ASAC-1 User Manual EN
Contents
1. 15P0071B600 ASAC 1 SOFT STARTER Issued on 20 12 14 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 1 GALTON SEATSIM a seccccie E AEN EEE E 2 2 Mechanical Installation 2 1 Dimensions and Weights 2 2 eae dats 3 3 Electrical Installation i2. Allow 50 mm 2 0 inch between the soft starter and solid surfaces ASAC 1 075 ASAC 1 110 Allow 200 mm 7 9 inch between the soft starter and solid surfaces Soft starters may be mounted side by side with no clearance that is if mounted without communications modules The soft starter may be mounted on its side Derate the soft starter s rated current by 15 Electrical Installation Power Terminations 10 35 i 8 2 Torx T20 3Nm 2 2 ft lb 7mm 3Nm 2 2 ft lb Control Voltages LAM L2 3 L3 5 T112 72 4 T3 6 M1 A2 A3 01 02 B4 B5 mm AWG 13 14 23 24 mm AWG 007 030 037 055 075 110 007 110 25 50 A 9 014 1 4 1 10 lt 02 0 33 7 eee i 6mm 55i 0 24 inch Torx T20 4Nm 2 9 ft lb 7mm A 4Nm 0 5 Nm max 2 9 ft lb 4 4 in lb max ASAC 1 soft starters can be supplied in either of two control voltage configurations ASAC 1 xxx xx 1 110 240 VAC 10 15 ASAC 1 xxx xx 2 24 VAC VDC 20 WARNING or 380 440 VAC 10 15 Always apply control voltage before or with mains voltage With 24 VAC VDC use contacts rated for low voltage and low current gold flash or similar A CAUTION ASAC 1 3 12 3 3 3 3 1 3 4 3 4 1 3 4 2 Z SANTERNO CARRARO GROUP Control Circuits Two wire Three wire o A3 1
3. running On Ready Motor running at full speed Flash Starter tripped Motor starting or stopping 19 Ei eee 14249 Lf Trip Codes The Ready LED will flash a different number of times to indicate the cause of the trip Description Power Circuit Check mains supply L1 L2 L3 motor circuit T2 T3 soft starter SCRs and bypass relays j x lt wa Excess Start Time Check load increase Current Limit or adjust Excess Start Time setting x N wa Motor Overload Allow motor to cool reset soft starter and restart The soft starter cannot be reset until the motor has cooled x ed Motor Thermistor Check motor ventilation and thermistor connection B4 B5 Allow motor to cool x lt A wa x lt Current imbalance Check for mains supply or line current imbalance L1 L2 L3 a Supply Frequency Check mains voltage is available and supply frequency is in range x D wa Phase sequence Check for correct phase sequence x lt wa Network Communication Failure between module and network Check network connections settings and configuration x lt O Starter Communication Failure between starter and module Remove and refit accessory module rs n Bypass Overloa
4. 10 240 VAC 75 110 240 VAC 8 8 24 2 24 0 01 reg 02 9 380 440 VAC Al 380 440 VAC 2 o o 01 1 eG 02 x Start stop To reset a trip open then close 02 Stop To reset a trip open then close 02 Motor Thermistor Motor thermistors can be connected directly to the ASAC 1 terminals B4 B5 If motor thermistors are not used there must be a link between B4 B5 the ASAC 1 is supplied with a link fitted B4 B5 x 03247 A WARNING Isolate the ASAC 1 completely from the power supply before attempting any work on the ASAC 1 or motor Control terminals may be at phase voltage potential CAUTION For ASAC 1 xxx x 2 24VAC VDC control voltage units you can connect an external 24 VDC supply into the control input terminals 01 02 Outputs Main Contactor Output The Main Contactor output terminals 13 14 closes as soon as the soft starter receives a start command and remains closed while the soft starter is controlling the motor until the motor starts a coast to stop or until the end of a soft stop The Main Contactor output will also open if the soft starter trips The Main Contactor output can be used to directly control a main contactor coil Programmable Output The programmable output relay terminals 23 24 can be used to signal either trip or run status This relay is normally open Trip The relay closes when the ASAC 1 trips
5. ALOMN Bypassed semiconductor motor starter form 1 Control Voltage A1 A2 A3 ASAC VRON tae hee he dae 110 240 VAC 10 15 or 380 440 VAC 10 15 24 VACIVDC 20 Current consumption during run oo eeseececceseesecessesecsessescesesneeeesesaeeceansseenesnsneesensesesensesesenseseesenseteaseuseeeessneeeeiesneensansaseneaneateesanes lt 100 mA Current consumption inrush eee 10A 2 Inputs Stark terminal OT Normally open 150 300 VAC and 5 6 24 VAC VDC SLOP termnalQ2 des E E ERS Normally closed sania 150 300 VAC and 5 6 24 VAC VDC Outputs Main contactor relay terminals 13 14 c eececcesessecsesseseceseseesesseeeeaesseeesansaeeesansseecssnseeessanseeeesenseeeessnseteassnseteassnseeeisenseteenenees Normally open RO E 6 A 30 VDC 6 A 250 VAC resistive Programmable relay terminals 23 24 c c csccsssssssesesesesseecesesseeseseeseesesneneeseaneaeeseseeaeeeseeseesssesseeessusseeessuseteassaseteasseeeteensnees Normally open 6 A 30 VDC 6 A 250 VAC resistive Environmental Degree of Protec
6. The relay can be used to operate the shunt trip mechanism of an upstream circuit breaker in order to isolate the motor branch circuit or to signal the trip to an automation system or externally The relay will open when the trip is reset Run The relay operates when the soft start is complete the bypass relays are closed and full voltage is being applied to the motor The relay can be used to operate a contactor for power factor correction capacitors or to signal soft starter run status to an automation system 4 12 ASAC 1 Z SANTERNO CARRARO GROUP 3 5 Electrical Schematics Soft starter installed with a system protection circuit breaker Soft starter installed with a system protection circuit breaker and complete with a shunt trip device main contactor 1 L1 2 71 a a x l 3 L2 4 T2 3 L2_p ee 4 2 8 o o AR M L T 58 6 T3 A ed l Go 1 Do T5 13 5 Paes Le 23 Ki 23 5 l M Motor three phase Main contactor 13 14 Main contactor output 23 24 Programmable output set to Trip 4 Adjustments Auxiliary Relay Function 6 Phase Sequence Protection 1 Current Ramp phie Select the initial start current A and ramp time B i
7. aN Current ramp starting extends the time soft starter takes to sell Mis reach the current limit and is suitable for generator set supplies loads requiring an extended start time or applications OFF 9 with extreme load variation between starts The ramp time does not control the time the motor will take to reach full speed 2 Current Limit 350 Select the current limit C 300 a 400 lt The current limit is the maximum level of current the soft starter will deliver to the motor during the soft start 250 450 03383 B ASAC 1 5 12 Z SANTERNO CARRARO GROUP Motor Trip Class 8 10 45 Select the trip class for motor overload protection Cold start curves Gy The trip class reflects the maximum time in seconds that the 4 motor can run at locked rotor current The Motor Trip Class 2 of 2 setting assumes a locked rotor current of 600 04975 A Setting the motor trip class to Off disables motor overload 44 Class 20 protection i 5006b0 700 FLC Motor FLC 70 80 Configure the soft starter to match the motor s full load current ay FLC Motor FLC 5 Configure according to the motor s nameplate current Divide Soft starter FLC 50 100 the motor s FLC by the soft starter s maximum current rating on the soft starter s nameplate label RMS 600 VAC max 2AWG 6 35 rm2 3 5 Nm 22437 lb ft 16 AWG 0 75 1 5 mm2 0 5 Nm 45 Ibin 2 B Soft St
8. ampere A ee 10 watts typical 10 12 ASAC 1 7 3 SANTERNO CARRARO GROUP Approvals CY eee IEC 60947 4 2 GE A IEC 60947 4 2 EAC formerly GOST ain 004 2011 ROMO Compliant with EU Directive 2002 95 EC WCHL aE aaie Eae S Ra UL 508 Operational Life ASAC 10077055 eee a ee Sl ee ee ote 1 000 000 operations ASAC TO T5241 10 irinin ianiai aaa A Aana AN a ia daaar iaat anaia 30 000 operations Model Code ASAC 1 Control voltage 1 110 240 VAC 380 440 VAC 2 24 VACIVDC Mains voltage 4 200 440 VAC 5 200 575 VAC Nominal kW rating 400 VAC 007 030 AC53b 4 6 354 037 110 AC53b 4 6 594 ASAC 1 11 12 Z SANTERNO CARRARO GROUP 12 12 ASAC 1
9. arter status monitoring Ready Starting Running Stopping Tripped e Performance monitoring motor current motor temperature e Trip code display e 4 20 mA analog output Motor Current Communication Modules ASAC 1 soft starters support network communication via easy to install communications modules Each soft starter can support one communications module at a time Available protocols Ethernet Profinet Modbus TCP Ethernet IP Profibus DeviceNet Modbus RTU and USB NOTE Ethernet communication modules are not suitable for use with ASAC starters using 380 440 V AC control voltage 8 12 ASAC 1 Z SANTERNO CARRARO GROUP PC Software WinMaster can be used with Santerno soft starters to provide the following functionality for networks of up to 99 soft starters e Operational control Start Stop Reset Quick Stop e Starter status monitoring Ready Starting Running Stopping Tripped e Performance monitoring motor current motor temperature To use WinMaster with the ASAC 1 the soft starter must be fitted with a USB Module Modbus Module or a Remote Operator AC53b 4 6 354 AC53b 4 20 340 AC53b 4 6 594 AC53b 4 20 580 Semiconductor Fuses Specifications Semiconductor fuses can be used with ASAC 1 soft starters to reduce the potential for damage to SCRs from transient overload currents and for Type 2 coordination ASAC 1 soft starters have been tested to achieve Type 2 coordination with semico
10. d Starter rating may be too low for the application rs x10 Protections The ASAC 1 includes the following types of protection for the motor and starter Excess Start Time Protection The ASAC 1 will trip on excess start time if the motor does not successfully start within the time selected in the Excess Start Time setting This may indicate that the load has stalled If the soft starter frequently trips on excess start time e check that the Current Limit setting is high enough for the application e check that the Excess Start Time setting is long enough for the application e check that the load has not stalled or increased since the soft starter was installed Motor Overload Protection The ASAC 1 will trip on motor overload if it calculates that the motor has been running above its operating range for longer than the time selected in the Motor Trip Class setting Motor Trip Class should be set to match the motor s locked rotor time If this information is not available from the motor datasheet use the default setting Motor Trip Class 10 Using a higher setting can damage the motor NOTE Motor overload protection does not protect the soft starter and does not protect the motor from short circuit Current Imbalance Protection The ASAC 1 will trip on current imbalance if the highest and lowest currents on the three phases vary by an average of 30 for more than 3 seconds Current imbalance protection is not adjustable and is only active whe
11. ds the safe operating level If the trip occurs frequently this indicates that the soft starter has not been selected correctly for the application Reset Trips can be cleared by pressing the Reset button on the soft starter sending a Reset command from the serial communications network or by switching the control inputs To clear a trip via the control inputs the soft starter requires a closed to open transition on the stop input 02 e In three wire control use the external stop button to momentarily open the stop input open A1 02 e In two wire control if the soft starter tripped with a start signal present remove the start signal open A1 to 01 02 e In two wire control if the ASAC tripped with no start signal present eg ASAC 1 motor thermistor trip apply then remove the start signal close then reopen A1 to 01 02 The Reset button is located on the front of the unit above the adjustment switches The soft starter will trip again immediately if the cause of the trip still exists Accessories Finger Guard Kit Finger guards may be specified for personnel safety Finger guards fit over the soft starter terminals to prevent accidental contact with live terminals Finger guards provide IP20 protection when used with cable of diameter 22 mm or greater Remote Operator The Remote Operator can control and monitor the soft starter s performance Functionality includes e Operational control Start Stop Reset Quick Stop e St
12. es 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 e Isolate the ASAC 1 completely from the power supply before attempting any work on the ASAC 1 or motor e Cables to the control inputs must be segregated from mains voltage and motor cabling e Some electronic contactor coils are not suitable for direct switching with PCB mount relays Consult the contactor manufacturer supplier to confirm suitability e Do not apply incorrect voltages to the control input terminals e Do not connect power factor correction capacitors to the output of ASAC 1 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 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 ELECTRICAL SHOCK HAZARD The ASAC 1 contains dangerous voltages when connected to mains voltage Only a qualified electrician sh
13. iciin iisraeli 3 3 1 Power TermiNatONS face dadesatsdaaveet seat seaacingsved aa NAi i aaa Siaa ERA asa 3 9 2 3 3 3 A ny 4 94 E 4 3 5 5 4 5 5 1 5 2 WHI COGS oer 7 5 3 naan 7 5 4 Reset Tesa a A e E 8 6 A 8 6 1 Pinger Guan Kil adi 8 6 2 Remote Operaio e sel ed 8 6 9 Communication 8 6 4 PG SOW AIC sees SERERE ESAE E EERE IERE IEA EEE EE EAEE EEA E 9 7 SPOCHICALIONS 9 7 1 nta a E E e eia 9 7 2 General Technical Data ccccssssssssescsescscscscscsssssssssssscssscscscscssssasesesesesesesesesesessssisisasasasavavavavavavavavanansnsssasasacscacacacasasasasasesasess 10 7 3 Model 11 5 SANTERNO CARRARO GROUP Elettronica Santerno S p A Via della Concia 7 40023 Castel Guelfo BO Italy Tel 39 0542 489711 Fax 39 0542 489722 www santerno com info santerno com Z SANTERNO CARRARO GROUP 1 Caution Statements Caution Statements cannot cover every potential cause of equipment damage but can highlight common caus
14. n the average motor current is 50 or more of the programmed motor FLC ASAC 1 7 12 5 3 4 5 3 5 5 4 6 2 6 3 Z SANTERNO CARRARO GROUP If the soft starter frequently trips on current imbalance e check that there is no imbalance on the mains voltage on the input side of the soft starter e insulation test the motor e move all input cables over one position move L1 cable to L2 move L2 cable to L3 move L3 cable to L1 to rule out a cabling fault Supply Frequency Protection The soft starter will trip on supply frequency if the frequency rises above 72 Hz or falls below 40 Hz for more than five seconds while the soft starter is running These trip points are not adjustable In pre start starting and stopping modes the high and low frequency limits both apply with no time delay A supply frequency trip will also occur if e all three input phases are lost while the soft starter is running e all three input phases fall below 120 VAC at start or while the soft starter is running e the line contactor opens while running Bypass Overload Protection Bypass overload protection protects the soft starter from severe operating overloads while running The protection is not adjustable and has two components e The soft starter will trip if it detects overcurrent at 600 of the programmed motor full load current e The soft starter models the temperature of the internal bypass relays and will trip if the temperature excee
15. nductor fuses Suitable Bussmann and Ferraz Mersen semiconductor fuses are detailed below Model SCR Ft A s eee Bussmann Fuse Bussmann Fuse North American Style Square Body 170M British Style BS88 ASAC 1 007 1150 LOTURI ees 170M 1314 63 FE ASAC 1 015 8000 170M 1317 160 FEE ASAC 1 018 10500 oie 170M 1318 160 FEE ASAC 1 022 15000 are 170M 1318 180 FM ASAC 1 030 18000 170M 1319 180 FM ASAC 1 037 51200 170M 1321 250 FM ASAC 1 045 80000 mee 170M 1321 250 FM ASAC 1 055 97000 170M 1321 250 FM ASAC 1 075 168000 170M 1322 500 FMM ASAC 1 090 245000 170M 3022 500 FMM ASAC 1 110 320000 170M 3022 500 FMM xxx Blade Type Contact Ferraz Mersen for options ASAC 1 9 12 7 2 SANTERNO CARRARO GROUP General Technical Data Mains Supply Mains voltage L1 L2 L3 3 x 200 VAC 440 VAC 10 15 Oa Pa estate atau E uate Nunes 3 x 200 VAC 575 VAC 10 15 Mains frequency at Start oo eceeececcessesecsesscsecsessescesesseenesnsseeessnsseessseeeessuseseassnseneassnseneassnceneansaseeeansaseneansasessansasentanseeeeseneess 45 Hz to 66 Hz Rated insulation voltage oo cceeseesscesseesesesseseeseeseeeeseeseesessseescsueeseaesueeseaesneeseaneaeeseaeeaeeseaeeaseesueaeeassesseeassaseneassaseteansaeeteaneaseseaneneeses 600 VAC FORM GOSIQM
16. op Time 86 105 495 Select the soft stop ramp time D s a Soft stop extends the time soft starter takes to reduce voltage ie to zero 2s 20s i M The ramp time does not control the time the motor will take to eth stop completely 04974 A 04984 A Excess Start Time Configure the soft starter s excess start time protection Select a time slightly longer than the motor requires for a normal healthy start The soft starter will trip if the start does not complete within the selected time E Auxiliary Relay Function Select the function of the soft starter s programmable output N terminals 23 24 N When set to Run the relay will operate when the soft start is complete When set to Trip the relay will operate when the soft starter trips 03387 B Phase Sequence Protection ANY ZANY Configure the soft starter s phase sequence protection Select the allowable phase sequences A setting of Fwd FW allows forward sequence positive rotation only and a setting of Any defeats the protection 04982 A NOTE Auxiliary relay function and phase sequence are configured using a shared switch Set the auxiliary relay function as required then set phase sequence protection 6 12 ASAC 1 5 5 1 5 2 5 3 5 3 1 5 3 2 5 3 3 Z SANTERNO CARRARO GROUP Troubleshooting LEDs LED Status Ready Run Off No control power Motor not
17. ould carry out the electrical installation Improper installation of the motor or the ASAC 1 may cause equipment failure serious injury or death Follow this manual and local electrical safety codes GROUNDING AND BRANCH CIRCUIT PROTECTION It is the responsibility of the user or person installing the ASAC 1 to provide proper grounding and branch circuit protection according to local electrical safety codes SHORT CIRCUIT The ASAC 1 is not short circuit proof After severe overload or short circuit the operation of the ASAC 1 should be fully tested by an authorised service agent 2 Mechanical Installation 2 1 Dimensions and Weights Depth mm inch Weight mm inch kg Ib Le B c D E F G H ASAC 1 007 ASAC 1 015 1 018 165 55 90 5 23 22 1 022 6 49 2 16 3 6 0 9 4 85 ASAC 1 030 ASAC 1 037 ASAC 1 055 7 59 4 4 1 5 8 81 ASAC 1 075 a lela ASAC 11 110 l 8 42 4 5 2 0 14 33 2 12 ASAC 1 2 2 3 3 1 3 2 Physical Installation SANTERNO CARRARO GROUP ASAC 1 007 ASAC 1 055 Allow 100 mm 3 9 inch between soft starters ASAC 1 075 ASAC 1 110 Allow 200 mm 7 9 inch between soft starters ASAC 1 007 ASAC 1 055
18. tion ASAC 1 007 to ASAC 1 055 oa eseeseceseescsessesessessesessnsseeesnsseesssusseeasenseeeassnseseacsueeeeansaseseansneeneansaeeneansaeeesanseteetentess IP20 Degree of Protection ASAC 1 075 to ASAC 1 110 oeeeseececcseesceessesessnsseeessnsseessssseeessuereesssnseteassueeneansuseneansaseneansaeeneaneaeeseaneneentanseeeasenteds IP00 Operating temperature oo esesceseeeseesesessesseecesesseeseseeseeceseeneecesneaeesseeseeeseeseeessueseeessueeseesseseseassneeseassaeeteansaeeteaneaeeteaneaeeses 10 C to 60 C Storage temperature oe eeeesececsessececsesseeseseeseeseseeseenesesseeessusseeassuseteassaeeseateaeeseaneaseses 25 C to 60 C to 70 C for less than 24 hours UMIGILY 5 to 95 Relative Humidity Ti Pollution Degree 3 ni aca ac Ae IEC 60068 Test Fc Sinusoidal E 4 Hz to 13 2 Hz 1mm displacement it 13 2 Hz to 200 Hz 0 7 g EMC Emission Equipment class EMG cissantait Meenas Class B Conducted radio frequency emission 0 15 MHz to 0 5 MHz lt 56 46 dB 0 5 MHz to 5 MHz lt 46 dB uV A 5 MHz to 30 MHz 50 dB Radiated radio frequency emission ccseescsesessssesseeessneseeeseeeeeeesneeeeeesueeessesneeneansaeeseansatensaneeeeetens 30 MHz
19. to 230 MHz lt 30 dB uV m E etree 230 MHz to 1000 MHz lt 37 dB uV m EMC Immunity Electrostatic discharge c escscssecsesseseeseseeseseesessceceaesneeeeansseeseanseeeesenseeeesenseeessnseseessseseeseneeaees 4 kV contact discharge kV air discharge Radio frequency electromagnetic field oo c seecceseesceessesessessesteseseesesueeeeaesneeeeansneeteansaeensansaeeesanssteatens 0 15 MHz to 1000 MHz 140 dB Rated impulse withstand voltage Fast transients 5 50 ns ceseecccseseeecsessesesesesesenseeetesneeeetesnseteeseneees 2 kV line to earth 1 kV line to line Voltage dip and short time interruption ceescecceseeecseseesecesesecsesneseeansneeceaesneeseansaeessaneatensanseteatenseteatens 100 ms at 40 nominal voltage Harmonics and 6 nnu a iia e IEC61000 2 4 Class 3 EN IEC61800 3 EAC TP TC 020 2011 Short Circuit Rated short circuit current ASAC 1 007 to ASAC 1 022 occ seseeteseesseseesnereesneeesseenisreeaneressneeesatenieseeaeeessneeinsatentaeneaneresaneeensaseneens 5 Rated short circuit current ASAC 1 030 to ASAC 1 110 oo eeseseenessesteseesnereesneeesseeateressnerstsneenesseeaieresaneretsneeenamennerneaneeessneeinanienns 10 kA 1These short circuit ratings are with fuses used as given in the table under Semiconductor Fuses on page 9 Heat Dissipation D ring Sta seca een naan at 3 watts
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