Santerno ASAB Technical specifications

INSTALLATION AND PROGRAMMING
INSTRUCTIONS
English
•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 from the use of non-original
spare parts.
•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, corrections will be included in 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.
Elettronica Santerno S.p.A.
S.S. Selice, 47 – 40026 Imola (BO) Italy
Tel. [phone] – Fax [phone]
www.santerno.com [email protected]
ASAB
ADVANCED SOFT STARTER
Issued on 22/05/13
R. 03
• 15P0078B1 •

ASAB
1/66
Contents
1About This Manual .....................................................................................................................................................3
2Caution Statements....................................................................................................................................................3
2.1 Electrical Shock Risk.....................................................................................................................................................................3
2.2 System Design and Safety of Personnel.......................................................................................................................................3
2.3 Disposal Instructions .....................................................................................................................................................................4
3Introduction ................................................................................................................................................................5
3.1 Feature List ...................................................................................................................................................................................5
3.2 Specifications ................................................................................................................................................................................5
4Installation ................................................................................................................................................................11
4.1 Physical Installation.....................................................................................................................................................................11
4.2 Control Terminals........................................................................................................................................................................11
4.3 Control Voltage............................................................................................................................................................................12
4.4 Control Wiring..............................................................................................................................................................................12
4.5 Relay Outputs..............................................................................................................................................................................12
4.6 Motor Thermistors .......................................................................................................................................................................12
4.7 Power Terminations ....................................................................................................................................................................13
4.8 Power Input and Output Configurations......................................................................................................................................14
4.9 Schematic Diagrams ...................................................................................................................................................................15
5Power Circuits ..........................................................................................................................................................16
5.1 Motor Connection........................................................................................................................................................................16
5.2 Bypass Contactor........................................................................................................................................................................19
5.3 Main Contactor............................................................................................................................................................................19
5.4 Circuit Breaker.............................................................................................................................................................................19
5.5 Earth Terminals...........................................................................................................................................................................19
5.6 Power Factor Correction .............................................................................................................................................................19
5.7 Power Supply Fuses ...................................................................................................................................................................19
6Operation ..................................................................................................................................................................24
6.1 Keypad and Feedback ................................................................................................................................................................24
6.2 Start, Stop and Reset Commands ..............................................................................................................................................26
6.3 Soft Start Methods.......................................................................................................................................................................26
6.4 Stop Methods ..............................................................................................................................................................................29
6.5 Jog Operation..............................................................................................................................................................................31
6.6 Inside Delta Operation ................................................................................................................................................................32
7Programming Menu..................................................................................................................................................33
7.1 Quick Setup.................................................................................................................................................................................34
7.2 Standard Menu............................................................................................................................................................................35
7.3 Extended Menu ...........................................................................................................................................................................36
7.4 Parameter Descriptions...............................................................................................................................................................38
7.5 Adjustment Lock..........................................................................................................................................................................49
7.6 Access Code ...............................................................................................................................................................................49
7.7 Setup Tools .................................................................................................................................................................................49
8Logs Menu ................................................................................................................................................................51
8.1 Trip Log .......................................................................................................................................................................................51
8.2 Event Log ....................................................................................................................................................................................51
8.3 Performance Counters ................................................................................................................................................................51
9Application Examples..............................................................................................................................................52
9.1 Installation with Main Contactor ..................................................................................................................................................52
9.2 Installation with Bypass Contactor ..............................................................................................................................................53
9.3 Emergency Run Operation..........................................................................................................................................................54
9.4 Auxiliary Trip Circuit ....................................................................................................................................................................55
9.5 DC Brake with External Zero Speed Sensor...............................................................................................................................56
9.6 Soft Braking.................................................................................................................................................................................57
9.7 Two Speed Motor........................................................................................................................................................................58
10 Troubleshooting.......................................................................................................................................................59

2/66
ASAB
10.1 Protection Responses .................................................................................................................................................................59
10.2 Trip Messages.............................................................................................................................................................................59
10.3 General Faults.............................................................................................................................................................................62
11 Accessories ..............................................................................................................................................................64
11.1 Communication Modules.............................................................................................................................................................64
11.2 Remote Control Panel (RCP)......................................................................................................................................................64
11.3 Finger Guard Kit..........................................................................................................................................................................64
11.4 PC Software ................................................................................................................................................................................64
12 Busbar Adjustment Procedure ...............................................................................................................................65

ASAB
3/66
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.
CAUTION
Indicates a hazard that may damage the equipment or installation.
NOTE
Provides helpful information.
2Caution Statements
This symbol is used throughout this manual to draw attention to topics of special importance to the installation and
operation of equipment.
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 ASAB 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 ASAB-0500B~ASAB-1600C: 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).
SHORT CIRCUIT
The ASAB is not short circuit proof. After severe overload or short circuit, the operation of the ASAB 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 ASAB 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.

4/66
ASAB
The system designer is responsible for ensuring that the complete system is safe and designed correctly according to the relevant safety
standards.
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.

ASAB
5/66
3Introduction
The ASAB is an advanced digital soft start solution for motors from 11 kW to 850 kW. ASAB soft starters provide a complete range of
motor and system protection features and have been designed for reliable performance in the most demanding installation situations.
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
 DeviceNet, Modbus, Profibus, Ethernet (Ethernet IP, Modbus
TCP, Profinet) or USB communication modules (optional)
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
3.2 Specifications
3.2.1 Model Code
ASAB-
–
–
–
Control voltage
12 = 110~120 VAC or 220~240 VAC
14 = 24 VAC/VDC
Mains voltage
5 = 200 ~ 525 VAC
7 = 380 ~ 690 VAC
Bypass
B = internally bypassed
C = non-bypassed (continuous connection)
Nominal current rating
3.2.2 Current Ratings
Contact your local supplier for ratings under operating conditions not covered by these ratings charts.
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 ASAB-0255C~ASAB-1600C must be externally bypassed.

6/66
ASAB
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
ASAB-0023B
23 A
20 A
17 A
15 A
ASAB-0043B
43 A
37 A
31 A
26 A
ASAB-0053B
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
ASAB-0076B
76 A
64 A
55 A
47 A
ASAB-0097B
97 A
82 A
69 A
58 A
ASAB-0100B
100 A
88 A
74 A
61 A
ASAB-0105B
105 A
105 A
95 A
78 A
ASAB-0145B
145 A
123 A
106 A
90 A
ASAB-0170B
170 A
145 A
121 A
97 A
ASAB-0200B
200 A
189 A
160 A
134 A
ASAB-0220B
220 A
210 A
178 A
148 A
ASAB-0255B
255 A
231 A
201 A
176 A
ASAB-0255C
255 A
231 A
201 A
176 A
ASAB-0350B
350 A
329 A
284 A
244 A
ASAB-0380C
380 A
380 A
359 A
299 A
ASAB-0425B
425 A
411 A
355 A
305 A
ASAB-0430C
430 A
430 A
368 A
309 A
ASAB-0500B
500 A
445 A
383 A
326 A
ASAB-0580B
580 A
492 A
425 A
364 A
ASAB-0620C
620 A
620 A
540 A
434 A
ASAB-0650C
650 A
650 A
561 A
455 A
ASAB-0700B
700 A
592 A
512 A
438 A
ASAB-0790C
790 A
790 A
714 A
579 A
ASAB-0820B
820 A
705 A
606 A
516 A
ASAB-0920B
920 A
804 A
684 A
571 A
ASAB-0930C
930 A
930 A
829 A
661 A
ASAB-1000B
1000 A
936 A
796 A
664 A
ASAB-1200C
1200 A
1200 A
1200 A
1071 A
ASAB-1410C
1410 A
1410 A
1319 A
1114 A
ASAB-1600C
1600 A
1600 A
1600 A
1353 A
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 40 ºC <1000
metres
AC53b 4.5-30:330
40 ºC <1000 metres
ASAB-0023B
34 A
30 A
26 A
22 A
ASAB-0043B
64 A
59 A
51 A
44 A
ASAB-0053B
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
ASAB-0076B
114 A
96 A
83 A
70 A
ASAB-0097B
145 A
123 A
104 A
87 A
ASAB-0100B
150 A
132 A
112 A
92 A
ASAB-0105B
157 A
157 A
143 A
117 A
ASAB-0145B
218 A
184 A
159 A
136 A
ASAB-0170B
255 A
217 A
181 A
146 A
ASAB-0200B
300 A
283 A
241 A
200 A
ASAB-0220B
330 A
315 A
268 A
223 A
ASAB-0255B
382 A
346 A
302 A
264 A
ASAB-0255C
382 A
346 A
302 A
264 A
ASAB-0350B
525 A
494 A
427 A
366 A
ASAB-0380C
570 A
570 A
539 A
449 A
ASAB-0425B
638 A
617 A
533 A
458 A
ASAB-0430C
645 A
645 A
552 A
464 A
ASAB-0500B
750 A
668 A
575 A
490 A

ASAB
7/66
ASAB-0580B
870 A
738 A
637 A
546 A
ASAB-0620C
930 A
930 A
810 A
651 A
ASAB-0650C
975 A
975 A
842 A
683 A
ASAB-0700B
1050 A
889 A
768 A
658 A
ASAB-0790C
1185 A
1185 A
1071 A
868 A
ASAB-0820B
1230 A
1058 A
910 A
774 A
ASAB-0920B
1380 A
1206 A
1026 A
857 A
ASAB-0930C
1395 A
1395 A
1244 A
992 A
ASAB-1000B
1500 A
1404 A
1194 A
997 A
ASAB-1200C
1800 A
1800 A
1800 A
1606 A
ASAB-1410C
2115 A
2115 A
1979 A
1671 A
ASAB-1600C
2400 A
2400 A
2400 A
2030 A
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
ASAB-0255C
255 A
222 A
195 A
171 A
ASAB-0380C
380 A
380 A
348 A
292 A
ASAB-0430C
430 A
413 A
355 A
301 A
ASAB-0620C
620 A
614 A
515 A
419 A
ASAB-0650C
650 A
629 A
532 A
437 A
ASAB-0790C
790 A
790 A
694 A
567 A
ASAB-0930C
930 A
930 A
800 A
644 A
ASAB-1200C
1200 A
1200 A
1135 A
983 A
ASAB-1410C
1410 A
1355 A
1187 A
1023 A
ASAB-1600C
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
ASAB-0255C
382 A
334 A
293 A
257 A
ASAB-0380C
570 A
570 A
522 A
437 A
ASAB-0430C
645 A
620 A
533 A
451 A
ASAB-0620C
930 A
920 A
773 A
628 A
ASAB-0650C
975 A
943 A
798 A
656 A
ASAB-0790C
1185 A
1185 A
1041 A
850 A
ASAB-0930C
1395 A
1395 A
1200 A
966 A
ASAB-1200C
1800 A
1800 A
1702 A
1474 A
ASAB-1410C
2115 A
2033 A
1780 A
1535 A
ASAB-1600C
2400 A
2400 A
2149 A
1840 A

8/66
ASAB
Minimum and Maximum Current Settings
The ASAB's minimum and maximum full load current settings depend on the model:
In-line connection
Inside delta connection
Model
Minimum
Maximum
Minimum
Maximum
ASAB-0023B
5 A
23 A
5 A
34 A
ASAB-0043B
9 A
43 A
9 A
64 A
ASAB-0053B
11 A
53 A
11 A
79 A
ASAB-0076B
15 A
76 A
15 A
114 A
ASAB-0097B
19 A
97 A
19 A
145 A
ASAB-0100B
20 A
100 A
20 A
150 A
ASAB-0105B
21 A
105 A
21 A
157 A
ASAB-0145B
29 A
145 A
29 A
217 A
ASAB-0170B
34 A
170 A
34 A
255 A
ASAB-0200B
40 A
200 A
40 A
300 A
ASAB-0220B
44 A
220 A
44 A
330 A
ASAB-0255B
51 A
255 A
51 A
382 A
ASAB-0255C
51 A
255 A
51 A
382 A
ASAB-0350B
70 A
350 A
70 A
525 A
ASAB-0380C
76 A
380 A
76 A
570 A
ASAB-0425B
85 A
425 A
85 A
638 A
ASAB-0430C
86 A
430 A
86 A
645 A
ASAB-0500B
100 A
500 A
100 A
750 A
ASAB-0580B
116 A
580 A
116 A
870 A
ASAB-0620C
124 A
620 A
124 A
930 A
ASAB-0650C
130 A
650 A
130 A
975 A
ASAB-0700B
140 A
700 A
140 A
1050 A
ASAB-0790C
158 A
790 A
158 A
1185 A
ASAB-0820B
164 A
820 A
164 A
1230 A
ASAB-0920B
184 A
920 A
184 A
1380 A
ASAB-0930C
186 A
930 A
186 A
1395 A
ASAB-1000B
200 A
1000 A
200 A
1500 A
ASAB-1200C
240 A
1200 A
240 A
1800 A
ASAB-1410C
282 A
1410 A
282 A
2115 A
ASAB-1600C
320 A
1600 A
320 A
2400 A

ASAB
9/66
3.2.3 Dimensions and Weights
E
087 18.E
A
C
D
B
E
A B
C
D
Model
A
mm (inch)
B
mm (inch)
C
mm (inch)
D
mm (inch)
E
mm (inch)
Weight
kg (lb)
ASAB-0023B
183
4.3
ASAB-0043B
(7.2)
(9.5)
ASAB-0053B
295
278
150
124
ASAB-0076B
(11.6)
(10.9)
(5.9)
(4.9)
4.5 (9.9)
ASAB-0097B
213
5.0
ASAB-0100B
(8.4)
(11.0)
ASAB-0105B
ASAB-0145B
ASAB-0170B
438
380
275
250
250
15
ASAB-0200B
(17.2)
(15.0)
(10.8)
(9.8)
(9.8)
(33.0)
ASAB-0220B
ASAB-0255B
440
392
424
376
296
26 (57.2)
ASAB-0350B
(17.3)
(15.4)
(16.7)
(14.8)
(11.7)
30.2
ASAB-0425B
(66.58)
ASAB-0500B
49.5
ASAB-0580B
(109.13)
ASAB-0700B
640
600
433
320
295
ASAB-0820B
(25.2)
(23.6)
(17.0)
(12.6)
(11.6)
60.0
ASAB-0920B
(132.3)
ASAB-1000B
ASAB-0255C
460 (18.1)
400 (15.7)
390 (15.4)
320 (12.6)
280 (11.0)
24 (52.9)
ASAB-0380C
ASAB-0430C
45.0
ASAB-0620C
689
522
430
320
300
(98.1)
ASAB-0650C
(27.1)
(20.6)
(16.9)
(12.6)
(11.8)
ASAB-0790C
ASAB-0930C
53.0 (116.8)
ASAB-1200C
856
727
585
500
364
117
ASAB-1410C
(33.7)
(28.6)
(23.0)
(19.7)
(14.3)
(257.9)
ASAB-1600C
130 (286.6)
3.2.4 Specifications
Supply
Mains voltage (L1, L2, L3)
5 ......................................................................................................................................................... 200 VAC ~ 525 VAC (± 10%)
7 .................................................................................................. 380 VAC ~ 600 VAC (± 10%) (in-line or inside delta connection)
7 ................................................................................................... 380 VAC ~ 690 VAC (± 10%) (earthed star supply system only)
Control voltage (A4, A5, A6)
12 ......................................................................................................... 110 ~ 120 VAC or 220 ~ 240 VAC (+ 10% / -15%), 600mA
14 ............................................................................................................................................................. 24 VAC/VDC ±20%, 2.8A