Santerno ASAC-0 User manual

- 15W0078B100 -
REMOTE OPERATOR
INSTRUCTIONS
FOR ASAC-0/ASAC-1
Issued on 15/02/17
R. 02
•This manual is integrant and essential to the product. Carefully read the instructions contained herein as
they provide important hints for use and maintenance safety.
•This device is to be used only for the purposes it has been designed to. Other uses should be considered
improper and dangerous. The manufacturer is not responsible for possible damages caused by improper,
erroneous and irrational uses.
•Elettronica Santerno is responsible for the device in its original setting.
•Any changes to the structure or operating cycle of the device must be performed or authorized by the
Engineering Department of Elettronica Santerno.
•Elettronica Santerno assumes no responsibility for the consequences resulting by the use of non-original
spareparts.
•Elettronica Santerno reserves the right to make any technical changes to this manual and to the device
without prior notice. If printing errors or similar are detected, the corrections will be included in the new
releases of the manual.
•The information contained herein is the property of Elettronica Santerno and cannot be reproduced.
Elettronica Santerno enforces its rights on the drawings and catalogues according to the law.
Contents
1Important User Information......................................................................................................................... 2
2General Description.................................................................................................................................... 3
3Installation .................................................................................................................................................. 4
4Specifications ............................................................................................................................................. 7
5Operation.................................................................................................................................................... 8
64-20 mA Analog Output.............................................................................................................................. 9
7Troubleshooting........................................................................................................................................ 11
Elettronica Santerno S.p.A.
Via della Concia 7, 40023 Castel Guelfo (BO) Italy
Tel. [phone] –Fax [phone]
www.santerno.com, [email protected]

1Important User Information
Observe all necessary safety precautions when controlling the soft starter remotely. Alert personnel that
machinery may start without warning.
It is the installer's responsibility to follow all instructions in this manual and to follow correct electrical practice.
Use all internationally recognised standard practice for RS-485 communications when installing and using this
equipment.
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.
2/12 Remote Operator

2General Description
The Remote Operator allows remote operation of the soft starter, and offers the following functionality:
•Operational control (Start, Stop, Reset, Quick Stop)
•Starter status monitoring (Ready, Starting, Running, Stopping, Tripped)
•Performance monitoring (motor current, motor temperature)
•Trip code display
•4-20 mA analog output (motor current)
•Optional RS485 network connection 1
1The Remote Operator can act as a gateway device for connection to an RS485 serial communications
network, allowing remote control of a motor using Modbus RTU or standard AP ASCII communications protocol.
For further information on Modbus control of a soft starter, please refer to the Modbus Module Instructions.
NOTE
In order to use the Remote Operator with ASAC starters, a Remote Operator Module or Modbus
Module must also be installed.
Remote Operator 3/12

3Installation
This section describes how to install the Remote Operator for basic control and monitoring of a soft starter. The
Remote Operator is pre-configured to control a soft starter once control supply power is applied to both devices.
For basic operation, no parameter adjustments are required on the Remote Operator or the soft starter.
In order to use the Remote Operator's 4-20 mA analog output to monitor motor current, follow the instructions in
the section 4-20 mA Analog Output on page 9.
3.1 Mounting
The Remote Operator is rated IP54 or NEMA 12 1when mounted correctly in accordance with these
instructions. It is intended for use on the flat surface of a panel, with all external wiring connected from behind
the panel.
The Remote Operator is supplied with a mounting bracket and four fasteners. The built-in gasket seal
guarantees protection from outside the panel.
Select the panel location of the Remote Operator. The required panel cutout is 92 mm x 92 mm. Place the
Remote Operator through the cutout and locate the mounting bracket at the rear of the panel onto the four
studs. Use the four fasteners to tighten the mounting bracket up to the rear of the panel.
1For use on a flat surface of a NEMA 1 or NEMA 12 enclosure.
1
2
4
3
Fasteners (x4)
Mounting bracket
Universal panel cutout (92 mm x 92 mm)
Remote Operator
3.2 Electrical Connections
The Remote Operator requires a minimum of three electrical connections - the external power supply, the
chassis earth and the RS485 Starter port. All external wiring, except the chassis earth (M4 stud provided), is
connected to spring operated clamp connector terminals with a maximum wire size of 2.5 mm2. No special tools
are required.
3.2.1 Grounding and Shielding
Twisted pair data cable with earth shield is recommended. The cable shield should be connected to the GND
device terminal at both ends and one point of the site protective earth.
3.2.2 Termination Resistors
In long cable runs prone to excessive noise interference, termination resistors should be installed between the
data lines at both ends of the RS-485 cable. This resistance should match the cable impedance (typically
120 Ω). Do not use wire wound resistors.
3.2.3 RS-485 Data Cable Connection
Daisy chain connection is recommended. This is achieved by parallel connections of the data cable at the
actual device terminals.
4/12 Remote Operator

3.2.4 Remote Operator RS-485 Network Connection Specifications
Input impedance: 12 kΩ
Common mode voltage range: - 7 V to + 12 V
Input sensitivity: ± 200 mV
Minimum differential output voltage: 1.5 V (with max loading of 54 Ω)
3.3 Soft starter connections
The Remote Operator connects to ASAC soft starters via a Remote Operator Module or Modbus Module.
1. Remove control power and mains
supply from the soft starter.
2. Fully pull out the top and bottom
retaining clips on the module.
3. Line up the module with the comms
port slot.
4. Push in the top and bottom retaining
clips to secure the module to the
starter.
5. Apply control power to the soft starter.
6. Connect the Remote Operator to the
module.
7. Apply control voltage to the Remote
Operator.
08477.A
CAUTION
Remove mains and control voltage from the soft starter before attaching or removing accessories.
Failure to do so may damage the equipment.
3.3.1 Connection
+ GND -
+ GND -
- GND + - GND ++ - ~/+ ~/-
1
2
4
3
ASAC
Remote Operator
Module – RS-485 serial port
B10, B11 - 4~20 mA analog output
B1, B2, B3 - RS-485 starter connection
B6, B7, B8 - RS-485 network connection
1, 2 - Supply voltage (18~30 VAC/VDC)
RS-485 Serial communication network
connection (Modbus RTU or AP ASCII)
ASAC: For the Remote Operator to accept fieldbus commands, a link must be fitted across terminals A1-02 on
the soft starter.
Remote Operator 5/12

3.3.2 Configuration
The DIP switches on the Modbus Module must be set as follows:
1 2 3 4 5 6
ON
1 2 3 4 5 6
ON
+16
+8
+4
+2
+1
0
0
0
0
0
11591.B
1
2
3
4
5
6
7
1
DIP Switch A
2
DIP Switch B
3
Protocol = AP ASCII
4
Address = 20
5
Baud Rate = 9600
6
Parity = No parity
7
Timeout = No timeout
The Remote Operator internal parameters must be set as follows:
Parameter 1 (RS485 network baud rate) = set to match Modbus master
Parameter 2 (RS485 network address) = unique number between 1 ~ 99
Parameter 3 (RS485 network timeout) = set as required
Parameter 4 (RS485 network protocol) = AP ASCII
6/12 Remote Operator

4Specifications
4.1 General Technical Data
Enclosure
Front Panel Height .................................................................................................................................. 120 mm
Front Panel Width .................................................................................................................................... 120 mm
Inside Panel Depth (when mounted) ............................................................................................... 30 mm (max)
Panel Cutout ........................................................................................................................................... 92 mm2
Weight ......................................................................................................................................................... 450 g
Power Supply
Voltage ................................................................................................................... 18 - 30 VDC/VAC (50/60 Hz)
Consumption ........................................................................................................... 100 mA (max - steady state)
Connection (Terminals 1, 2) ................................................................. 2 pole spring clamp connector terminals
RS485 Serial Network Port (Optional)
RS485 Network Interface .......................................................... AP ASCII or Modbus RTU protocol (selectable)
Connection (Terminals B6, B7, B8) ...................................................... 3 pole spring clamp connector terminals
RS485 Serial Starter Port (Soft Starter Connection)
RS485 Soft Starter Interface ............................................................................... AP ASCII protocol as standard
Connection (Terminals B1, B2, B3) ...................................................... 3 pole spring clamp connector terminals
Analog Output
Motor Current Monitoring Interface ....................................................................... 4-20 mA (max burden 200 Ω)
Connection (Terminals B10, B11) ........................................................ 2 pole spring clamp connector terminals
Sundry
Enclosure Rating ..................................................................... IP54 or NEMA 12 when correctly panel mounted
Pollution Degree ..................................................................................................................... Pollution Degree 3
Operating Temperature ................................................................................................................ - 5 oC / + 60 oC
Relative Humidity .............................................................................................. 5 to 95% (max non-condensing)
This product has been designed as Class A equipment. Use of this product in domestic environments may
cause radio interference, in which case the user may be required to employ additional mitigation methods.
Approvals
CE ................................................................................................................................................ EN 60947-4-2
UL / C-UL .................................................................................................................................................. UL 508
4.2 Dimensions
mm (inch)
120 (4.72) 37.5 (1.48)
7.0 (0.28)
AMPS
CODE
TEMP
START RUN TRIP RS485
START STOP
+
RESET
-
DATA
PROG
Remote Operator 7/12

5Operation
5.1 Operation
The Remote Operator performs all soft starter functions except programming of the soft starter. The Remote
Operator can only be used to program its own parameters.
03206.B
AMPS
CODE
TEMP
START RUN TRIPRS485
START STOP
+
RESET
-
DATA
PROG
1
2
4
3
Display: Indicates the value of the selected data.
Display mode indicator: Indicates the data type shown on
the display.
Status LEDs: Indicates the status of the starter and the
communication link.
Start (green): soft starter is starting, running or stopping
Run (green): soft starter is providing full voltage to the motor
Trip (red): soft starter has tripped
RS485 ON: the serial link between the Remote Operator
and the starter is healthy
RS485 FLASHING: communication between the Remote
Operator and the starter has been lost
Control buttons
Start: Starts the motor
Stop: Stops the motor 1
Reset: Resets the starter 1
Data/Prog: Selects the data type to be shown on the display
(motor current or motor temperature), or accesses
Programming Mode.
1Simultaneously pressing the STOP and RESET buttons initiates a quick stop, which immediately removes
voltage from the motor, ignoring any soft stop time set on the starter.
NOTE
Motor current and motor temperature information is only available from ASAC-1 starters. If connected
to a ASAC-0 open loop soft starter, the display will show 2222 instead of motor current and 1.11
instead of motor temperature.
5.2 Trip Codes
If the soft starter trips, the CODE and TRIP LEDs illuminate and the relevant trip code is reported on the
Remote Operator display.
Code
Description
1-1
Excess start time
1-2
Motor overload
1-3
Motor thermistor
1-4
Current imbalance
1-5
Frequency
1-6
Phase sequence
1-8
Power circuit
1-b
Bypass overload
1-C
Communications failure between module and starter
1-H
Forced communications trip from the network master
8/12 Remote Operator

64-20 mA Analog Output
6.1 Overview
The Remote Operator has a 4-20 mA analog output for monitoring motor current. The 4-20 mA output is
available on terminals B10, B11.
The analog output signal spans from 4 mA when the motor current is zero (when the soft starter is not running)
to 20 mA when the motor current is 125% of the Motor FLC setting in the Remote Operator (parameter 6).
NOTE
The 4-20 mA output only operates when the Remote Operator is connected to ASAC-1 soft starters.
6.2 Calibration
The Remote Operator Motor FLC parameter (parameter 6) must be adjusted to match the Motor FLC setting in
the soft starter.
The lower end of the analog output signal can be calibrated using the Remote Operator Analog Output 4 mA
Offset parameter (parameter 7). This is set to give a 4 mA output signal when the motor current is zero.
The 4-20 mA analog output has an accuracy of ±10%. It is not designed for process signal control and should
only be used for motor current monitoring and metering.
NOTE
The analog output uses only one Motor FLC setting. This function is not suitable for applications
using two motor parameter sets.
6.3 Programming
When the 4-20 mA output is being used, the Remote Operator's Motor FLC and Analog Output 4 mA Offset
parameters (Parameters 6 and 7) must be set appropriately (see Calibration). Programming can only be
carried out while the soft starter is not running.
6.3.1 Programming Procedure
1. To enter Programming Mode, hold down the Data/Prog pushbutton for four seconds. The default value of
the first parameter will be displayed.
2. Use the Data/Prog pushbutton to advance to the next parameter.
3. Use the Stop and Reset pushbuttons to adjust parameter values.
Programming Mode closes when the Data/Prog pushbutton is pressed after parameter 9.
NOTE
There is a 20 second timeout when the Remote Operator is in Programming Mode. Programming
Mode will automatically close if no input is registered for 20 seconds. Any changes already made
will be saved.
Remote Operator 9/12

6.3.2 Programmable Parameters
The Remote Operator offers the following programmable parameters:
Parameters 1 to 5 only apply when the Remote Operator is being used as a Modbus or AP ASCII network
gateway.
Parameter
Number
Description
Default
Setting
Adjustable Range
1
RS485 network
baud rate
4
(9600 baud)
2 = 2400 baud
3 = 4800 baud
4 = 9600 baud
5 = 19200 baud
6 = 38400 baud
2
RS485 network
satellite
address
20
1 to 99
3
RS485 network
timeout
0 seconds
(= off)
0 to 100 seconds
4
RS485 network
protocol
1
(AP ASCII)
1 = AP ASCII protocol
2 = Modbus RTU protocol
5
Modbus
protocol parity
0
(no parity)
0 = no parity
1 = odd parity
2 = even parity
3 = 10-bit transmission
6
Motor FLC (A)
10
1 to 2868
7
Analog output
4 mA offset (%)
100
80 to 120
8
Start, Stop,
Quick stop
function disable
0
0 = Remote Operator and Network start, stop, quick stop function
enabled.
1 = Remote Operator start, stop, quick stop function enabled.
Network start, stop, quick stop function disabled. 2
2 = Remote Operator start, stop, quick stop function disabled.
Network start, stop, quick stop function enabled. 1
3 = Remote Operator start, stop, quick stop function disabled.
Network start, stop, quick stop function disabled.
1, 2
9
Reserved
0
0 = off (default)
1Remote Operator Reset pushbutton is always enabled.
2RS485 Network reset and forced communication trip functions are always enabled.
10/12 Remote Operator

7Troubleshooting
7.1 General Faults
Display Indication
Problem
Possible Solution
No display
No control voltage
Check that correct voltage is present at terminals
1, 2.
AMPS or TEMP
LED flashing
Soft starter in restart delay
mode
Wait for the restart delay (programmed in the
soft starter) to elapse.
Four dashes on display
and RS485 LED flashing
The Remote Operator has
detected a loss of
communication on the RS485
link to the soft starter
Verify and solve the cause for loss of
communication.
If communication is restored before the soft
starter trips, the display will return to active
status and the RS485 LED will illuminate. If
communication is restored after the soft starter
has tripped, the display will indicate the trip code.
Use the Reset button to reset the soft starter
fault.
-
Incorrect or no 4-20 mA analog
output signal
•
Check the correct voltage is present at
terminals 1, 2.
•Check that correct polarity is used at
terminals B10, B11.
•Check that the Motor FLC, Analog Output 4
mA Offset and Current ÷10 parameters are
set correctly.
-
The motor cannot be started
•
Check that control voltage is connected to
the soft starter.
•Check that terminals A1-02 on the ASAC
soft starter are linked.
Parameter 8 on the Remote Operator must be
set to 0 or 1.
Remote Operator 11/12

12/12 Remote Operator