ASAC USER MANUAL - BCH Electric Limited
Contents
1. Standard Optional 2 3 Part Number Format PI L Control Supply Voltage 1 110 240 VAC amp 380 440 VAC 2 24VAC VDC Supply Voltage 4 200 VAC 440 5 200 VAC 575 Nominal kW Rating 400 VAC AC53b 4 6 354 Motor Protection 0 Without motor protection 1 With motor protection Overload Phase Loss Excess Start Time Phase Rotation Motor Thermistor 4 2 15P0071B5 INSTALLATION GUIDE 3 SPECIFICATIONS 3 1 CURRENT RATINGS ASAC SOFT STARTER Maximum overload 400 FLC Maximum overload 450 FLC AC53b 4 6 354 1000 metres AC53b 4 20 340 1000 metres FLC FLC ASAC 007 18A 17A ASAC 015 34A 30A ASAC 018 42A 36A ASAC 022 48A 40A ASAC 030 60A 49A AC53b 4 6 594 1000 metres AC53b 4 20 580 1000 metres ASAC 037 75 65 ASAC 045 85 73A ASAC 055 100A 96A ASAC 075 140A 120A ASAC 090 170A 142A ASAC 110 200A 165A FLC maximum motor Full Load Current AC53 b Utilization Category Format 90 A AC 53b 3 5 15 345 Off Time seconds Start Time seconds Start Current multiple of FLC Starter Current Rating amperes Starter Current Rating The Full Load Current rating of the soft starter given the parameters detailed in the remaining sections of the utilization code Start Current The2. 022 550 3 6 Power terminators xxx Blade Refer Ferraz for options 007 030 10 35 8 2 10 35 8 2 11 1 12 3 13 5 11 2 2 4 T3 6 mm AWG 14 0 55 mm inch 037 055 075 110 11 0 43 26 08 5 1 02 0 33 mm inch mm inch 1 2 01 02 4 B5 13 14 23 24 mm AWG 007 110 D t1 I 0 24 mm inch Torx T20 3 5Nm 2 2 3 7 ft lb Torx T20 4 6 Nm 2 9 4 4 ft Ib 3 5Nm 2 2 3 7 ft lb 75 C Wire Use copper conductors only 7mm 4 6Nm 2 9 4 4 ft lb 9 3 15 0071 5 ASAC SOFT STARTER INSTALLATION GUIDE 3 7 General Technical Data Mains supply L1 L2 L3 ASAC xxx 4 x 3 x 200 440 10 15 ASAC xxx 5 x 3 x 200 575 10 15 Supply frequency eei ee Cete ea edo nt st 45Hz to 66 Hz Rated insulation voltage e AR Rae PER Made ge RERUM UEM 600 VAC Rated impulse withstand voltage 2222 2 0000 4 kV 1 2 50us at 2000 m Form designation c ee ee eene ee e pe Bypassed semiconductor motor starter form 1 Control supply A1 A2 A3 ASAGhOOUXI T eicit ri edet 110 240VAC 41096 15 or 380 440
3. ASCII to binary Left shift 2 to last byte 4 bits Add to last byte to get binary LRC Remove last two bytes from message Add remaining bytes of message Add binary LRC Round to one byte The result should be zero Response or status bytes are sent from the ASAC Remote Operator as an ASCII string STX d1 h 91 30h 92 30h d2 h d4 h LRC1 LRC2 03 30h plus upper nibble of status byte right shifted by four binary places d4 30h plus lower nibble of status byte For example status byte 1Fh response is 30h 31h 46h LRC1 LRC2 STX 30h 29 29 15 0071 5 ASAC SOFT STARTER INSTALLATION GUIDE 6 13 4 20mA Output The ASAC Remote Operator has a 4 20 mA analogue output for monitoring motor current CAUTION The 4 20mA output is operational only when the Remote Operator is connected to ASAC 1 models Calibration ASAC Remote Operator Motor FLC parameter Par 6 must be adjusted to match the Motor FLC setting in the soft starter The 4 mA end of the analogue output signal can be calibrated using the Remote Operator Analogue Output 4 mA Offset parameter Par 7 This is set to give a 4 mA output signal when the motor current is zero Refer section 6 10 for the adjustment procedure The analogue output signal spans from 4 mA when the motor current is zero ie soft starter is not running to 20 mA when the motor current is 12596 of the Motor FLC setting in the Remote Operator par
4. GLO OP ERATIONS rt RER EM RIP 6 4 Trip Codes 6 5 Overview 6 6 08 6 7 General Technical Data 6 8 Dimensions 6 9 COMME CUON REM RP RE 6 10 Configurations rete RN RU EHE IRR ect adnate ee ree I OE ee 6 11 Modbus 6 12 AP ASCII Protocol 6 13 4 20mA Output 6 14Trouble Shooting 6 14 1 General Faults 7 MOBBUS INTERFACES ha eee he Gaede eae FENCE IER 7 2 Adjustment 7 3 Connection 7 4 Modbus register 7 5 Modbushex Functions 7 6 Network status led 8 OTHERS ACCESSORIES g Mei M EMI EE 8 2 Profibus Module 8 3 DeviceNet Module 8 4 AS Module idc ere Dette o eade dett des O BG SET D P SOETWARE erra er E eset eee re au D ct EU re UL p Lice 2 2 15 0071 5 ASAC SOFT STARTER INSTALLATION GUIDE 1 CAUTION STATEMENTS This symbol is used throughout this manual to draw attention to topics of special importance to the installation and operation of the ASAC Series soft starter Caution Statements cannot cover every potential cause of equipment damage but can highlight common causes of damage It is therefore the installer s respo
5. STARTER INSTALLATION GUIDE 4 5 Trimmin EL Start Voltage Local Reset n h Optional Accessory Connection Port Initial Start Voltage Ue o 2 P 2 D 3 5 3 Start Ramp ty second ti 105 as 18 12 Ue d s 4s hes 1 5 gps Voltage Start Stop Ramp Time Time is mm um oya um 6 O 0 Stop Ramp Time 12 seconds t2 88 108 12 Ue 4 6 Led LLL Siatus Ready Run Off No control power Motor not running On Ready Motor running at full speed Flash Starter tripped Motor starting or stopping 4 7 Diagnostic trip codes Description Ready LED Power Circuit Check mains supply L1 L2 amp L3 motor circuit T1 T2 amp T3 soft starter SOR Supply Frequency Check supply frequency is in range Network Comms Failure between accessory module and network Check network connections and settings Starter Comms Failure between starter and accessory module Remove and refit accessory module 14 10 15 0071 5 ASAC SOFT STARTER INSTALLATION GUIDE 5 ASAC 1 SERIES 5 1 Overview ASAC 1 starter provide current limit soft start soft stop and a range of motor protection functions 5 2 Electrical schematics Example 1 ASAC 1 Series starter installed with system protection circuit breaker complete with a shunt trip device 1 Auxillary Rdily Functi
6. assembled into complete messages as described in the sections that follow CAUTION Data transmitted to and from the ASAC Remote Operator must be in 8 bit ASCII no parity 1 stop bit Message Fragment Type Send Address ASCII Character String or Hexadecimal Character String EOT nn Irc ENQ or 04h nn Irc 05h ST ccc Irc or 02h ccc Irc 03 ddddl Irc or 02h dddd Irc 03h 5555 Irc or 02h 5555 Irc 03 06 15h BEL or Send Command Send Request Receive Data Receive Status ACK acknowledge NAK negative acknowledge ERR error 07h nn two byte ASCII number representing the soft starter address where each decimal digit is represented by n Irc two byte longitudinal redundancy check in hexadecimal three ASCII command number where each character is represented by dddd four byte ASCII number representing the current or temperature data where each decimal digit is represented by d 5555 four byte ASCII number The first two bytes ASCII zero The last two bytes represent the nibbles of a single byte of status data in hexadecimal Commands Commands can be sent to the ASAC Remote Operator using the following format Send sen Address ces Command Possible error responses Inval
7. maximum available start current given the parameters detailed in the remaining sections of the utilisation code Start Time The maximum available start time given the parameters detailed in the remaining sections of the utilisation code Off Time The minimum allowable time between the end of one start and the beginning of the next start given the parameters detailed in the remaining sections of the utilisation code Contact your local supplier ratings under operating conditions not covered by the above ratings charts 5 3 15P0071B5 INSTALLATION GUIDE 3 2 APPLICABLE MOTOR RATINGS Soft Starter Model SAC 0 ASAC 1 SAC 0 ASAC 1 SAC 0 ASAC 1 SAC 0 ASAC 1 SAC 0 ASAC 1 SAC 0 ASAC 1 SAC 0 ASAC 1 SAC 0 ASAC 1 SAC 0 ASAC 1 SAC 0 ASAC 1 SAC 0 ASAC 1 00 01 01 02 03 03 04 05 7 9 11 0 0 Soft starter power supply TA 5 8 2 0 T 5 5 5 200 240Vac k pU RC fe 55 1 W 5 2 11 11 15 2 2 0 5 55 55 ASAC SOFT STARTER Applicable motor power 380 415Vac kW 2 2 15 22 30 37 45 55 75 10 200 440Vac 460 575Vac FLC maximum motor Full Load Current at 40 C environmental temperature 6 2 15 0071 5 ASAC SOFT STARTER INSTALLATION GUIDE 3 3 Dimensions amp Weights ASAC 0 007 ASAC 0 030 2 0kg ASAC 1 007 ASAC 1 030 2 1kg 188 740 203 7 99 23 23 09 09 ASAC 0 0
8. the ASAC Remote Operator the unit must be powered up with the soft starter in the off mode Programming Procedure 1 Enter program mode by holding down the DATA PROG pushbutton for 4 seconds The value of the first parameter will be displayed 2 If required adjust the parameter value using the START 4 and or STOP pushbuttons 3 Confirm the setting and move to the next parameter by pressing the DATA PROG pushbutton 4 Repeat steps 2 amp 3 until all parameters have been set The ASAC Remote Operator will automatically exit programming mode when the last parameter value has been set or if the if the keypad is left inactive for more than 20 seconds Parameter Description Default Setting Adjustable Range 1 RS485 Network 4 9600 baud 2 2400 baud Baud Rate 4800 baud 4 9600 5 19200 baud 6 38400 baud 2 RS485 Network 20 1 to 99 Satellite Address 3 RS485 Network 0 seconds 0 100 seconds Time Out off 4 RS485 Network 1 AP ASCII 1 AP ASCII protocol Protocol 2 Modbus RTU protocol 5 Modbus Protocol 0 no parity 0 no parity Parity 1 odd parity 2 even parity 6 Motor FLC 10A 1to 2868 A 7 Analogue Output 10096 80 to 12096 4mA Offset 25 25 15 0071 5 ASAC SOFT STARTER INSTALLATION GUIDE 6 11 Modbus RTU Only available ENIES Function Type Description from ASAC 1 units 40002 Command Write 1 Start 2 Stop 3 Reset 4 Quick
9. 37 ASAC 0 055 4 0kg ASAC 1 037 ASAC 1 055 4 3kg 193 7 60 196 7 71 215 8 46 110 5 4 35 7 3 15 0071 5 ASAC SOFT STARTER INSTALLATION GUIDE 5 0 075 ASAC 0 110 6 1kg ASAC 1 075 ASAC 1 110 6 8kg 214 8 43 240 9 45 114 5 4 5 3 4 Mounting AN VULT min 100 50 3 94 1 97 7 Lil EN E Eu A Derate ASAC FLC by 15 TN ii min 50 1 97 8 2 15 0071 5 INSTALLATION GUIDE 3 5 Fuses The fuses can be used with the ASAC Series soft starter to reduce the potential for damage to SCRs from transient overload currents and for Type 2 coordination Suitable Bussman amp Ferraz semiconductor fuses are detailed below ASAC SOFT STARTER ASAC SCR Ft European IEC Style Bussman Fuse Model 25 North American Style 007 1150 UD in 170 13 14 50 015 8000 170M 13 17 100 018 10500 170M 13 18 125 A 022 15000 170 13 18 125 030 18000 R 170M 13 19 16 0 007 51200 1 170M 13 21 250 045 80000 170 13 21 250 055 97000 dE E 170M 13 21 250 A 075 168000 RE E 170M 13 22 3 15 030 245000 RASA 170M 3 022 550 A 110 320000 AR 170M 3
10. AC SERIES REMOTE OPERATOR RS485 SERIAL COMMS Al NETWORK CONNECTION 201 Modbus RTU ASCII 02 4 dp REMOTE INTERFACE NN LED N RS485 4 20mA RS485 RS485 POWER yer SERIAL PORT STARTER NETWORK SUPPLY GND GND4 B3 B2 B10 B11 Bt B2 B3 B6 B7 B8 1 2 o 1 i NL E 4 20 SUPPLY VOLTAGE 5485 SERIAL COMMS ANALOGUE OUTPUT 18 30VAC DC NETWORK CONNECTION MOTOR CURRENT Modbus RTU or AP ASCII Grounding and Shielding Twisted pair data cable with earth shield is recommended The cable shield should be connected to a GND device terminal at both ends and one point of the site protective earth Termination Resistors In long cable runs prone to excessive noise interference termination resistors should be installed This resistance should match the cable impedance typically 120 Do not use wire wound resistors RS485 Data Cable Connection Daisy chain connection is recommended This is achieved by parallel connections of the data cable at the actual device terminals Remote Operator RS485 Network Connection Specifications Input Impedance 12 KW Common Mode Voltage range 7 to 12 V Input Sensitivity 200 mV Minimum Differential Output Voltage 1 5 V with max loading of 54 24 18 15 0071 5 INSTALLATION GUIDE ASAC SOFT STARTER 6 10 Configuration The ASAC Remote Operator must be configured to operate on the network When configuring
11. AC SOFT STARTER INSTALLATION GUIDE 7 6 Network status led Network LED OFF ON FLASH No connection Healthy communications Communication failure communications are restored the Network Status LED will cease flashing When a communications failure occurs the ASAC will trip if the communication time out function has been set When communications are restored the ASAC will require CAUTION When communications failure occurs the Network Status LED will flash When an independent reset CAUTION 35 35 15 0071 5 ASAC SOFT STARTER INSTALLATION GUIDE 8 OTHERS ACCESSORIES 8 1 Overview The ASAC Series includes a range of others accessories including Profibus Interface DeviceNet Interface ASi Interface PC Set up Software The accessory items interface with the ASAC Series starters by way of plug in module 35 mm 1 38 starters before attachment or removal of accessory items Failure to do so may Control power and mains supply must be removed from the ASAC Series soft AX CAUTION result in equipment damage 8 2 Profibus Module Part Number ZZ The Profibus Module can be used with both ASAC 0 and ASAC 1 models enable control and monitoring via a Profibus network Available 4nd Q uarter 2004 8 3 DeviceNet Module Part Number 270071001 The DeviceNet Module can be used with both ASAC 0 an
12. LC w s ASAC FLC 60 D 50 100 Current Ramp Current Ramp 1 Ramp Time Ig ty Seconds e Ee 2s 55 1 o 28 AEA gt eX 5s Qs 15 OFF E Current Limit 350 300 400 200 Is 0 Metor Trip Class d 1055 Cold Start Curves ASAC SOFT STARTER Local Reset Soft Stop Time Stop Time t seconds 8s 10S 1 6s 145 45 165 25 20s Soft Stop Optional Accessory Connection Port Excess Start Time 7 Excess max 400 13 seconds Ig 200 i E Phase sequence Protection WD Sequence i OQ E nid ANY ANY Lt gt ASAC 1 1000 1012 Auxiliary Relay 2 gg 20 Function 100 F IN 20 10 Class 20 i Trip Run i Aux Relay Class 10 1 1 RUN Too 300 500 600 700 1 FLC Trip Fault OFF No overload protection gg m Phase Phase Sequence ANY Sequence FWD UNE ANY SANT ruv P dun rupe 17 11 15 0071 5 ASAC SOFT STARTER INSTALLATION GUIDE Trip Run Trip un AuxRelay Trip AuxRelay Run 18 10 15 0071 5 ASAC SOFT STARTER INSTALLATION GUIDE 5 7 Led 7 Bu amp XNX LED RARE Status Ready Run Off No control power Motor not running On Ready M
13. Statements Piae E A aad 2 1 OVERVIEW PH iden 2 2 Feature list 2 3 Part Number Format 3 SPECIFICATIONS 3 SPECIFICATIONS 3 1 CURRENT RATINGS 3 2 APPLICABLE MOTOR RATINGS 9 3 Dimensions amp Weights a reed a Oed te E deep Perseo eee Pe e een tente dace eins 3 4 2 2 222 3 5 F SES inet 3 6 Power terminators 3 7 General Technical Data 4 ASAC 0 4 1 OVerVIeW eit erf ote he Es D eth Loess ks cette cla dozen 4 2 bs da be oak Ee edu se 4 3 Control voltage 4 4 Control circuits 4 7 Diagnostic trip codes BrASAG AUSERIES LEM E cor cee E E E M etui Siete e LN OVERVIC Wisse RM HP M Pc E 5 2 Electrical schematics 5 3 Control voltage 5 4 GOhltFOl CIFGUIES Coes chad a aded eoe uu itai Rada 5 5 Motor thermistor 5 6 TRIMMING 5 7 1 Diagnostic Trip codes 6 REMOTE OPERATOR 6 1 Installation 6 2 Connection
14. Stop 5 Forced Comms Trip MODBUS HEX 40003 Starter Status Read Bit Description Functions 0 3 O Not used 1 Ready Two functions are 2 Starting supported 3 Running 03 Multiple Read 4 Stopping 06 Single write 6 Tripped The ASAC Series 4 1 Forward Phase Sequence does not accept 5 Unallocated broadcast functions 6 Unallocated 7 Unallocated 40004 Trip Code Read 255 No Trip 1 Excess start time 2 Motor overload 3 Motor thermistor 4 Phase imbalance 5 Supply frequency 6 sequence 8 Power circuit 16 Comms failure 40005 Current Read 1 40006 Temp Read 1 CAUTION Command Starter Status Trip Code Current and Temperature must be sent individually ie one data word request at a time Examples Command Start Function Register Address 40002 CRC1 CRC2 40002 1 CRC1 CRC2 O Starter Status ASAC Running Function Address Bytes Read Number 03 40003 1 CRC1 CRC2 Out 20 03 2 0011 CRC1 CRC2 26 18 15 0071 5 ASAC SOFT STARTER INSTALLATION GUIDE Trip Code Motor overload Function Code Bytes Read Number Address 20 03 0 1 CRC1 CRC2 20 03 2 CRC1 CRC2 6 12 AP ASCII Protocol The details of the message fragments used in communicating with the ASAC Remote Operator are shown in the table below The message fragments may be
15. U protocol selectable Connection Terminals B6 B7 B8 3 pole spring clamp connector terminals RS485 Serial Starter Port Soft Starter Connection RS485 Soft Starter Interface Connection Terminals B1 B2 B3 AP ASCII protocol as standard 3 pole spring clamp connector terminals Analogue Output Motor Current Monitoring Interface 4 20 mA max burden 200 Connection Terminals B10 B11 2 pole spring clamp connector terminals Enclosure Rating IP54 or NEMA 12 when correctly panel mounted Pollution degree Pollution Degree 3 Operating Temperature 5 C 60 C Relative Humidity 5 95 max condensing This product has been designed for environment A Use of this product in environment B may cause unwanted electromagnetic disturbances in which case the user may be required to take adequate mitigation measures Standards Approvals CE IEC 60947 4 2 UL and C UL UL 508 C IEC 60947 4 2 23 23 15 0071 5 ASAC SOFT STARTER INSTALLATION GUIDE 6 8 Dimensions 7 8 c d Om Ll Ce Osm Oe OF amp 3 EEE Le 128 75 6 9 Connection This section details how to connect the ASAC Remote Operator to a RS485 serial communications network using either AP ASCII or Modbus RTU protocols AS
16. VAC 10 15 ASAOIXXXIXID ait nre d au eA 24 VAC VDC 20 Control Inputs Start Terminal NT tenete D PUR eet ete a Autun Normally Open 300 VAC max Stop Termin l IN2 ooo oit doe rete ror ec beers Normally Closed 300 VAC max Relay Outputs Main Contactor Terminals 13 amp 14 Normally Open 6 A 30 VDC resistive 2 A 400 VAC AC11 Programmable Relay Terminals 23 82 Normally Open 6 A 30 VDC resistive 2 A 400 VAC AC11 Environmental Degree of protection ASAC 007 to ASAC 055 IP20 Degree of protection ASAC 075 to ASAC 110 nen 00 Operating 2 2 12 ci ceded aae nn Eae 10 C to 60 C EE 5 to 95 Relative Humidity Pollution Degree sirosis cities Mi ei m TH oh Pollution Degree 3 IEC 60068 Test Fc Sinusoidal 4Hz to 13 2Hz 1mm displacement 13 2Hz to 200Hz 0 70 Vibration EMC Emission Equipmentsclass EMC ein EE REPE BE etta e MES Class A Conducted radio frequency emission 2 0 15 MHz to 0 5 MHz 90dB uV 0 5 MHz to 5 MHz lt 76dB uV 5 MHz to 30 MHz 80 60dB uV Radiated radio frequency emission 30 MHz to 230 MHz 30dB uV m 230 MHz to 1000 MHz 37dB uV m This product has been designed for Class A equipme
17. ameter 6 The 4 20 mA analogue output must only be used for motor current monitoring and metering It is not designed for process signal control use 30 18 15P0071B5 INSTALLATION GUIDE 6 14Trouble Shooting 6 14 1 GENERAL FAULTS Indication No display Problem No control supply voltage ASAC SOFT STARTER Possible Solution Check that correct voltage is present at terminals 1 and 2 Four dashes on display and RS485 LED flashing A loss of communication has been detected on the RS485 link to the soft starter Verify and solve the cause for loss of communication If communication is restored before a soft starter RS485 Time Out trip the display will regain active status and the RS485 LED will illuminate If communication is restored after a soft starter RS485 Time Out trip the display will indicate a trip code Use the Reset pushbutton to reset the soft starter fault nEt on display A loss of communication has been detected on the RS485 link to the network Incorrect or no 4 20 mA analogue output signal The Remote Operator has RS485 Network Time Out Protection setting Parameter 3 This mode is entered when loss of communication is longer than this time setting If communication is restored the system becomes active again To clear nEt on the display press the DATA PROG pushbutton momentarily Check the correct voltage is present at terminals 1 and 2 Check that correct pol
18. amp temperature ASAC Trip Code Display 4 20mA Output motor current ASAC 1 models only The ASAC Remote Operator can also acts as a gateway device for connection to a Modbus RTU or AP ASCII network 6 6 Warnings The Remote Operator allows remote operation of the soft starter Observe all necessary safety precautions when controlling the soft starter remotely Alert personnel that machinery may start without Warning It is the installers responsibility to follow all instructions in this manual and to follow correct electrical practice Use all International recognised standard practice for RS485 communications when installing and using this equipment Users are cautioned that 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 22 18 15 0071 5 ASAC SOFT STARTER INSTALLATION GUIDE 6 7 General Technical Data Front Panel Height 120 mm Front Panel Width 120 mm Inside Panel Depth when mounted 30 mm max Panel Cut out 92 mm Weight 4504 Power Supply Voltage 18 30 V DC or 50 60Hz Consumption 250 mA max Connection Terminals 1 2 2 pole spring clamp connector terminals RS485 Serial Network Port This Network Connection is Optional RS485 Network Interface AP ASCII or Modbus RT
19. arity is used at terminals B10 and B11 Check that Motor FLC and Analogue Output 4 mA Offset parameters are set correctly The motor cannot be started Check that control voltage is connected to the ASAC and that terminals 01 and 02 are linked and connected to A1 31 31 15 0071 5 ASAC SOFT STARTER INSTALLATION GUIDE 7 MODBUS INTERFACE Part number ZZ0071000 7 1 Installation 35 mm 1 38inches Control power and mains supply must be removed from the ASAC before CAUTION attachment or removal of accessory modules Failure to do so may result in equipment damage 7 2 Adiustment AP ASI Protocol d Examp Address 24 2 16 OF 0 8 Oo gt Address 4 Oo O 32 gt Z PL o ON EN 22 Rate O C OFF 2 5 No Parity ODI Parity OFF OFF 1 olg ON rjoevLI No Timg Out 105 Time OFF ON 32 18 15 0071 5 ASAC SOFT STARTER INSTALLATION GUIDE 7 3 Connection ASAC SERIES Ai No 01 REMOTE INTERFACE RS485 SERIAL PORT GND B3 B2 B1 Q 7 4 Modbus register 1 Only available from Address Function Type Description ASAC 1 units 40002 Command Writ
20. d ASAC 1 models enable control and monitoring via a DeviceNet network Available 4nd Q uarter 2004 8 4 AS i Module Part Number ZZ The AS i Module can be used with both ASAC 0 and ASAC 1 models enable control and monitoring via a AS i network Available 4nd Q uarter 2004 36 18 15 0071 5 ASAC SOFT STARTER INSTALLATION GUIDE 9 PC SET UP SOFTWARE The PC Set Up Software can be used with ASAC 0 ASAC 1 and ASA soft starters to provide the following functionality for networks of up to 99 soft starters Feature ASAC 0 ASAC 1 ASA Operational Control start stop reset quick stop Status monitoring ready starting running stopping tripped Performance monitoring motor current motor temperature Upload parameter settings Download parameter settings System Requirements An x86 based personal computer 486 minimum Pentium or Pentium Pro Pentium recommended A hard disk with 6 megabytes of free space A Microsoft Mouse or other compatible pointing device An EGA VGA or compatible display VGA or higher is recommended 32 MB of random access memory 48 MB recommended Microsoft Windows 95 98 2000 and Windows NT or later An RS485 communication port or RS232 to RS485 converter Additionally each ASAC Series soft start connected to the network must be fitted with an MODBUS Module ZZ0071000 37 37
21. d to be used with an external motor protection device 4 2 Electrical schematics Example 1 ASAC 0 Series starter installed with a motor protection circuit breaker ERN ud Example 3 ASAC 0 Series starter installed with system protection circuit breaker separate overload and line contactor 12 10 15 0071 5 ASAC SOFT STARTER INSTALLATION GUIDE 4 3 Control voltage ASAC 0 Series be supplied in either of two control voltage configurations ASAC 0 xxx x 1 110 240 10 15 or 38 0 440 VAC 10 15 ASAC 0 xxx x 2 24 VACIVDC 20 ASAC xxx 2 1 110 240 24 VAC VDC 10 15 20 c 2 380 440 VAC 41096 15 WARNIG Always apply control voltage before or with mains voltage 4 4 Control circuits 2 Wire 3 Wire o 110 240 VAC 1 models 110 240 1 models lo A1 24 VAC VDC 2 models A2 24 VACNDC 2 models Sr 1 A20 START 01 STOP o o 02 02 Te A3 bLA 380 440 VAC 1 models Al 380 440 VAC 1 models Ai A2 sanr 7 2 START 01 STOP x2 02 o 02 Also resets trip states CAUTION W ith 24Vac Vdc use contacts rated for low voltage and low current godl flash or similar 13 11 15 0071 5 ASAC SOFT
22. e 1 Start 2 Stop 3 Reset 4 Quick Stop 5 Forced Comms Trip 40003 Starter Status Read Bit Description 0 3 OzNot used 1 Ready 2 Starting 3 Running 4 Stopping 6 Tripped 1 Forward Phase Rotation Unallocated Unallocated Unallocated 40004 Trip Code Read 255 No Trip 0 Shorted SCR 1 Excess start time 2 Motor overload 3 Motor thermistor 4 Phase imbalance 5 Supply frequency 6 Phase sequence 8 Power circuit 16 Comms failure 1 NY OJA 40005 Current Read 40006 Temp Read 1 33 33 15 0071 5 ASAC SOFT STARTER INSTALLATION GUIDE 7 5 Modbushex Functions Two functions are supported 03 Multiple Read 06 Single write The ASAC Series does not accept broadcast functions CAUTION Command Starter Status Trip Code Current and Temperature must be sent individually ie one data word request at a time Examples Command Start 0 28 26 g 8 238 58 83 G S 9 ue ca In 20 06 40002 1 CRC1 CRC2 Out 20 06 40002 1 CRC1 CRC2 Starter Status ASAC Running o el 8 88 8 SS Q 59 56 58 ES S lt lt gt 2 In 20 03 40003 1 CRC1 CRC2 Out 20 03 2 0011 CRC1 CRC2 Trip Code Motor overload KD a T ya 8 8 8 a Eal Sel z zo dem 2 In 20 03 40004 1 CRC1 CRC2 Out 20 03 2 00000010 CRC1 CRC2 34 18 15P0071B5 AS
23. e 15P0071B5 o ASAC COMPACT SOFT STARTER USER MANUAL OPERATION GUIDE Agg 05 07 04 j ES English e 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 e 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 BCH ELECTRIC LTD 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 BCH ELECTRIC LTD e BCH ELECTRIC LTD assumes no responsibility for the consequences resulting by the use of non original spare parts e BCH ELECTRIC LTD 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 BCH ELECTRIC LTD is responsible for the information contained in the original version of the Italian manual e The information contained herein is the property of BCH ELECTRIC LTD and cannot be reproduced BCH ELECTRIC LTD enforces its rights on the drawings and catalogues according to the law 15 0071 5 ASAC SOFT STARTER INSTALLATION GUIDE INDEX 1 Caution
24. es soft starter contains dangerous voltages when connected to line DANGER voltage Only a competent electrician should carry out the electrical installation Improper installation of the motor or the ASAC may cause equipment failure serious injury or death Follow this manual IEC rules and local safety codes SHORT CIRCUIT CAUTION The ASAC is not short circuit proof Therefore after severe overload or short circuit the operation of the starter should be fully tested 3 3 15 0071 5 ASAC SOFT STARTER INSTALLATION GUIDE 2 SERIES OVERVIEW 2 1 OVERVIEW The ASAC Series comprises two separate ranges ASAC 0 and ASAC 1 These ranges share common power and mechanical designs but offer different features sets These ranges include an internal bypass function that bypass the soft starter SCRs during run This allows the ASAC to be installed in a non ventilated enclosure without the need for an external bypass contactor 2 2 Feature list Feature ASAC 0 ASAC 1 Starting Timed Voltage Ramp Current Limit Current Ramp Stopping Coast To Stop Soft Stop Protection Motor Overload Phase Loss Excess Start Time Phase Sequence Motor Thermistor Power Circuit Fault Supply Frequency Communications Failure Interface Fixed Relay Output Main Contactor Relay Programmable Relay Trip or Run Accessories Remote Operator MODBUS Interface Profibus Interface DeviceNet Interface AS I Interface PC Set up Software
25. id LRC 1 1 Slave ASAC 0 ASAC 1 L 27 27 15 0071 5 INSTALLATION GUIDE ASAC SOFT STARTER Command ASC Start B10 Initiates a start Stop B12 Initiates a stop Reset B14 Resets a trip state Coast to stop B16 Initiates an immediate removal of voltage from the motor Any soft stop settings are ignored Forced comms trip B18 Causes a communications trip Status retrieval Starter status can be retrieved from the ASAC Remote Operator using the following format Send Send Receive sis Possible error responses Invalid LRC Master Slave ASAC 0 ASAC 1 Request Trip Code Starter Status ASC C18 C22 Receive Status ssss Requests the trip status of the ASAC 0 ASAC 1 255 Notrip 1 Excess start time 2 Motor overload 3 Motor thermistor 4 Phase imbalance Supply frequency 6 Phase sequence Electronic shearpin Power circuit fault 16 Comms failure 1 ASAC 1 models only Bit No Description 0 3 Not used 1 Waiting 2 Starting incl Pre start tests Running 4 Stopping 6 Tripped 4 1 Forward phase sequence detected 5 Unallocated 6 Unallocated 7 Unallocated Data retrieval Data can be retrieved from the ASAC 1 Series soft starter via the ASAC Remote Operator using the following format Send Send 1 Receive dul Pale Possible err
26. nsibility to adhere to all instructions in this manual to follow good electrical practice and to seek advice before operating this equipment in a manner other than as detailed in this manual e Ensure that the ASAC is completely isolated from the power supply before attempting any work on the unit e Do not apply incorrect voltages to the control input terminals e Ensure cables to the control inputs are segregated from AC power and control wiring e Some electronic contactor coils are not suitable for direct switching with PCB mount relays Consult the contactor manufacturer supplier to see if this is advisable e Do not connect Power Factor Correction capacitors to the output of ASAC Series soft starters If static power factor correction is employed it must be connected to the supply side of the soft starter The examples and diagrams in this manual are included solely for illustrative purposes Users are cautioned that 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 or indirect or consequential damages resulting from the use or application of this equipment GROUNDING AND BRANCH CIRCUIT PROTECTION CAUTION It is the responsibility of the user or person installing the ASAC to provide proper grounding and branch circuit protection according to the IEC rules and local codes WARNING ELECTRICAL SHOCK HAZARD ASAC Seri
27. nt Use of the product in domestic environments may cause radio interference in which case the user may be required to employ additional mitigation methods EMC Immunity Electro st tic discharge sr ren rm ente Ee EP e 4 kV contact discharge 8 kV air discharge Radio frequency electromagnetic field 28 0 15 MHz to 1000 MHz 140dB pV Fast transients 5 50 ns Main amp control circuits 022000000 000000 eene enne enne 2 kV 5 0 kHz Surges 1 2 50 ys 8 20 ms Main amp control circuits 7 2 kV line to earth 1 kV line to line Voltage dip and short time interruption seseeenm eeaeae 5000 ms at 096 nominal voltage 10 10 15 0071 5 ASAC SOFT STARTER INSTALLATION GUIDE Short Circuit Rated short circuit current ASAC 007 to 037 5 kA Rated short circuit current ASAC 045 to ASAC 110 10 kA During Start 2 ee etg ee ee A EE ERE ER erat he AYER ERR prt adus 3 watts Ampere D ring RUN lt 4 watts E IEC 60947 4 2 ULZGUL UL508 GE n ER IEC 60947 4 2 elc EET PR GB 14048 6 11 11 15 0071 5 ASAC SOFT STARTER INSTALLATION GUIDE 4 ASAC 0 SERIES 4 1 Overview 5 0 starters provide soft start and soft stop control They are designe
28. on Trip Example 2 ASAC 1 Series starter installed with a system protection circuit breaker and line contactor m ee p amp 1 1 2171 a 3 L2 9 E a 41 5 Motor 2 s 5 L3 ema 13 8 1 5 3 Control voltage ASAC 1 Series can be supplied in either of two control voltage configurations 1 1 110 240 10 15 or 38 0 440 VAC 10 15 ASAC 1 xxx x 2 24 VAC VDC 20 ASAC xxx 2 1 40 110 240 VAC 24 VAC VDC 10 15 20 5 A2 380 440 VAC 10 15 9 WARNIG Always apply control voltage before or with mains voltage 15 11 15 0071 5 ASAC SOFT STARTER INSTALLATION GUIDE 5 4 Control circuits 2 Wire 3 Wire 110 240 VAC 1 models OR 24 VAC VDC 2 models 110 240 VAC 1 models OR 24 VAC VDC 2 models 380 440 VAC 1 models 380 440 1 models Also resets trip states CAUTION W ith 24Vac Vdc use contacts rated for low voltage and low current flash or similar 5 5 Motor thermistor Motor thermistors if any can be connected directly to the ASAC 1 terminals B4 amp B5 If no motor thermistors are connected there must be a link between B4 amp B5 o B4 B4 4 5 5 5 16 10 15 0071 5 INSTALLATION GUIDE 5 6 TRIMMING Motor Motor FLC Starter FLC Motor F
29. or responses lt Invalid LRC Master Slave ASAC 1 28 18 15P0071B5 INSTALLATION GUIDE ASAC SOFT STARTER Request ASCII Receive Data Current D10 Requests motor current The data is 4 byte decimal ASCII Minimum value 0000 A maximum value 9999 A Temperature D12 Requests the calculated value of the motor thermal model as a of Motor Thermal Capacity The data is 4 byte decimal ASCII Minimum value 000095 Trip point 010596 Calculating the check sum LRC Each command string sent to and from the ASAC Remote Operator includes a check sum The form used is the Longitudinal Redundancy Check LRC in ASCII hex This is an 8 bit binary number represented and transmitted as two ASCII hexadecimal characters To calculate LRC 1 Sum all ASCII bytes 2 Mod 256 3 2 s complement 4 ASCII convert For example Command String Start B 1 0 42h 31h 30h ASCII Hex Binary ASCII STX or 02h STX 02h B 42h 1 31h 0 30h A5h A5h 5Ah 01h 5Bh ASCII 5 or 35h 0000 0010 0100 0010 0011 0001 0011 0000 1010 0101 1010 0101 0101 1010 0000 0001 0101 1011 B 42h SUM 1 MOD 256 2 1 s COMPLEMENT 1 2 s COMPLEMENT 3 ASCII CONVERT 4 LRC CHECKSUM The complete command string becomes 1 ASCII 02h B 0 5 B ETX 42h 31h 30h 35h 42h 03h To verify a received message containing an LRC cc Convert last two bytes of message from
30. otor running at full speed Flash Starter tripped Motor starting or stopping 1 e Qn 5 7 1 Diagnostic Trip codes Ready LED Description 1 T2 8 T3 and soft starter SCRs Excess Start Time setting restart Soft starter cannot be reset until motor has cooled adequately Motor Thermistor Check motor ventilation and thermistor connection B4 amp B5 Allow motor to cool Phase Imbalance Check line current L1 L2 amp L3 Supply Frequency Check supply frequency is in range Phase Sequence Check for correct phase sequence Network Comms Failure between accessory module and network Check network connections and settings Starter Comms Failure between starter accessory module 9 Remove refit accessory module ous Motor Overload Allow motor to cool reset soft starter and x2 3 4 19 19 15 0071 5 ASAC SOFT STARTER INSTALLATION GUIDE 6 REMOTE OPERATOR Part number ZZ0071700 REMOTE OPERATOR Part number ZZ0071003 Remote operator interface module AP ASCII Part number 220071004 Kit Remote operator interface module AP ASCII REMOTE OPERATOR The Basic Set up Procedure describes the installation and connection procedures required for basic control and remote indication of ASAC Series soft starters To make use of the more advanced ASAC Remote Operator functions consult the other sections of this manual 6 1 Installation ASAC Remote Ope
31. rator Interface Module 1 Connect the ASAC Remote Operator Interface Module to the ASAC soft starter Control power and mains supply must be removed from the ASAC before CAUTION attachment or removal of accessory modules Failure to do so may result in equipment damage 2 Cut a 92mm hole in the panel and fit the ASAC Remote Operator 3 Wire between the Remote Operator and ASAC as shown below 6 2 Connection ASAC SERIES REMOTE OPERATOR 01 02 nn RS485 420mA RS485 RS485 SERIAL PORT STARTER NETWORK SUPPLY 4 GND atu GND 4 B3 B2 B1 B10 B11 B1 B2 B3 Be B7 B8 1 2 2 5 o o olg q t Ww Ww E SUPPLY VOLTAGE ANALOGUE OUTPUT 18 30VAC DC MOTOR CURRENT First application of control voltage to the ASAC will start the motor Operational CAUTION control is then possible via the ASAC Remote Operator Ensure it is safe to start the motor when implementing the circuit above 20 18 15 0071 5 ASAC SOFT STARTER INSTALLATION GUIDE 6 3 OPERATION Display Display Mode Oaurs O TEMP Qrwe Status LEDs DATA PROG Start Push Stop Push Button Data Prog Push Button Reset Push Button Start Push Button Starts the motor Stop Push Button Stops the motor Reset Push Button Rese
32. ts the ASAC Data Prog Push Button Select the data type to be shown on the display Motor Current or Motor Temperature Display Mode Indicates data type shown on the display Motor Current Motor Temperature Trip Code Display Indicates the value of the currently selected data Motor current and motor temperature are only available when the Remote Operator is N CAUTION connected to ASAC 1 models If connected to a ASAC 0 model the display will be show 1 11 instead of motor temperature and 2222 instead of motor current Status LEDs Indicates status of the ASAC and the RS485 link between the Remote Operator and ASAC Simultaneously pressing the Stop and Reset pushbuttons initiates a quick stop which CAUTION immediately removes voltage from the motor ignoring any soft stop time set on the ASAC soft starter 21 21 15 0071 5 ASAC SOFT STARTER INSTALLATION GUIDE 6 4 Trip Codes Description ASAC 0 ASAC 1 Excess Start Time Motor Overload Motor Thermistor Phase Imbalance Supply Frequency Phase Sequence Power Circuit Communications Failure A do ro 6 5 Overview The ASAC Remote Operator can control and monitor ASAC Series soft starter performance Functionality includes Push Button Control Start Stop Quick Stop amp Reset ASAC Status LEDs Start Run amp Trip Communication Status LED Motor Data Display motor current
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