GE Industrial Solutions ASTAT-CD Plus Solid-State Starters User Manual

NOTE: POWER MUST BE REMOVED

BEFORE SERVICING.

Size F, G, H or I
Cover removal

Terminal connector

Cover

Figure 1. Terminal removal

Step 1. Remove the two 12- point plug-in terminal

connectors by inserting a flat-head screwdriver
between the terminal connector and the
ASTAT-CD Plus cover.

Do not remove wiring from terminal
connectors.

Carefully release the terminal connector from
pins (Figure 1). Carefully pull the terminal
connectors (with wiring) straight off the
ASTAT-CD Plus starter.

Step 2. Remove the plastic cover by using a flat-head

screwdriver to depress and release the plastic
tab on each side of the cover (Figure 2).

Figure 2. Cover removal

1

ASTAT®-CD Plus Solid-State Starters

DEH-40418 Service Instructions

Contents

Size F, G, H or I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

To replace Logic Board . . . . . . . . . . . . . . . . . . . . 2

To replace Power Supply Board . . . . . . . . . . . . . 2

To replace Protection Board . . . . . . . . . . . . . . . . 4

To replace SCR modules . . . . . . . . . . . . . . . . . . . 5

Size J, K, L or M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

To replace Logic Board . . . . . . . . . . . . . . . . . . . . 7

To replace Power Supply Board . . . . . . . . . . . . . 8

To replace Protection Board . . . . . . . . . . . . . . . . 9

To replace SCR modules . . . . . . . . . . . . . . . . . . 10

Size N, Q, R or S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

To replace Logic Board . . . . . . . . . . . . . . . . . . . 13

To replace Power Supply Board . . . . . . . . . . . . 14

To replace Protection Board . . . . . . . . . . . . . . . 15

To replace SCRs . . . . . . . . . . . . . . . . . . . . . . . . . 16

Size T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

To replace Logic Board . . . . . . . . . . . . . . . . . . . 18

To replace Power Supply Board . . . . . . . . . . . . 19

To replace Protection Board . . . . . . . . . . . . . . . 20

To replace SCRs . . . . . . . . . . . . . . . . . . . . . . . . . 21

Size U or V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

To replace Logic Board . . . . . . . . . . . . . . . . . . . 24

To replace Power Supply Board . . . . . . . . . . . . 25

To replace Protection Board . . . . . . . . . . . . . . . 26

To replace SCR modules . . . . . . . . . . . . . . . . . . 27

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . 30

Renewal Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Instructions For Changing Circuit
Boards and SCRs

On Sizes F, G, H, I, J, K, L, M, N, Q, R, S, T, U, V

Logic Board, QCX000143

Power Supply Board, QCX000144

Protection Board, See Renewal Parts List, p. 32

SCRs - See Renewal Parts List, p. 32

ASTAT-CD Plus Service Instructions

2

To replace Logic Board (top board)

Important: Always handle boards by
edges and do not distort parts on board.

Unplug Logic

Screws ribbon cable Board

Power Unplug ribbon cable

Supply Board (Step3)

Figure 3. Board and part locations

Step 3. To remove Logic Board, unplug the two

ribbon cables from the Logic Board.

Step 4. Remove the 4 corner screws holding the

Logic Board to the stand-offs below the Logic
Board. Remove the Logic Board.

Logic Board

Ribbon cable

Figure 4. Logic Board removal

Step 5. Reassemble Logic Board to the starter. With

the display on the Logic Board at the upper
left corner, place the board on the standoffs
and attach the Logic Board in the reverse
order as listed in Steps 3 and 4 above. Make
sure the ribbon cable at the bottom of the
ASTAT is fully seated on both circuit boards
and that the ribbon cable will not interfere
with or touch the cover.

Step 6. Reassemble the plastic cover and the terminal

connectors by lowering the cover over the
boards. Carefully push down the cover until
the two tabs snap into place. It may be
necessary to push in slightly on the outside of
the lower plastic housing.

Replace the terminal connectors through the
plastic cover, onto the connector strips. Make
certain that the terminal connectors snap into
place.

To replace Power Supply Board

NOTE: POWER MUST BE REMOVED
BEFORE SERVICING.

The Power Supply Board location is shown
in Figure 5. It has gray and orange
transformers visible from the sides.

Step 7. Remove the cover and Logic Board using

steps 1 - 4.

Ribbon cable

Power Supply Board Control housing

Figure 5. Power Supply Board

ASTAT-CD Plus Service Instructions

3

Step 8. Remove the 4 screws holding the Power

Supply Board to the black plastic housing
(Figure 6).

Screws to remove

Figure 6. Removing screws holding Power

Supply Board

Step 9. Lower the top of the Power Supply Board to

view the yellow and blue gate leads to the
SCRs (Figure 7).

NOTE: Check the blue and yellow gate wires
for a number marking before removing
these wires. Each gate wire must have a
number marking correlating to the terminal
numbers on the Power Supply Board (1
through 12) to facilitate reassembly.

Gate leads Protection Board

Bottom of Power Supply Board Gate terminal board

Figure 7. Gate leads, Protection and

Power Supply Boards

Step 10. Remove the blue and yellow gate wires from

the small 4- point gate Terminal Boards, 1 on
the component side and 2 on the solder side
of the Power Supply Board, with a small
screwdriver.

These wires must be reconnected to the new
Power Supply Board at the proper numbered
terminals for proper operation of the starter.

Remove the Power Supply Board. Remove
the hex standoffs, nuts and washers from the
Power Supply Board for use on the
replacement board.

Step 11. Reassemble the standoffs to the new Power

Supply Board. Reconnect the gate wires.
Reference Figure 8 for gate lead connections.

Step 12. Reassemble the Logic Board, cover and

terminal connectors using Steps 5 - 6.

Figure 8. Gate lead connections

Y= yellow wire.

B = blue wire.

SCR lead pairs are to be twisted to reduce EMI

(not shown in sketch).

ASTAT-CD Plus Service Instructions

4

To replace Protection Board

NOTE: POWER MUST BE REMOVED
BEFORE SERVICING.

Current
transformers

6- point Terminal
Board

MOVs

Protection Board

Figure 9. Protection Board

Step 13. Remove the cover, Logic Board and Power

Supply Board using steps 1 - 10.

Step 14. Reposition red MOVs as shown. Raise MOVs

and twist so that Protection Board can be
removed over the MOVs (Figure 10).

MOV

Power
Supply
and Logic
Board
assembly

Figure 10. MOV positioning

Step 15. Disconnect the 4 leads from the 2 current

transformers and remove the jumper on pins
1 and 2 on the 6 -point Terminal Board (TB),
located at the top right edge of the Protection
Board. Identify these lead locations to assure
the same connections are made to the 6­point Terminal Board on the new Protection
Board (Figure 11).

Current
transformer leads

6- point Terminal
Board

Small screwdriver

Figure 11. Removing wires from Terminal

Board

Step 16. Loosen the 6 screws holding the Protection

Board to the main bus bars. Remove the
Protection Board from the ASTAT-CD Plus
(Figure 12).

Remove 6 screws holding Protection Board

Figure 12. Remove screws

ASTAT-CD Plus Service Instructions

5

Reassembly

Step 17. Reassemble the new Protection Board to the

starter with screws, CT leads and jumper.
Reassemble the Power Supply Board, Logic
Board, cover and terminal connections using
Steps 11, 5 and 6.

To replace SCR modules
(Sizes F, G,H and I)

NOTE: POWER MUST BE REMOVED
BEFORE SERVICING.

Disassembly

Step 18. Remove the Logic Board, Power Supply

Board and Protection Board using Steps
13-16.

Step 19. Remove MOVs and bus bars from the SCR

Module to be replaced (Figure 13).

Step 20. Remove the mounting screws at each end of

the SCR Module and remove the SCR
Module. Retain all parts and hardware
removed from the SCR module for
reassembly.

Current
transformers

SCR modules

MOV

Bus bars

Figure 13. Removing bus bars

Figure 14. SCR Modules removed

Assembly

Requires tools (#2 Phillips head screwdriver, Allen
wrench and Torque wrench for screws), Scotchbrite
or equivalent abrasive, a mild solvent to clean surfaces
and Electrolube 2 GX or equivalent thermal grease.

The mounting surface of the heatsink must be flat
and clean (i.e., bare metal) and the SCR surface must
be clean. Thermal compound must be coated on all
mating surfaces between the SCR package and the
heatsink. Care must be taken to use the specified
torque for mounting the SCR package.Step 21.
For SCR module mounting, clean the heatsink
surface with a fine abrasive such as Scotchbrite,
remove all particles from the surface of the heatsink
and wipe the SCR mounting surface with a mild
solvent. Apply a light coat of thermal compound such
as Electrolube 2 GX to both the SCR and heatsink
surfaces. Place the contact face of the SCR package on
the mating heatsink surface and move the SCR
package back and forth several times to distribute the
thermal compound evenly over the contact surfaces.

Step 22. Use the screws provided to attach the SCR

package to the heatsink. Tighten the screws
alternately to the specified torque
requirement for the SCR package.

Torque requirements are as follows: Tighten
the screws through the SCR package to
heatsink— 44 in lb.

ASTAT-CD Plus Service Instructions

6

Step 23. Reassemble Bus Bars and MOVs to SCR

Modules with torque of 26 in lbs.

Step 24. Reassemble Protection Board, Power Supply

Board, Logic Board, cover and terminal
connectors using Steps 17, 11, 5 and 6.





Remove all power from ASTAT-CD Plus

SCR must be disconnected from ASTAT-CD Plus control (yellow and blue
leads disconnected from SCR) and no load connected to ASTAT-CD Plus.



S2

+

5VDC

-

SCR Test Circuit 

Anode

20Ω

Gate

1W

Light

(~.15AMP to .20AMP LOAD)

(SCR)
Cathode

S1

+

-

Figure STC

With S1 closed and S2 open, the lamp should be off. 
If lamp is on, SCR is shorted.

With S1 closed and S2 closed, the lamp should turn on. 
When S2 is opened, lamp should stay on. SCR is good.

ASTAT-CD Plus Service Instructions

7

Sizes J, K, L or M

Cover Removal

NOTE: POWER MUST BE REMOVED
BEFORE SERVICING.

Steel cover

Terminal connector

Figure 1. Remove terminal connectors

Step 1. Remove the two 12- point plug-in terminal

connectors by inserting a flat-head
screwdriver between the terminal connector
and the ASTAT-CD Plus cover.

Do not remove wiring from terminal
connectors.

Carefully release the terminal connectors
from pins (Figure 1). Carefully pull the
terminal connectors (with wiring) straight off
the ASTAT-CD Plus starter.

Step 2. Remove the front steel cover by removing the

4 Phillips screws. Set steel cover aside.

Screwdriver
through slot in
side of steel
housing

Figure 2. Cover removal

Step 3. Remove the plastic cover by using a flat-head

screwdriver to depress and release the plastic
tab on each side of the cover (Figure 2).

To replace the Logic Board (top board)

Important: Always handle boards by
edges and do not distort parts on board.

Step 4. To remove Logic Board, unplug the two

ribbon cables from the Logic Board.

Screws

Logic Board

Figure 3. Board location

Step 5. Remove the 4 corner screws holding the

Logic Board to the standoffs below the Logic
Board. Remove the Logic Board.

Step 6. Reassemble Logic Board to the starter. With

the display on the Logic Board at the upper
left corner, place the board on the standoffs
and attach the Logic Board in the reverse
order as listed in Steps 5 and 4 above. Make
sure the ribbon cable at the bottom of the
ASTAT is fully seated on both circuit boards
and that the ribbon cable will not interfere
with or touch the cover.

Step 7. Reassemble the plastic cover and the terminal

connectors by lowering the cover over the
boards. Carefully push down the cover until
the two tabs snap into place. It may be
necessary to push in slightly on the outside of
the lower plastic housing.

Replace the front steel cover using the 4
Phillips screws.

ASTAT-CD Plus Service Instructions

8

Step 10. If a yellow/green ground wire is connected to

the bottom of the Power Supply Board, it
must be disconnected. Lower the top of the
Power Supply Board to view the yellow and
blue gate leads to the SCRs (Figure 6).

NOTE: Check the blue and yellow gate wires
for a number marking before removing these
wires. Each gate wire must have a number
marking correlating to the terminal numbers
on the Power Supply Board (1 through 12)
to facilitate reassembly.

Protection
Board

Gate leads
Gate Terminal

Board
Bottom of Power

Supply Board

Figure 6. Gate leads, Protection and Power

Supply Boards

Step 11. Remove the blue and yellow gate wires from

the small 4- point gate terminal boards, 1 on
the component side and 2 on the solder side
of the Power Supply Board, with a small
screwdriver. These wires must be reconnected
to the new Power Supply Board at the proper
numbered terminals for proper operation of
the starter. Remove the Power Supply Board.
Remove the hex standoffs, nuts and washers
from the Power Supply Board for use on the
replacement board.

Remove gate leads Protection Board

Gate leads Power Supply & Logic Board assembly

Figure 7. Board location

Replace the terminal connectors through the
plastic cover, onto the connector strips. Make
certain that the terminal connectors snap into
place.

To replace Power Supply Board

NOTE: POWER MUST BE REMOVED
BEFORE SERVICING.

The Power Supply Board location is shown
below (Figure 4). It has gray and orange
transformers visible from the sides.

Step 8 Remove the cover and Logic Board using

Steps 1 - 5.

Power Supply Board Ribbon cable

Control housing

Figure 4. Removing Logic Board

Step 9. Remove the 4 screws holding the Power

Supply Board to the black plastic housing
(Figure 5).

Screws to
remove

Figure 5. Removing screws holding

Power Supply Board

ASTAT-CD Plus Service Instructions

9

Step 12. Reassemble the standoffs to the new Power

Supply Board. Reconnect the gate wires.
Reference Figure 8 for gate lead connections
for Size J, Figure 9 for Size K, or Figure 10 for
Sizes L and M.

Step 13. Reassemble the Logic Board, cover and

terminal connectors using Steps 6 - 7.

Figure 8. Gate lead connections (Size J)

Figure 10. Gate lead connections

(Sizes L and M)

SCR lead pairs are to be twisted to

reduce EMI (not shown in sketch).

Figure 9. Gate lead connections (Size K)

Y= yellow wire (gate). B = blue wire (cathode)

A PHASE

SCR

4567 4567 4567

Y
YB

234

1

TB1

B = Blue(SCR-Cathode connection)
Y = Yellow(SCR-Gate connection)

POWER BOARD - INVERTED

B PHASE

SCR

B

5678 91011 12

TB2 TB3

C PHASE

SCR

A PHASE

SCR

4
5

Y
YB

234

1

TB1

B PHASE

SCR

674

5

B

5678 91011 12

674

TB2 TB3

C PHASE

SCR

5

6
7

A PHASE

SCR

4567 4567 4567

Y
Y

234

1

TB1

B = Blue(SCR-Cathode connection)
Y = Yellow(SCR-Gate connection)

POWER SUPPLY BOARD - SOLDERSIDE

B PHASE

SCR

B
B

5678 91011 12

TB2 TB3

C PHASE

SCR

B = Blue(SCR-Cathode connection)
Y = Yellow(SCR-Gate connection)

POWER SUPPLY BOARD - SOLDERSIDE

ASTAT-CD Plus Service Instructions

10

To replace the Protection Board.

NOTE: POWER MUST BE REMOVED

BEFORE SERVICING.

Step 14. Remove the cover and Logic Board/ Power

Supply Board assembly using steps 1 - 3, 9-10.

Step 15. Remove 6 wire connectors from the

Protection Board (Figure 11). Note the
locations of these terminals for reassembly.

6- point Terminal
Board

Protection
Board

Wire connectors

Figure 11. Remove push on wire connectors

Step 16. Disconnect the 4 leads from the two current

transformers and the 2 leads from the
thermostat to the 6 -point Terminal Board
(TB) (located at the top right edge of the
Protection Board)(Figure 10). Label these
leads to assure connections are the same to
the 6- point terminal board on the new
Protection Board.

Step 17. Loosen the 4 screws holding the Protection

Board to the housing. Remove the Protection
Board from the ASTAT-CD Plus.

Step 18. Reassemble the new Protection Board, CT

leads, thermostat leads, screws, gate wires and
ground wire, Logic and Power Supply Board
assembly, screws and ribbon connectors in the
reverse order of the above listed disassembly
(steps 12 and 6).

Step 19. Reassemble the plastic cover, connectors and

sheet metal covers using step 7.

To replace SCR modules

NOTE: POWER MUST BE REMOVED
BEFORE SERVICING.

SCR disassembly instructions - Size J

Current
transformers

SCR modules

Bus bars

Figure 12. SCR module, MOV and bus bar

location (Size J)

SCR disassembly instructions ­Sizes L and M

MOV

SCR modules

Bus bars

Connectors to
Protection Board

Figure 13. SCR module, MOV and bus bar

location (Sizes L and M)