Enertronica Santerno ASA 4.0 Basic User manual

Enertronica Santerno S.p.A.

Via della Concia, 7 - 40023 Castel Guelfo (BO) Italy

Tel. +39 0542 489711 – Fax +39 0542 489722

www.santerno.com - info@santerno.com

- 15P0092B100 -

ASA 4.0 Basic

SOFT STARTER

User Manual

Issued on 01/08/2020

R. 02

•This manual is integrant and essential to the product. Carefully read the instructions contained herein as they provide important

hints for use and maintenance safety.

•This device is to be used only for the purposes it has been designed to. Other uses should be considered improper and

dangerous. The manufacturer is not responsible for possible damages caused by improper, erroneous and irrational uses.

•Enertronica Santerno is responsible for the device in its original setting.

•Any changes to the structure or operating cycle of the device must be performed or authorized by the Engineering Department

of Enertronica Santerno.

•Enertronica Santerno assumes no responsibility for the consequences resulting by the use of non-original spare parts.

•Enertronica Santerno reserves the right to make any technical changes to this manual and to the device without prior notice. If

printing errors or similar are detected, the corrections will be included in the new releases of the manual.

•The information contained herein is the property of Enertronica Santerno and cannot be reproduced. Enertronica Santerno

enforces its rights on the drawings and catalogues according to the law.

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ASA 4.0 Basic

Contents

1About This Manual.....................................................................................................................................................4

1.1 Disclaimer......................................................................................................................................................................................4

2Caution Statements....................................................................................................................................................5

2.1 Electrical shock risk.......................................................................................................................................................................5

2.2 Unexpected Operation..................................................................................................................................................................5

2.3 Avertissements à l'attention des clients canadiens.......................................................................................................................6

3System Design............................................................................................................................................................7

3.1 Feature List ...................................................................................................................................................................................7

3.2 Model Code...................................................................................................................................................................................7

3.3 Model Selection.............................................................................................................................................................................7

3.4 Current Ratings.............................................................................................................................................................................8

3.5 Dimensions and Weights ..............................................................................................................................................................9

3.6 Physical Installation.....................................................................................................................................................................10

3.7 Accessories.................................................................................................................................................................................10

3.8 Main contactor or circuit breaker.................................................................................................................................................11

3.9 Power Factor Correction.............................................................................................................................................................11

3.10 Short Circuit Protection Devices (SCPD)....................................................................................................................................11

3.11 IEC Coordination with Short Circuit Protection Devices.............................................................................................................12

3.12 UL Coordination with Short Circuit Protection Devices...............................................................................................................12

3.13 Fuse Selection for Type 2 Coordination......................................................................................................................................14

3.14 Specifications..............................................................................................................................................................................14

3.15 Disposal Instructions...................................................................................................................................................................15

4Installation................................................................................................................................................................16

4.1 Command Source.......................................................................................................................................................................16

4.2 Setup Procedure Overview.........................................................................................................................................................16

4.3 Inputs...........................................................................................................................................................................................17

4.4 Outputs........................................................................................................................................................................................18

4.5 Control Voltage............................................................................................................................................................................19

4.6 Power Terminations....................................................................................................................................................................20

4.7 Typical Installation.......................................................................................................................................................................22

4.8 Quick Setup.................................................................................................................................................................................23

5Setup Tools...............................................................................................................................................................24

5.1 Command Source.......................................................................................................................................................................24

5.2 Commissioning............................................................................................................................................................................24

5.3 Run simulation.............................................................................................................................................................................24

5.4 Load/Save Settings.....................................................................................................................................................................25

5.5 USB Save & Load.......................................................................................................................................................................25

5.6 Network Address.........................................................................................................................................................................26

5.7 Digital I/O State...........................................................................................................................................................................27

5.8 Analog I/O State..........................................................................................................................................................................27

5.9 Serial Number & Rating ..............................................................................................................................................................27

5.10 Software Versions.......................................................................................................................................................................27

5.11 Thermistor Reset.........................................................................................................................................................................27

5.12 Reset Thermal Model..................................................................................................................................................................27

6Logs...........................................................................................................................................................................28

6.1 Event Log....................................................................................................................................................................................28

6.2 Counters......................................................................................................................................................................................28

6.3 QR Code .....................................................................................................................................................................................28

7Keypad and Feedback.............................................................................................................................................29

7.1 The Keypad.................................................................................................................................................................................29

7.2 Remote Keypad...........................................................................................................................................................................29

7.3 Lighten/Darken the Display.........................................................................................................................................................29

7.4Starter status LEDs.....................................................................................................................................................................30

7.5 Displays.......................................................................................................................................................................................30

8Operation..................................................................................................................................................................32

ASA 4.0 Basic

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8.1 Start, Stop and Reset Commands ..............................................................................................................................................32

8.2 Command Override.....................................................................................................................................................................32

8.3 Emergency Mode........................................................................................................................................................................32

8.4 Auxiliary Trip................................................................................................................................................................................32

8.5 Typical Control Methods .............................................................................................................................................................33

8.6 Soft Start Methods.......................................................................................................................................................................34

8.7 Stop Methods..............................................................................................................................................................................35

9Programmable Parameters......................................................................................................................................37

9.1 Main Menu...................................................................................................................................................................................37

9.2 Altering Parameter Values..........................................................................................................................................................37

9.3 Adjustment Lock..........................................................................................................................................................................37

9.4 Parameter List.............................................................................................................................................................................37

9.5 1 Motor Details............................................................................................................................................................................40

9.6 2 Motor Start/Stop.......................................................................................................................................................................41

9.7 5 Protection Levels......................................................................................................................................................................42

9.8 6 Protection Action......................................................................................................................................................................43

9.9 7 Inputs........................................................................................................................................................................................45

9.10 8 Relay Outputs...........................................................................................................................................................................46

9.11 9 Analog Output..........................................................................................................................................................................47

9.12 10 Display....................................................................................................................................................................................48

9.13 12 Communications Card............................................................................................................................................................49

9.14 20 Advanced ...............................................................................................................................................................................51

9.15 30 Smart Card Parameters.........................................................................................................................................................52

10 Troubleshooting.......................................................................................................................................................53

10.1 Protection Responses.................................................................................................................................................................53

10.2 Trip Messages.............................................................................................................................................................................53

10.3 General Faults.............................................................................................................................................................................56

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ASA 4.0 Basic

1About This Manual

WARNING

Indicates a hazard that may cause personal injury or death.

CAUTION

Indicates a hazard that may damage the equipment or installation.

NOTE

Provides helpful information.

1.1 Disclaimer

The examples and diagrams in this manual are included solely for illustrative purposes.

The information contained in this manual is subject to change at any time and without prior notice. In no event will responsibility or

liability be accepted for direct, indirect or consequential damages resulting from the use or application of this equipment.

ASA 4.0 Basic

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2Caution Statements

Caution Statements cannot cover every potential cause of equipment damage but can highlight common causes of damage. It is the

installer's responsibility to read and understand all instructions in this manual prior to installing, operating or maintaining the equipment,

to follow good electrical practice including applying appropriate personal protective equipment and to seek advice before operating this

equipment in a manner other than as described in this manual.

NOTE

The ASA 4.0 Basic is not user serviceable. The unit should only be serviced by authorised service personnel.

Unauthorised tampering with the unitwill void theproductwarranty.

FOR YOUR SAFETY

The STOP function of the soft starter does not isolate dangerous voltages from the output of the starter. The soft starter

must be disconnected by an approved electrical isolation device before accessing electrical connections.

Soft starter protection features apply to motor protection only. It is the user’s responsibility to ensure safety of personnel

operating machinery.

The soft starter is a component designed for integration within an electrical system; it is therefore the responsibility of the

system designer/user to ensure the system is safe and designed to comply with relevant local safety standards.

2.1 Electrical shock risk

WARNING – ELECTRICAL SHOCK RISK

The voltages present in the following locations can cause severe electric shock and may be lethal:

AC supply cables and connections

Output cables and connections

Many internal parts of the starter

SHORT CIRCUIT

The ASA 4.0 Basic is not short circuit proof. After severe overload or short circuit, the operation of the ASA 4.0 Basic should

be fully tested by an authorised service agent.

GROUNDING AND BRANCH CIRCUIT PROTECTION

It is the responsibility of the user or person installing the ASA 4.0 Basic to provide proper grounding and branch circuit

protection according to local electrical safety codes.

2.2 Unexpected Operation

WARNING – ACCIDENTAL STARTS

In some installations, accidental starts may pose an increased risk to safety of personnel or damage to the machines being

driven. In such cases, it is recommended that the power supply to the soft starter is fitted with an isolating switch and a

circuit-breaking device (eg power contactor) controllable through an external safety system (eg emergency stop, fault

detector).

WARNING – STARTER MAY START OR STOP UNEXPECTEDLY

The ASA 4.0 Basic will respond to control commands from various sources, and could start or stop unexpectedly. Always

disconnect the soft starter from mains voltage before accessing the starter or load.

WARNING – DISCONNECT MAINS BEFORE ACCESSING STARTER OR LOAD

The soft starter has built-in protections which can trip the starter in the event of faults and thus stop the motor. Voltage

fluctuations, power cuts and motor jams may also cause the motor to trip.

The motor could restart after the causes of shutdown are rectified, which may be dangerous for personnel. Always

disconnect the soft starter from mains voltage before accessing the starter or load.

CAUTION – MECHANICAL DAMAGE FROM UNEXPECTED RESTART

The motor could restart after the causes of shutdown are rectified, which may be dangerous for certain machines or

installations. In such cases, it is essential that appropriate arrangements are made against restarting after unscheduled stops

of the motor.

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ASA 4.0 Basic

2.3 Avertissements à l'attention des clients canadiens

AVERTISSEMENT

L'icône AVERTISSEMENT ci-contre signale les informations concernant des risques pouvant entraîner des blessures

graves, voire mortelles. Pour votre sécurité, veuillez consulter les avertissements sur cette page ou demander une copie du

présent manuel en français auprès de votre distributeur local.

AVERTISSEMENT – RISQUE DE CHOC ÉLECTRIQUE

Les zones suivantes sont soumises à des tensions pouvant provoquer des risques de chocs électriques graves, voire

mortels :

Raccordement et câbles d'alimentation AC

Câbles et raccordements de sortie

De nombreuses pièces internes du démarreur

PAR SÉCURITÉ

La fonction STOP du démarreur progressif n'isole pas des tensions dangereuses de la sortie du démarreur. Le

démarreur progressif doit être déconnecté par un dispositif d'isolement électrique approprié avant d'accéder aux

connexions électriques.

Les fonctions de protection du démarreur progressif ne concernent que la protection du moteur. Il relève de la

responsabilité de l'utilisateur d'assurer la sécurité des personnes travaillant sur les machines.

Le démarreur progressif est un appareil conçu pour s'intégrer dans un système électrique ; il relève donc de la

responsabilité du concepteur ou de l'utilisateur de veiller à ce que ce système soit sûr et conçu selon les normes de

sécurité locales en vigueur.

AVERTISSEMENT – DÉMARRAGES ACCIDENTELS

Dans certaines installations, des démarrages accidentels peuvent provoquer un risque supplémentaire pour la sécurité des

personnes ou endommager les machines contrôlées. Dans de tels cas, il est recommandé de doter l'alimentation du

démarreur progressif d'un interrupteur d'isolement et d'un coupe-circuit (par exemple, un disjoncteur) contrôlable à partir d'un

système de sécurité externe (par exemple, un arrêt d'urgence, un détecteur de défaut).

AVERTISSEMENT – LE DÉMARREUR PEUT DÉMARRER OU S'ARRÊTER À TOUT MOMENT

Le démarreur progressif répond aux commandes de contrôle de différentes origines et peut par conséquent démarrer ou

s'arrêter à tout moment. Toujours déconnecter le démarreur de la tension secteur avant d'accéder au démarreur ou à la

charge.

AVERTISSEMENT – DÉCONNECTER L'ALIMENTATION PRINCIPALE AVANT D'ACCÉDER AU DÉMARREUR OU À LA

CHARGE

Le démarreur progressif comporte des protections intégrées qui peuvent déclencher des mises en sécurité dans l'éventualité

de défauts et ainsi arrêter le moteur. Des fluctuations de tension, des coupures d'alimentation et des blocages du moteur

peuvent produire des mises en sécurité de celui-ci.

Le moteur pourrait redémarrer une fois que les causes de l'arrêt ont été résolues, ce qui pourrait mettre en danger le

personnel. Toujours déconnecter le démarreur de la tension secteur avant d'accéder au démarreur ou à la charge.

AVERTISSEMENT

Ne pas appliquer la tension du secteur au démarreur tant que tout le câblage n'est pas terminé.

AVERTISSEMENT

Toujours appliquer la tension de commande avant (ou en même temps que) la tension secteur.

AVERTISSEMENT

Si l'entrée de démarrage est fermée lorsque la tension de commande est appliquée, le démarreur tentera d'effectuer un

démarrage.

Vérifier que l'entrée de démarrage/arrêt est ouverte avant d'appliquer la tension de commande..

ASA 4.0 Basic

7/58

3System Design

3.1 Feature List

Streamlined setup process

•Configuration profiles for common applications

•Built-in metering and inputs/outputs

Easy to understand interface

•Multi-language menus and displays

•Descriptive option names and feedback messages

•Real-time performance graphs

Supports energy efficiency

•IE3 compatible

•99% energy efficient when running

•Internal bypass

•Soft start technology avoids harmonic distortion

Extensive range of models

•24 A~580 A (nominal)

•200~525 VAC

•380~600 VAC

Versatile starting and stopping options

•Adaptive Control

•Constant Current

•Current Ramp

•Timed voltage ramp soft stop

•Coast To Stop

Customisable protection

•Motor overload

•Excess Start Time

•Undercurrent

•Overcurrent

•Current imbalance

•Input Trip

•Motor thermistor

Extensive input and output options

•Remote control inputs

(2 x fixed, 2 x programmable)

•Relay outputs

(1 x fixed, 2 x programmable)

•Analog output

Optional features for advanced applications

•Smart cards

•Communication options:DeviceNet, Ethernet/IP,

Modbus RTU, Modbus TCP, Profibus, Profinet

3.2 Model Code

ASA4.0-B

–

Control voltage

12 = 110~120 VAC or 220~240 VAC

14 = 24 VAC/VDC

Mains voltage

5 = 200~525 VAC

7 = 380~600 VAC

Bypass

B = internally bypassed

Nominal current rating

3.3 Model Selection

3.3.1 Starter sizing

The soft starter must be the correct size for the motor and the application.

Select a soft starter that has a current rating at least equal to the motor's full load current (nameplate) rating, at the start duty.

The soft starter's current rating determines the maximum motor size it can be used with. The soft starter's rating depends on the number

of starts per hour, the length and current level of the start, and the amount of time the soft starter will be off (not passing current)

between starts.

The soft starter's current rating is only valid when used in the conditions specified in the AC53b code - the soft starter may have a higher

or lower current rating in different operating conditions.

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ASA 4.0 Basic

3.4 Current Ratings

For operating conditions not covered by these ratings charts, download Santerno's free WinStart selection application, or contact your

local supplier.

3.4.1 IEC ratings

AC53b format

80 A

AC-53b

3.5

345

Off time (seconds)

Start time (seconds)

Start current (multiple of motor full load current)

Starter current rating (amperes)

Ratings

All ratings are calculated at altitude of 1000 metres and ambient temperature of 40 ºC.

3.0-10:350

3.5-15:345

4.0-10:350

4.0-20:340

5.0-5:355

ASA4.0-B 0024B

ASA4.0-B 0042B

ASA4.0-B 0052B

3.0-10:590

3.5-15:585

4.0-10:590

4.0-20:580

5.0-5:595

ASA4.0-B 0064B

ASA4.0-B 0069B

ASA4.0-B 0105B

105

ASA4.0-B 0115B

115

108

105

ASA4.0-B 0135B

135

129

126

103

115

ASA4.0-B 0184B

184

144

139

116

127

ASA4.0-B 0200B

200

171

165

138

150

ASA4.0-B 0229B

229

194

187

157

170

ASA4.0-B 0250B

250

244

230

200

202

ASA4.0-B 0352B

352

287

277

234

258

ASA4.0-B 0397B

397

323

311

263

289

ASA4.0-B 0410B

410

380

400

ASA4.0-B 0550B

550

527

506

427

464

ASA4.0-B 0580B

580

579

555

470

508

ASA 4.0 Basic

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3.5 Dimensions and Weights

B4 B510 11 12 13 14 15 21 22 33 34 41 42 44 53 54

A3 A1 A2

2/T1 4/ T2 6/T3

1/L 1 3/L2 5/L3

B4 B510 11 12 13 14 15 21 22 33 34 41 42 44 53 54

A3 A1 A2

2/T1 4/ T2 6/T3

33 34 41 42 44 53 54B4 B510 11 12 13 14 15 21 22

A3 A1 A2

2/T1 4/T2 6/ T3

18541.A

Width

mm (inch)

Height

mm (inch)

Depth

mm (inch)

Weight

kg (lb)

ASA4.0-B 0024B

4.7

ASA4.0-B 0042B

(10.4)

ASA4.0-B 0052B

4.8

(10.7)

ASA4.0-B 0064B

152

336

307

231

ASA4.0-B 0069B

(6.0)

(3.6)

(13.2)

(12.1)

(9.1)

ASA4.0-B 0105B

5.0

(11.0)

ASA4.0-B 0115B

ASA4.0-B 0135B

ASA4.0-B 0184B

ASA4.0-B 0200B

495

11.7

ASA4.0-B 0229B

216

(8.5) 180

(7.1)

(19.5)

450

(17.7) 243

(9.6)

(25.8)

ASA4.0-B 0250B

ASA4.0-B 0352B

12.5

(27.6)

ASA4.0-B 0397B

523

(20.6)

ASA4.0-B 0410B

ASA4.0-B 0550B

15.0

ASA4.0-B 0580B

(33.1)

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ASA 4.0 Basic

3.6 Physical Installation

18542.A

2/T1 4/ T2 6/T 3

33 34 41 42 44 53 54

2/T1 4/ T2 6/T3

B4 B5 101

1 12 13 14 15 21 22

A3 A1 A2

33 34 41 42 44 53 54

2/T1 4/ T2 6/T 3

B4 B5 1011 12 13 14 15 21 22

A3 A1 A2

33 34 41 42 44 53 54

2/T1 4/ T2 6/T 3

B4 B5 1011 12 13 14 15 21 22

A3 A1A2

33 34 41 42 44 53 54

2/T1 4/ T2 6/T 3

B4 B5 1011 12 13 14 15 21 22

A3 A1A2

33 34 41 42 44 53 54

2/T1 4/ T2 6/T 3

B4 B5 101

1 12 13 14 15 21 22

A3 A1A2

Between starters

Solid surfaces

> 100 mm (3.9 inch)

> 10 mm (0.4 inch)

> 100 mm (3.9 inch)

> 10 mm (0.4 inch)

3.7 Accessories

3.7.1 Expansion Cards

The ASA 4.0 Basic offers expansion cards for users requiring additional inputs and outputs or advanced functionality. Each ASA 4.0

Basic can support a maximum of one expansion card.

Smart Card

The smart card has been designed to support integration with pumping applications and provides the following additional inputs and

outputs:

•3 x digital inputs

•3 x 4-20 mA transducer inputs

•1 x RTD input

•1 x USB-B port

•Remote keypad connector

Communication Expansion Cards

The ASA 4.0 Basic supports network communication via easy-to-install communications expansion cards. Each communications card

includes a remote keypad connector port.

Available protocols:

DeviceNet, Ethernet/IP, Modbus RTU, Modbus TCP, Profibus, Profinet.

3.7.2 Remote Keypad

ASA 4.0 Basic starters can be used with a remote keypad, mounted up to 3 metres away from the starter. Each expansion card includes

a keypad connection port, or a dedicated keypad connector card is available.

3.7.3 Finger Guard Kit

Finger guards may be specified for personnel safety. Finger guards fit over the soft starter terminals to prevent accidental contact with

live terminals. Finger guards provide IP20 protection when used with cable of diameter 22 mm or greater.

Finger guards are compatible with models ASA4.0-B 0184B ~ ASA4.0-B 0580B.

3.7.4 RemoteDrive Management Software

RemoteDrive PC software allows real-time integrated management of ASA 4.0 Basic soft starters as well as all other Santerno products.

RemoteDrive can monitor, control and program the starter across the network.

•RemoteDrive must connect to the ASA 4.0 Basic via a Modbus RTU card.

•RemoteDrive supports networks of up to 247 devices.

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