ratings................................................................................................................................80!
14!Appendix 2: ASTAT XL Output Relay Compatibility ......................................................................... 82!
14.1!Overview....................................................................................................................................................................................................... 82!
14.2!Using the Soft Starter to Switch a Contactor Coil ..................................................................................................................... 82!

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1About This Manual
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.
WARNING
Indicates a hazard that may cause personal injury or death.
AVERTISSEMENT
Indique un risque pouvant provoquer des blessures éventuellement mortelles.
CAUTION
Indicates a hazard that may damage the equipment or installation.
NOTE
Provides helpful information.

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DET-812
2Caution Statements
Caution Statements cannot cover every potential cause of equipment damage but can highlight
common causes of damage. It is the installer's responsibility to read and understand all instructions
in this manual prior to installing, operating or maintaining the equipment, to follow good electrical
practice including applying appropriate personal protective equipment and to seek advice before
operating this equipment in a manner other than as described in this manual.
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.
2.1 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).
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.
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.
2.2 System Design and Safety of Personnel
The starter is intended as a component for professional incorporation into complete equipment or a
system. If installed incorrectly, the starter may present a safety hazard.
The starter uses high voltages and currents, carries stored electrical energy, and is used to control
equipment which can cause injury.
Close attention is required to the electrical installation and the system design to avoid hazards either in
normal operation or in the event of equipment malfunction. System design, installation, commissioning
and maintenance must be carried out by personnel who have the necessary training and experience.
They must read this safety information and this guide carefully.
None of the starter functions must be used to ensure safety of personnel, ie they must not be used
for safety-related functions.
Careful consideration must be given to the functions of the starter which might result in a hazard,
either through their intended behaviour or through incorrect operation due to a fault. In any
application where a malfunction of the starter or its control system could lead to or allow damage, loss
or injury, a risk analysis must be carried out, and where necessary, further measures taken to reduce
the risk.
The system designer is responsible for ensuring that the complete system is safe and designed
correctly according to the relevant safety standards.

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2.2.1 STOP function
The STOP function does not remove dangerous voltages from the starter, the motor or any external
option units.
2.3 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.

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DET-812
3Introduction
3.1 Feature List
Extensive starting and stopping options
•Adaptive Control
•Constant Current
•Current Ramp
•Timed voltage ramp soft stop
•Brake
Models for all connection requirements
•23 A to 1600 A (nominal)
•200 VAC to 525 VAC
•380 VAC to 690 VAC
•Internally bypassed options
•In-line or inside delta connection (auto-detect)
Inputs and outputs
•Remote control inputs
(3 x fixed, 1 x programmable)
•Relay outputs
(3 x programmable)
•Analog output
•Communication modules: Ethernet (Profinet,
Modbus TCP, Ethernet IP), Profibus, DeviceNet,
Modbus RTU, and USB
Easy-to-read display with comprehensive
feedback
•Multi-language feedback
•Multiple status screens and performance
graphs
•Date and time stamped event logging
•Operational counters (number of starts,
hours-run, kWh)
•Performance monitoring (current, voltage,
power factor, kWh)
•User-programmable monitoring screen
Customisable protection
•Motor overload
•Excess Start Time
•Undercurrent
•Instantaneous overcurrent
•Current imbalance
•Mains frequency
•Input Trip
•Motor thermistor
•Power circuit
•Phase sequence

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4Specifications
4.1 Model Code
Example: Model QL21B023D
Q
L
2
1
B
023
D
ASTAT
L = XL Series
Mains voltage
2 = 200 ~ 525 VAC
4 = 380 ~ 690 VAC
Control voltage
1 = 110~120 VAC or 220~240 VAC
2 = 24 VAC/VDC
Bypass
B = internally bypassed
X = non-bypassed
Nominal current rating
D = Built-in display
4.2 Current Ratings
Contact your local supplier for ratings under operating conditions not covered by these ratings charts.
4.2.1 Current Ratings for Bypass Operation
80 A
:
AC-53b
3.5
-
15
:
345
Off time (seconds)
Start time (seconds)
Start current (multiple of motor full load current)
Starter current rating (amperes)
NOTE
Models QLxxX255D~QLxxX1k6D must be externally bypassed.

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DET-812
In-line connection
AC53b 3.0-10:350
40 ºC <1000 metres
AC53b 3.5-15:345
40 ºC <1000 metres
AC53b 4.0-20:340
40 ºC <1000 metres
AC53b 4.5-30:330
40 ºC <1000 metres
QLxxB0023D
23 A
20 A
17 A
15 A
QLxxB0043D
43 A
37 A
31 A
26 A
QLxxB0050D
50 A
44 A
37 A
30 A
QLxxB0053D
53 A
53 A
46 A
37 A
AC53b 3.0-10:590
40 ºC <1000 metres
AC53b 3.5-15:585
40 ºC <1000 metres
AC53b 4.0-20:580
40 ºC <1000 metres
AC53b 4.5-30:570
40 ºC <1000 metres
QLxxB0076D
76 A
64 A
55 A
47 A
QLxxB0097D
97 A
82 A
69 A
58 A
QLxxB0100D
100 A
88 A
74 A
61 A
QLxxB0105D
105 A
105 A
95 A
78 A
QLxxB0145D
145 A
123 A
106 A
90 A
QLxxB0170D
170 A
145 A
121 A
97 A
QLxxB0200D
200 A
189 A
160 A
134 A
QLxxB0220D
220 A
210 A
178 A
148 A
QLxxB0255D
255 A
231 A
201 A
176 A
QLxxX0255D
255 A
231 A
201 A
176 A
QLxxB0350D
350 A
329 A
284 A
244 A
QLxxX0360D
360 A
360 A
310 A
263 A
QLxxX0380D
380 A
380 A
359 A
299 A
QLxxB0425D
425 A
411 A
355 A
305 A
QLxxX0430D
430 A
430 A
368 A
309 A
QLxxB0500D
500 A
445 A
383 A
326 A
QLxxB0580D
580 A
492 A
425 A
364 A
QLxxX0620D
620 A
620 A
540 A
434 A
QLxxX0650D
650 A
650 A
561 A
455 A
QLxxB0700D
700 A
592 A
512 A
438 A
QLxxX0790D
790 A
790 A
714 A
579 A
QLxxB0820D
820 A
705 A
606 A
516 A
QLxxB0920D
920 A
804 A
684 A
571 A
QLxxX0930D
930 A
930 A
829 A
661 A
QLxxB1000D
1000 A
936 A
796 A
664 A
QLxxX1200D
1200 A
1200 A
1200 A
1071 A
QLxxX1410D
1410 A
1410 A
1319 A
1114 A
QLxxX1600D
1600 A
1600 A
1600 A
1353 A

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Inside delta connection
AC53b 3.0-10:350
40 ºC <1000 metres
AC53b 3.5-15:345
40 ºC <1000 metres
AC53b 4.0-20:340
40 ºC <1000 metres
AC53b 4.5-30:330
40 ºC <1000 metres
QLxxB0023D
34 A
30 A
26 A
22 A
QLxxB0043D
64 A
59 A
51 A
44 A
QLxxB0050D
75 A
66 A
55 A
45 A
QLxxB0053D
79 A
79 A
69 A
55 A
AC53b 3.0-10:590
40 ºC <1000 metres
AC53b 3.5-15:585
40 ºC <1000 metres
AC53b 4.0-20:580
40 ºC <1000 metres
AC53b 4.5-30:570
40 ºC <1000 metres
QLxxB0076D
114 A
96 A
83 A
70 A
QLxxB0097D
145 A
123 A
104 A
87 A
QLxxB0100D
150 A
132 A
112 A
92 A
QLxxB0105D
157 A
157 A
143 A
117 A
QLxxB0145D
218 A
184 A
159 A
136 A
QLxxB0170D
255 A
217 A
181 A
146 A
QLxxB0200D
300 A
283 A
241 A
200 A
QLxxB0220D
330 A
315 A
268 A
223 A
QLxxB0255D
382 A
346 A
302 A
264 A
QLxxX0255D
382 A
346 A
302 A
264 A
QLxxB0350D
525 A
494 A
427 A
366 A
QLxxX0360D
540 A
540 A
465 A
395 A
QLxxX0380D
570 A
570 A
539 A
449 A
QLxxB0425D
638 A
617 A
533 A
458 A
QLxxX0430D
645 A
645 A
552 A
464 A
QLxxB0500D
750 A
668 A
575 A
490 A
QLxxB0580D
870 A
738 A
637 A
546 A
QLxxX0620D
930 A
930 A
810 A
651 A
QLxxX0650D
975 A
975 A
842 A
683 A
QLxxB0700D
1050 A
889 A
768 A
658 A
QLxxX0790D
1185 A
1185 A
1071 A
868 A
QLxxB0820D
1230 A
1058 A
910 A
774 A
QLxxB0920D
1380 A
1206 A
1026 A
857 A
QLxxX0930D
1395 A
1395 A
1244 A
992 A
QLxxB1000D
1500 A
1404 A
1194 A
997 A
QLxxX1200D
1800 A
1800 A
1800 A
1606 A
QLxxX1410D
2115 A
2115 A
1979 A
1671 A
QLxxX1600D
2400 A
2400 A
2400 A
2030 A

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DET-812
4.2.2 Current Ratings for Continuous Operation (Not bypassed)
351 A
:
AC-53a
3.5
-
15
:
50
-
6
Starts per hour
On-load duty cycle (%)
Start time (seconds)
Start current (multiple of motor full load current)
Starter current rating (amperes)
In-line connection
AC53a 3-10:50-6
40 ºC <1000 metres
AC53a 3.5-15:50-6
40 ºC <1000 metres
AC53a 4-20:50-6
40 ºC <1000 metres
AC53a 4.5-30:50-6
40 ºC <1000 metres
QLxxX0255D
255 A
222 A
195 A
171 A
QLxxX0360D
360 A
351 A
303 A
259 A
QLxxX0380D
380 A
380 A
348 A
292 A
QLxxX0430D
430 A
413 A
355 A
301 A
QLxxX0620D
620 A
614 A
515 A
419 A
QLxxX0650D
650 A
629 A
532 A
437 A
QLxxX0790D
790 A
790 A
694 A
567 A
QLxxX0930D
930 A
930 A
800 A
644 A
QLxxX1200D
1200 A
1200 A
1135 A
983 A
QLxxX1410D
1410 A
1355 A
1187 A
1023 A
QLxxX1600D
1600 A
1600 A
1433 A
1227 A
Inside delta connection
AC53a 3-10:50-6
40 ºC <1000 metres
AC53a 3.5-15:50-6
40 ºC <1000 metres
AC53a 4-20:50-6
40 ºC <1000 metres
AC53a 4.5-30:50-6
40 ºC <1000 metres
QLxxX0255D
382 A
334 A
293 A
257 A
QLxxX0360D
540 A
527 A
455 A
388 A
QLxxX0380D
570 A
570 A
522 A
437 A
QLxxX0430D
645 A
620 A
533 A
451 A
QLxxX0620D
930 A
920 A
773 A
628 A
QLxxX0650D
975 A
943 A
798 A
656 A
QLxxX0790D
1185 A
1185 A
1041 A
850 A
QLxxX0930D
1395 A
1395 A
1200 A
966 A
QLxxX1200D
1800 A
1800 A
1702 A
1474 A
QLxxX1410D
2115 A
2033 A
1780 A
1535 A
QLxxX1600D
2400 A
2400 A
2149 A
1840 A

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4.2.3 Minimum and Maximum Current Settings
The ASTAT XL's minimum and maximum full load current settings depend on the model:
In-line connection
Inside delta connection
Model
Minimum
Maximum
Minimum
Maximum
QLxxB0023D
5 A
23 A
5 A
34 A
QLxxB0043D
9 A
43 A
9 A
64 A
QLxxB0050D
10 A
50 A
10 A
75 A
QLxxB0053D
11 A
53 A
11 A
79 A
QLxxB0076D
15 A
76 A
15 A
114 A
QLxxB0097D
19 A
97 A
19 A
145 A
QLxxB0100D
20 A
100 A
20 A
150 A
QLxxB0105D
21 A
105 A
21 A
157 A
QLxxB0145D
29 A
145 A
29 A
217 A
QLxxB0170D
34 A
170 A
34 A
255 A
QLxxB0200D
40 A
200 A
40 A
300 A
QLxxB0220D
44 A
220 A
44 A
330 A
QLxxB0255D
51 A
255 A
51 A
382 A
QLxxX0255D
51 A
255 A
51 A
382 A
QLxxB0350D
70 A
350 A
70 A
525 A
QLxxX0360D
72 A
360 A
72 A
540 A
QLxxX0380D
76 A
380 A
76 A
570 A
QLxxB0425D
85 A
425 A
85 A
638 A
QLxxX0430D
86 A
430 A
86 A
645 A
QLxxB0500D
100 A
500 A
100 A
750 A
QLxxB0580D
116 A
580 A
116 A
870 A
QLxxX0620D
124 A
620 A
124 A
930 A
QLxxX0650D
130 A
650 A
130 A
975 A
QLxxB0700D
140 A
700 A
140 A
1050 A
QLxxX0790D
158 A
790 A
158 A
1185 A
QLxxB0820D
164 A
820 A
164 A
1230 A
QLxxB0920D
184 A
920 A
184 A
1380 A
QLxxX0930D
186 A
930 A
186 A
1395 A
QLxxB1000D
200 A
1000 A
200 A
1500 A
QLxxX1200D
240 A
1200 A
240 A
1800 A
QLxxX1410D
282 A
1410 A
282 A
2115 A
QLxxX1600D
320 A
1600 A
320 A
2400 A

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DET-812
4.3 Dimensions and Weights
A
C
D
B
E
A B
C
D
E
08718.F
Height
mm (inch)
Width
mm (inch)
Depth
mm (inch)
Weight
kg (lb)
Model
A
B
C
D
E
QLxxB0023D
QLxxB0043D
183
4.1
QLxxB0050D
(7.2)
(9.0)
QLxxB0053D
295
278
150
124
QLxxB0076D
(11.6)
(10.9)
(5.9)
(4.9)
4.4 (9.7)
QLxxB0097D
213
4.9
QLxxB0100D
(8.4)
(10.8)
QLxxB0105D
QLxxB0145D
13.6 (30.0)
QLxxB0170D
438
380
275
250
248
13.8 (30.4)
QLxxB0200D
(17.2)
(15.0)
(10.8)
(9.8)
(9.8)
14.6
QLxxB0220D
(32.2)
QLxxB0255D
440
392
424
376
296
26 (57.3)
QLxxB0350D
(17.3)
(15.4)
(16.7)
(14.8)
(11.7)
29.4
QLxxB0425D
(64.8)
QLxxB0500D
49
QLxxB0580D
(108.0)
QLxxB0700D
640
600
433
320
293
62.5
QLxxB0820D
(25.2)
(23.6)
(17.0)
(12.6)
(11.5)
(137.8)
QLxxB0920D
63
QLxxB1000D
(138.9)
QLxxX0255D
460 (18.1)
400 (15.7)
390 (15.4)
320 (12.6)
278 (10.9)
23 (50.7)
QLxxX0360D
QLxxX0380D
36
QLxxX0430D
(79.4)
QLxxX0620D
689
522
430
320
301
QLxxX0650D
(27.1)
(20.6)
(16.9)
(12.6)
(11.9)
39.5
QLxxX0790D
(87.1)
QLxxX0930D
51.5 (113.5)
QLxxX1200D
860
727
574
500
362
128.5 (283.3)
QLxxX1410D
(33.9)
(28.6)
(22.6)
(19.7)
(14.3)
130 (286.6)
QLxxX1600D
140 (308.6)

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4.4 Specifications
Supply
Mains voltage (L1, L2, L3)
2 ............................................................................................................................................. 200 VAC ~ 525 VAC (± 10%)
4 ..................................................................... 380 VAC ~ 600 VAC (± 10%) (in-line or inside delta connection)
4 ..................................................................... 380 VAC ~ 690 VAC (± 10%) (earthed star supply system only)
Control voltage (A4, A5, A6)
1 ................................................................................ 110 ~ 120 VAC or 220 ~ 240 VAC (+ 10% / -15%), 600mA
2 .................................................................................................................................................... 24 VAC/VDC ±20%, 2.8A
Mains frequency .................................................................................................................................................. 45 Hz ~ 66 Hz
Rated insulation voltage to earth ........................................................................................................................... 600 VAC
Rated impulse withstand voltage .................................................................................................................................... 4 kV
Form designation ............................................ Bypassed or continuous, semiconductor motor starter form 1
Short circuit capability
Coordination with semiconductor fuses ................................................................................................................ Type 2
Coordination with HRC fuses ....................................................................................................................................... Type 1
QLxxB0023D ~ QLxxB0220D ....................................................................................... prospective current 65 kA
QLxxB0255D ~ QLxxB1000D ....................................................................................... prospective current 85 kA
QLxxX0255D ~ QLxxX0930D ....................................................................................... prospective current 85 kA
QLxxX1200D ~ QLxxX1600D ..................................................................................... prospective current 100 kA
Electromagnetic capability (compliant with EU Directive 89/336/EEC)
EMC Emissions .................................................... IEC 60947-4-2 Class B and Lloyds Marine No 1 Specification
EMC Immunity ...................................................................................................................................................... IEC 60947-4-2
Inputs
Input rating ............................................................................................................................... Active 24 VDC, 8 mA approx
Start (54, 55) ........................................................................................................................................................ Normally Open
Stop (56, 57) ...................................................................................................................................................... Normally Closed
Reset (58, 57) .................................................................................................................................................... Normally Closed
Programmable input (53, 55) ....................................................................................................................... Normally Open
Motor thermistor (64, 65) ........................................................................................................ Trip >3.6 kΩ, reset <1.6kΩ
Outputs
Relay outputs ........................................................................... 10A @ 250 VAC resistive, 5A @ 250 VAC AC15 pf 0.3
Programmable outputs
Relay A (13, 14) .................................................................................................................................... Normally Open
Relay B (21, 22, 24) ...................................................................................................................................... Changeover
Relay C (33, 34) .......................................................................................................................................... Normally Open
Analog output (40, 41) ................................................................................................ 0-20 mA or 4-20 mA (selectable)
Maximum load ...................................................................................................................... 600 Ω(12 VDC @ 20 mA)
Accuracy ........................................................................................................................................................................... ± 5%
24 VDC output (55, 41)
Maximum load ......................................................................................................................................................... 200 mA
Accuracy ........................................................................................................................................................................ ± 10%
Environmental
Protection
QLxxB0023D ~ QLxxB0105D ..................................................................................................................................... IP20
QLxxB0145D ~ QLxxX1600D ..................................................................................................................................... IP00
Operating temperature .......................................................................... -10 ˚C to 60 ˚C, above 40 ˚C with derating
Storage temperature ................................................................................................................................... -25 °C to + 60 °C
Operating Altitude ....................................................................................... 0 - 1000 m, above 1000 m with derating
Humidity ................................................................................................................................. 5% to 95% Relative Humidity
Pollution degree ......................................................................................................................................... Pollution Degree 3
Vibration (QLxxB0023D ~ QLxxB1000D) ............................................................................................... IEC 60068-2-6

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DET-812
Heat Dissipation
During Start ........................................................................................................................................... 4.5 watts per ampere
During Run
QLxxB0023D ~ QLxxB0053D ....................................................................................................... ≤39 watts approx
QLxxB0076D ~ QLxxB0105D ....................................................................................................... ≤51 watts approx
QLxxB0145D ~ QLxxB0220D ..................................................................................................... ≤120 watts approx
QLxxB0255D ~ QLxxB0500D ..................................................................................................... ≤140 watts approx
QLxxB0580D ~ QLxxB1000D ..................................................................................................... ≤357 watts approx
QLxxX0255D ~ QLxxX1600D ................................................................................ 4.5 watts per ampere approx
Certification
C.............................................................................................................................................................................. IEC 60947-4-2
CE ............................................................................................................................................................................. IEC 60947-4-2
RoHS .................................................................................................................. Compliant with EU Directive 2002/95/EC
CCC (pending) ............................................................................................................................................................... GB 14048.6
GOST (pending) ................................................................................................................................... GOST R 50030.4.1-2002
Marine (pending) ............................................ Lloyds Marine No 1 Specification, ABS: 2010 Steel Vessels Rules
UL / C-UL (pending) ............................................................................................................................................................ UL 508*
QLxxB0023D ~ QLxxB0425D, QLxxX0255D ~ QLxxX1600D .................................................................. UL Listed
QLxxB0500D ~ QLxxB1000D .................................................................................................................... UL Recognised
* For UL certification additional requirements may apply, depending on the models. For details, see UL
Compliant Installation.
4.5 UL Compliant Installation
This section details additional requirements and configuration settings for the ASTAT XL soft starters to
be UL-compliant. See also UL Fuse Selection and Short Circuit Ratings on page 80.
4.5.1 Models QLxxB0023D ~ QLxxB0105D
There is no additional requirement for these models.
4.5.2 Models QLxxB0145D ~ QLxxB0220D
•Use with finger guard kit part no. 995-09452-00.
•Use the recommended pressure terminal/connector kit. See Terminal/Connector Kit on page 15 for
more information.
4.5.3 Models QLxxB0255D ~ QLxxB0425D
•Use with finger guard kit part no. 995-14791-00.
•Use the recommended pressure terminal/connector kit. See Terminal/Connector Kit on page 15 for
more information.
4.5.4 Models QLxxX0255D
•Use the recommended pressure terminal/connector kit. See Terminal/Connector Kit on page 15 for
more information.
4.5.5 Models QLxxX0360D ~ QLxxX1600D
•Configure the busbars for line / load terminals at opposite ends of the soft starter (i.e. Top In,
Bottom Out or Top Out, Bottom In).
•Use the recommended pressure terminal/connector kit. See Terminal/Connector Kit on page 15 for
more information.
4.5.6 Models QLxxB0500D ~ QLxxB1000D
These models are UL recognised components. Separate cable landing busbars may be required within
the electrical cabinet when terminating cables sized according to the National Wiring Code (NEC)
regulations.

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15
4.5.7 Terminal/Connector Parts
For models QLxxB0145D~QLxxB0425D and QLxxX0255D~QLxxX1600D to be UL compliant, you must
use the recommended pressure terminal/connector as detailed in the table below.
Model
FLC (A)
No. of wires
Recommended lugs part No.
QLxxB0145D
145
1
OPHD 95-16
QLxxB0170D
170
1
OPHD 120-16
QLxxB0200D
200
1
OPHD 150-16
QLxxB0220D
220
1
OPHD 185-16
QLxxB0255D
255
1
OPHD 240-20
QLxxB0350D
350
1
OPHD 400-16
QLxxB0425D
425
2
OPHD 185-16
QLxxX0255D
255
1
OPHD 240-20
QLxxX0360D
360
2
1 x 600T-2
QLxxX0380D
380
QLxxX0430D
430
QLxxX0620D
620
QLxxX0650D
650
QLxxX0790D
790
4
2 x 600T-2
QLxxX0930D
930
3
2 x 600T-2
QLxxX1200D
1200
4
1 x 750T-4
QLxxX1410D
1410
QLxxX1600D
1600
5
1 x 750T-4 and
1 x 600T-3

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DET-812
5Installation
5.1 Physical Installation
1
4
3
2
2
1/L1 5/ L33/L 2
2/T1 6/ T34/T 2
1/L1 5/ L33/L 2
2/T1 6/ T34/T 2
B
1/L15/L3
3/
L2
2/T16/T3
4/
T2
1/ L 1 5/ L33 /L 2
1
QLxxB0023D ~ QLxxB0220D: Allow 100 mm (3.94
inches) between soft starters.
QLxxB0255D ~ QLxxB1000D: Allow 200 mm (7.88
inches) between soft starters.
QLxxX0255D: Allow 100 mm (3.94 inches) between
soft starters.
QLxxX0360D ~ QLxxX1600D: Allow 200 mm (7.88
inches) between soft starters.
2
QLxxB0023D ~ QLxxB0220D: Allow 50 mm (1.97
inches) between the soft starter and solid surfaces.
QLxxB0255D ~ QLxxB1000D: Allow 200 mm (7.88
inches) between the soft starter and solid surfaces.
QLxxX0255D: Allow 100 mm (3.94 inches) between
the soft starter and solid surfaces.
QLxxX0360D ~ QLxxX1600D: Allow 200 mm (7.88
inches) between the soft starter and solid surfaces.
3
Soft starters may be mounted side by side with no
clearance (that is, if mounted without
communications modules).
4
The soft starter may be mounted on its side. Derate
the soft starter's rated current by 15%.
5.2 Control Terminals
Control terminations use 2.5mm2plug-in terminal blocks. Unplug each block, complete the wiring, then
reinsert the block.
1314 21 2224 33 34
40 41 53 54 55 56 57 58 64 65A4A5A6
5 4 3 2 1
9 8 7 6
A4 A5 A6 40 41 53 54 55 56 57 5 8 64 65
13 14 21 22 2 4 33 34
13 14 21 22 24 33 34
40 41 53 54 55 56 57 58 64 65
A4 A5 A6
5 4 3 2 1
9 8 7 6
5 4 3 2 1
9 8 7 6
1
2
3
4
1
2
3
4
1
Relay outputs
4
Inputs and outputs
13, 14
Relay output A
54, 55
Start
21, 22, 24
Relay output B
56, 57
Stop
33, 34
Relay output C
58, 57
Reset
2
Control voltage (model dependent)
53, 55
Programmable input A
A5, A6
110~120 VAC
64, 65
Motor thermistor input
A4, A6
220~240 VAC
40, 41
Analog output
A5, A6
24 VAC/VDC
55, 41
24 VDC output
3
DB9 connector for remote control panel
NOTE
If you are not using a thermistor, do not short terminals 64, 65.
NOTE
The DB9 connector on the soft starter should only be used to connect to a remote control

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17
panel. Connecting other equipment to this port can damage the soft starter or the
equipment.
5.3 Control Wiring
The ASTAT XL 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).
1
A
B
A B
C
A
B
C
C
2 3
57
56
55
54
58
57
56
55
54
58
57
56
55
54
58
08721.B
1
Two-wire control
2
Three-wire control
3
Four-wire control
A
Start
B
Stop
C
Reset
CAUTION
Do not apply voltage to the control input terminals. These are active 24 VDC inputs and
must be controlled with potential free contacts.
Cables to the control inputs must be segregated from mains voltage and motor cabling.
5.4 Relay Outputs
The ASTAT XL has three programmable relay outputs.
Operation of the programmable outputs is determined by the settings of parameters 7A~7I.
•If assigned to Main Contactor, the output activates as soon as the soft starter receives a start
command and remains active while the soft starter is controlling the motor (until the motor starts a
coast to stop, or until the end of a soft stop).
•If assigned to Run, the output activates when the soft start is complete (when the starting current
falls below 120% of the programmed motor full load current) and remains closed until the
beginning of a stop (either soft stop or coast to stop).
•If assigned to a trip function, the output activates when a trip occurs.
•If assigned to a flag, the output activates when the specified flag is active (parameters 7J~7L).
CAUTION
Some electronic contactor coils are not suitable for direct switching with PCB mount relays.
Consult the contactor manufacturer/supplier to confirm suitability. See also ASTAT XL Output
Relay Compatibility on page 82 for more information.
5.5 Motor Thermistors
Motor thermistors can be connected directly to the ASTAT XL. The soft starter will trip when the
resistance of the thermistor circuit exceeds approximately 3.6 kΩor falls below 20 Ω.
No motor thermistors
Motor thermistors
65
64
65
64
08722.A
Thermistor input
NOTE
If no motor thermistors are connected to the ASTAT XL thermistor input terminals 64, 65 must be
open. If 64, 65 are shorted, the ASTAT XL will trip.
The thermistor circuit should be run in screened cable and must be electrically isolated from
earth and all other power and control circuits.

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DET-812
5.6 Power Terminations
NOTE
For personnel safety, the power terminals on models up to QLxxB0105D 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.
Use only copper stranded or solid conductors, rated for 75 ºC or higher.
QLxxB0023D~QLxxB0105D
05966.E
Cable size:
6-50 mm2(AWG
10-1/0)
Torque: 4 Nm (2.9 ft-lb)
11290.A
14 mm (0.55 inch)
Torx T20 x 150
Flat 7 mm x 150
QLxxB0145D
QLxxB0170D~QLxxB0220D
QLxxB0255D
19 Nm (14.0 ft-lb)
38 Nm (28.0 ft-lb)
38 Nm (28.0 ft-lb)
6 mm19 mm
8.5 mm
(M8)
08351.B
08352.B
6 mm19 mm
10.5 mm
(M10)
5 mm
28 mm
11 mm
(M10)
13181.B
QLxxB0350D~QLxxB0425D
QLxxB0500D~QLxxB1000D
QLxxX0255D
38 Nm (28.0 ft-lb)
38 Nm (28.0 ft-lb)
38 Nm (28.0 ft-lb)
6 mm
28 mm
11 mm
(M10)
14543.A
13 mm
32 mm
11 mm
(M10)
0986 6.B
6 mm
32 mm
10.5 mm
(M10)
08353.B
QLxxX0360D~QLxxX0930D
QLxxX1200D~QLxxX1600D
38 Nm (28.0 ft-lb)
66 Nm (48.7 ft-lb)
13 mm32 mm
10.5 mm
(M10)
08354.B
16 mm51 mm
12.5 mm
(M12)
08355.B

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19
5.7 Power Input and Output Configurations
5.7.1 Internally Bypassed Models (QLxxB0023D~QLxxB1000D)
Models QLxxB0023D ~ QLxxB0220D have power inputs at the top of the unit and outputs at the bottom
of the unit.
Internally bypassed models QLxxB0255D ~ QLxxB0425D have output busbars at the bottom of the unit
and input busbars at both the top and bottom of the unit. The AC supply can be connected 'Top in,
Bottom out' or 'Bottom in, Bottom out'.
Internally bypassed models QLxxB0500D ~ QLxxB1000D have input and output busbars at the top and
bottom of the unit. The AC supply can be connected 'Top in, Bottom out', 'Top in, Top out', 'Bottom in,
Bottom out' or 'Bottom in, Top out'.
QLxxB0023D~
QLxxB0105D
QLxxB0145D~
QLxxB0220D
QLxxB0255D~
QLxxB0425D
QLxxB0500D~
QLxxB1000D
1/L1, 3/L2, 5/L3
2/T1, 4/T2, 6/T3
1/L1 3/L2 5/L3
2/T1 4/T2 6/T3
1/L1 3/L2 5/L3
2/T1 4/T2 6/T3
1/L1 3/L2 5/L3
2/T1 4/T2 6/T3
1/L1 3/L2 5/L3
1/L1 3/L2 5/L3
2/T1 4/T2 6/T3
15614 .A
Status Graphs Logs
Exit Enter
Menu
Local
Remote
Local
Ready
Run
Trip
Start
Reset
Stop
RemoteInputs
InputA Start Stop Reset
Status Graphs Logs
Exit Enter
Menu
Local
Remote
Local
Ready
Run
Trip
Start
Reset
Stop
RemoteInputs
InputA Start Stop Reset
Status Graphs Logs
Exit Enter
Menu
Local
Remote
Local
Ready
Run
Trip
Start
Reset
Stop
RemoteInputs
InputA Start Stop Reset
Status Graphs Logs
Exit Enter
Menu
Local
Remote
Local
Ready
Run
Trip
Start
Reset
Stop
RemoteInputs
InputA Start Stop Reset
5.7.2 Non-bypassed Model - QLxxX0255D
QLxxX0255D has dedicated bypass terminals at the bottom of the unit.
The bypass terminals are T1B, T2B, T3B.
15613.A
Status Graphs Logs
Exit Enter
Menu
Local
Remote
Local
Ready
Run
Trip
Start
Reset
Stop
RemoteInputs
InputA Start Stop Reset
1/L1 3/L2 5/L3
T1B T2B T3B
2/T1 4/T2 6/T3
5.7.3 Non-bypassed Models (QLxxX0360D~QLxxX1600D)
QLxxX0360D~QLxxX1600D have dedicated bypass terminals, on the input busbars. The bypass
terminals are L1B, L2B, L3B.
The busbars on non-bypassed models QLxxX0360D ~ QLxxX1600D can be adjusted for top or bottom
input and output as required. All units are manufactured top in/bottom out.
NOTE
For models QLxxX0360D ~ QLxxX1600D to be UL compliant, these must be mounted Top In,
Bottom Out or Top Out, Bottom In. See UL Compliant Installation on page 14 for more
information.

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DET-812
(L1B L2B L3B)
1/L1 3/L2 5/L3
2/T1 4/T2 6/T3
1/L1 3/L2 5/L3
(L1B L2B L3B)
2/T1 4/T2 6/T3
(L1B L2B L3B)
1/L1 3/L2 5/L3
2/T1 4/T2 6/T3
1/L1 3/L2 5/L3
(L1B L2B L3B)
2/T1 4/T2 6/T3
08723.D
5.8 Schematic Diagrams
Internally bypassed models
Non-bypassed models
22
21
6/T3
2/T1
13
14
4/T2
24
33
34
65
64
41
40
56
57
58
53
54
A6
A5
A4
5/L3
3/L2
55
PE
1/L1
24 VDC
200 mA
08724.B
+4
1
2
3
+
A
6/T3
2/T1
4/T2
5/L3
3/L2
1/L1
L3B
L2B
L1B
4
1
2
3
PE
55
A4
A5
A6
54
53
58
57
56
40
41
64
65
34
33
24
14
13
21
22
A
08725.B
*
*
*
+
+
24 VDC
200 mA
1
Control voltage (model dependent)
54, 55
Start
2
Remote control inputs
56, 57
Stop
3
Motor thermistor input
58, 57
Reset
4
Relay outputs
53, 55
Programmable input A
40, 41
Analog output
13, 14
Relay output A
55, 41
24 VDC output
21, 22, 24
Relay output B
33, 34
Relay output C