GE Industrial Solutions ASTAT-CD Plus User Manual

ASTAT®-CD Plus

USER MANUAL

DEH-40397B

GE Industrial Systems

SOLID-STATE SOFT STARTER

REMARKS:

1. Read this manual thoroughly before using the AST A T -CD Plus and store in a safe place

for reference.

2. Make sure that this manual is delivered to the end user.

3. CE Marking

When using ASTAT-CD Plus in the EU, compliance with EMC is required.
All ASTAT-CD Plus sizes comply with the generic EN 50081-2 and EN 50082-2

4. The policy of GE Industrial Systems is one of continuous improvement.
The right is reserved to alter the design on any structural details of the products at any
time without giving notice.

ASTAT®-CD Plus Soft Starters

WARNINGS

1. Disconnect power before installing or servicing.

2. Hazardous voltages are present in the motor circuit even when the starter is OFF. An

isolation contactor configured to provide automatic isolation when the motor is turned
OFF is recommended.

3. Unit may contain more than one live circuit. Disconnect both control and main circuits
before installing or servicing.

4. Soft stop should not be used as an Emergency stop.

5. Stopping mode must be set to meet applicable standards for operator safety.

6. Separate motor overcurrent protection is required to be provided in accordance with the

Canadian Electrical Code, Part 1. ASTAT-CD Plus provides separate motor protection.

CAUTIONS

1. Semi-conductor fuses specified may not provide branch circuit protection. Refer to local

applicable electrical codes.

2. Overload relay setting should be properly coordinated with motor.

3. Slow speed running will affect the motor thermal characteristic due to reduced cooling.

Care must be taken when operating motor under these conditions.

4 DC braking - braking current may cause motor overheating. Select the lowest braking

current and time.

5. DC braking must use additional (DC3) in the motor circuit. See wiring diagram page 6-1.

6. Abnormal starting times in excess of 30 seconds, or closely repeated operations of

acceleration ramp/deceleration ramp, slow speed, or DC injection braking may cause
motor damage. Contact motor manufacturer to ensure proper motor selection has been
made for these conditions.

7. If control power is lost between starts, the overload relay protection is reset to cold start
conditions.

ASTAT®-CD Plus Soft Starters

PRECAUTIONS

1. Debranchez l'alimentation en courant électrique avant de raccorder ou d'intervenir.

2. Des tensions dangereuses sort présente dans le circuit moteur même si le soft starter

indique la position "arrêt". Un contacteur d'isolement assurant un isolement automatique
quand le moteur est arrête, est recommendé.

3. L'appareil peut renfermer plus d'un circuit sous tension de'brancher les circuits principaux
et les circuits de controle avant de raccorder ou d'intervenir.

4. Délestage "soft stop" ne devrait jamais être utilisé en lieu de délestage d'urgence.

5. Procédés de délestage doivent être conforme aux normes de sécurité des utilisateurs.

AVERTISSEMENTS

1. Les fusibles semi-conducteurs specifies ne protégent pas obligatoirement les circuits se

conformer aux codes locaux d'installations électriques.

2. Le relais de courant de surcharge doit être proprement coordonné avec la marche du
moteur.

3. La marche en sous-régime agira sur les caracteristiques thermiques à cause de la
réduction de refroidessement. Opérez le moteur avec précaution dans en ce cas.

4. Ralentissement courant continu peut provoquer la surchauffe de moteur. Choisissez le
plus foible courant de décéleration et la durée de ralentissement la plus courte.

5. Pour freinage courant continu, un contacteur (DC3) additional est nécessaire dans le
circuit moteur, voir le schéma de raccordement page 6-1.

6. Les délais anormaux de mise en service d'une durée supérieure à 30 secondes, ainsi
que les montées/descentes en regime, les exploitations régime lent ou les freinages par
injection de courant continu répétés et rapportes sont suseptibles d'edommager le
moteur. Mettez-vous en rapport avec votre fabricant en ce qui concerne le choix du
moteur adéquat.

7. En cas d'interruption de l'alimentation entre deux dèmarrages, la protection assurée par
démarrage à froid.

8. Le moteur doit être muni d'une protection distincte contre les surintensites, et la
surchauffe conformement au code de l'electricite, premiere partie. ASTAT-CD Plus le
relais de courant de surcharge doit être proprement coordonne avec la marche du
moteur.

INDEX

Section 1. Overview ........................................................................................................................ 1-1

1-1 Applications ....................................................................................................................... 1-1

1-2 Features and benefits ........................................................................................................ 1-2

Section 2. T ypes and Ratings........................................................................................................ 2-1

2-1 IEC Ratings........................................................................................................................ 2-1

2-2 UL Ratings ......................................................................................................................... 2-2

2-3 Thermal characteristics...................................................................................................... 2-3

Section 3. Technical Specifications ............................................................................................. 3-1

3-1 General specifications ....................................................................................................... 3-1

3-2 I/O Terminal board specifications....................................................................................... 3-2

3-3 I/O wiring............................................................................................................................ 3-3

3-4 Operating modes ............................................................................................................... 3-4

3-5 Programmable inputs and outputs..................................................................................... 3-6

Section 4. Programming................................................................................................................ 4-1

4-1 Keypad and display description ......................................................................................... 4-1

4-2 Parameter block configuration ........................................................................................... 4-2

4-3 Monitor block parameters .................................................................................................. 4-4

4-4 Calibration block parameters ............................................................................................. 4-5

4-5 Basic block parameters ..................................................................................................... 4-6

4-6 Advanced block parameters .............................................................................................. 4-7

4-7 Application and basic settings ........................................................................................... 4-9

4-8 Saving parameters to E2PROM ........................................................................................ 4-9

Section 5. Installation .................................................................................................................... 5-1

5-1 Equipment installation........................................................................................................ 5-1

5-2 General .............................................................................................................................. 5-1

5-3 Fuses, contactors and supply wiring.................................................................................. 5-2

5-4 Start-up .............................................................................................................................. 5-3

5-5 Troubleshooting ................................................................................................................. 5-3

5-6 Thyristor check .................................................................................................................. 5-4

Section 6. Appendix....................................................................................................................... 6-1

6-1 Application diagrams ......................................................................................................... 6-1

6-2 Serial communications....................................................................................................... 6-4

6-3 Dimensions ........................................................................................................................ 6-9

6-4 PCBs layout ....................................................................................................................... 6-10

i i

1. Overview

1-1. Applications

There are numerous applications where soft starting and limited
current peaks are needed for the starting of squirrel cage induction
motors. Traditionally reduced voltage starting was accomplished
using electromechanical starters such as star delta starters,
autotransformer starters, stator resistance starters or by using part
winding motors. These methods would provide a two, three or four
step torque change by switching the motor voltage from reduced
value to full voltage (in steps) after a preset time interval.

ASTAT-CD Plus Solid State Reduced-Voltage Starters (also known
as soft starters) use solid state devices to gradually increase the
voltage from an initial preset level (initial torque) to full voltage over a
selected time period. The same solid state devices may also be used
to reduce the voltage for the deceleration of the motor should this be
required in the application. This starting and stopping method
provides smooth, stepless acceleration and deceleration of AC
squirrel-cage induction motors. The ASTAT-CD Plus control circuitry
allows many additional functions to be accomplished, such as the
monitoring, protection and secondary functions listed.

Versatile Use

ASTAT-CD Plus Solid State Reduced-Voltage Starters offer
customer-configurable functions, including pedestal voltage, kick start
(selectable), acceleration ramp, current limit, and soft stop
(selectable). Typical applications include the following:

• Belted equipment • Centrifugal fans

• Centrifuges • Compressors

• Conveyors • Crushers

• Extruders • Fans and blowers

• Mixers • Packaging equipment

• Pumps • Textile machinery

Advanced Features

The ASTAT-CD Plus incorporates many additional advanced features
to insure suitability for most applications.

Monitoring

• Motor Current

• Line Voltage (1)

• Line Power Factor

• Elapsed Time

• Fault History

Protection

• Password

• Lockout

• Undervoltage (1)

• Overvoltage (1)

• Undercurrent

• Overcurrent

• Long Start Time

• Stalled Rotor

Secondary Functions

• Secondary Ramp Up

• Secondary Ramp Down

• Tachometer Feedback

• Dual Motor Switch

• Slow Speed (7&14%)

• Reverse Slow Speed (20%)

• Retry

• DC Injection Braking

• Energy Saving

The ASTAT-CD Plus also features two programmable inputs, three
programmable output relays and serial communications control.

1-1

Note: (1) Monitors L1

1-2. Features and benefits

1. Overview

An increase in productivity and reliability with the use of
static soft starters.

The ability to start and stop the motor without steps or transitions lengthens the
life of power-driven machines’ mechanical parts, and it reduces stress on
transmission belts and coupling parts. Consequently, maintenance time is
reduced and machine/facility lifespans are lengthened.

Improvement in acceleration / deceleration characteristics

By starting with the voltage ramp or, alternatively, by starting current limitation,
the acceleration and deceleration ramp more closely fits the load characteristics.
A kick start also may be selected in instances of high static friction load.

Protected motor

The ASTAT-CD Plus protects the motor from overloads and from incorrect
operating conditions such as loss of an input or output phase, stalled rotor,
thyristor short circuit, etc.

Digital technology

The control system is based upon the use of a highly specialized microcontroller
that treats the signals digitally, thereby avoiding deratings and adjustments
common to analog circuits. This type of control ensures excellent precision and
speed of execution. The control board uses surface-mounted devices (SMD) to
increase equipment reliability.

High level of immunity

The control signals are optoelectronically isolated. Various levels of protection
have been set up in the circuits to immunize the equipment against external
disturbances and their harmful effects.

Easy to run and adjust

The ASTAT-CD Plus can be used for a wide range of applications. A keypad and
digital display make it easy to select options that allow the equipment capabilities
to be customized to application needs.

Easy maintenance due to full monitoring

Advanced microprocessor technology allows starters to identify 21 different
types of fault conditions. The last four errors are retained in memory to facilitate
troubleshooting and minimize downtime.

Pump control

The ASTAT-CD Plus includes a pump control function that is more effective in
fluid systems than standard soft starting and stopping. The control reduces fluid
surges and hammering in a pipeline system. This method controls the motor
speed by monitoring the motor parameters with voltage control in a closed-loop
system.

Advanced functions

The ASTAT-CD Plus includes advanced functions, such as, linear acceleration
ramp, programmable I/O, and connection to a computer by serial communication
(RS 232).

1-2

2. Types and Ratings

2-1. IEC Ratings (1)

HEAVY DUTY (2) LIGHT DUTY Degree of Cat. No. Weight Cooled

Current 220V / 380V / 440V 480V / Current 220V / 380V / 440V 480V / protection
rating 240V 415V 500V rating (3) 240V 415V 500V

AkW(4) kW(4) kW(4) kW(4) A kW(5) kW(5) kW(5) kW(5) Kg. Lbs.
14 3 5.5 7.5 - 17 4 7.5 7.5 - IP-00 QC1FDP 4.3 9.48 Natural

35.5 7.5 7.5 4 7.5 7.5 11 IP-00 QC2FDP 4.3 9.48 Natural

17 4 7.5 7.5 - 21 5.5 11 11 - IP-00 QC1GDP 4.3 9.48 Natural

47.5 7.5 11 5.5 11 11 13 IP-00 QC2GDP 4.3 9.48 Natural

22 5.5 11 11 - 27 7.5 13 15 - IP-00 QC1HDP 4.6 10.14 Natural

5.5 11 11 15 7.5 13 15 15 IP-00 QC2HDP 4.6 10.14 Natural

32 7.5 15 18.5 - 38 10 18.5 22 - IP-00 QC1IDP 4.6 10.14 Natural

7.5 15 18.5 22 10 18.5 22 25 IP-00 QC2IDP 4.6 10.14 Natural

48 13 22 22 - 58 15 25 30 - IP-00 QC1JDP 12.5 27.56 By fan

13 22 22 30 15 25 30 37 IP-00 QC2JDP 12.5 27.56 By fan

63 15 30 37 - 75 22 37 45 - IP-00 QC1KDP 12.5 27.56 By fan

15 30 37 37 22 37 45 45 IP-00 QC2KDP 12.5 27.56 By fan

72 20 37 37 - 86 25 45 50 - IP-00 QC1LDP 17.0 37.48 By fan

20 37 37 45 25 45 50 50 IP-00 QC2LDP 17.0 37.48 By fan

105 30 55 55 - 126 37 63 75 - IP-00 QC1MDP 17.0 37.48 By fan

30 55 55 75 37 63 75 80 IP-00 QC2MDP 17.0 37.48 By fan

156 40 75 90 - 187 55 90 110 - IP-00 QC1NDP 45.0 99.20 By fan

40 75 90 110 55 90 110 132 IP-00 QC2NDP 45.0 99.20 By fan

240 63 110 132 - 288 80 150 165 - IP-00 QC1QDP 45.0 99.20 By fan

63 110 132 160 80 150 165 200 IP-00 QC2QDP 45.0 99.20 By fan

315 90 160 200 - 378 110 200 220 - IP-00 QC1RDP 55.0 121.3 By fan

90 160 200 220 110 200 220 250 IP-00 QC2RDP 55.0 121.3 By fan

370 110 200 220 - 444 132 220 250 - IP-00 QC1SDP 55.0 121.3 By fan

110 200 220 250 132 220 250 315 IP-00 QC2SDP 55.0 121.3 By fan

475 150 250 250 - 570 160 300 355 - IP-00 QC1TDP 80.0 176.4 By fan

150 250 250 335 160 300 355 400 IP-00 QC2TDP 80.0 176.4 By fan

610 200 315 400 - 732 220 400 450 - IP-00 QC1UDP 105.0 231.5 By fan

200 315 400 400 220 400 450 500 IP-00 QC2UDP 105.0 231.5 By fan

850 250 450 530 - 1020 300 560 600 - IP-00 QC1VDP 120.0 264.5 By fan

250 450 530 600 300 560 600 750 IP-00 QC2VDP 120.0 264.5 By fan

1075 355 600 670 - 1290 395 715 750 - IP-00 QC1XDP 150.0 330.7 By fan

355 600 670 750 395 715 750 850 IP-00 QC2XDP 150.0 330.7 By fan

Notes: (1) = Ratings in Amps. given for ambient temperature up to 40

Derate output current by 1.5% /
Derate output current by 1% / 100m above 1000m.

(2) = Heavy duty ratings, IEC Class 10 and 20 protections allowed.
(3) =Light duty ratings, only IEC Class 10 protection allowed.
(4) = Maximum recommended Motor Power for IEC Class 20 protection. Set ASTAT-CD Plus's parameters "N" and "o" accordingly.
(5) = Maximum recommended Motor Power for IEC Class 10 protection. Set ASTAT-CD Plus's parameters "N" and "o" accordingly.

°

C above 40°C.

°

C and 1000m altitude.

2-1

2. Types and Ratings

2-2. UL Ratings (1)

Current Max. HEAVY DUTY STANDARD DUTY Degree of Cat. No. Weight Cooled
rating starting 200V 230V 460V 200V 230V 460V protection

current
AAHP HP HP HP HP HP Kg. Lbs.
14 63 3 3 7.5 3 3 7.5 IP-00 QC2FDP 4.3 9.48 Natural
17 77 3 3 10 3 3 10 IP-00 QC2GDP 4.3 9.48 Natural
22 99 5 7.5 15 5 7.5 15 IP-00 QC2HDP 4.6 10.14 Natural
34 153 7.5 7.5 20 10 10 25 IP-00 QC2IDP 4.6 10.14 Natural
48 216 10 15 30 15 15 30 IP-00 QC2JDP 12.5 27.56 By fan
63 284 15 20 40 20 20 40 IP-00 QC2KDP 12.5 27.56 By fan
72 324 20 20 40 20 25 50 IP-00 QC2LDP 17.0 37.48 By fan
105 473 30 30 60 30 30 75 IP-00 QC2MDP 17.0 37.48 By fan
156 702 40 50 100 50 60 125 IP-00 QC2NDP 45.0 99.20 By fan
240 1080 60 75 150 75 75 200 IP-00 QC2QDP 45.0 99.20 By fan
315 1418 75 100 200 100 125 250 IP-00 QC2RDP 55.0 121.25 By fan
370 1665 100 125 250 125 150 300 IP-00 QC2SDP 55.0 121.25 By fan
500 2250 150 150 350 150 200 400 IP-00 QC2TDP 80.0 176.36 By fan
630 2835 200 200 400 200 250 500 IP-00 QC2UDP 105.0 231.47 By fan
850 3825 250 300 600 300 350 700 IP-00 QC2VDP 120.0 264.54 By fan

°

Notes: (1) = Ratings in Amps. given for ambient temperature up to 40

Derate output current by 1.5% /
Derate output current by 1% / 100m above 1000m.

°

C above 40°C.

C and 1000m altitude.

2-2

2. Types and Ratings

2-3. AST AT®-CD Plus, Thermal characteristics

The ASTAT-CD Plus allows the user to select motor protection according to IEC Class 10, 20 and NEMA 10, 20 or 30, selectable by "o" -overload- parameter

IEC Class 10 IEC Class 20

Sec. Sec.

COLD

COLD

HOT

Multiples of motor FLA rating In

NEMA 10 NEMA 20

Sec.

COLD

HOT

Multiples of motor FLA rating In

Sec.

HOT

Multiples of motor FLA rating In

COLD

HOT

Multiples of motor FLA rating In

NEMA 30

Sec.

COLD

HOT

Multiples of motor FLA rating In

Thermal memory:

If the control voltage is not removed, the unit has a cool down
characteristic. The time for cool down is 300 sec. after the overload trip.
If the control voltage is removed after tripping, you must wait at least 2
minutes before the unit can be restarted.

Operations per hour:

Using a cycle T, with starting time of t1, running time of T-2t1 at rated
current and OFF time of t1 sec. (minimum), the ASTAT-CD Plus allows
the following operations per hour.

Starting Operations / Hour. Operations / Hour
Current Starting time t1= 10sec. Starting time t1=20 sec.

2 Ir 180 90
3 Ir 160 60
4 Ir 30 10

2-3

3. Technical Specifications

3-1. ASTAT®-CD Plus, General specifications

Voltage Ratings 3ph AC Systems

Freq. Range 50/60 Hz Control range of 45-65 Hz

Control Control system Digital system with microcontroller
Specifications Starting ramp with progressive increase in voltage and current limitation

Initial voltage (pedestal) % 30 - 95 U
Starting torque % 10 - 90 M

Kick start % 95 Un (90% M
Motor unit ratio (N) 0.4 - 1.2
Current limit (starting) 1 to 4.5 (Ir/In) Max 7.0 I
Acceleration ramp time s 1 to 99 (types: standard or linear ramp up)
Energy savings Output voltage reduction according to power factor
Override Fixed output voltage permanently equal to supply voltage
Bypass Direct control of a bypass contactor
Brake time by ramp s 1 to 120 (1 to 99 in secondary ramp) adjustable independently of starting ramp time (types: standard,

DC braking 0 to 99 s.; 0.0 to 2.5xI
Slow speed Direct torque: 7% or 14% of nominal speed; reverse torque: 20% of nominal speed
Retry 0 to 4 attemps, and 1 to 99 sec. retry time
Monitoring Motor current, line voltage (1), power, power factor and elapsed time

Running External control Start - Stop

Acceleration phase Adjustable time
Permanent phase Energy savings / Override choice
Stop phase Power cut-off / Ramp / DC braking/Pump control

Inputs / Outputs Inputs 4 digital optocoupled. Two fixed (Start , Stop), and 2 programmable (I3, I4)

Outputs 3 programmable relays (1r, 2r, 3r)

Up to 500V,

1 Analog 0-5VDC for Tachogenerator input feedback

1 Analog 0-10VDC output for current metering

+10%, -15% for

n

direct start

direct start

pump control or linear ramp down)

QC2xDP ASTAT-CD Plus series

), adjustable 0 to 999 ms

n

n

I Actual measured motor current

I

m

I

n

I

r

L Current limit for starting Im/I

L

max

M

direct start

NI
SF Service factor
U

n

Abbreviations

Maximum starting current desired

Nominal motor nameplate FLA
ASTAT rated nameplate FLA

450/N

Full voltage starting torque

n/Ir

Full line voltage

r

Protections Current limit Adjustable from 1 to 4.5 (Ir/In) Max 7.0 I

Overload IEC class 10 and 20 ; NEMA class 10, 20 and 30 all selectable
Cool-down time after
overload trip s 300 for reset
Loss on input phase s Trip at 3
Thyristor short circuit ms Trip at 200
Heatsink overheating ms Trip at 200
Motor thermistor ms Trip at 200 if thermistor impedance > response value
Loss on output phase s Trip at 3
Stalled rotor ms Trip at 200
Supply frequency error Hz If f < 45 or f > 65, will not start
Overcurrent 100 to 150% In; trip time adjustable from 0 to 99 sec.
Undercurrent 0 to 99% In; trip time adjustable from 0 to 99 sec.
Overvoltage (1) 100 to 130% Un; trip time adjustable from 0 to 99 sec.
Undervoltage (1) 0 to 50% Un; trip time adjustable from 0 to 99 sec.
Error (CPU) ms 60
Memory 4 former errors
Long start time s 2 x ta (ta = acceleration ramp time)
Long slow speed time s 120

Environmental Temperature °C 0 to +55 (derate output current by 1.5% / °C above 40°C)
conditions Relative humidity % 95% without condensation

Maximum altitude m 3000 (derate output current by 1% / 100m above 1000m)
Mounting position Vertical
Protection Degree IP00, UL Open

Standards CE, cUL, UL CE Conforming IEC 947-4-2; UL, cUL conforming to UL508

Conducted & radiated emissions Conforming IEC 947 -4-2, Class A
Electrostatic discharges Conforming to IEC 1000-4-2, level 3
Radioelectric interference Conforming to IEC 1000-4-6, level 3 and to IEC 1000-4-3, level 3
Immunity to fast trasients Conforming to IEC 1000-4-4, level 3
Immunity to Surge Voltage Conforming to IEC 1000-4-5, level 3

n

Note: (1) Monitors L1

3-1

3. Technical Specifications

3-2. I/O Terminal board specifications

Power I/O terminals

Terminal Function Description
1L1, 3L2, 5L3 Mains Input 3ph input voltage 200-480 volts QC2xxx type

2T1, 4T2, 6T3 Motor output Output terminals to 3ph AC motor

A1, A2, B1, B2 Input Control Voltage 110/120V AC, +10%, -15% 220/240V AC, +10%, -15%

Digital Inputs

Terminal Function Description
57 Common for digital inputs This is a common terminal for the digital input terminals specified below.

1 Run Run order. Command signal may be provided by one NO dry momentary contact to terminals 1 and 57.
2 Stop Stop order. Command signal may be provided by one NC dry momentary contact to terminals 2 and 57.

NOTE: Run/Stop permanent command allows linking 1-57 and using one dry NO contact to 2-57

terminals.

3 Programmable input I3 These two inputs are programmable. They can be assigned to the following internal functions:
4 Programmable input I4

-soft stop -DC brake -Linear ramp

-pump control -slow speed control -dual ramp selection

-kick start -reverse slow speed -bypass function

-override -local / remote control

Command signal should be provided by one NC dry contact to terminals 57-3 or terminals 57-4. By switching
this contact ON / OFF it is possible to enable or disable the assigned function.

Digital Outputs

Terminal Function Description
11, 12, 14 Programmable relay 1r 11-12 = NC, 11-14 = N.O. dry contacts. This relay can be assigned to several internal

As default assigned to function RUN

23, 24 Programmable relay 2r 23-24 = N.O. dry contact. This relay can be assigned to several internal output functions (page 3-6).

As default assigned to function EOR

33, 34 Programmable relay 3r 33-34 = N.O. dry contact. This relay can be assigned to several internal output functions (page 3-6).

As default assigned to function DC BRAKE
Common for all relay output contacts Maximum usage voltage: 380VAC (B300-UL)

Thermal current: 8A
AC-15 use: 220V / 3A, 380V / 1A
DC-15 use: 30V max/ 3.5A

Analog I/O

Terminal Function Description
8 Analog input common (-) This is a common terminal for the analog input terminal number 7 and analog output terminal number 9.
7 TG feedback input (+) 0-5V analog input for speed feedback. It should be provided by a DC tacho-generator coupled to the motor.

This speed feedback signal is required when the "linear ramp" function is used.

9 Current output (+) 0-10V DC analog Output for current measurement purpose. (1 x Ir = 2V DC output)

Load Impedance 10KΩ or higher.

Motor thermistor terminals

Terminal Function Description

5 , 6 Motor thermistor input This input allows a motor thermistor with a response value from 2.8 to 3.2KΩ , and a reset value from 0.75 to

1KΩ to control motor temperature.

When the motor thermistor is not used, a link must be used between terminals 5-6.

output functions (p. 3.6).

Communications

Terminal Function Description
TD, RD, SG Tx, Rx, Gr data RS232C, 3 wires, half duplex. Maximum cable length 3meters (10 feet).

Asynchronous data transmission, 9600 Bauds, 1 bit start, 8 bits data, 2 bits stop, no parity.

3-2

3. Technical Specifications

3-3. I/O wiring

ASTAT-CD Plus terminal layout and wiring configuration is shown in the diagram below

Control Voltage

110 / 120V AC

L1 L2 L3

(1*)

A1A2 B1B2

Control Voltage

220 / 240V AC

A1A2 B1B2

57 57 57 6 8

12

(Permanent Command)

Start /Stop

12 11 14

1r 2r 3r

Programmable Relay Outputs

Programmable Inputs

I3 I4

23

24

(2*)

33

3457

34

(3*)

+-

Serial Comm.

RS232C

Tx Rx Gr

RDSG

TD

9

-+

V

(1*)

1 L1 3 L2 5 L3

2 T1 4 T2 6 T3

M

3 ~

57 57

1 2

Input

Analog Input

Motor Thermistor

Tacho feedback

Start Stop

(Command by push-buttons)

(4*)

Inputs

Programmable

(4*)

Notes: (1) Control and Mains wiring recommendations are given in chapter 5.

(2) The programmable inputs I3, I4 are not assigned to any function as default. Check pages 3-6 prior to using these inputs.

(3) The programmable relay outputs are assigned to the following functions as default:

Relay (1r): RUN, (RUN status)
Relay (2r): EOR, (End of Ramp)
Relay (3r): DCBR, (DC Braking control)

(4) Important: Use dry contacts only

0-10V

Analog Output

3-3

3-4. Operating modes

Starting and Stopping

3. Technical Specifications

Initial ramp
Initial voltage (pedestal)
Kick start
Acceleration ramp

Current limit
Permanent state

Stopping modes (All selectable)

1

1a

2
3

3a

4
5

5a

6
7
8

8a

5 main frequency cycles

30 to 95% Un (adjustable via initial torque setting T)
95% Un. Enabled by parameter "Pxxx" to ON, 0-999 ms (adjustable)
1-99 sec (adjustable). Dual ramp option.
Linear speed ramp by tacho feedback also possible
Fast ramp (if motor is up to speed before end of normal ramp time

100% to 450% x Ir/I

Max 700% I

n

n

)

Rated voltage (override)
Rated current
Energy savings. Enabled by "Fxxx" to OFF
Motor power cut-off. "Sxxx" to OFF, "Cxxx" to OFF
Deceleration ramp 1-120 sec (adjustable). Secondary ramp 1-99 sec
Ramp down modes available are:

- Soft Stop -Voltage ramp down-. Enabled by "Sxxx" to ON

- Pump control. Selectable by "Sxxx" to ON and "Cxxx" to ON

- Linear ramp down (Tacho feedback needed)

Evolution of current in deceleration ramp mode

Starting by voltage ramp

Override

U/Un

2

1A

1

3A

3

3

Energy savings

U/Un

1

2

1A

1

3A

3

3

9

DC brake (0-99 sec adjustable). Enabled by "Bxxx" to ON

Starting by current limitation

Override

5

8

7

9

9

t

l/ln

1

4

5a

7

8a

9

9

t

Energy savings

l/ln

6

7

8

9

9

t

4

8a

6

9

7

9

t

3-4

Jog and linear ramp

T

3. Technical Specifications

Linear acceleration and deceleration ramp Ramp time adjustable (Selectable by parameter "Dxxx" to ON
Low slow (7%) and High slow (14%) speeds Enabled by parameter "Jxxx" to ON and "jxxx" to LO or HI
Reverse slow speed (20%) Enabled by parameter "Jxxx" to ON and "rxxx" to ON
Slow speed (7% or 14%) Enabled by parameter "Jxxx" to ON
Acceleration ramp Ramp time adjustable
Soft stop (deceleration ramp) Ramp time adjustable
Slow speed (7% or 14%) Enabled by parameter "Jxxx" to ON
DC Brake Current and time adjustables, Enabled by parameter Bxxx to ON, and bxx, Ixxx adjustments

Linear ramp with T.G. feedback

100

11a

% of motor full load speed

1
2

3a

4
5
6
7
8

1a

3

Slow speed. Basic diagram

100

14
7

% of motor full load speed

t

20

3

2

3a

t

Slow speed. Full diagram

100

% of motor full load speed

ERMINALS

CLOSED

4-57

OPEN

CLOSED

1-57

OPEN

CLOSED

2-57

OPEN

5

4

6

7

8

t

t

3-5

3. Technical Specifications

3-5. Programmable Inputs and Outputs

Programmable inputs and functions

The ASTAT-CD Plus functions such as soft stop, kick start, etc., can be enabled (ON) or disabled (OFF) in their dedicated parameters by using the keypad.
Most of these functions can be enabled or disabled remotely as well, through the programmable inputs I3 or I4 (terminals 3-57 and 4-57).

Function Parameter

Soft Stop

Pump Control

Kick Start

Override

By-pass

DC Brake

Linear Ramp

(Jog). Slow Speed

Reverse Jog

Dual Motor

Remote Control

S xxx
C xxx
P xxx
F xxx
z xxx
B xxx
D xxx
J xxx
r xxx
A xxx
X xxx

More than one function can be enabled in the ASTAT-CD Plus, either by the keypad or through the programmable inputs I3 and I4, but there are some functions
which may not work as expected during stopping, such as when they are simultaneously enabled. When two or more of the below functions are simultaneously
enabled, the priority is defined in the following table:

Set Value

_OFF

_ON

_I3

_I4

<Remarks>

The function is permanently disabled

The function is permanently enabled

The status of the function depends upon I3 input

The status of the function depends upon I4 input

NOTE: One programmable input may enable or

disable more than one function

Condition Action

○○○○○○○○

○○○○○○○○

○○○○○○○○

DC Brake (B=ON)  abc

Linear Ramp (S, D=ON) a  aa

Soft Stop (S=ON) b a  c

○○○○○○○○○○○

○○○○○○○○○○○

○○○○○○○○○○○

a The unit stops by Linear Ramp

b The unit stops by DC brake after the Soft Stop is completed.

c The unit stops by Pump Control

Pump Control (S, C=ON) c a c 

DC Brake (B=ON)

Linear Ramp (S, D=ON)

Soft Stop (S=ON)

Pump Control (S, C=ON)

Programmable Relay Outputs

The ASTAT-CD Plus includes three programmable relays 1r, 2r and 3r (dry contacts). ASTAT-CD Plus terminals are 11-12-14, 23-24 and 33-34
These relays can be assigned to several functions, as shown below.

Relay N#

Relay 1r

Relay 2r

Relay 3r

Parameter

1r xx

1r xx

3r xx

Set Value

20

21

22

23

24

25

26

27

28

29

30

EOR Detects end of voltage ramp. -This function can only be assigned to relay 2r­DC Brake DC Brake command -This function can only be assigned to relay 3r­Fault Detects ASTAT-CD Plus fault status
Undervoltage Detects limit set in parameter UVxx (1)
Overvoltage Detects limit set in parameter OVxx (1)
RUN Detects ASTAT-CD Plus run status
JOG Detects Jog (slow speed) status
Undercurrent Detects limit set in parameter UCxx
Overcurrent Detects limit set in parameter OCxx
Disabled Disables the relay function
Future use

<Remarks>

Note: (1) Monitors L1

3-6

4. Programming

4-1. Keypad and display description

1

2

C / V

Display

Display Structure

Function code

FVVV

1

Data

Keypad

C / V

Displays monitoring, status indications, error messages and function set values

FVVV Status code

ON Equipment is

STOP Stop
LOCK Remote stop
PULS Kick start
RAMP Acceleration ramp
FULL Full conduction or

SAVE Energy saving
SOFT Soft stop
PUMP Pump control
DCBK DC braking
INCH Inching / slow speed
TACH Linear ramp (tacho)

2

Allows setting of parameters and functions

SELECTION

Use with

or

be displayed and/or modified

to select the parameter or function code to

connected
to main supply
(equipment is ON)

Override

FVVV Error code
E010 Frequency out of range

E011 Overload trip
E013 Loss of synchronism
E014 Phase U scr
E015 Phase V scr
E016 Phase W scr
E017 Heatsink overtemperature
E018 Motor thermistor
E019 Phase U lost
E020 Phase V lost
E021 Phase W lost
E022 Stalled rotor
E023 Internal error
E025 Long start time
E026 Long slow speed time
E027 Lock-out
E028 Undervoltage
E029 Overvoltage
E030 Undercurrent
E031 Overcurrent
E032 Retry, attempts exceeded

SEARCH / ADJUSTMENT

Decreases the value of the selected parameter

FF/V V V Function code (*)
Mx x x Motor current

vxxx Software version
. .
. .
PFxx Power factor
. .
. .
Lxxx Current limit
Txxx Starting torque
axxx Ramp up time
dxxx Ramp down time
Sxxx Soft stop selection
..
. .
LKxx Lock out
..
. .

(*) These are examples. Full details in sections

4-2, 4-3, 4-4, 4-5 and 4-6

SEARCH / ADJUSTMENT

Increases the value of the selected parameter

ENTER / SAVE

-Introduces the new parameter value into memory

- Updates the selected parameter value with the
displayed value

4-1

4. Programming

4-2. Parameter block configuration

Mode Selection

The ASTAT-CD Plus includes a large number of parameters which are divided in four
blocks: Monitor, Calibration, Basic and Advanced. The parameters of each group can be
displayed or skipped according the selection done in parameter "G".
The monitor parameters are always displayed regardless of the mode selected

Monitoring
Parameters

G ALL

G CAL

Calibration
Parameters

Settings in parameter "G" GCAL The Calibration parameters are displayed

GBAS The Basic parameters are displayed
GADV The Advanced parameters are displayed

G BAS

Basic

Parameters

GALL All parameters are displayed

G ADV

Advanced

Parameters

Searching and Setting Parameters

The ASTAT-CD Plus displays the parameters sequentially while depressing the key and pushing repeteadly or keys. Proceed in this way
untill the parameter "G" is displayed.

There is a quick way to search automatically the parameter "G" by pressing and Keys. "Gxxx" will be shown on the display.

Once the parameter "G" is displayed, choose the value desired by pressing or Keys. The display will sequence "GBAS", "GCAL", "GADV" and

"GALL" values repeatedly. The actual value displayed can be stored in a temporal memory buffer by pressing key.

Values stored in the temporal memory are lost upon control power loss, unless saved in the permanent E2PROM memory through parameter "W". Additional
instructions are given on page 4-9.

The above is an example given for parameter "G", but all ASTAT-CD Plus parameters can be modified from its default factory value in a similar way.

C / V

C / V

Parameter layout

Monitor parameters

Status

M

v

V

C / V

+

PF

w

E

e

K

W

G

Shown automatically ON, STOP, LOCK, PULS, ...

Motor current

Software version

Line voltage

Line power factor

Line power

Elapsed time

Fault history buffer

Password

E2PROM writing

Parameter block selector

GBAS

GADV GALL

12

(see page 4-4)

e0, e1, e2, e3

GCAL

Calibration parameters

U

Line voltage

t

Voltage calibration

Unit frame

UF

Current calibration

m

N

Motor unit ratio

o

Overload protection

Service factor

f

100-500

0-600

F,G ,H , ... ,X

0-1300

40-120

0, N1, N2, N3,C1,C2

100-130

4-2

4. Programming

1

Basic Parameters

L

Current limit

T

Starting torque

Ramp up time

a

d

Ramp down time

p

Kick start

b

DC brake time

DC brake current

I

S

Soft stop switch

Pump control switch

C

Pump curve selection

ST

starting

Pump curve selection

SP

stopping

Kick start switch

P

Override switch

F

By-pass switch

z

B

DC brake switch

(1) 100-450 (Ir/In) ; 700 max.

Unit

%

%

sec.

sec.

ms

sec.

%

Range

100-700 (1)

010-090

01-99

01-120

000-999

000-099

000-250

OFF, ON, I3, I4

OFF, ON, I3, I4

00-03

00-05

OFF, ON, I3, I4

OFF, ON, I3, I4

OFF, ON, I3, I4

OFF, ON, I3, I4
PON, PI3, PI4

2

Advanced Parameters

LK

Lock-out

R

E2PROM reading

Factory settings

Q

Y

Retry

y

Retry time

UV

Undervoltage

Undervoltage trip time

uv

OV

Overvoltage

ov

Overvoltage trip time

UC

Undercurrent

uc

Undercurrent trip time

Overcurrent

OC

Overcurrent trip time

oc

2a

Secondary ramp up

2d

Secondary ramp down

Secondary starting torque

2t

Tacho control switch

D

J

Slow speed switch

j

Low / High slow speeds

r

Reverse slow speed

Dual motor switch

A

X

Remote control switch

Comm protocol selection

XP

Unit

minutes

n. attempts

sec.

%

sec.

%

sec.

%

sec.

%

sec.

sec.

sec.

%

Range

00-45

ON, OFF

ON, OFF

000-004

001-099

00-50

00-99

00-30

00-99

00-99

00-99

00-50

00-99

01-99

01-99

10-90

ON, OFF, I3, I4

OFF, I3, I4

LO, HI

OFF, ON, I3, I4

OFF, ON, I3, I4

OFF, ON, I3, I4

00-02

4-3

s

1r

2r

3r

Station number

Output relay 1r

Output relay 2r

Output relay 3r

001-247

22-30

20, 22-30

21, 30

4-3. Monitor block parameters

4. Programming

Display

ON

M xxx

v xxx

V xxx

PFxx

Function

Status

Motor current

Software version

Main source voltage (1)

Power factor

Default Range Unit

ON

ON
STOP
LOCK

PULS

RAMP

FULL

SAVE
SOFT
PUMP
DCBK

INCH
TACH

000-999

1.0-9.9

-

-

00-99

-

-

-

-

-

-

-

-

-

-

-

-

A
kA
%

-

V

%

Description

Switch on time. Equipment is connected to main supply
Stop
Remote control through serial port
Kick start
Acceleration ramp
Full conduction / Override (full voltage)
Energy saving
Soft stop
Pump control
DC braking
Inching / slow speed
Linear ramp (tacho feedback needed)

Displays motor current in Amps.
Current higher than 999A is displayed in kA.
If parameter UFxx is not calibrated, the motor current is
displayed in % I

xxx = Version number.

Displays line voltage in Volts.

Displays line Power Factor.

n

w xxx

E xxx

e xxx

K xxx

W xxx

G xxx

Note:

(1) Monitors L1

Line power

Elapsed time

Error trace buffer

Password

E2PROM writing

Parameter display
selection

K 000

W OF F

G BAS

-

-

e0xx-e3xx

000-999

ON, OFF

CAL, BAS, ADV,

ALL

kW

Displays Line Power.

Hrs

Displays RUN time in Hours (x 1000)

-

Saves the last four errors:
e0xx: Fault 1 -Latest fault- xx: Fault code error
e1xx: Fault 2
e2xx: Fault 3
e3xx: Fault 4

-

= 69 allows E2PROM writing operation
= 10 Key lock enabled
= 20 Key lock disabled

-

Saves the unit current parameters to the E2PROM.
This rewrites the last values saved. (Password 69 required)

-

CAL: Displays Calibration Parameters
BAS: Displays Basic Parameters
ADV: Displays Advanced Parameters
ALL: Displays All parameters

4-4

4. Programming

4-4. Calibration block parameters

FunctionDisplay

U xxx

t xxx

UF x

m xxx

N xxx

o xxx

Line voltage setting

Voltage calibration

Unit frame

Current calibration

Motor rated current

Overload protection

-CAL-

Default Range Unit

U 480

t 480

UF 0

m 000

N 100

o N2

100-500

000-600

F, G, H, I, J, K, L,

M, N, Q, R, ...X

000-1300

040-120

OFF

N1, N2, N3,

C1, C2

Description

Line Voltage from 200 to 500V. Set rated value.

V

Setting of this parameter allows better accuracy in

V

monitoring and voltage protections (see the voltage
calibration procedure).

Unit frame rating (F,G,H,...X).

­Setting “0” disables current calibration.

Setting of this parameter allows better accuracy in

A

monitoring and current protections (see the current
calibration procedure).

100 x (In/Ir)

%

When this parameter is adjusted at a value higher than
105% the overload protection curve is automatically
adjusted to Class 10. "C1" if Cx was selected, or to NEMA
20 "N2" if Nx was selected.

Selects either the following overload curves:

­OFF: Overload protection disabled

(external overload relay must be used)
N1: NEMA 10
N2: NEMA 20

N3: NEMA 30 - (not available if N ≥ 105)

C1: Class 10

C2: Class 20 - (not available if N ≥ 105)

f xxx

Service factor

f 100

100-130

Motor service factor.

%

Voltage calibration procedure

When the ASTAT-CD Plus is installed on site for the first time or after the logic printed circuit board is replaced, the voltage measurements will have
an accuracy of ±10%. To improve the voltage measurement accuracy up to ±3%, proceed as follows:

1. Turn the ASTAT-CD Plus ON and measure the RMS voltage on phases 1L1-3L2 using a calibrated voltmeter.

2. Search for the parameter “txxx”, set the measured voltage, and save this value by depressing the enter key. It is not necessary to save
this to the E2PROM, as the ASTAT-CD Plus does this automatically. NOTE: Set the actual, measured voltage while the ASTAT-CD Plus is
ON. DO NOT enter the motor nameplate voltage rating.

3. Once the ASTAT-CD Plus has been calibrated, this operation does not need to be repeated unless the logic printed circuit board has
been replaced or the ASTAT-CD Plus has been installed into a new application. NOTE: The parameter “txxx” will show the latest
calibration entry, which may differ from the actual voltage value.

Current calibration procedure

When the ASTAT-CD Plus is installed on site for the first time or after the logic printed circuit board is replaced, the current measurements will have
an accuracy of ±10%. The internal electronic overload protection is also affected by this procedure. To improve the current measurement accuracy
up to ±3% and to improve the accuracy of the motor overload protection, proceed as follows:

1. Search for the parameter “UF_ x” and enter the correct ASTAT-CD Plus frame type letter (“F”,”G”,”H”,..etc.).

2. Start the motor and measure the rms motor current using a calibrated ammeter. This measurement should be done at full load and full
speed and after the motor current has stabilized.

3. Search for the parameter “mxxx”, set the measured current and save this value by depressing the enter key. It is not necessary to save
this to the E2PROM, as the ASTAT-CD Plus does this automatically. NOTE: Set the actual rms measured current while motor is running
at full speed and under full load. DO NOT enter the motor nameplate current rating.

Once the ASTAT-CD Plus has been calibrated, this operation does not need to be repeated unless the logic printed circuit board has been replaced or
the ASTAT-CD Plus has been installed into a new application. NOTE: The parameter “mxxx” will show the latest entry, which may differ from the
actual current value.

4-5

4. Programming

4-5. Basic block parameters.

-BAS-

4-5-1. Basic Functions

Display

L xxx

T xx

a xx

d xxx

p xxx

b xx

I xxx

Note: (1) Parameters "p ", "b " and "I " are disabled while "C" is ON.

Function

Current limit

Starting torque

Ramp up time

Ramp down time

Kick start (1)

DC Brake time (1)

DC Brake Current (1)

Default Range Unit

L 400

t 25

a 15

d 020

p 000

b 00

I 050

100-L

10-90

01-99

001-120

000-999

00-99

000-250

max

Description

Sets Device current limit. Sets motor starting current limit

%

if parameter "N" is properly adjusted.

The maximum range setting is automatically calculated
by the unit according the following expression:
L

450 (Ir/In); Max. 700

max=

Sets the initial voltage applied to the motor.

%

Sets Voltage ramp up time. Motor acceleration time will

sec.

depend of load conditions.

Sets Voltage ramp down time. Motor deceleration time

sec.

will depend of load conditions.
Enabled only if the parameter "Sxxx" is ON.

During the time adjusted, provides 95% of full voltage to

ms.

motor at starting time. Useful for high static-friction loads
Enabled only if the parameter "Pxxx" is ON.

Provides DC braking at stopping time.

sec.

Enabled only if the parameter "Bxxx" is ON.

% I

%

n

4-5-2. Programmable basic functions

Display

S xxx

C xxx

STXX

SPXX

P xxx

Function

Soft stop selector

Pump control selector

Pump curve selection
at starting phase

Pump curve selection
at stopping phase

Notes:

- Curve 0 (both ST00, SP00): Standard voltage ramp up -starting- and ramp down -soft stop-

- Curve 1 (both ST01, SP01): Pump Algorithm based on estimated average PF -power factor- , with large sampling period.

- Curve 2 (both ST02, SP02): Pump Algorithm based on instantaneous PF with short sampling period.

- Curve 3 (both ST03, SP03): Pump Algorithm based on estimated average PF with short sampling period. Application: low pressure

- Curve 4 (SP04): Same as Curve 3, but with higher accuracy on PF average estimation. Application: high head pressure/low flow rate change.

- Curve 5 (SP05): Pump Algorithm based on former ASTAT-CD.

Kick start selector

Default Range

S OF F

C OF F

ST02

SP02

system/low flow rate change.

P OF F

OFF, ON, I3, I4

OFF, ON, I3, I4

00-03

00-05

OFF, ON, I3, I4

Description

Enables or disables all modes of Soft stop.

Enables the Pump control function. Usefull to limit fluid hammering.
The parameter "Sxxx" must also be enabled.
NOTE: Parameters "p ", "b " and "I " are disabled while "C" is ON

Choice of various pump control algorithms for starting:
0: Voltage ramp up 01-03: Various pump algorithms

Choice of various pump control algorithms for stopping phase:
0: Voltage ramp down 01-05: Various pump algorithms

Enables or disables the Kick start function.
If Pump control function “C” is enabled, both Kick start and DC Brake
functions are internally disabled.

F xxx

Override selector

F OF F

OFF, ON, I3, I4

4-6

When this function is enabled, the unit provides constant full voltage
after starting, producing the lowest harmonic distortion. Note that the
energy saving function is disabled when Override is enabled.

4. Programming

Programmable Basic Functions (follow from previous page)

z xxx

B xxx

4-6. Advanced block parameters

By-pass selector

DC Brake selector

z OF F

B OF F

-ADV-

OFF, ON, I3, I4

OFF, ON, I3, I4,

PON, PI3, PI4

This function provides control of an external by-pass contactor,
significantly lowering heating losses and eliminating harmonics.
When the By-Pass function “z” is enabled, the programmable relay
output 2r is automatically assigned to this function, and must be used
to control the external by-pass contactor.

Enables or disables the DC brake function.
When the DC Brake function “B” is enabled, the programmable relay
output 3r is automatically assigned to this function.
PON, PI3 or PI4 settings enable the DC Brake function just before
starting the motor. This is usefull to stop a fan which is rotating in
reverse at the starting time.

4-6-1. Advanced functions

Display Description

LKxx

R xxx

Function

Lock-out

E2PROM reading

Default Range Unit

LK02

R OF F

00-45

ON, OFF

min.

-

Sets time between consecutive starts. Setting "0" disables
this function.

Loads the parameters from the E2PROM to the temporal
buffer.

Q xxx

Y x

y xx

UVxx

uvxx

OVxx

ovxx

UCxx

ucxx

OCxx

ocxx

Factory settings

Retry

Retry time

Undervoltage (1)

Undervoltage trip time

Overvoltage (1)

Overvoltage trip time

Undercurrent

Undercurrent trip time

Overcurrent

Overcurrent trip time

Q OF F

Y 0

y 10

UV00

uv20

OV00

ov20

UC00

uc20

OC00

oc20

ON, OFF

0-4

01-99

00-50

00-99

00-30

00-99

00-99

00-99

00-50

00-99

sec.

%

sec.

%

sec.

%

sec.

%

sec.

Loads default factory settings to the temporal buffer.

­Resave to E2PROM if default settings are desired.

Allows up to four tries of automatic restart after a fault.

­Setting “0” disables this function.
Time between retries.

The unit trips if the line voltage decreases below the
percentage set. Setting “0” disables this protection.
NOTE: Perform voltage calibration procedure on page

4-5 before enabling this protection.

Delay trip time.

The unit trips if the line voltage increases above the per­centage set. Setting “0” disables this protection.
NOTE: Perform voltage calibration procedure on page

4-5 before enabling this protection.

Delay trip time.

The unit trips if the current decreases below the percent­age set. Setting “0” disables this protection.
NOTE: Perform current calibration procedure on page

4-5 before enabling this protection.

Delay trip time.

The unit trips if the current increases above the percent­age set. Setting “0” disables this protection.
NOTE: Perform current calibration procedure on page

4-5 before enabling this protection.

Delay trip time.

2axx
2dxx
2Txx

Note:

(1) Monitors L1

Dual ramp up
Dual ramp down
Dual starting torque

2a15
2d20
2T20

01-99
01-99
10-90

4-7

These are a secondary set of ramp up, ramp down and

%

starting torque parameters, which take over the primary

%

"a", "d" and "T" when the programmable function “A” is

%

enabled.

4-6-2. Programmable advanced functions

4. Programming

D xxx

J xx x

j xx

r xxx

A xxx

X xxx

XPxx

s xxx

FunctionDisplay

Linear ramp

Slow speed

Speed changeover

Reverse

Dual motor selector

Remote control selector

Comunication protocol

Station number

Default Range

D OF F

J OF F

j LO

r OF F

A OF F

X OF F

XP00

s 001

OFF, ON, I3, I4

OFF, I3, I4

LO, HI

OFF, ON, I3, I4

OFF, ON, I3, I4

OFF, ON, I3, I4

00-02

001-247

Description

This function provides linear acceleration and deceleration ramps in
a wider range of load conditions using tachogenerator feedback.
A DC Tacho-Generator coupled to motor must be used to provide an
analog signal feedback of 0-5VDC to terminals 7 and 8.

This function enables slow speed operation
Maximum operation time 120sec.
LO: Low Speed, 7% of rated speed.
HI: High Speed, 14% of rated speed.
Reverse direction is allowed in "High slow speed" mode only.
It provides 20% of rated speed.

This function allows dual motor control settings of acceleration,
deceleration and starting torque, and is useful to start or stop a motor
in diferent load conditions.
When this function is enabled, the parameters 2a, 2d and 2T take
over the parameters a, d and T. It allows dual motor control settings.

Allows serial communication control by SG, TD and RD terminals.
Check Appendix section for more details
Sets serial communications protocol

0: ASCII 1: Future use
2: Future use

ASCII protocol allows a maximum of 90 stations only.

4-6-3. Programmable relay output functions

FunctionDisplay

1r xx

2r xx

3r xx

The programmable relays can be set to the functions shown in the following table:

Output relay 1r

Output relay 2r

Output relay 3r

Range

20
21
22
23
24
25
26
27
28
29
30

Function

EOR
DC Brake
FAULT
Undervoltage
Overvoltage
RUN
Slow Speed
Undercurrent
Overcurrent
Disabled
Future use

Default Range

1r 25
(RUN)

2r 20
(EOR)

3r 21
(DC Brake)

Remarks

Detects end of voltage ramp. -This function may only be assigned to relay 2r-
DC Brake control command -This function may only be assigned to relay 3r-
Detects unit Fault status. ON is normal status and switches OFF if a fault occurs
Detects Undervoltage according limit adjusted in function “UV”
Detects Overvoltage according limit adjusted in function “OV”
Detects unit RUN status
Detects slow speed status
Detects Undercurrent according limit adjusted in function “UC”
Detects Overcurrent limits as adjusted in function “OC”
Disables the relay function

22-30

20, 22-30

21-30

Description

This is a programmable relay with one NO / NC dry contact to
ASTAT-CD Plus terminals 11-12-14.

This is a programmable relay with one NO dry contact to ASTAT-CD
Plus terminals 23-24.
This relay is automatically assigned to BY-Pass control if the function “z”
is ON. Any other assignment by the user is overwritten in this case.

This is a programmable relay with one NO dry contact to ASTAT-CD
Plus terminals 33-34.
This relay is automatically assigned to DC-Brake control if the
function “B” is ON. Any other assignment by the user is overwritten in
this case.

4-8

4. Programming

4-7. Application and basic settings

Different applications will require different characteristics and settings for the ASTAT-CD Plus. The table below lists typical settings for
various applications.

Settings (X X X)

Display

Parameters (1)

Nominal motor current N x x x 100

Current limit L x x x 400 375 400

Initial torque T x x x 025 030 035 020 020

Acceleration ramp time a x x x 015 015 030 030 015

Deceleration ramp time d x x x 020 040

Kick start time (2) p x x x 000 100

Soft stop S x x x OFF ON

Pump control C x x x OFF ON

Pump curve starting S T x x 02 02

Pump curve stopping S P x x 02 02

Kick start P x x x OFF ON

Overload trip curve(3) o x x x ooN2 ooN2 ooN2 ooC2 ooC1 ooC1

Service Factor(3) f x x x 100

Notes: (1) = GBAS Block Parameters unless noted(2)(3)

(2) = Parameter “p” is disabled while “C” is ON.
(3) = GCAL Block Parameters

Parameter

Factory
Default

Compressor

Mill Fan

Machine

Tool

Control

Pump

4-8. Saving parameters to E2PROM

Advance the display to K000 with
the C/V and up arrow button.

Change the parameter to K069 with
the up arrow button.

With K069 displayed, press the
enter button.

Display will show SET momentarily
and then display K ON.

Advance the display to WOFF with
the C/V and up arrow button.

Change parameter to W ON by using
the up arrow button.

With W ON displayed, press the
enter button.

Display the show SET momentarily
and then display WOFF.

4-9

5. Installation

5-1. Equipment installation

CAUTION! DISCONNECT POWER BEFORE INSTALLING OR SERVICING

ONLY SPECIALIZED PERSONNEL SHOULD INSTALL THE EQUIPMENT AND ONLY
AFTER HAVING READ THIS USER'S GUIDE.

THE USER IS RESPONSIBLE FOR ANY PHYSICAL INJURY OR MATERIAL DAMAGE
RESULTING FROM MISHANDLING THE EQUIPMENT.

5-2. General

Terminal Connections

Use minimum of 75°C copper wire only for connections to ASTAT-CD Plus terminals. The minimum wire size must conform to the 75°C
table according to applicable electrical codes. Tighten connections to the torque values given below. Supply conductors should have, as
a minimum, the same cross section as a full voltage starter.

Catalog Numbers Wire Range Torque, in-lb

QC*FDP - QC*KDP #14 - #3 AWG 40
QC*LDP - QC*MDP #14 - #2 AWG 125
QC*NDP - QC*QDP #6 AWG - 350kcmil 275
QC*RDP - QC*SDP #2 AWG - 2x250 or 1x600kcmil 550

QC*TDP #4 AWG - 6 x350kcmil 275

QC*UDP #4 AWG - 4x250 or 2x600kcmil 550

QC*VDP #4 AWG - 3x600kcmil 500

Signal Wiring

Signal wiring should be no longer than 18 feet (up to 80 feet when
using shield cable). It must be separated from power wires (line,
motor, commands relays, etc.) by at least four inches and, if they
cross, they should do so at a 90° angle.

10 cm 8 cm

Coil Surge Suppression

Relays and contactors located in the same housing as the equipment
should have an RC suppressor parallel to the coil (or a reverse
diode, if controlled by DC).

SIGNAL
POWER

CORRECT INCORRECT

A A C D D C

Power Factor Capacitors

Do not install capacitors to correct the power factor between equipment output and motor.

Transformers

If the equipment is fed by a line transformer, its rated power should be at least 1.5 times, but less than 10 times, higher than equipment supply.

Environment

When installing equipment, keep the following points in mind:

- The equipment should be installed vertically and hang over a
platform or bars. The vertical position is essential for proper cool air
circulation.

- Environmental conditions are in accordance with the following
ranges and maximum values:

- Operating temperature: 0°C to +55°C

- Relative humidity (without condensation): 95%

- Maximum altitude: 3000m
Reduce rating by 1.5% / °C from 40°C and 1% / 100m from 1000m

- Do not install equipment in environments containing explosive or
flammable gases, or near important heat sources.

- Equipment should be well ventilated, with minimum keeping
clearances as indicated in the illustration.

- When equipment is to be mounted on a platform subject to strong
vibrations, there should be an elastic base to protect the equipment.

- When mounted in an enclosure, the temperature inside the enclosure
must be kept within the range of 0-45°C (32-113°F).

50mm 50mm

5-1

150mm

ASTAT

100mm

5. Installation

5-3. Fuses, contactors and supply wiring

IEC Class 10
Ratings

Cat Number A W A mech. design) Size In A VA mm
QC _ F DP 17 67 25 6,600 CP URC 14.51/40 00 40 1 18 CL02 CL02 4

QC _ G DP 21 78 32 6,6 URD 30 XX 0063 00 50 1 18 CL03 CL03 4
QC _ H DP 27 88 40 6,6 URD 30 XX 0080 00 80 1 18 CL04 CL03 6
QC _ I DP 38 116 63 6,6 URD 30 XX 0100 00 100 1 18 CL45 CL04 10
QC _ J DP 58 208 80 6,6 URD 30 XX 0125 00 125 2 55 CL07 CL45 16
QC _ K DP 75 277 100 6,6 URD 30 XX 0160 00 160 2 55 CL08 CL06 25
QC _ L DP 86 302 125 6,6 URD 30 XX 0160 00 200 2 55 CL09 CL06 35
QC _ M DP 126 389 200 6,6 URD 30 XX 0250 00 250 2 55 CK75 CL07 50
QC _ N DP 187 719 250 6,6 URD 30 XX 0315 00 315 2 78 CK08 CL10 95
QC _ Q DP 288 1097 400 6,6 URD 31 XX 0500 2 550 2 78 CK95 CK85 185
QC _ R DP 378 1286 500 6,6 URD 31 XX 0630 2 630 4 118 CK10 CK85 240
QC _ S DP 444 1374 630 6,6 URD 32 XX 0800 2 800 4 118 CK11 CK95 Bus bar (1)
QC _ T DP 570 2086 800 6,6 URD 33 XX 1000 3 1000 4 118 CK12 CK10 Bus bar (1)
QC _ U DP 732 2352 1000 6,6 URD 33 XX 1250 3 1250 4 248 CK12 CK10 Bus bar (1)
QC _ V DP 1020 3000 1250 6,6 URD 233 XX 2000 - - 4 248 CK13 CK11 Bus bar (1)
QC _ X DP 1290 3839 2x800 6,6 URD 233 XX 2000 - - 4 248 CK13 CK12 Bus bar (1)

IEC Class 20
Ratings

Cat Number A W A mech. design) Size In A VA mm
QC _ F DP 14 56 20 6,600 CP URC 14.51/40 00 40 1 18 CL01 CL01 4

QC _ G DP 17 65 25 6,6 URD 30 XX 0063 00 50 1 18 CL02 CL02 4
QC _ H DP 22 74 32 6,6 URD 30 XX 0080 00 80 1 18 CL03 CL03 4
QC _ I DP 32 99 63 6,6 URD 30 XX 0100 00 100 1 18 CL04 CL04 6
QC _ J DP 48 178 80 6,6 URD 30 XX 0125 00 125 2 55 CL06 CL04 10
QC _ K DP 63 236 80 6,6 URD 30 XX 0160 00 160 2 55 CL07 CL04 16
QC _ L DP 72 257 100 6,6 URD 30 XX 0160 00 200 2 55 CL08 CL06 25
QC _ M DP 105 325 160 6,6 URD 30 XX 0250 00 250 2 55 CL10 CL06 35
QC _ N DP 156 591 200 6,6 URD 30 XX 0315 00 315 2 78 CK75 CL07 70
QC _ Q DP 240 901 315 6,6 URD 31 XX 0500 2 550 2 78 CK85 CK75 120
QC _ R DP 315 1063 400 6,6 URD 31 XX 0630 2 630 4 118 CK95 CK85 185
QC _ S DP 370 1136 500 6,6 URD 32 XX 0800 2 800 4 118 CK10 CK85 240
QC _ T DP 475 1721 630 6,6 URD 33 XX 1000 3 1000 4 118 CK11 CK95 Bus bar (1)
QC _ U DP 610 1950 800 6,6 URD 33 XX 1250 3 1250 4 248 CK12 CK10 Bus bar (1)
QC _ V DP 850 2491 1000 6,6 URD 233 XX 2000 - - 4 248 CK13 CK10 Bus bar (1)
QC _ X DP 1075 3168 1250 6,6 URD 233 XX 2000 - - 4 248 CK13 CK12 Bus bar (1)

In Total Fuses Fuses Fuses Control voltage Contactor Contactor Conductor

losses aM FERRAZ type BUSSMANN type DC 1 DC 3 section
100% In (F1) (XX=according (Typower Sicu 660V~) Fuse Consumpt. (2)

In Total Fuses Fuses Fuses Control voltage Contactor Contactor Conductor

losses aM FERRAZ type BUSSMANN type DC 1 DC 3 section
100% In (F1) (XX=according (Typower Sicu 660V~) Fuse Consumpt. (2)

(1) As per IEC 947 (2) The 3 contacts of DC3 must be connected in parallel

2

2

Branch circuit protection, UL

Gould-Shawmut, semi-conductor fuses Short-Circuit Rating Max @480V

Type Type Rating Class Breaker Non-

Cat Number A50QS
QC _ F DP 50A - 30A 35A 25KA 5KA

QC _ G DP 60A - 35A 40A 25KA 5KA
QC _ H DP 80A - 40A 50A 25KA 5KA
QC _ I DP 100A - 70A 80A 25KA 5KA
QC _ J DP 150A - 100A 125A 25KA 10KA
QC _ K DP 200A - 125A 150A 25KA 10KA
QC _ L DP 225A - 150A 150A 25KA 10KA
QC _ M DP 350A - 200A 250A 25KA 10KA
QC _ N DP 450A - 350A 350A 65KA 25KA
QC _ Q DP 600A - 500A 600A 65KA 25KA
QC _ R DP 2X500A in parallel - 600A 700A 65KA 25KA
QC _ S DP 2x600A in parallel - 600A 800A 65KA 25KA
QC _ T DP - 2x1000A in parallel - 800A 65KA 30KA
QC _ U DP - 2x1200A in parallel - 1000A 65KA 30KA
QC _ V DP - 2x1600A in parallel - 1200A 65KA 65KA

1

A50P

2

Max. Fuse Max. Circuit

RK5 & J Size Combination Combination <Remarks>

(1) Suitable for use on a circuit capable of

delivering not more than 100KA RMS
symetrical amperes, for 208V, 240V and up to
480V maximum, when used with the semi­conductor fuse for short-circuit protection. Listed
with Gould Shawmut Form 101, Type A5QS
or A50P.

(2) Suitable for use on a circuit capable of

delivering not more than 65KA RMS symetrical
amperes, for 208V, 240V and up to 480V
maximum, when used with contactors (isolation

*2
*2

or by-pass) that are also rated for 65KA
withstand.

NOTE: When ASTAT-CD Plus reduced voltage starters are used in conjunction with semi-conductor fuses, Type 2 Coordination to IEC 947-4 is attained. These
fuses are recommended for best overall short-circuit protection. The semiconductor fuse specified may provide branch circuit protection. Refer to local applicable
electrical codes.

5-2

5-4. Start-up

- Make sure equipment wiring corresponds to one of
the recommended routing diagrams or equivalent.

- Make sure the control wire harness corre­sponds to the control voltage used.

5. Installation

- If the motor has thermal protection sensor, remove the link between
terminals 5 and 6 prior to wire the sensor

110/120V ac

A1 A2 B1 B2

220/240V ac

A1 A2 B1 B2

- Adapt equipment rated current to motor, setting
the motor current In.

In

N x x x ; x x x =

x 100

Ir

1. Enter the motor nameplate full load amperes: (I

2. Enter the ASTAT-CD Plus nameplate full load amperes: (I

3. Divide Line 1 by Line 2 and multiply by 100. This is your N parameter value. _________

4. Enter the facility or installation maximum allowable amperes: _________

5. Divide Line 4 by Line 1 and multiply by 100. This is your maximum allowable
L parameter value governed by facility limitations. _________

6. Divide 450 by Line 3 and multiply by 100. If the result is greater than 700, enter 700.
This is you maximum allowable L parameter value governed by ASTAT-CD Plus limitations. _________

7. Enter the value of Line 5 or Line 6, whichever is lower. This is your maximum
allowable L parameter value. _________

) _________

n

- Set starting parameters as needed:

L x x x = 450/N

L x x x =

Im (start)

In (motor)

x 100

Starting torque T _ x x T _ 2 5
Acceleration ramp time a x x x a _ 1 5
Kickstart P ON/OFF/I3/I4 P OFF
Kickstart time p x x x (if P enabled) p 0 0 0
Current limit L x x x L 4 0 0

- Set overload trip curve as needed:

oxxx ; xx x OFF = disabled (extermal overload relay must be used

C1/C2 = IEC Class 10 or Class 20
N1/N2/N3= Nema 10, 20 or 30

- Set braking parameters as needed:

Soft stop S ON/OFF/I3/I4 S OFF
Decceleration ramp time d x x x d _ 2 0
DC injection brake B ON/OFF/I3/I4 B OFF
DC braking time b _ x x (if B enabled) b 0 0 0
DC braking current I x x x (if B enabled) I 0 5 0

If you change the default configuration and wish
to keep it, remember to rewrite the parameters
in E2PROM as follows:
(See page 4-9 for details)

- Set parameter K to ON (ON = 69 + )

- Set parameter W to ON

- Press (parameter W is set to OFF automatically)

- Send run command to equipment and make sure that operation is correct.

) _________

r

Factory setting

N 1 0 0

Factory setting

Factory setting

o N2

Factory setting

5-5. Troubleshooting

Symptom or Error & (Error Code) Possible Cause Measures to be taken

Display OFF

Fans not running
Equipment does not respond to

STOP / START controls

Motor will not start but display shows –
Ramp, Full, etc.

No control voltage
Main breaker tripped or fuse blown

F1 fuse blown on power supply PCB
Bad connection of flat ribbon wire joining

power supply PCB to control PCB

No voltage to fans

F2 fuse blown on power supply PCB

No power to gate circuits

Check wire harness and control voltage
Check and change, page 6-10

Verify connectors
Check Power Supply Board and Logic Board
for 5VDC. Use a DC voltmeter on the Power
Supply Board, (-) lead of voltmeter on the top
lead of C6 (located next to the black heatsink
on the right edge of the Power Supply Board)
and the (+) lead of voltmeter on top lead of
Diode AD21 or R25 (located on the upper
right corner of the Power Supply Board).

Verify voltage and connections

Check and change, page 6-10

Check 12VDC on Power Supply Board. Use a DC
voltmeter on the Power Supply Board, (-) lead of
voltmeter on the top lead of C6 (located next to the
black heatsink on the right edge of the Power Supply
Board) and the (+) lead of voltmeter on bottom lead
of Diode AD20 (located near the lower left corner of
the black heatsink on the Power Supply Board).

5-3

5. Installation

V

Symptom or Error & (Error Code) Possible Cause Measures to be taken

Frequency error (Ex10)
(admits 45Hz

≤

f main ≤ 65Hz)

Overload trip (Ex11)

Synchronism loss (Ex13)
Phase A, B, C thyristor (Ex14)

(Ex15)
(Ex16)

Heatsink thermostat (Ex17)

Motor thermistor (Ex18)

Phase A, B, C loss (Ex19)

(Ex20)
(Ex21)

Stalled rotor (Ex22)

No 1L1 phase or frequence is out of range

Excessive load or excessive current during
starting

Check 1L1 phase and/or mains frequence

Verify overload conditions during starting time and
steady state.

Check settings in parameters "Nxxx", "Lxxx", and "oxxx"
Phase 1L1 lost
Short circuited thyristor

Check 1L1 phase
Check thyristor module

Check ground connections and voltage to ground
Poor ribbon cable connection

No output phases
Heatsink thermostat tripped by overheating or

defective
Motor thermistor tripped by overheating or defective

Check 2T1, 4T2 and 6T3 phases
Check for adequate ventilation

Check thermostat and wiring
Check thermistor and wiring, if no thermistor

terminal 5 and 6 must be jumpered

No input / output phases

Check power wire harness for 1L1, 3L2, 5L3,
2T1, 4T2 and 6T3

Defective thyristor or ribbon wire harness
loose or defective

Equipment detected stalled motor rotor

Verify gate and cathode wire
harness. Verify thyristors

Restart equipment and check for an appreciable loss in
motor speed at any time

Internal error (Ex23)

Micro-controller malfunction

Check IC1 and IC8 are correctly inserted in their sockets.

Check for noise on control voltage power or line

Long start time (Ex25)

Current limit condition present more than
2 x ta sec. or 240 sec.

Increase current limit and / or acceleration
ramp time

(ta = acceleration ramp time)

Long slow speed time (Ex26) Reduce time slow speed is engaged

Equipment has been in slow speed mode more
than 120 sec.

Lock-out (Ex27)

The time between startings is less that the
adjusted in parameter "LKxx"

Undervoltage (Ex28)
Overvoltage (Ex29)

Undercurrent (Ex30)
Overcurrent (Ex31)

Retry (Ex32)

The line voltage exceeds of limit set in
parameters "UVxx" or "OVxx"

The motor current exceeds of limit set in
parameters "UCxx" or "OCxx"

The retry feature could not re-start the motor
after a fault

5-6. Thyristor check

S

hortcircuit

Use a testing lamp to check the defective power module between input and output phases.
If the lamp goes on, at least one of the thyristors has a short circuit.
With a tester, check the value or the R resistance between input and output of the same phase
(connector B on main PCB must be previously removed).

Check if settings are correct

This protection may be disabled

Check if settings are correct.

This protection may be disabled

Check if settings are correct.

This protection may be disabled

Check last message "e1xx" and correct.

Be sure that retry settings are correct as well.

1L1 (3L2 or 5L3)

Testing
lamp

3 to 6V

If R < 50KΩ, at least one of the thyristors is defective.

2T1 (4T2 or 6T3)

Open thyristor

S

With the simple assembly shown, the lamp should light when the S switch is closed and remain lit when open.
If not, the thyristor is defective.

5-4

10 ohms

L

3 to 6

6-1. Application diagrams

Basic diagram

Control Voltage
110 / 120V AC

A1A2 B1 B2

Control Voltage

220 / 240V AC

12 11 14

A1A2 B1 B2

Programmable Inputs

57 57 57 6 8

12

I3 I4

3457

DC1

1r 2r 3r

Programmable relay Outputs

6. Appendix

REMARKS:

1) The isolation contactor DC1, is not required to perform

L1 L2 L3

DC1 (1)

23

33

24

RDSG

TD

34

9

1 L1 3 L2 5 L3

2 T1 4 T2 6 T3

(

operation to the motor.
Be aware however that DC1 provides galvanic
isolation from the incoming line increasing the safety.

(2) In this example, Start and Stop command is enabled

by push-buttons. Permanent command is allowed as
well, wiring 1, 2 and 57 terminals as shown on
page 3-3.

(3) The output relays allow for direct action on contactors

according to ratings specified on page 3-2 of this
manual.

(4) The ASTAT-CD Plus is provided with an electronic

motor overload protection, which should be adequate
protection for most of the applications.
An external overload should be used if required by
local codes or to protect the motor against current
unbalance.

Start

Push-Button command (2)

Stop

Motor Thermistor

Basic diagram with by-pass control

Control Voltage
110 / 120V AC

Control Voltage

A1A2 B1B2

Control Voltage

220 / 240V AC

A1A2 B1B2

57 57 57 6 8

12

Start /Stop

(Permanent Command)

57 57

1

Start Stop

(Command by push-buttons)

12 11 1423243334

1r 2r 3r

Programmable Relay Outputs

Programmable Inputs

I3 I4

3457

2

Programmable

Inputs

DC1

DC2

Input

Motor Thermistor

Serial Comm.

RS232C

Tx

TD

+-

Analog Input

Tacho feedback

Rx Gr

RDSG

9

-+

V

0-10V

Analog Output

M

3 ~

L1 L2 L3

1 L1 3 L2 5 L3

2 T1 4 T2 6 T3

M

3 ~

6-1

FLT (4)

M2

Bypass

REMARKS:
(1) The isolation contactor DC1, is not re-

quired to perform operation to the motor.
Be aware however that DC1 provides gal­vanic isolation from the incoming line in­creasing the safety.

(2) In this example, Start and Stop command

is enabled by permanent command. Push­button control is allowed as well, wiring 1,
2 and 57 terminals as shown on page 3-3.

(3) The output relays allow for direct action on

contactors according to ratings specified
in page 3-2 of this manual.

(4) CAUTION:

In by-pass mode an external overload
relay must be used.

(5) By-pass control using function "zxxx" and

external contactor DC2. Details given bel­low.

By-pass control. Programming steps

1. The by-pass function may be enabled by

setting "zxxx" to ON. In this case the by­pass is automatically done after starting.
An alternative, if "zxxx" is set to one of the
programmable inputs "I3" or "I4", the by­pass may be controlled by one remote
signal (5). Check section 4-5-2 for more
details.

2. Once this function is enabled, the relay 2r
is automatically assigned to this function
(check section 4-6-3). This relay must be
used to control the by-pass contactor.

6. Appendix

6-1. Application diagrams

Basic diagram with jog (slow speed) function

Control Voltage

110 / 120V AC

A1A2 B1B2

Control Voltage

220 / 240V AC

12 11 14

A1A2 B1B2

Programmable Inputs

57 57 57 6 8

12

Start

Push-Button command (2)

I3 I4

3457

Forward Reverse

Stop

Jog (Slow Speed)

DC1

23

33

24

1r 2r 3r

Programmable relay Outputs

Motor Thermistor

RDSG

34

TD

9

L1 L2 L3

1 L1 3 L2 5 L3

2 T1 4 T2 6 T3

M

3 ~

DC1 (1)

FLT (4)

REMARKS:
(1) The isolation contactor DC1, is not required to perform

operation to the motor.
Be aware however that DC1 provides galvanic isolation
from the incoming line increasing the safety.

(2) In this example, Start and Stop command is enabled by

push-buttons. Permanent command is allowed as well,
wiring 1, 2 and 57 terminals as shown on page 3-3.

(3) The output relays allow for direct action on contactors

according to ratings specified on page 3-2 of this manual.

(4)

The ASTAT-CD Plus is provided with an electronic motor
overload protection, which should be adequate protec­tion for most of the applications.
You should use an external overload protection if
required by local codes or to protect the motor against
current unbalance.

(5) Slow Speed for Jog forward or reverse using program-

mable inputs I3, I4. Details given bellow.

Jog (Slow Speed) function. Programming steps

1. The slow speed function may be enabled by setting

"Jxxx" to I3. In this case Slow Speed is allowed by a push­button wired to ASTAT-CD Plus's terminals 3-57.
Reverse jog is also possible by setting "rxxx" to ON. As
alternative, if "rxxx" is set to programmable input I4,
forward or reverse may be controlled by remote push­button signal (5). Check section 4-6-3 for more details.

2. Slow Speed can be effected with ASTAT-CD Plus in stop
status. Slow speed and normal run commands are
internally interlocked.

Basic diagram with DC brake injection

Control Voltage

110 / 120V AC

A1A2 B1B2

Control Voltage

220 / 240V AC

A1A2 B1B2

57 57 57 6 8

12

Start /Stop (2)

(permanent Command)

FLT

DC1

12 11 14

Programmable relay Outputs

Programmable Inputs

I3 I4

3457

23

24

1r 2r 3r

Motor Thermistor

DC3

33

TD

34

RDSG

9

L1 L2 L3

1 L1 3 L2 5 L3

2 T1 4 T2 6 T3

DC3

M

3 ~

6-2

DC1 (1)

FLT (4)

REMARKS:
(1) The isolation contactor DC1, is not required to perform

operation to the motor.
Be aware however that DC1 provides galvanic isolation
from the incoming line increasing the safety.

(2) In this example, Start and Stop command is enabled by

permanent command. Push-buttons control is allowed
as well, wiring 1, 2 and 57 terminals as shown on
page 3-3.

(3) The output relays allow for direct action on contactors

according to ratings specified in page 3-2 of this manual.

(4)

The ASTAT-CD Plus is provided with an electronic motor
overload protection, which should be adequate protec­tion for most of the applications.
An external overload relay should be used if required
by local codes or to protect the motor against current
unbalance.

(5) DC brake at stopping time is provided by the DC brake

function and external contactor DC3.
CAUTION:
The 3 contacts of DC3 must be connected in parallel.
Mandatory between 2T1 and 4T2 phases, otherwise a
short-circuit can occur

DC brake function. Programming steps

1. The DC function may be enabled by setting "Bxxx" to ON.

2. Once this function is enabled, the relay 3r is automatically

assigned to this function. This relay must be used to
control the DC brake contactor.

Check section 4-5-1 and 4-5-2 for more details

6-1. Application diagrams

Basic diagram with linear ramp

Control Voltage

110 / 120V AC

A1A2 B1B2

Control Voltage

220 / 240V AC

12 11 14

A1A2 B1B2

Programmable Inputs

57 57 57 6 8

12

Start

Push-Button command (2)

I3 I4

3457

Stop

DC1

23

24

1r 2r 3r

Programmable relay Outputs

Motor Thermistor

6. Appendix

REMARKS:

L1 L2 L3

DC1 (1)

33

RDSG

34

TD

9

1 L1 3 L2 5 L3

2 T1 4 T2 6 T3

M

3 ~

FLT (4)

(1) The isolation contactor DC1, is not required to perform

operation to the motor.
Be aware however that DC1 provides galvanic isolation
from the incoming line increasing the safety.

(2) In this example, Start and Stop command is provided by

push-buttons. Permanent command is allowed as well,
wiring 1, 2 and 57 terminals as shown on page 3-3.

(3) The output relays allow for direct action on contactors

according to ratings specified in page 3-2 of this manual.

(4)

The ASTAT-CD Plus is provided with an electronic motor
overload protection, which should be adequate protec­tion for most of the applications.
An external overload relay should be used if required
by local codes or to protect the motor against current
unbalance.

(5) Linear ramp provided by "Dxxx" function. A tacho

generator must be used as feedback. Details given
bellow.

Linear ramp function. Programming steps

1. The linear ramp function may be enabled by setting

"Dxxx" to ON. In this case, linear ramp is independent of
the load.
This function needs the speed feedback provided by an
external tacho generator. Check section 4-6-2 for more
details.

6-3

6. Appendix

6-2. Serial communications

ASTAT-CD Plus is able to send and receive data through a serial RS232 port. Within this port ASTAT-CD Plus communicates with a host PC.

For RS232 ASCII communications, parameter "XP" must be set to 0.

6-2-1. RS232 port, wiring and communications settings

RS232 is an operating standard of communication only in terms of electrical characteristics (voltage, timing, etc.) while the communication
procedures are defined by ASCII.
The maximum allowed RS232 cable length is 3 meters. ASTAT-CD Plus uses a connector with only 3 pins: TD, RD, SG.

Astat Terminal Name

TD Transmit Data
RD Receive Data
SG Signal Common

Pin

Computer 2 TD ASTAT-CD Plus

RS232 connector 3 RD

D-SUB9 5 SG

RS232 cable

The following table indicates the communications setting used by ASTAT-CD Plus to perform data communication via its serial port.

Name Setting Description

Baud Rate 9600 bps Bits per second transmission rate
Parity None Data error checking method
Data Bits 8 Number of data bits in each transmission
Start Bits 1 Number of bits to indicate beginning of transmission
Stop Bits 2 Number of bits to indicate ending of transmission
Data ASCII Communications protocol used
Handshaking None No need to request to send or clear to send

6-4

6. Appendix

6-2-2. ASCII protocol

To select this communications protocol, XP must be set to 0.
It is possible to operate the ASTAT-CD Plus from a host using standard ASCII characters. Two functions are available to be able to READ and
WRITE parameters.

Write Parameters to ASTAT-CD Plus:

To write data into a parameter, the command format is the following:

Request from host : :ssWxxxyyy➥
Response from the ASTAT : :ssWxxxyyy➥

where ‘:’ is a char to indicate the command start, ‘ss’ is the station address, ‘xxx’ (3 bytes needed) is the parameter number, and

‘yyy’ (3 bytes needed) is the value to write into the parameter. The ‘➥‘ is the return key to indicate the command stop.

Note: the parameters modification is not allowed while the motor is operating.

Read Parameters from ASTAT-CD Plus:

To read a parameter, the command format is the following:

Request from host : :ssRxxx➥
Response from the ASTAT : :ssRxxxyyyyy➥

where ‘:’ is a char to indicate the command start, ‘ss’ is the station address, ‘xxx’ (3 bytes needed) is the parameter number, and

‘yyyyy’ (5 chars response) is the value of the parameter. The ‘➥‘ is the return key to indicate the command stop.

Examples:

If we are trying to communicate with station 2:

- to start the unit, the command will be: :02W060000➥

- to stop the unit, the command will be: :02W060001➥

- to set the acceleration ramp time to 35 sec., the command will be: :02W005035➥

- to know which overload curve is selected, the command will be: :02R016➥ ; ( if, for instance the response is :02R01600004➥,

this means that the overload curve selected is IEC class 10 ).

The Table shown in 6-2-3 provides a complete reference for the parameters that can be controlled by the serial interface.

6-5

6. Appendix

6-2-3. List of parameters that can be controlled by the serial interface

Parameter Parameter Function Read/Write Range Comments
number name (R/W)

0 Status Soft starter status R/ - 0 - 14 0: ON

1: STOP
2: LOCK
3: Alarm (errors)
4: PULS
5: RAMP
6: FULL
7: SAVE
8: SOFT
9: DCBK
10: FULL (override)
11: Not used
12: INCH
13: TACH
14: PUMP

1MMotor current R/-

2NNominal motor current (% In/Ir)R/W40-120
3LCurrent limit (% Im/In)R/W 100-700
4TStarting torque (% DOL torque) R/W 10-90
5aAcceleration ramp time (sec) R/W 1-99
6dDeceleration ramp time (sec) R/W 1-120
7pKick start time (msec) R/W 0-999
8bDC brake time (sec) R/W 0-99
9I DC brake current (% In)R/W 000-250
10 S Soft stop control R/W 0-3 0: OFF

11 C Pump control R/W 0 -3 0 : OFF

12 P Kick start control R/W 0 -3 0: OFF

13 F Override R/W 0-3 0: OFF

14 B DC brake control R/W 0-6 0: OFF

15 LK Lockout (min.) R/W 0-45
16 o Overload trip curve R/W 0-5 0: OFF

17 internal use
18 W Write EEPROM -/W 1
19 RRead EEPROM -/W 1
20 — - internal use
21 v Software version R/- xx x vxxx
22 — - internal use
23 — - internal use

% In or Amps depending on UF parameter

1: ON
2: I3
3: I4

1: ON
2: I3
3: I4

1: ON
2: I3
3: I4

1: ON
2: I3
3: I4

1: ON
2: I3
3: I4
4: PON
5: PI3
6:PI4

1: N1
2: N2
3: N3
4: C1
5: C2

6-6

6. Appendix

Parameter Parameter Function Read/Write Range Comments
number name (R/W)

24 1r Programmable relay 11-12-14 R/W 22-30 See programmable

relays functions in page 3-6

25 2r Programmable relay 23-24 R/W 20,22-30
26 3r Programmable relay 33-34 R/W 21-30
27 OC Overcurrent (%I
28 oc Overcurrent time (sec) R/W 0-99
29 r Reverse slow speed R/W 0-3 0: OFF

30 Y Retry attempts R/W 0-4
31 y Retry time (sec) R/W 1-99
32 UV Undervoltage (%U) R/W 0-50 0: OFF
33 uv Undervoltage time (sec) R/W 0-99
34 OV Overvoltage (%U) R/W 0-30 0: OFF
35 ov Overvoltage time (sec) R/W 0-99
36 UC Undercurrent (%I
37 uc Undercurrent time (sec) R/W 0-99
38 PF Power factor (%) R/- 00-99
39 U Nominal voltage (volt) R/W 100-500
40 V Line voltage (volt) R/­41 w Power (KW*10) R/­42 X Local/remote control 0-3 0: OFF

43 DLinear ramp control R/W 0-3 0: OFF

44 J Slow speed control R/W 0 -2 0: OFF

45 j Slow speed type R/W 0- 1 0: HI

46 2a Secondary acceleration ramp time (sec) R/W 1-99
47 2d Secondary deceleration ramp time (sec) R/W 1-99
48 A Dual ramp selection R/W 0-3 0: OFF

49 UF Unit frame R/W 0-16 0: not defined

50 E Elapsed time (hours) R/­51 — - internal use
52 QRecall factory settings -/W 1
53 2T Secondary starting torque (%DOL torque) R/W 10-90
54 m Current calibration R/­55 — - internal use
56 z Bypass function R/W 0 -3 0: OFF

57 — - internal use
58 f Service factor (%I
59 t Voltage calibration R/- 000-600
60 RUN/STOP RUN/STOP order -/W 0: RUN

61 — - internal use
62 — - internal use
63 — - internal use
64 — - internal use

n)

n)

n)

R/W 0-50 0: OFF

1: ON
2: I3
3: I4

R/W 0-99 0: OFF

1: ON
2: I3
3: I4

1: ON
2: I3
3: I4

1: I3
2: I4

1: LO

1: ON
2: I3
3: I4

1 to 16: F to X frames

1: ON
2: I3
3: I4

R/W 100-130

1: STOP

6-7

6. Appendix

Parameter Parameter Function Read/Write Range Comments
number name (R/W)

65 — - internal use
66 — - internal use
67 — - internal use
68 — - internal use
69 — - internal use
70 ST Pump Control selection curve R/W 0-3 0 : standard voltage ramp

71 — - internal use
72 — - internal use
73 SP Pump Control selection curve R/W 0-5 0 : standard voltage ramp

74 — - internal use
75 — - internal use
76 — - internal use
77 — - internal use
78 — - internal use
79 — - internal use
80 — - internal use
81 — - internal use
82 — - internal use
83 XP Communication protocol R/W 0-2 0 : ASCII

84 s Station number for communication R/W 1-247
85 e0xx error e0 R/- xx: error code
86 e1xx error e1 R/- xx: error code
87 e2xx error e2 R/- xx: error code
88 e3xx error e3 R/- xx: error code

1-3 : Pump algorithms

1-5 : Pump algorithms

1 : Future use
2 : Future use

6-8

6-3. Dimensions

6. Appendix

ABC

QC_FDP 200 160 6
QC_GDP 200 160 6
QC_HDP 200 160 6
QC_IDP 250 200 31

QC _ JDP , QC _ KDP QC _ LDP , QC _ MDP

6-9

6-3. Dimensions

6. Appendix

Terminal detail

Terminal

details

ABCDEFGHI J KL

QC_NDP 510 490 305 460 465 9 53 106 54 259 70 168
QC_QDP 510 490 305 460 465 9 53 106 54 259 70 168
QC_RDP 550 540 317 480 495 9 59 118 54 275 78 168
QC_SDP 550 540 317 480 495 9 59 118 54 275 78 168
QC_TDP 590 685 317 520 640 9 59 118 64,5 270 100 168
QC_UDP 790 850 402 700 805 11 60 120 120 352 120 175
QC_VDP 790 850 402 700 805 11 60 120 120 352 120 175
QC_XDP 810 1000 407 720 955 11 70 140 110 357 120 175

QC _ NDP
QC _ QDP

QC _ TDP A

QC _ RDP
QC _ SDP

QC _ UDP 6
QC _ VDP 10

6-4. P.C.B.s layout

MAIN

TRANSFORMER

F2 F1

PULSE
TRAFO

PULSE
TRAFO

QC _ XDP

ControlSupply

A

C / V

PULSE

TRAFO

B

6-10

DEH-40397B 0902

GE Industrial Systems

General Electric Company
41 Woodford Avenue, Plainville,CT 06062
www.GEindustrial.com

©2002 General Electric Company