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AUTOMATION STARTER
AS6
INSTRUCTION MANUAL

REV 01/02 P/N: 027-2063

February 2002
© Copyright Saftronics, Inc. 2002
Saftronics, Inc. retains the right to change specifications and illustrations in the text, without prior
notification. The contents of this document may not be copied without the explicit permission of
Saftronics, Inc.
AS6 Instruction Manual
SAFETY INSTRUCTIONS [Link]

Safety
The soft starter should be installed in a cabinet or in an electrical control room.

The device must be installed by trained personnel.

Disconnect all power sources before servicing.

Short circuit protection in the form of circuit breaker or time delay fuses must be provided per code.

Operating and Maintenance Personnel

1. Read the whole Instruction Manual before installing and putting the equipment into operation.
2. During all work (operation, maintenance, repairs, etc.) observe the switch-off procedures given in this
instruction as well as any other operating instruction for the driven machine or system. See Emergency
below.
3. The operator must avoid any working methods which reduce the safety of the device.
4. The operator must do what he can to ensure that no unauthorised person is working on the device.
5. The operator must immediately report any changes to the device which reduce its safety to the user.
6. The user must undertake all necessary measures to operate the device in perfect condition only.

Installation of Spare Parts

We expressly point out that any spare parts and accessories not supplied by Saftronics, Inc. have also not been test-
ed or approved by Saftronics, Inc.
Installing and/or using such products can have a negative effect on the characteristics designed for your device. The
manufacturer is not liable for damage arising as a result of using non-original parts and accessories.

Emergency
You can switch the device off at any time with the mains switch connected in front of the soft starter (both motor and
control voltage should be switched off).

Dismantling and Scrapping

The enclosure of the soft starter is made of recyclable material, such as aluminium, iron and plastic. Legal require-
ments for disposal and recycling of these materials must be complied with.
The soft starter contains a number of components demanding special treatment, as for example thyristors. The cir-
cuit board contain small amounts of tin and lead. Legal requirements for disposal and recycling of these materials
must be complied with.

2 © 2002 Saftronics, Inc.

 AS6 Instruction Manual
[Link] TABLE OF CONTENTS

TABLE OF CONTENTS

1.0 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

1.1 Integrated safety systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.2 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.3 Notes to the Instruction Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.4 How to use the Instruction Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.5 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.6 Tests in accordance with norm EN60204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.7 Inspection at delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.7.1 Transport and packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2.0 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.2 AS6 control methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2.2.1 General features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3.0 HOW TO GET STARTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3.1 Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3.2 Main functions/Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
3.3 Motor Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
3.4 Setting of the start and stop ramps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
3.5 Setting the start command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3.6 Viewing the motor current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3.7 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
4.0 APPLICATION AND FUNCTION SELECTION . . . . . . . . . . . . . . . . . . . . . . . . .18
4.1 Soft starter rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
4.2 The application ratings list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
4.3 The application functions list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
4.4 Function and combination matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.5 Special condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
4.5.1 Small motor or low load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
4.5.2 Ambient temperature below 0oC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
4.5.3 Power Factor Correction Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
4.5.4 Pole-changing contactor and two speed motor . . . . . . . . . . . . . . . . . . . . . . . . .23
4.5.5 Shielded motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
4.5.6 Slip ring motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
4.5.7 Pump control with soft starter and frequency inverter together . . . . . . . . . . . . .23
4.5.8 Starting with counter clockwise rotating loads . . . . . . . . . . . . . . . . . . . . . . . . . .24
4.5.9 Running motors in parallel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
4.5.10 How to calculate heat dissipation in cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . .24
4.5.11 Insulation test on motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
4.5.12 Operation above 1000 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
4.5.13 Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
5.0 OPERATION OF THE SOFT STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
5.1 General description of user interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
5.2 PPU unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
5.3 LED display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
5.4 The Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
5.5 The keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
5.6 Keyboard lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
5.7 Overview of soft starter operation and parameter set-up. . . . . . . . . . . . . . . . . .28
6.0 INSTALLATION AND CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
6.1 Installation of the soft starter in a cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

© 2002 Saftronics, Inc. 3

AS6 Instruction Manual
TABLE OF CONTENTS [Link]

6.2 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

6.3 Connection and setting on the PCB control card . . . . . . . . . . . . . . . . . . . . . . . .34
6.4 Minimum wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
6.5 Wiring examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
7.0 FUNCTIONAL DESCRIPTION SET-UP MENU . . . . . . . . . . . . . . . . . . . . . . . . .37
7.1 Ramp up/down parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
7.1.1 RMS current [005] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
7.2 Start/stop/reset command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
7.2.1 2-wire start/stop with automatic reset at start . . . . . . . . . . . . . . . . . . . . . . . . . .39
7.2.2 2-wire start/stop with separate reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
7.2.3 3-wire start/stop with automatic reset at start. . . . . . . . . . . . . . . . . . . . . . . . . . .39
7.3 Menu expansion setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
7.4 Voltage control dual ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
7.5 Torque control parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
7.6 Current limit (Main Function) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
7.6.1 Voltage ramp with current limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
7.6.2 Current limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
7.7 Pump control (Main Function) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
7.8 Analogue Input Control (Main Function) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
7.9 Full voltage start, D.O.L. (Main Function) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
7.10 Torque control (Main function) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
7.11 Torque boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
7.12 Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
7.13 Power Factor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
7.14 Brake functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
7.15 Slow speed and Jog functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
7.15.1 Slow speed controlled by an external signal. . . . . . . . . . . . . . . . . . . . . . . . . . . .49
7.15.2 Slow speed during a selected time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
7.15.3 Jog Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
7.15.4 DC-brake after slow speed at stop [040] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
7.16 Motor data setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
7.17 Programmable relay K1 and K2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
7.18 Analogue output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
7.19 Digital input selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
7.20 Parameter Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
7.21 Motor protection, overload (F2 alarm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
7.22 Mains protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
7.23 Application protection (load monitor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
7.23.1 Load monitor max and min/protection (F6 and F7 alarms) . . . . . . . . . . . . . . . .58
7.23.2 Pre-alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
7.24 Resume alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
7.24.1 Phase input failure F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
7.24.2 Run at current limit time-out F4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
7.25 Slow speed with JOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
7.26 Automatic return menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
7.27 Communication option, related Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
7.28 Reset to factory setting [199] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
7.29 View operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
7.30 Keyboard lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
7.31 Alarm list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
8.0 PROTECTION AND ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
8.1 Alarm description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

4 © 2002 Saftronics, Inc.

 AS6 Instruction Manual
[Link] TABLE OF CONTENTS

8.1.1 Alarm with stop and requiring a separate reset . . . . . . . . . . . . . . . . . . . . . . . . .67

8.1.2 Alarm with stop and requiring only a new start command . . . . . . . . . . . . . . . . .67
8.1.3 Alarm with continue run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
8.2 Alarm overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
9.0 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
9.1 Fault, cause and solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
10.0 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
11.0 OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
11.1 Serial communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
11.2 Field bus systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
11.3 External PPU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
12.0 SET-UP MENU LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
13.0 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

LIST OF TABLES
Table 1 Application Rating List . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Table 2 Application Function List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Table 3 Combination matrix . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Table 4 Start/stop combination. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Table 5 The keys . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Table 6 Control modes . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Table 7 AS6-017 to AS6-250. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Table 8 AS6-017 to AS6-250 . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Table 9 PCB Terminals . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Table 10 Set-up Menu overview . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

LIST OF FIGURES
Fig. 1 Scope of delivery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Fig. 2 Voltage control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Fig. 3 Current control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Fig. 4 Torque control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Fig. 5 Standard wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Fig. 6 Example of start ramp with main function voltage ramp . . . . . . . . . . . . . . . . . .17
Fig. 7 PPU unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Fig. 8 LED indication at different operation situation. . . . . . . . . . . . . . . . . . . . . . . . . . .26
Fig. 9 Menu structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Fig. 10 AS6 dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Fig. 11 Hole pattern for AS6-017 to AS6-250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Fig. 12 Hole pattern for AS6-170 to AS6-250 with upper mounting bracket instead
of DIN-rail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Fig. 13 Connection of AS6-017 to AS6-085. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Fig. 14 Connection of AS6-110 to AS6-145. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Fig. 15 Connection of AS6-170 to AS6-250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Fig. 16 Connections on the PCB, control card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Fig. 17 Wiring circuit, “Minimum wiring”. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Fig. 18 Analogue input control, parameter set selection, analogue output . . . . . . . . . . .36
Fig. 19 Motor overtemp protection via PTC sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Fig. 20 Menu numbers for start/stop ramps, initial voltage at start and step down voltage
at stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Fig. 21 Menu numbers for dual voltage ramp at start/stop, initial voltage at start and step
down-voltage at stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

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AS6 Instruction Manual
TABLE OF CONTENTS [Link]

Fig. 22 Current limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Fig. 23 Current limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Fig. 24 Pump control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Fig. 25 Wiring for analogue input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Fig. 26 Setting voltage or current for analogue input. . . . . . . . . . . . . . . . . . . . . . . . . . .43
Fig. 27 Full voltage start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Fig. 28 Torque control at start/stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Fig. 29 Current and speed in torque control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Fig. 30 The principle of the Torque Booster when starting the motor in voltage
ramp mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Fig. 31 Current transformer position when Bypass AS6-017 to AS6-250. . . . . . . . . . . .46
Fig. 31a Current transformer location for Bypass operation . . . . . . . . . . . . . . . . . . . . . . .46
Fig. 32 Braking time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Fig. 33 Soft brake wiring example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Fig. 34 Slow speed controlled by an external signal. . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Fig. 35 Slow speed at start/stop during a selected time. . . . . . . . . . . . . . . . . . . . . . . . .50
Fig. 36 Start/stop sequence and relay function “Operation” and “Full voltage”. . . . . . . . .52
Fig. 37 Wiring for analogue output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Fig. 38 Setting of current or voltage output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Fig. 39 Setting of J1 for current or voltage control. . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Fig. 40 Wiring for slow speed external input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Fig. 41 Parameter overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Fig. 42 Connection of external control inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Fig. 43 The thermal curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Fig. 44 Load monitor alarm functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Fig. 45 The 2 Jog keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Fig. 46 Option RS232/485 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Fig. 47 Option Profibus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Fig. 48 Shows an example of the External PPU after it has been built in. . . . . . . . . . . .73

6 © 2002 Saftronics, Inc.

 AS6 Instruction Manual
[Link] GENERAL INFORMATION
1.0 GENERAL INFORMATION
1.1 Integrated safety systems
The device is fitted with a protection system which reacts to:

Over temperature.

Voltage unbalance.

Over- and under voltage.

Phase reversal

Phase loss

Motor overload protection thermal and PTC.

Motor load monitor, protecting machine or process max or min alarm

Starts per hour limitation

The soft starter is fitted with a connection for earth ground (PE).

1.2 Safety measures

These instructions are a constituent part of the device and must be:

Available to competent personnel at all times.

Read prior to installation of the device.

Observed with regard to safety, warnings and information given.

The tasks in these instructions are described so that they can be understood by people trained in electrical engi-
neering. Such personnel must have appropriate tools and testing instruments available. Such personnel must have
been trained in safe working methods, and follow all standard safety procedures.

The user must obtain any general and local operating permits and meet any requirements regarding:

Safety of personnel.

Product disposal.

Environmental protection.

NOTE! The safety measures must remain in force at all times. Should questions or uncertainties arise,
please contact your local sales outlet.

1.3 Notes to the Instruction Manual

! WARNING! Warnings are marked with a warning triangle.

Important
For all enquiries and spare parts orders, please quote the correct name of the device and serial number to ensure
that your inquiry or order is dealt with correctly and swiftly.

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AS6 Instruction Manual
GENERAL INFORMATION [Link]

1.4 How to use the Instruction Manual

This instruction manual tells you how to install and operate the AS6 soft starter. Read the whole Instruction Manual
before installing and putting the unit into operation. For simple start-up, read chapter 2. page 10 to chapter 3. page
14.
Once you are familiar with the soft starter, you can operate it from the keyboard by referring to the chapter 13. page
75. This chapter describes all the functions and possible setting.

1.5 Standards
The device is manufactured in accordance with these regulations.

IEC 947-4-2

EN 60204-1 Electrical equipment of machines, part 1, General requirements and VDE 0113.

EN 50081-2, EMC Emission

EN 50081-1, EMC Emission with bypass

EN 50082-2, EMC Immunity

GOST

UL508

1.6 Tests in accordance with norm EN60204

Before leaving the factory, the device was subjected to the following tests:

Through connection of earthing system;
a) visual inspection.
b) check that earthing wire is firmly connected.

Insulation

Voltage

Function

1.7 Inspection at delivery

www.s
aftron
[Link]

AUTO
M
ATION
STAR
INSTR AS6 TER
UCTIO
N MA
NUAL

Figure 1: Scope of Delivery

1.7.1 Transport and packing

The device is packed in a carton or plywood box for delivery. The outer packaging can be returned. The devices are
carefully checked and packed before dispatch, but transport damage cannot be ruled out.

Check on receipt:

Check that the goods are complete as listed on the delivery note, see type no. etc. on the rating plate.

Is the packaging damaged?

8 © 2002 Saftronics, Inc.

 AS6 Instruction Manual
[Link] GENERAL INFORMATION

Check the goods for damage (visual check).
If you have cause for complaint
If the goods have been damaged in transport:

Contact the transport company or the supplier immediately.

Keep the packaging (for inspection by the transport company or for returning the device).

Packaging for returning the device

Pack the device so that it is shock-resistant.

Intermediate storage
After delivery or after it has been dismounted, the device can be stored before further use in a dry room.

© 2002 Saftronics, Inc. 9

AS6 Instruction Manual
DESCRIPTION [Link]

2.0 DESCRIPTION
2.1 General

The AS6 is installed directly between the mains and the supply cable to the motor. If a mains contactor is used it can
be activated by the integrated K1 relay.

AS6
03-F03

The AS6 is developed for soft starting, stopping and braking three-phase motors.

There are 3 different kinds of soft starting control methods:

Control method 1-Phase
The single phase controlled soft starters provide only a reduction in starting torque no control of current or torque.
These starters need a main and bypass contactor as well as external motor protections. This is a open loop voltage
controller. These starters are mainly in the power up to 7.5 kW.

Control method 2-Phase
The two phase starters can start a motor without a mains contactor, but in that case voltage still is present at the
motor when it´s stopped. These starters are mainly in the power up to 22 kW.

Control method 3-Phase
In the three phase Soft Starters there are different technologies:

Voltage control

Current control

Torque control

Voltage control
This method is the most used control method. The starter gives a smooth start but doesn’t get any feedback on cur-
rent or torque. The typical settings to optimize a voltage ramp are: Initial voltage, ramp time, dual ramp time.

Current (A)

FLC

Time
03-F116

Figure 2: Voltage Control

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 AS6 Instruction Manual
[Link] DESCRIPTION
Current control
The voltage ramp can be used with a current limit which stops the voltage ramp when the set maximum current level
is reached. The maximum current level is the main setting and must be set by the user depending the maximum cur-
rent allowed for the application.

Current (A)

Current
Limit

FLC

03-F111 Time
Figure 3: Current Control

Torque control
Is the most efficient way of starting motors. Unlike voltage and current based systems the soft starter monitors the
torque need and allows to start with the lowest possible current. Using a closed loop torque controller, linear ramps
are possible. The voltage ramp can not hold back the motor starting torque; this results in a current peak and unlin-
ear ramps. In the current ramp, there will be no peak current, but a higher current for a longer period of time during
the start will result compared to torque control. Current starting doesn’t give linear ramps. The linear ramps are very
important in many applications. For an example, to stop a pump with an unlinear ramp will give water hammer. Soft
starters which doesn’t monitor the torque, will start and stop too fast if the load is lighter than the setting of current or
ramp time.

Current (A)

FLC

Time
Figure 4: Torque Control

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AS6 Instruction Manual
DESCRIPTION [Link]

2.2 AS6 control methods

AS6 Soft Starters control all three phases supplied to the motor. It manages all the 3 possible starting methods
where the closed loop Torque control is the most efficient way of starting and stopping motors.

2.2.1 General features

As mentioned above soft starters offer you several features and the following functions are available:

Torque controlled start and stop

Current limit control at start

Application “Pump”

External analogue input control

Torque booster at start

Full voltage start (D.O.L.)

Dual voltage ramp at start and stop

Bypass

Dynamic DC-brake or Softbrake

Slow speed at start and stop

Jogging forward and reverse

Four parameter sets

Analogue output indicating current, power or voltage

Viewing of current, voltage, power, torque, power consumption, elapsed time etc.

Integrated safety system acc. to § 1.1, page 7, with an alarm list.

12 © 2002 Saftronics, Inc.

 AS6 Instruction Manual
[Link] HOW TO GET STARTED
3.0 HOW TO GET STARTED
P1
L1 L1 T1

L2 L2
P1
T2
M
L3 L3 T3

BL BR BL BR
01
CONTROL 75
POWER
02
76
PE
77

2 WIRE 3 WIRE
START START

11
RUN STOP
OR 12

13

21
K1
22

23
K2
24

31

32 K3

33

Figure 5: Standard wiring

This chapter describes briefly the set-up for basic soft start and soft stop by using the default “Voltage
Ramp” function.

WARNING! Mounting, wiring and setting the device into operation must be carried out

! by properly trained personnel. Before set-up, make sure that the installation is accord-
ing to chapter 6, page 28 and the Checklist below.

3.1 Checklist

Mount the soft starter in accordance with chapter 6. page 28.

Consider the power loss at rated current when dimensioning a cabinet, max. ambient temperature is
104oF (40ºC). Starter will generate approx. 3 Watts per Amp.

Connect the motor circuit according to Fig. 5.

Connect the protective earth.

Connect the control voltage to terminals 01 and 02 (100 - 240 VAC).

Connect terminals 11, 12, and 13 to control devices as indicated.1)

Check that the motor and supply voltage corresponds to values on the soft starter’s rating plate.

Ensure the installation complies with the appropriate local regulations.

1) The menu 006 must be put to 02 for start/stop command from terminal strip.

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AS6 Instruction Manual
HOW TO GET STARTED [Link]

3.2 Main functions/Applications

! WARNING! Make sure that all safety measures have been taken before switching on the supply.

Switch on the control voltage (normally 1 x 120 V), all segments in the display and the two LED’s will be illuminated
for a few seconds. Then the display will show menu 001. An illuminated display indicates there is supply voltage on
the PCB. Check that you have mains voltage on the mains contactor or on the thyristors. The settings are carried out
according to following:
The first step in the settings is to set menu 007 and 008 to “ON” to reach the main functions 020-025 and motor data
041-046.

NOTE! The main function is chosen according to the application. The tables in the applications and
functions selection (table 1, page 19), gives the information to choose the proper main function.

3.3 Motor Data

Set the data, according to the motor nameplate to obtain optimal settings for starting, stopping and motor protection.

NOTE! The default settings are for a standard 4-pole motor acc. to the nominal power of the soft-starter. The
soft starter will run even if no specific motor data is selected, but the performance will not be
optimal, and the motor may not be protected.

0 4 1 Nominal motor voltage 0 4 3 Nominal motor power

460 Volts 2 2 HP

Default: 460 V Default: Nominal power soft starter

Range: 200-700 V Range: 25% - 150% of Starter HP

0 4 2 Nominal motor current 0 4 4 Nominal power speed

45 Amps 17 64
Default: Nominal current soft starter Default: 1764 rpm
Range: 25% - 150% of Starter Amps Range: 500-3600 rpm

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 AS6 Instruction Manual
[Link] HOW TO GET STARTED

0 4 5 Nominal motor cos phi 0 4 6 Nominal frequency

(Nameplate Power Factor)

.86 60
Default: 0.86* Default: 60 Hz
Range: 0.50-1.00 Range: 50/60 Hz
*If not known, satisfactory operations should be
obtained with .86 (Default)
NOTE! Now go back to menu 007 and set it to “oFF” and then to menu 001.

3.4 Setting of the start and stop ramps

The menu´s 002 and 003 can now be set to adjust the start ramp up time and the stop ramp down time.

0 0 2 Start time ramp 1 0 0 4 Stop time ramp 1

10 o FF
Default: 10 sec Default: oFF
Range: 1-60 sec Range: oFF, 2-120 sec
Estimate the starting-time for the motor/machine. Set ”ramp down time” at stop (2-120 s).
Set ”ramp up time” at start (1-60 sec). “oFF” if only soft start requires.
Key “ENTER
“ to confirm new value.
Key “NEXT“, “PREV ” to change menu.

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AS6 Instruction Manual
HOW TO GET STARTED [Link]

3.5 Setting the start command

As default the start command is set for remote operation via terminal 11, 12 and 13. For easy commissioning it is
possible to set the start command on the start key on the keyboards. This is set with menu 006.

0 0 6 Selection of control mode

2
Default: 2
Range: 1,2,3
Menu 006 must be set to 1 to be able to operate from keyboard.

NOTE! Factory default setting is remote control (2).

To start and stop from the keyboard, the “START/STOP” key is used.

To reset from the keyboard, the “ENTER
/RESET” key is used. A reset can be given both when the
motor is running and when the motor is stopped. A reset by the keyboard will not start or stop the motor.

3.6 Viewing the motor current

Set the display to menu 005. Now the Motor current can be viewed on the display.

0 0 5 RMS current read-out

0. 0
Default: -
Range: 0.0-9999 Amp.

NOTE! The menu 005 can be selected at any time when the motor is running.

16 © 2002 Saftronics, Inc.

 AS6 Instruction Manual
[Link] HOW TO GET STARTED

3.7 Starting

!
WARNING! Make sure that all safety measures have been taken before starting the motor in
order to avoid personal injury.

Start the motor by pressing the “START/STOP“ key on the keyboard or through the remote control, PCB terminal 11,
12 and 13 and the motor then starts softly.

Current (A)

FLC

Time
03-F116

Figure 6: Example of start ramp with main function voltage ramp.

© 2002 Saftronics, Inc. 17

AS6 Instruction Manual
APPLICATION & FUNCTIONS [Link]

4.0 APPLICATION AND FUNCTION SELECTION

This chapter is a guide to select the correct soft starter rating and the selection of the Main function and additional
functions for each different application.
To make the right choice the following tools are used:

The Application Function List.
This table gives an complete overview of most common applications and duties. For each applications the
menu’s that can be used are given. See table 2, page 21.

Function and Combination matrix.
With these tables it is easy to see which combinations of Main and additional functions are possible, see
table 3, page 22 and table 4, page 23.

4.1 Soft starter rating

Selecting the starter using standard horsepower at voltage ratings will ensure satisfactory operation in the harshest
of applications (this is strongly recommended). Duty rated units can be supplied for high volume special applications,
please consult factory.

4.2 The application ratings list

Table 1 gives the Application Ratings List. With this list the rating for the soft starter and Main Function menu can be
selected.

Description and use of the table:

Applications.
This column gives the various applications. If the machine or application is not in this list, try to identify a
similar machine or application. If in doubt please contact your supplier.

Typical Starting current.
Gives the typical starting current for each application.

Main Function menu.
The Main Function menu is advised here. "25;=1", means: program selection 1 in menu 25.

Stop function.
Gives a possible Stop function if applicable. "36;=1 / 38-40", means: program selection 1 in menu 36, also
menus 38 to 40 can be selected.

EXAMPLE Roller Mill:

This is an application for heavy duty,

Typical starting current of 450%.

Main function Torque ramp start (menu 25) will give the best results.

Stop function Dynamic Brake (menu 36, selection 1) can be used.

As well as the Slow Speed at start and stop (menu 38-40) can be used for better start and stop
performance.

18 © 2002 Saftronics, Inc.

 AS6 Instruction Manual
[Link] APPLICATION & FUNCTIONS

Typical starting Main function Menu Stop function

Applications current % nr. Menu nr. *

General & Water

Centrifugal Pump 300 22 22
Submersible Pump 300 22 22
Conveyor 300-400 25:=1 36:=1 / 38-40
Compressor: Screw 300 25 -
Compressor, Reciprocating 400 25:=1 -
Fan 300 25:=2 -
Mixer 400-450 25:=1 -
Agitator 400 25:=1 -
Metals & Mining
Belt Conveyor 400 25:=1 36:=1 / 38-40
Dust Collector 350 -
Grinder 300 25:=1 36:=1
Hammer Mill 450 25:=1 36:=2
Rock Crusher 400 25:=1 -
Roller Conveyor 350 25:=1 36:=1 / 38-40
Roller Mill 450 25:=1 36:=1 or 2
Tubler 400 25:=1 -
Wire Draw Machine 450 25:=1 36:=1 or 2
Food Processing
Bottle Washer 300 25:=2
Centrifuge 400 25:=1 36:=1 or 2
Dryer 400 25:=2
Mill 450 25:=1 36:=1 or 2
Palletiser 450 25:=1
Separator 450 25:=1 36:=1 or 2
Slicer 300 25:=1
Pulp and Paper
Re-Pulper 450 25:=1
Shredder 450 25:=1
Trolley 450 25:=1
Petrochemical
Ball Mill 450 25:=1
Centrifuge 400 25:=1 36:=1 or 2
Extruder 500 25:=1
Screw Conveyor 400 25:=1
Transport & Machine Tool
Ball Mill 450 25:=1
Grinder 350 25:=1 36:=1
Material Converyor 400 25:=1 36:=1 / 38-40
Palletiser 450 25:=1
Press 350 25:=1
Roller Mill 450 25:=1
Rotary Table 400 25:=1 36:=1 / 38-40
Trolley 450 25:=1
Escalator 300-400 25:=1
Lumber & Wood Products
Bandsaw 450 25:=1 36:=1 or 2
Chipper 450 25:=1 36:=1 or 2
Circular Saw 350 25:=1 36:=1 or 2
Debarker 350 25:=1 36:=1 or 2
Planer 350 25:=1 36:=1 or 2
Sander 400 25:=1 36:=1 or 2

* Softstart can be packaged with standalone full wave DC injection brake for heavy loads or
faster stopping.
Table 1: Application Rating List

© 2002 Saftronics, Inc. 19

AS6 Instruction Manual
APPLICATION & FUNCTIONS [Link]

4.3 The Application Functions List

This list gives an overview of many different applications/duties and a possible solution with one of the many AS6
functions.

Description and use of the table:

Application / Duty
This column gives the various applications and level of duty. If the machine or application is not in this list, try
to identify a similar machine or application. If in doubt please contact your supplier.

Problem
This column describes possible problems that are familiar for this kind of application.

Solution AS6
Gives the possible solution for the problem using one the AS6 function.

Menus
Gives the menu numbers and selection for the AS6 function.
“25;=1", means: program selection 1 in menu 25.
"36;=1 / 34,35", means: program selection 1 in menu 36, menus 34 and 35 are related to this function.

20 © 2002 Saftronics, Inc.

 AS6 Instruction Manual
[Link] APPLICATION & FUNCTIONS
Application/ Problem Solution AS6 Menus
Duty
PUMP Too fast start and stops MSF Pump application with following start / stop features 22

Normal Non linear ramps Linear ramps without tacho

Water hammer Torque ramps for quadratic load
High current and peaks during starts
Pump is going in wrong direction Phase reversal alarm 88
Dry running Shaft power underload 96-99
High load due to dirt in pump Shaft power overload 92-95
COMPRESSOR Mechanical shock for compressor, motor and Linear Torque ramp or current limit start. 25:=1 or
transmissions 20,21
Normal Small fuses and low current available.
Screw compressor going in wrong direction Phase sequence alarm 88
Damaged compressor if liquid ammonia enters Shaft power overload 92-95
the compressor screw.
Energy consumption due to compressor is Shaft power underload 96-99
running unloaded
CONVEYOR Mechanical shock for transmissions and Linear Torque ramp 25:=1
transported goods.
Normal/Heavy Filling or unloading conveyors Slow speed and accurate position control 37-40,57,58
Conveyor jammed Shaft power overload 92-95
Conveyor belt or chain is off but the motor is still Shaft power underload 96-99
running
Starting after screw conveyor have stopped due Jogging in reverse direction and then starting in forward.
to overload
Conveyor blocked when starting Locked rotor function 75
FAN High starting current in end of ramps Torque ramp for quadratic need 25:=2
Slivering belts
Normal Fan is going in wrong direction when starting Catches the motor and going easy to zero speed and
then starting in right direction.
Belt or coupling broken Shaft power underload 96-99
Blocked filter or closed damper.
PLANER High inertia load with high demands on torque Linear Torque ramp gives linear acceleration and lowest 25:=1
and current control. possible starting current.
Heavy Need to stop quick both by emergency and Dynamic DC brake without contactor for medium loads 36:=1,34,35
production efficiency reasons. and controlled sensor less soft brake with reversing 36:=2,34,35
contactor for heavy loads. *
High speed lines Conveyor speed set from planer shaft power analog 54-56
output.
Worn out tool Shaft power overload 92-95
Broken coupling Shaft power underload 96-99
ROCK CRUSHER High enertia Linear Torque ramp gives linear acceleration and lowest 25:=1
possible starting current.
Heavy Heavy load when starting with material Torque boost 30,31
Low power if a diesel powered generator is
used.
Wrong material in crusher Shaft power overload 92-95
Vibrations during stop Dynamic DC brake without contactor 36:=1,34,35
BANDSAW High inertia load with high demands on torque Linear Torque ramp gives linear acceleration and lowest 25:=1
and current control. possible starting current.
Heavy Need to stop quick both by emergency and Dynamic DC brake without contactor for medium loads 36:=1,34,35
production efficiency reasons. and controlled sensor less soft brake with reversing 36:=2,34,35
contactor for heavy loads. *
High speed lines Conveyor speed set from band saw shaft power analog 54-56
output.
Worn out saw blade Shaft power overload
Broken coupling, saw blade or belt Shaft power underload
Table 2: Application Function List

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AS6 Instruction Manual
APPLICATION & FUNCTIONS [Link]

Application/ Problem Solution AS6 Menus

Duty
CENTRIFUGE High inertia load Linear Torque ramp gives linear acceleration and lowest 25:=1
possible starting current.
Heavy Too high load or unbalanced centrifuge Shaft power overload
Controlled stop Dynamic DC brake without contactor for medium loads and 36:=1,34,35
controlled sensor less soft brake with reversing contactor for 36:=2,34,35
heavy loads. *
Need to open centrifuge in a certain position Braking down to slow speed and then positioning control. 37-40,57,58
MIXER Different materials Linear Torque ramp gives linear acceleration and lowest 25:=1
possible starting current.
Heavy Need to control material viscosity Shaft power analog output 54-56
Broken or damaged blades Shaft power overload 92-95
Shaft power underload 96-99
HAMMER MILL Heavy load with high breakaway torque Linear Torque ramp gives linear acceleration and lowest 25:=1
possible starting current.
Heavy Torque boost in beginning of ramp. 30,31
Jamming Shaft power overload 92-95
Fast Stop Controlled sensor less soft brake with reversing contactor for 36:=2,34,35
heavy loads. *
Motor blocked Locked rotor function 75

* Standalone full-wave DC injection brake is recommended for these applications. Integrated package can be shipped from factory.
Table 2: Application Function List

EXAMPLE Hammer Mill:

This is an application for heavy duty,

Main function Torque ramp start (menu 25) will give the best results.

Torque boost to overcome high breakaway torque (menu 30 and 31)

Overload alarm function for jamming protection (menu 92 and 95)

If braking is desired, full-wave DC injection brake is recommended.

4.4 Function and combination matrix

Table 3 gives an overview of all possible functions and combination of functions.

1. Select function in the horizontal “Main Function” column. Only one function can be selected in this column, at a
time.
2. In the vertical column “Additional Functions” you will find all possible function that can be used together with your
selected main function.
Jogging with keyboard / terminal

External controlled slow speed

Dynamic Vector Brake (036-1)

Timer controlled slow speed
Power factor control (033)

Parameter sets (061)

Additional functions

Complete protection
Torque boost (030)

Softbrake (036-2)
Dual ramp start

Dual ramp stop

Bypass (032)

Main Functions
Voltage ramp start / stop (default) X X X X X X X X X X X
Torque control start / stop (menu 025) X X X X X X X X X
Voltage ramp with current limit (menu 020) X X X X X X X X X X X
Current limit start (menu 021) X X X X X X X X X X X
Pump control (menu 022) X X X
Analog input (menu 023) X X
Direct on line start (menu 024) X X X
Table 3: Combination matrix

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 AS6 Instruction Manual
[Link] APPLICATION & FUNCTIONS
By using one parameter set, the following start/stop table is given.

NOTE! Voltage and torque ramp for starting only with softbrake.

Dynamic Vector Brake

Torque control stop
Voltage ramp stop

Direct on line stop

Stop Function

Pump control

Analog input

Softbrake
Start Function
Voltage ramp start X X X X
Torque control start X X X X
Current limit start X X X X
Voltage ramp with current limit X X X X
Pump control X X
Analog input X X
Direct on line start X
Table 4: Start / Stop combination

By using different parameter sets for start and stop, it is possible to combine all start and stop functions.

4.5 Special condition

4.5.1 Small motor or low load

The minimum load current for the soft starter is 10% of the rated current of the soft starter. Example AS6-60, rated
current = 60 A. Min. Current 6 A. Please note that this is “min. load current“ and not min. rated motor current.

4.5.2 Ambient temperature below 0oC

For ambient temperatures below 0oC e.g. an electrical heater must be installed in the cabinet. The soft starter can
also be mounted in some other place, because the distance between the motor and the soft starter is not critical.

4.5.3 Power Factor Correction Capacitors

If a power factor correction capacitor is to be used, it must be connected at the inlet of the soft starter, not between
the motor and the soft starter.

4.5.4 Pole-changing contactor and two speed motor

The switching device must be connected between the output of the soft starter and the motor.

4.5.5 Shielded motor cable

It is not necessary to use shielded motor cables with soft starters. This is due to the very low radiated emissions.

NOTE! The soft starter should be wired with shielded control cable to fulfill EMC regulations acc. to § 1.5,
page 8.

4.5.6 Slip ring motors

The starter can be packaged for use with wound rotor induction motors, or synchronous motors. Consult factory for
quotation.

4.5.7 Pump control with soft starter and frequency inverter together
It is possible e.g. in a pump station with two or more pumps to use one frequency inverter on one pump and soft
starters on each of the other pumps. The flow of the pumps can then be controlled by one common control unit.

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APPLICATION & FUNCTIONS [Link]

4.5.8 Starting with counter clockwise rotating loads

It is possible to start a motor clockwise, even if the load and motor is rotating counter clockwise e.g. fans. Depending
on the speed and the load “in the wrong direction“ the current can be very high.

4.5.9 Running motors in parallel

When starting and running motors in parallel the total amount of the motor current must be equal or lower than the
connected soft starter. Please note that it is not possible to make individual settings for each motor. The start ramp
can only be set for an average starting ramp for all the connected motors. This applies that the start time may differ
from motor to motor. This is also even if the motors are mechanically linked, depending on the load etc.

4.5.10 How to calculate heat dissipation in cabinets

See chapter 12. page 74 “Technical Data”, “Power loss at rated motor load (IN)“, “Power consumption control card“
and “Power consumption fan“. For further calculations please contact your local supplier of cabinets.

4.5.11 Insulation test on motor

When testing the motor with high voltage e.g. insulation test the soft starter must be disconnected from the motor.
This is due to the fact that the thyristors will be seriously damage by the high peak voltage.

4.5.12 Operation above 1000 m

All ratings are stated at 1000 m over sea level.
If a AS6 is placed for example at 3000 m it must be derated unless the maximum temperature is lower than 40oC to
compensate for this higher altitude.
To get information about motors and drives at higher altitudes please contact your supplier.

4.5.13 Reversing
Motor reversing is always possible. See Fig. 19 on page 36 for the advised connection of the reverse contactors.
At the moment that the mains voltage is switched on, the phase sequence is monitored by the control board. This
information is used for the Phase Reverse Alarm (menu 88, see § 7.22, page 58).
However if this alarm is not used (factory default), it is also possible to have the phase reversal contactors in the
input of the soft starter.

24 © 2002 Saftronics, Inc.

 AS6 Instruction Manual
[Link] OPERATION

5.0 OPERATION OF THE SOFT STARTER

5.1 General description of user interface

!
WARNING! Never operate the soft starter with removed front cover.

To obtain the required operation, a number of parameters must be set in the soft starter.
Setting/configuration is done either from the built-in keyboard or by a computer/control system through the serial
interface or bus (option). Controlling the motor i.e. start/stop, selection of parameter set, is done either from the key-
board, through the remote control inputs or through the serial interface (option).

Setting

!
WARNING! Make sure that all safety measures have been taken before switching on the supply.

Switch on the supply (normally 1 x 120 V), all segments in the display will light up for a few seconds. Then the dis-
play will show menu 001. An illuminated display indicates there is supply voltage on the PCB.
Check that you have voltage on the mains contactor or on the thyristors. To be able to use all extended functions and
optimize of the performance, program the motor data.

5.2 PPU Unit

The programming and presentation unit (PPU) is a build-in operator panel with two light emitting diodes, three + four
seven-segment LED-displays and a keyboard.

RUNNING

START/STOP
MENU

VALUE
01 Initia l voltage at sta r t (%)
02 Star t r amp 1 ( sec.)
03 Step down voltage at sto p (%)
04 Stop ramp 1 ( sec.)
05 Current readout
06 Cont rol mode
07 Extended functions

JOG JOG

START
STOP PREV
V NEXT

ENTER

RESET

Figure 7: PPU unit

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OPERATION [Link]

5.3 LED display

The two light emitting diodes indicates start/stop and running motor/machine. When a start command is given either
from the PPU, through the serial interface (option) or through the remote control inputs, the start/stop-LED will be
illuminated.
At a stop command the start/stop-LED will switch off. When the motor is running, the running-LED is flashing during
ramp up and down and is illuminated continuously at full motor voltage.

Voltage

UN

Time

Running-LED, Running- Running-LED, Running-

flashing LED, on flashing LED, off
Start/stop- Start/stop-
LED, on LED, off

Figure 8: LED indication at different operation situation

5.4 The Menu Structure

The menus are organised in a simple one level structure with the possibility to limit the number of menus that are
reachable by setting the value in menu 007 to ”oFF” (factory setting). With this setting only the basic menus 001,
002, 003, 004, 005, 006 and 007 can be reached.
This to simplify the setting when only voltage start/stop ramps are used.
If menu 007 is in “on” and menu 008 “oFF” it is possible to reach all viewing menus and alarm lists as well.
901-915 Alarm list
Key lock status 221 001 Initial voltage
RMS currents and voltages 002 Start ramp time
211-216
in each phase 003 Step down voltage at stop
004 Stop ramp time
Viewed soft starter data 201-208
005 RMS current
006 Control mode
Reset to factory settings 199
007 Menu expander
Serial communication 111-114 008 Menu expander

Automatic return menu 105 011-014 Dual ramp start/stop

016-018 Initial and end torque at start
"JOG" enable 103-104 020-025 Main functions
030-040 Additional functions
Run at F1&F4 alarm 101-102

041-046 Nominal motor parameters

Machine protection 089-099

051-052 Relay K1&K2 functions

Main supply protection 081-088 Analogue output

054-056

Motor protection 071-075 057-058 Digital input

061 Parameter set

Figure 9: Menu structure 03-F30

26 © 2002 Saftronics, Inc.

 AS6 Instruction Manual
[Link] OPERATION
5.5 The keys

The function of the keyboard are based on a few simple

rules. At power up menu 001 is shown automatically. Use Start / Stop motor operation
START

the “NEXT ” and “PREV ” keys to move between STOP

menus. To scroll through menu numbers, press and hold

either the “NEXT ” or the “PREV ” key. The ”+” and ”–” Display previous menu PREV
keys are used to increase respectively decrease the
value of setting. The value is flashing during setting. The
”ENTER
” key confirms the setting just made, and the Display next menu NEXT
value will go from flashing to stable. The ”START/STOP”
key is only used to start and stop the motor/machine.
Decrease value of setting
The and
JOG

keys are only used for JOG from the

JOG

keyboard. Please note one has to select enable in menu

103 or 104, see § 7.25, page 62. Increase value of setting

ENTER
Confirm setting just made
Alarm reset

RESET

JOG Reverse JOG

JOG Forward JOG

Table 5: The keys

5.6 Keyboard lock

The keyboard can be locked to prohibit operation and

parameter setting by an unauthorised. Lock keyboard by
pressing both keys "NEXT " and "ENTER
" for at least 2
2 2 1 Locked keyboard info
sec. The message ’- Loc’ will display when locked. To
unlock keyboard press the same 2 keys "NEXT " and
"ENTER
" for at least 2 sec. The message ’unlo’ will dis-
play when unlocked.
In locked mode it is possible to view all parameters and
read-out, but it is forbidden to set parameters and to oper-
ate the soft starter from the keyboard.
no
The message ’-Loc’ will display if trying to set a parameter
or operate the soft starter in locked mode. Default: no
The key lock status can be read out in menu 221.
Range: no, yes
no Keyboard is not locked
YES Keyboard is locked

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OPERATION [Link]

5.7 Overview of soft starter operation and parameter set-up

Table with the possibilities to operate and set para-meters in soft starter.
Control mode is selected in menu 006 and Parameter set is selected in menu 061. For the keyboard lock function,
see § 7.30, page 66.

Setting of parameters
Operation / JOG Parameter set with Parameter set with
Start/Stop Alarm reset
Set-up fwd/rev external selection internal selection
Control mode Menu 061=0 Menu 061=1-4
Unlocked
Keyboard Keyboard Keyboard ______ Keyboard
Keyboard keyboard
Menu 006=1 Locked
______ ______ ______ ______ ______
keyboard
Unlocked Remote and
Remote Remote Remote Keyboard
Remote keyboard keyboard
Menu 006=2
Locked
Remote Remote Remote Remote ______
keyboard
Unlocked Serial Serial Remote and
______ Serial Comm
Serial Comm. keyboard Comm Comm keyboard
Menu 006=3
Locked Serial Serial Serial
______ Serial Comm
keyboard Comm Comm Comm
Table 6: Control modes

6.0 INSTALLATION AND CONNECTION

Mounting, wiring and setting the device into operation must be carried out by trained personnel (electricians
specialised in heavy current technology):

In accordance with the local safety regulations of the electricity supply company.

In accordance with DIN VDE 0100 for setting up heavy current plants.

Care must be taken to ensure that personnel do not come into contact with live circuit components.

! WARNING! Never operate the soft starter with removed front cover.

6.1 Installation of the soft starter in a cabinet

When installing the soft starter:

Ensure that the cabinet will be sufficiently ventilated, after the installation.

Keep the minimum free space, see the tables on page 30.

Ensure that air can flow freely from the bottom to the top.

NOTE! When installing the soft starter, make sure it does not come into contact with live components. The
heat generated must be dispersed via the cooling fins to prevent damage to the thyristors (free
circulation of air).

28 © 2002 Saftronics, Inc.

 AS6 Instruction Manual
[Link] INSTALLATION & CONNECTION
NOTE! The soft starter should be wired with shielded control cable to fulfill EMC regulations acc. to
§ 1.5, page 8.

NOTE! For UL-approval use copper wire at 75°C rating.

W1

H
H1

03-F07 W D 03-F98

Figure 10: AS6 Dimensions

AS6-017 to AS6-250
208,50

16,80
h1

547

30,20
h2

46

w1 03-F122

Figure 11: Hole pattern for AS6-17 to AS6-250 Figure 12: Hole pattern for AS6-170 to AS6-250 with
(backside view) upper mounting bracket instead of DIN-rail

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AS6 Instruction Manual
INSTALLATION & CONNECTION [Link]

AS6-017 to AS6-250

Dimension Hole dist. Hole dist. Weight

AS6 model Class Connection Conv./Fan Diam./screw
HxWxD (mm) w1 (mm) h1 (mm) (kg)
-017, -030 IP 20 Busbars Convection 320x126x260 78.5 265 5.5 / M5 6.7
-045, -060,
IP 20 Busbars Fan 320x126x260 78.5 265 5.5 / M5 6.9
-075, -085
-110, -145 IP 20 Busbars Fan 400-176-260 128.5 345 5.5 / M5 12.0
-170, -210,
IP 20 Busbars Fan 500-260-260 208.5 445 5.5 / M5 20
-250
Table 7: AS6-017 to AS6-250

Minimum free space (mm) Tightening torque for bolt (Nm)

Dimension Connection
AS6 model Supply
above 1) below at side busbars Cu Cable PE-cable
and PE
-017, -030, -045 100 100 0 15x4 (M6), PE (M6) 8 8 0.6
-060, -075, -085 100 100 0 15x4 (M8), PE (M6) 12 8 0.6
-110, -145 100 100 0 20x4 (M10), PE (M8) 20 12 0.6
-170, -210, -250 100 100 0 30x4 (M10), PE (M8) 20 12 0.6
1) Above: wall-soft starter or soft starter-soft starter

Table 8: AS6-017 to AS6-250

30 © 2002 Saftronics, Inc.

 AS6 Instruction Manual
[Link] INSTALLATION & CONNECTION
6.2 Connections

01 02 PE
J2
J1 I U
I U
21 22 23 24 31 32 33
11 12 1314 15 16 17 18 19

01 02 PE 69 70 71-72 73-74 75 76 77 78

3 2
6
T1 T2 T3

7
L1 L2 L3 5

1 1
4

03-F54_1

Figure 13: Connection of AS6-017 to AS6-085

Connection of AS6-017 to AS6-085

Device connections
1. Protective earth, (PE), Mains supply, Motor 5. Motor power supply T1, T2, T3
(on the right and left inside of the cabinet) 6. Current transformers (possible to mount outside
2. Protective earth, (PE), Control voltage for bypass see § 7.12, page 45)
3. Control voltage connection 01, 02 7. Mounting of EMC gland for control cables
4. Mains supply L1, L2, L3

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INSTALLATION & CONNECTION [Link]

01 02 PE
J2
J1 I U
I U
21 22 23 24 31 32 33
11 12 13 14 15 16 17 18 19

3 2
01 02 03 69 70 71-72 73-74
75 76 77 78

T1 T2 T3

5
6
L1 L2 Lo

4
7

03-F55_1

Figure 14: Connection of AS6-110 to AS6-145

Connection of AS6-110 to AS6-145

Device connections
1. Protective earth, (PE), Mains supply, Motor 5. Motor power supply T1, T2, T3
(on the left inside of the cabinet) 6. Current transformers (possible to mount outside
2. Protective earth, (PE), Control voltage for bypass see § 7.12, page 45)
3. Control voltage connection 01, 02 7. Mounting of EMC gland for control cables
4. Mains supply L1, L2, L3

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 AS6 Instruction Manual
[Link] INSTALLATION & CONNECTION

01 02 PE
J2
J1 I U
I U
21 22 23 24 31 32 33
11 12 13 14 15 16 17 18 19

01 02 PE 69 70 71-72 73-74 75 76 77 78 79

3 2

6
T1 T2 T3
7
5
L1 L2 L3

1 1

03-F104
Figure 15: Connection of AS6-170 to AS6-250
Connection of AS6-170 to AS6-250

Device connections
1. Protective earth, (PE), Mains supply, Motor 5. Motor power supply T1, T2, T3
(on the left inside of the cabinet) 6. Current transformers (possible to mount outside
2. Protective earth, (PE), Control voltage for bypass see § 7.12, page 45)
3. Control voltage connection 01, 02 7. Mounting of EMC gland for control cables
4. Mains supply L1, L2, L3

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INSTALLATION & CONNECTION [Link]

6.3 Connection and setting on the PCB control card

J2
J1
I U
I U
11 12 13 14 15 21 22 23 24 31
16 17 18 19 32 33

01 02
PE 69 70 03-F53
71-72 75 76 77
73-74 78 79

03-F107

Figure 16: Connections on the PCB, control card

Terminal Function Electrical characteristics

1
Supply Voltage 100-240 VAC ⫾10%/380-500 VAC ⫾10%
2
PE Gnd
11 0-3 V  0: 8-27 V  1. Max. 37 V for 10 sec. Impedance
Digital inputs for start / stop and reset.
12 to 0 VDC: 2.2 kΩ.
Supply / control voltage to PCB terminal 11 and 12, 10 +12 VDC ⫾5%. Max current from +12 VDC: 50 mA.
13
kΩ potentiometer, etc. Short circuit proof.
Remote analogue input control, 0-10 V, 2-10 V, 0-20 mA Impedance to terminal 15 (0 VDC) voltage signal:
14
and 4-20 mA / digital input. 125kΩ, current signal: 100 Ω.
15 GND (common) 0 VDC
16 0-3 V  0: 8-27 V  1. Max. 37 V for 10 sec. Impedance
Digital inputs for selection of parameter set.
17 to 0 VDC: 2.2 kΩ.
Supply / control voltage to PCB terminal 16 and 17, 10 +12 VDC ⫾5%. Max current from +12 VDC: 50 mA.
18
kΩ potentiometer, etc. Short circuit proof.
Analogue Output contact: 0-10V, 2-10V; min load
19 Remote analogue output control impedance 700Ω; 0-20mA and 4-20mA; max load
impedance 750Ω
21 Programmable relay K1. Factory setting is "Operation" 1-pole closing contct, 250 VAC 8A or 24 VDC 8A
22 indication by closing terminal 21-22. resistive, 250 VAC, 3A inductive.
23 Programmable relay K2. Factory setting is "Full voltage" 1-pole closing contct, 250 VAC 8A or 24 VDC 8A
24 indication by closing terminal 23-24. resistive, 250 VAC, 3A inductive.
31 Alarm relay K3, closed to 33 at alarm.
1-pole change over contact, 250 VAC 8A or 24 VDC 8A
32 Alarm relay K3, open at alarm.
resistive, 250 VAC, 3A inductive.
33 Alarm relay K3, common terminal.
69-70 PTC Thermistor input Alarm level 2.4 kΩ Switch back level 2.2 kΩ.
71-72* Clickson thermistor Used on larger softstarts
73-74* NTC thermistor Temperature measuring of soft starter cooling fine
75 Current transformer input, cable S1 (blue) Connection of L1 or T1 phase current transformer
76 Current transformer input, cable S1 (blue) Connection of L3 or T3 phase (AS6-017 -AS6-250)
77 Current transformer input, cable S2 (brown) Common connection for temrinal 75 and 76
78* Fan connection 24 VDC
79* Fan connection 0 VDC
*Internal connection, no customer use
Table 9: PCB Terminals

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 AS6 Instruction Manual
[Link] INSTALLATION & CONNECTION
6.4 Minimum Wiring
P1
L1 L1 T1

L2 L2
P1
T2
M
L3 L3 T3

BL BR BL BR
01
CONTROL 75
POWER
02
76
PE
77

2 WIRE 3 WIRE
START START

11
RUN STOP
OR 12

13

21
K1
22

23
K2
24

31

32 K3

33

Figure 17: Wiring circuit, “Minimum wiring”

The figure above shows the “minimum wiring”. See

§ 6.1, page 28, for tightening torque for bolts etc.

1. Connect Protective Earth (PE) to earth screw marked (PE)

2. Connect the soft starter between the 3-phase mains supply and the motor. On the soft starter the mains side is
marked L1, L2 and L3 and the motor side with T1, T2 and T3
3. Connect the control voltage (100-240 VAC) for the control card at terminal 01 and 02
4. Connect relay K1 (terminals 21 and 22) to the control circuit. (If used)
5. Connect PCB terminals 11, 12, and 13 for desired control (2 or 3 wire)
6. Ensure the installation complies with the appropriate local regulations

NOTE! The soft starter should be wired with shielded control cable to fulfill EMC regulations acc. to § 1.5,
page 8.

NOTE! If local regulations say that a mains contactor should be used, the K1 then controls it. Always provide
short circuit protection in the form of a circuit breaker or properly rated time delay fuses.

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INSTALLATION & CONNECTION [Link]

6.5 Wiring examples

Fig. 18 gives an wiring example with the following func-
Analogue output, see § 7.18, page 53
tions.
PTC input, see § 7.21, page 56

Analogue input control, see § 7.7, page 42

Parameter set selection, see § 7.20, page 55 For more information see § 6.3, page 34.

+
14 Analog Input
- 0-10V OR 4-20mA
15 See Sect. 7.7 pg 42

PS1 PARAMETER SET PSI PSZ

AS6 16
CONTROL PS2 #1 OPEN OPEN
TERMINALS 17 #2 CLOSED OPEN
#3 OPEN CLOSED
18
#4 CLOSED CLOSED

+
19 Analog Output
- 0-10V OR 4-20mA
See Sect. 7.18 pg 53

Figure 18: Analog input control, parameter set selection, analogue output

AS6
PTC Sensor
in Motor

69

70

Motor Overtemp Alarms

if resistance exceeds 2.4k ,
resets when resistance drops
below 2.2k

Figure 19: Motor overtemp protection via PTC sensor

36 © 2002 Saftronics, Inc.

 AS6 Instruction Manual
[Link] SET-UP MENU
7.0 FUNCTIONAL DESCRIPTION SET-UP MENU
This chapter describes all the parameters and functions in numerical order as they appear in the AS6. Table 10
gives an overview of the menus, see also Chapter 12. page 75 (set-up menu list).

Menu Menu
Parameter group See §
number numbers

Ramp up / down parameters 001-005 7.1

Basic
001-008 Basic
Functions
Start / Stop / Reset command 006 7.2

Menu Expansion 007-008 7.3

Voltage control dual ramp 011-014 7.4
Torque control parameters 016-018 7.5
Main functions 020-025 7.6 - 7.10
Additional functions 030-036 7.11 - 7.14
037-040,
7.15, 7.19,
Slow speed and Jog functions 57-58, 103-
7.25
104
Motor Data Setting 041-046 7.16
Extended
011-199 Relays 051-052 7.17
functions Outputs
Analogue output 054-056 7.18
Input Digital input 057-058 7.19
Parameter set selection 061 7.20
Motor protection 071-075 7.21
Main protection 081-088 7.22
Application protection 089-099 7.23
Resume alarms 101, 102 7.24
Auto return menu 105 7.26
Factory defaults 199 7.27
Main view 201-208 7.28
RMS current per phase 211-213 7.28
View
201-915 RMS voltage per phase 214-216 7.28
functions
Keyboard lock status 221 7.29
Alarm list 901-915 7.30
Table 10: Set-up Menu Overview

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AS6 Instruction Manual
SET-UP MENU [Link]

7.1 Ramp up / down parameters

Setting of step down

UN Voltage 003 voltage stop ramp 1
100
Time

Figure 20: Menu numbers for start / stop ramps, initial

voltage at start and step down voltage at stop
Default: 100%
Determine the starting time for the motor/machine. Range: 100 - 40% of Un
When setting the ramp times for starting and stopping, Step down voltage at stop can be used to stop
initial voltage at start and step down voltage at stop, pro- smoothly.
ceed as follows:

Setting the initial 004 Setting of stop ramp 1

001 voltage at start ramp 1
30 o FF

Default: 30% Default: oFF

Range: 25 - 90% Un Range: oFF, 2-120 sec
Set the initial voltage. Normally the factory set- oFF Stop ramp disabled
ting, 30% of Un, is a suitable choice. 2-120 Set “Ramp down time” at stop

7.1.1 RMS current [005]

RMS current
Setting of start ramp 1 005
002
10 0. 0

Default: -----
Default: 10 sec Range: 0.0-9999 Amp
Range: 1-60 sec Read-out of the RMS motor current
Set “Ramp up time” at start.
NOTE! This is the same read-out as function 201,
see § 7.28, page 64.

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 AS6 Instruction Manual
[Link] SET-UP MENU
7.2 Start/stop/reset command 7.2.1 2-wire start/stop with automatic reset at start

Start/stop of the motor and reset of alarm is done either Closing PCB terminals 12 and 13, and a jumper between
from the keyboard, through the remote control inputs or terminal 11 and 12, will give a start command. Opening
through the serial interface (option). The remote control the terminals will give a stop. If PCB terminals 12 and 13
inputs start/stop/reset (PCB terminals 11, 12 and 13) is closed at power up a start command is given (auto-
can be connected for 2-wire or 3-wire control. matic start at power up). When a start command is given
there will automatically be a reset.

Selection of control mode

006 J1
J2

2
I U
Start / I U
Reset 21 22 23 24 31
11 12 13 14 15
16 17 18 19 32 33

Stop

7.2.2 2-wire start/stop with separate reset

Default: 2 Closing PCB terminals 11, 12 and 13 will give a start

Range: 1, 2, 3 and opening the terminals 12 and 13 will give a stop. If
PCB terminals 12 and 13 are closed at power up a start
START/STOP/RESET command via the key-
command is given (automatic start at power up). When
board.
1 - Press the “START/STOP” key on the key
PCB terminals 11 and 13 are opened and closed again a
reset is given. A reset can be given both when the motor
board to start and stop the soft starter.
is running and stopped and doesn’t affect the start/stop.
- Press “ENTER/RESET” key to reset a trip
condition.
Via Remote control. START/STOP/RESET
commands. The following control methods are J2
J1
possible: I U
Start /
- 2-wire start/stop with automatic reset, see Stop
I U
2 § 7.2.1, 39.
11 12 13 14 15
16 17 18 19
21 22 23 24 31
32 33

- 2-wire start/stop with separate reset, see Reset

§ 7.2.2, page 39.

- 3-wire start/stop with automatic reset at start,
7.2.3 3-wire start/stop with automatic reset at start
see § 7.2.3, page 39.
WARNING! The motor will start if terminals
PCB terminal 12 and 13 are normally closed and PCB
11, 12, 13 is in start position.
terminal 11 and 13 are normally open. A start command
START/STOP/RESET commands via serial
is given by momentarily closing PCB terminal 11 and 13.
3 interface option. Read the operating instruction
To stop, PCB terminal 12 and 13 are momentarily
supplied with this option.
opened.
NOTE! A reset via the keyboard will not start or stop When a start command is given there will automatically
the motor. be a reset. There will not be an automatic start at power
NOTE! Factory default setting is 2, remote control. up.

To start and stop from the keyboard, the “START/STOP”

key is used. J2
J1
I U
To reset from the keyboard, the “ENTER
/RESET” key
Stop I U
11 12 13 14 15 21 22 23 24 31
16 17 18 19 32 33
is used. A reset can be given both when the motor is
running and when the motor is stopped. A reset from the Start / Reset

keyboard will not start or stop the motor.

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7.3 Menu expansion setting

In order to use the viewing menus and/or the extended Setting the initial
011 voltage at start ramp 2
functions menu 007 must be set to “On”, then one reach
read out of the viewing menus 201-915. To be able to set
any extended functions in the menus 011-199 menu 008 90
must be set to “on” as well.
Default: 90%
Selecting of extended Range: 30-90% Un
007 functions and viewing Set the start voltage for start ramp 2. The initial volt-
functions age for start ramp 2 is limited to the initial voltage at

oFF start (menu 001), see § 7.1, page 38.

Setting of start ramp 2

Default: oFF 012
Range: oFF, on
oFF Only function 1-7 are visible
- View functions 201-915 are visible
oFF
on - Extended functions (menu 008) Default: oFF
selectable Range: oFF, 1-60 sec
oFF Start ramp 2 disabled
1-60 Set the start ramp 2 time. A dual
008 Selecting of extended
functions
voltage ramp is active.

oFF
Setting of step down
013 voltage in stop ramp 2
Default:
Range:
oFF
oFF, on 40
oFF Only view function 201-915 are visible Default: 40%
on All the function menus are visible Range: 100-40% Un
Set the step down voltage for stop ramp 2. The
7.4 Voltage control dual ramp step down voltage for stop ramp 2 is limited to
To achieve even smoother ramps at start and or stop, a the step down voltage at stop (menu 003).
dual ramp can be used.

UN Voltage

Setting of stop
014 ramp time 2
Time

Figure 21: Menu numbers for dual voltage ramp at start/stop,

oFF
initial voltage at start and step down-voltage at stop Default: oFF
Range: oFF, 2-120 sec
The settings are carried out by beginning with the set- oFF Stop ramp 2 disabled
tings in menus 001-004 and 007-008 and proceed with
the following steps:
1-60 Set the stop ramp 2 time. A dual
voltage ramp is active.

40 © 2002 Saftronics, Inc.

 AS6 Instruction Manual
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7.5 Torque control parameters 7.6 Current limit (Main Function)

See also § 7.10, page 44 and chapter 4. page 18 for The Current Limit function is used to limit the current
more information on the Torque control setting. drawn when starting (150 - 500% of In). This means that
current limit is only achieved during set start-up time.
Initial torque at start
016 Two kinds of current limit starts are available.

Voltage ramp with a limited current.
10 If current is below set current limit, this start will act
exactly as a voltage ramp start.
Default: 10
Current limit start.
Range: 0-250 of Tn The soft starter will control the current up to set
Insert initial torque at start in percent of nominal shaft current limit immediately at start, and keep it there
torque (Tn), see chapter 12, page 75. until the start is completed or the set start-up time
expires.
See Fig. 22 Current limit.
End torque at start NOTE! Make sure that nominal motor current in
017 menu 042 is correctly inserted.

150 7.6.1 Voltage ramp with current limit

Default: 150 The settings are carried out in three steps:

Range: 50-250% of Tn 1. Estimate starting-time for the motor/machine and
Insert end torque at start in percent of nominal shaft
select that time in menu 002 (see § 7.1, page 38).
torque. 2. Estimate the initial voltage and select this voltage in
menu 001 (see § 7.1, page 38).
3. Set the current limit to a suitable value e.g. 300% of
End torque at stop In in menu 020.
018
Voltage ramp with current
020
0 limit at start

Default: 0 oFF
Range: 0-100% of Tn Default: oFF
Insert end torque at stop in percent of the nominal Range: oFF, 150-500% In
motor torque.
oFF Voltage ramp mode with current limit
disabled. Voltage ramp enabled.
150-500 Current limit level in Voltage ramp
mode.

NOTE! Only possible when Voltage Ramp mode is

enabled. Menus 021-025 must be “oFF”.
Current

Voltage ramp
Current
limit at
start

03-F109

Figure 22: Current limit

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AS6 Instruction Manual
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7.6.2 Current limit 7.7 Pump control (Main Function)

The settings are carried out in two steps: By choosing pump control you will automatically get a
Estimate starting time for the motor/machine and select stop ramp set to 15 sec. The optimising parameters for
that time in menu 002 (see § 7.1, page 38). this main function are start and stop time; initial torque at
Set the current limit to a suitable value e.g. 300% of In in start and end torque at start and stop. End torque at stop
menu 021. is used to let go of the pump when it´s no longer produc-
ing pressure/flow, which can vary on different pumps.
See Fig. 24.
Current limit at start
021
Current (A)

oFF
Default: oFF
Range: oFF, 150-500% In
oFF Curent limit mode disabled. Voltage
Ramp enabled.
150-500 Current limit level in current limit mode.

NOTE! Only possible when Voltage Ramp mode is FLC

enabled. Menus 020, 022-025 must be “oFF”.

NOTE! Even though the current limit can be set as Time

low as 150% of the nominal motor current value, this Speed
minimum value cannot be used generally.
Considerations must be given to the starting torque
and the motor before setting the appropriate current
limit. "Real start time" can be longer or shorter than
the set values depending on the load conditions.
This applies to both current limit methods.

Current

03-F118 Time

Figure 24: Pump control

Pump application
Current The pump application is using Torque ramps for quadrat-
Limit ic load. This gives lowest possible current and linear start
and stop ramps. Related menus are 2, 4 (see § 7.1,
FLC page 38), 16, 17 and 18 (see § 7.5, page 41).

Setting of pump control

022
Starting time Time

Figure 23: Current limit

03-F110
oFF
If the starting time is exceeded and the soft starter is still Default: oFF
operating at current level, an alarm will be activated. It is Range: oFF, on
possible to let the soft starter to either stop operation or oFF Pump control disabled. Voltage Ramp
to continue. Note that the current will rise uncontrolled if enabled.
the operation continues (see § 7.24.2, page 62). 150-500 Pump control application is enabled.

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 AS6 Instruction Manual
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7.8 Analogue Input Control (Main Function) 7.9 Full voltage start, D.O.L.
Soft starting and soft stopping can also be controlled via (Main Function)
the Analogue Input Control (0-10 V, 2-10 V, 0-20 mA and The motor can be accelerated as if it was connected
4-20 mA). This control makes it possible to connect directly to the mains. For this type of operation:
optional ramp generators or regulators. Check whether the motor can accelerate the required
After the start command, the motor voltage is controlled load (D.O.L.-start, Direct On Line start). This function can
through the remote analogue input. be used even with shorted thyristors.

WARNING! The remote analogue control may

!
Setting of D.O.L. start
not be used for continuous speed regulation
024
of standard motors. With this type of opera-
tion the increase in the temperature of the oFF
motor must be taken into consideration.
Default: oFF
1. To install the analogue input control, proceed by: Range: oFF, on
Connect the ramp generator or regulator to terminal 14 oFF D.O.L. start disabled.
(+) and 15 (–). Voltage Ramp enabled.
on D.O.L. start enabled.
J2 NOTE! Only possible when Voltage Ramp mode is
J1
I U enabled. Menu 020-023, 025 must be “oFF”.
I U
11 12 13 14 15 21 22 23 24 31
16 17 18 19 32 33
6-7xInom

Figure 25: Wiring for analogue input

2. Set Jumper J1 on the PCB control card to voltage (U)
or current control (I) signal position, see Fig. 13 on page
31. Factory setting is voltage (U). [For setting J2 refer to
page 53]

J2 FLC
J1
I U
I U
11 12 13 14 15 21 22 23 24 31
16 17 18 19 32 33 Time
Figure 27: Full voltage start
Figure 26: Setting voltage or current for analogue input
Selection of analogue
023 input control

oFF
Default: oFF
Range: oFF, 1, 2
oFF Analogue input disabled.
Voltage ramp enabled.
1 Analogue input is set for 0-10V/
0-20mA control signal.
2 Analogue input is set for 2-10V/
4-20mA control signal.

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7.10 Torque control (Main function)

This main function can be used to make a start accord-
Torque control at
ing to a pre-defined torque reference curve. Two different 025 start/stop
load characteristics, linear and square, are possible to
select.
At start/stop the torque controller will follow the selected oFF
characteristic. Default: oFF
A torque start/stop behaviour can be seen in Fig. 26.
A perfect start and stop with torque ramps have a good
Range: oFF, 1, 2
linearity of current. To optimise this, use the setting of ini- oFF Torque control is disabled.
tial torque (menu 16) and end torque (menu 18). See Voltage ramp enabled.
also § 7.5, page 41. 1 Torque control with linear torque
characteristics.
Example: 2 Torque control with square torque
Default for initial torque is 10% so if starting a more characteristics.
heavy load this will result in a small current peak in
NOTE! Torque control mode is only possible when
beginning of ramp. By increasing this value to 30/70%
Voltage Ramp mode is enabled (menu
the current peak will not appear.
020-024 are “oFF”).
The end torque is increased mainly if the application has
a high inertial load, like planers, saws and centrifuges. A
current peak will appear in the end of ramp because the
load is pushing the speed more or less by itself. By
increasing this level to 150-250% the current will be lin-
ear and low.

2.5 Tn

2 Tn 1 Linear
2 Square
End Torque
1.5 Tn

Nominal Torque
Tn

1 1
2 2
0.5 Tn
Initial Torque End torque at stop

Start Time Stop Time

Figure 28: Torque control at start/stop.

Current (A) Speed

FLC

Time Time
03-F113 03-F114

Figure 29: Current and speed in torque control.

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 AS6 Instruction Manual
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7.11 Torque boost 7.12 Bypass
The Torque Booster enables a high torque to be
obtained by providing a high current during 0.1 - 2 sec at In cases of high ambient temperatures or for use in non-
start. This enables a soft start of the motor even if the vented enclosures it may be necessary to use a by-pass
break away torque is high at start. For example in crush- contactor to minimize the power loss at nominal speed
ing mills applications etc. (see Technical Data). By using the built-in Full Voltage
When the torque booster function has finished, starting Relay function an external contactor can be used to
continues according to the selected start mode. Bypass the soft starter when operating at nominal
speed.
Bypass contactor can also be used if soft stop is
required. Normally a Bypass contactor is not necessary
Torque boost as the device is designed for continuous running condi-
Current Limit tions, see Fig. 31a on page 46 for wiring example.

NOTE! To use the alarm functions, the extended

Full Speed functions or the viewing functions the 2-pcs current
Load current transformers must be mounted outside the soft start
as shown in Fig. 31 on page 46. For this purpose the
current transformer secondary leads must be
03-F40 Time
extended.

Figure 30: The principle of the Torque Booster when

Setting of Bypass
starting the motor in voltage ramp mode. 0 32
See § 4.4, page 22, which main function that can be
used with the torque boost.
oFF
Default: oFF
Torque boost active time Range: oFF, on
030
oFF Bypass disabled.

oFF on
Bypass enabled.
Program either relay K1 or K2 to
Default: oFF function 2 to control the bypass
Range: oFF, 0.1 - 2 sec contactor, see menu 51/52.

oFF Torque boost disabled.

CAUTION! If the current transformers are
0.1-2.0
!
Set the Torque boost time. not mounted as in Fig. 31a on page 46 the
alarm and viewing functions will not work.
Do not forget to set menu 032 to ON, other-
Torque boost current limit
031 wise there will be an F12 alarm and at the
stop command will be a freewheeling stop.
300
For further information see chapter 6.2 page 31.
Default: 300
Range: 300 - 700% of In
The Torque boost current controller use selected value
as the motor current reference.

NOTE! Check whether the motor can accelerate the

load with "Torque booster", without any
harmful mechanical stress.

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AS6 Instruction Manual
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LINE

T1 T2 T3
Brown to
Brown to
terminal 77
terminal 77
Current transformers may
be located on line or load
P1 P1 side of softstarts, but
P2 must be located in the
P2
proper phase and orient-
ed properly. Locate CT’s
on phases 1 and 3 with
PI towards the line.
Blue to Blue to
terminal 75 terminal 76

U V W

LOAD 03-F56

Figure 31: Current transformer position when Bypass AS6-017 to AS6-250.

BP

P1
L1 L1 T1

L2 L2 T2
P1
M
L3 L3 T3

BL BR BL BR
01
CONTROL 75
POWER
02
76
PE
77
NOTE: CT'S LOCATED
2 WIRE 3 WIRE EXTERNALLY TO MONITOR
START START CURRENT DURING BYPASS
OPERATION.
11
RUN STOP
OR 12

13

21
K1
22

23
K2
BP 24

31

32 K
K3

33

Figure 31a: Current transformer location for Bypass operation

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 AS6 Instruction Manual
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7.13 Power Factor Control
At 30% of the nominal speed a DC-brake is activated
During operation, the soft starter continuously monitors until the motor is standing still or the selected
the load on the motor. Particularly when idling or when Braking Time has expired (menu 34).
only partially loaded, it is sometimes desirable to
For extra safety, the soft starter has a digital input
improve the power factor. If Power factor control (PFC) is signal for monitoring standstill. So that the output
selected, the soft starter reduces the motor voltage when voltage is stopped immediately (see menu 57-58, §
the load is lower. Power consumption is reduced and the 7.19, page 54).
degree of efficiency improved.
See Fig. 33 on page 48 for the following set-up
setting of PFC
033 sequence:

Soft brake is activated if menu 36=2 and menu 34
oFF

has a time selected (see next page).
Menu 51 and 52 are automatically set to 5 and 4 to
Default: oFF get the correct relay functions on K1 and K2 (see §
7.17, page 52).
Range: oFF, on
Relay K1 should be used to connect a contactor for
oFF PFC disabled supply L1, L2, L3 to AS6 or motor.
on PFC enabled. The Full voltage relay
Relay K2 is used to connect phase shifting contactor
function does not work. to change L1, L2 and L3 to AS6 or motor.
NOTE! If the PFC is used the EMC-directive is not
At start K1 is activated and connects L1, L2, L3 then
fulfilled and bypass contactor may not be used. the motor starts. At stop K1 opens and disconnects
L1, L2, and L3 and after 1s K2 connects with the
other phase sequence and the braking of the motor
7.14 Brake functions is active.
There are two built in braking methods for applications
were the normal stop ramp is not enough. NOTE! Soft brake uses both programmable relays.

Dynamic DC-brake For other functions, see also the function table in
Increases the braking torque by decreasing speed. chapter 7, page 37.

Soft brake
Gives a high torque at the start of the braking and NOTE! For several start/stops it is recommend to
then also increasing torque by decreasing speed. use the PTC input.
In both methods the AS6 detects when the motor is WARNING! If the Soft Brake function has

!
standing still, so rotating in wrong direction is avoided. been selected once and after that the
Bypass function is selected, then the relay
Dynamic Vector Brake functions on K1 and K2 remain in the Soft

Possible to stop motors with high inertia loads from Brake functionality. Therefore it is necessary to
close to synchronous speed. change the relay functions in menu 51-52 manually

At 70% of the nominal speed a DC-brake is activated to the Bypass functions (see § 7.17, page 52) or
until the motor is standing still or the selected reset to default in menu 199 (see § 7.28, page 64)
Braking Time has expired (see menu 34). and select the Bypass function again.

No contactor needed.

For extra safety, the soft starter has a digital input
signal for monitoring standstill so that at real motor Braking time
standstill will stop the output voltage immediately
034
(see § 7.19, page 54).
Soft brake oFF

Even very high inertia loads can be stopped

The Soft brake is a controlled reversing of the motor Default: oFF
as the AS6 measures the speed during braking. Range: oFF, 1-120 sec

Two contactors are needed which can be placed on oFF Brake function disabled.
the in- or output of the soft starter. On the input the on Brake time.
first contactor is connected to relay K1 which is also
used as a mains contactor.

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AS6 Instruction Manual
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Torque Braking Strength

035

Softbrake
100
Default: 100
Range: 100 - 500%
Dynamic DC

Braking method
036
O-Speed
Nom. Speed
03-F121
1
Default: 1
Figure 32: Braking time
Range: 1, 2
1 Dynamic vector brake, active
2 Soft brake active

REV

FWD
P1
L1 L1 T1

L2 L2
P1
T2
M
L3 L3 T3

BL BR BL BR
01
CONTROL 75
POWER
02
76
PE
77

2 WIRE 3 WIRE
START START

11
RUN STOP
OR 12

13

21
K1
FWD 22

23
K2
REV 24

31

32 K3

33

Figure 33: Soft brake wiring example

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 AS6 Instruction Manual
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7.15 Slow speed and Jog functions 4. Select in menu 57 (see § 7.19, page 54) the number
The soft starter is able to run the motor at a fixed slow of edges to be ignored by the Slow Speed input,
speed for a limited period of time. before a start or stop is executed at slow speed. The
The slow speed will be about 14% of the full speed in edges are generated by an external sensor (photo
the forward direction and 9% in the reverse direction. cell, micro switch, etc.).
The Slow Speed torque (menu 37) and DC-Brake after
The following functions are possible: Slow Speed (menu 40) can be selected if needed. (see

Slow speed controlled by an external signal. § 7.15.4, page 50).
The digital input is used to run at slow speed at a
start or stop command for a selected number of When the number of edges exceeds or the time expire, a
pulses (edges) generated by an external sensor start according to selected main function is made.
(photo cell, micro switch, etc.). See § 7.19, page 54 At stop, the motor will ramp down (if selected) and DC
for more instructions. brake (if selected) before a slow speed forward at stop

Slow Speed during a selected time period. will begin. Slow speed will last as long as the number of
The slow speed will be active after a stop command edges on the external input is below parameter value in
for a selected time period. See § 7.19, page 54 for menu 036 and the max duration time doesn’t expires.
more instructions. When the number of edges exceeds or the time expire, a

Slow Speed using the "JOG"-commands. stop is made.
The slow Speed can be activated via the JOG keys In Fig. 33 on page 48 the selected number of edges are
on the keyboard or externally via the analogue input. 4. It is recommended to select DC-brake (see § 7.14,
See § 7.25, page 62 for more instructions. page 47) before a slow speed at stop if it is a high inertia
load. See Fig. 17 on page 35 for wiring diagram. In case
7.15.1 Slow speed controlled by an external signal. one use DC-brake, see § 7.15.4, page 50.
With these setting it is possible to have an external pulse
or edge signal controlling the time that the Slow Speed Speed

is active either after a Start command or a Stop com-

mand or at both commands. The following menu’s are
involved: nN

Menu Function See page

57 Digital input selection page 53
58 Pulse selection page 53
37 Slow speed torque page 49 0.14
nN Slow Full voltage Ramp time Slow speed
38 Slow speed time at start page 49 speed
Ramp time
at start running at stop at stop
Time
at start including
39 Slow speed time at stop page 49 Start
DC-brake
Stopped
time
40 Dc-Brake at slow speed page 49 command

Closed
Installation is as follows: External Open
signal
1. Set the analogue input selection for Slow Speed Time when signal is ignored
operation. Menu 57=2. See § 7.19, page 54. See Fig. 03-F44
25 on page 43 for a wiring example.
2. Select in menu 38 (see § 7.15.2, page 50) the Slow Figure 34: Slow speed controlled by an external signal.
Speed at Start time. This time will now be the
absolute maximum time for Slow Speed to be active This additional function can be used together with most
after a start command, in case the external signal will of the main functions (see § 4.4, page 22).
not appear.
3. Select in menu 39 (see § 7.15.2, page 50) the Slow
Slow speed torque
Speed at Stop time. This time will now be the 037
absolute maximum time for Slow Speed to be active
after a stop command, in case the external signal will
not appear.
10
Default: 10
Range: 10-100
Select the magnitude of the slow speed torque.

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AS6 Instruction Manual
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7.15.2 Slow speed during a selected time 7.15.3 Jog Functions

The Jog commands can be used to let the motor run at
It is possible to have a slow speed in forward direction a Slow speed (forward or reverse) as long as the Jog
before a start and after a stop. The duration of the slow command is active.
speed is selectable in menus 038 and 039. The Jog commands can be activated in 2 different ways:
It is recommended to select DC brake (see § 7.14, page
Jog keys
47) before a slow speed at stop if it is a high inertia load. The Jog-Forward and Jog-reverse keys on the con-
This slow speed function is possible in all control modes, trol panel. The keys can be programmed separate for
keyboard, remote and serial communication. each function. See § 7.25, page 62 for more instruc-
tions
Slow speed time at start
External Jog command
038 The external command is given via terminal 14 at
the digital input. Only 1 function (forward or reverse)
oFF can be programmed to the digital input at the time.
See § 7.19, page 54 for more instructions.
Default: oFF
Range: oFF, 1-60 sec 7.15.4 DC-brake after slow speed at stop [040]
oFF Slow speed at start is disabled. A DC-brake after a slow speed at stop is possible to
1-60 Set slow speed time at start. have, i.e. for a high inertia load or for a precise stop.
The current is controlled and the reference value for the
Slow speed time at stop normal DC-brake function is used (see § 7.15.4, page
039 50).
The duration for the DC-brake is possible to select.
oFF This DC-brake function is not applied when the “JOG
“ and “JOG JOG

“ keys are used.

JOG

Default: oFF
Range: oFF, 1-60 sec 040 DC-Brake at slow speed
oFF Slow speed at stop is disabled.
1-60 Set slow speed time at stop.
oFF
Speed
Default: oFF
Range: oFF, 1-60
oFF DC-Brake after slow speed at stop
disabled.
nN Nominal speed
1-60 DC-Brake duration time after slow
speed at stop.

0.14 Slow speed

nN
Slow Ramp time Full voltage Ramp time Slow speed
speed running at stop at stop
Time
at start
at start including
DC-brake
time
Start Stopped
03-F41 command Stop
command

Figure 35: Slow speed at start/stop during a selected

time

The Slow speed torque (menu 37) and the DC-Brake

after Slow speed (menu 40, § 7.15.4, page 50) can be
selected if needed.

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 AS6 Instruction Manual
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7.16 Motor data setting
The first step in the settings is to set menu 007 and 008
Nominal motor cos phi
to “on” to be able to reach the menus 041-046 and enter 045
the motor data.

NOTE! The default factory settings are for a standard 0. 8 6

4-pole motor acc. to the nominal current and power Default: 0.86
of the soft starter. The soft starter will run even if no
specific motor data is selected, but the performance
Range: 0.50-1.00
will not be optimal and motor may not be protected.
Nominal frequency
Nominal motor voltage 046
041

400 50
Default: 50 Hz
Default: 400 V Range: 50 / 60 Hz
Range: 200-700 V
Make sure the soft starts maximum voltage rating is NOTE! Now go back to menu 007, 008 and set it to
suitable for chosen motor voltage. “oFF” and then to menu 001.

Nominal motor current

042

17
Default: Nominal soft starter current
Range: 25% - 150% of Insoft in Amp.

Nominal motor power

043

7. 5 HP
Default: Nominal soft starter power
Range: 25% - 300% of Pnsoft in HP

Nominal motor speed

044

1450
Default: Nnsoft in rpm
Range: 500-3600 rpm

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AS6 Instruction Manual
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7.17 Programmable relay K1 and K2

The soft starter has three built-in auxiliary relays, K3 Setting of K2 indication
(change over contacts), is always used as an alarm 052
relay. The other two relays, K1 and K2 (closing contacts),
are programmable.
K1 and K2 can be set to either “Operation”, “Full Voltage”
2
or “Pre-alarm” indication. If DC-brake is chosen the relay Default: 2
K2 will be dedicated to this function. Range: 1, 2, 3, 4, 5
1 K2 is set for “Operation”.
2 K2 is set for “Full Voltage”.
Motor
volt age UN
3 K2 is set for “Power pre-alarm”.
4 K2 is set for “Softbrake”
Time 5 K2 is set for “Run”.

!
WARNING! If the Soft Brake function has
Function
been selected once and after that the
Operation Time Bypass function is selected, then the relay
functions on K1 and K2 remain in the Soft
Brake functionality. Therefore it is neces-
Run
Time
sary to change the relay functions in menu
51-52 manually to the Bypass functions
(see § 7.12, page 45) or reset to default in
Function menu 199 (see § 7.28, page 64) and select
Full volt age Time
the Bypass function again.

Starting Full
tim e volt age

Start Stopping
delay tim e
0,1 sec.

Figure 36: Start/stop sequence and relay function

“Operation” and “Full voltage”

Setting of K1 indication
051

1
Default: 1
Range: 1, 2, 3, 4, 5
1 K1 is set for “Operation”.
2 K1 is set for “Full Voltage”.
3 K1 is set for “Power pre-alarm”.
4 No function
5 K1 is set for “Run”.

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 AS6 Instruction Manual
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7.18 Analogue output 4. Choose a read-out value in menu 055.

Analogue output value

The soft starter can present current, voltage and power 055
on an analogue output terminal, for connection to a
recording instrument or a PLC. The output can be config-
ured in 4 different ways, 0-10V, 1
2-10V, 0-20mA or 4-20 mA. To install the instrument pro- Default: 1
ceed as follows:
Range: 1, 2, 3
1. Connect the instrument to terminal 19 (+) and 1 RMS current, default range 0-5xIn
15 (-). 2 Line input RMS voltage, default range
0-720V
3 Output shaft power, default range
J2 0-2xPn
J1
I U
I U
21 22 23 24 31 Analogue output gain
056
11 12 13 14 15
16 17 18 19 32 33

Figure 37: Wiring for analogue output 100

Default: 100%
2. Set Jumper J2 on the PCB board to voltage (U) or
current (I) signal position. Factory setting is voltage Range: 5-150%
(U). See Fig. 38 and Fig. 13 on page 31. [For setting
J1 refer to page 43] Examples on settings:

Set value Iscale Uscale Pscale

100% 0-5xIn 0-720V 0-2xPn
J2 50% 0-2.5xIn 0-360V 0-Pn
J1
I U
I U
11 12 13 14 15 21 22 23 24 3
16 17 18 19

Figure 38: Setting of current or voltage output

2. Set the parameter on menu 54.

Analogue output
054

oFF
Default: oFF
Range: oFF, 1, 2
oFF Analogue output is disabled.
1 Analogue output is set to 0-10V/0-20mA
2 Analogue output is set to 0-10V/4-20mA

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7.19 Digital input selection NOTE! Jog forward, reverse has to be enabled,
The analogue input can be used as a digital input. This is see § 7.25, page 62.
programmed in Menu 57. There are 4 different functions:

Rotation sensor input for braking functions. See Depending on the selection made in menu 57, menu 58
§ 7.14, page 47. is used to program the number of the edges. The edges

Slow speed external controlled. See § 7.15.1, can be generated by an external sensor (photo cell,
page 49. micro switch etc.).

Jog functions forward or reverse enabled.
See § 7.25, page 62.
Digital input pulses
058
Fig. 39 shows how to set the input for voltage or current
control, with jumper J1 the control board. The default set-
ting for J1 is voltage control. 1
Default: 1
J2 Range: 1-100
If Menu 57=1.
J1 A positive or negative edge at analogue input from a
I U rotation sensor will give a signal to stop the braking
I U voltage.
If Menu 57=2.
11 12 13 14 15 21 22 23 24 31
16 17 18 19 32 33 The number of edges to be ignored by the slow speed
input, before a start or stop is executed at slow speed.

Figure 39: Setting of J1 for current or voltage control

Fig. 39 shows a wiring example for the analogue input as

it is used for digital input.

J2
J1
I U
I U
11 12 13 14 15 21 22 23 24 31
Open 16 17 18 19 32 33
Closed

Figure 40: Wiring for slow speed external input

NOTE! If the Main Function Analogue control is pro-

gram-med (see § 7.8, page 43) the analogue input
can not be used for digital signal input. The menu 57
is then automatically set to OFF.
Digital input selection
057

oFF
Default: oFF
Range: oFF, 1-4
oFF No digital input control
1 Rotation sensor for brake functions
2 Slow speed function
3 Jog forward command
4 Job reverse command

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7.20 Parameter Set Parameter set
061
Parameter Set, an important function which can be
handy when using one soft starter to switch in and start
different motors, or working under variable load condi-
1
tions. For example; starting and stopping conveyor belts Default: 1
with different weight on the goods from time to time. Range: 0, 1, 2, 3, 4
For sets of parameters can be controlled either from the 0 Parameter set are selected by the
keyboard, the external control inputs or the serial inter- external input 16 and 17 (see below.)
face (option). Up to 51 different parameters can be set
1, 2, 3, 4 Selection of parameter set 1-4
for each Parameter Set.

J2
Parameter Set 4 J1
I U
Parameter Set 3 I U
11 12 13 14 15 21 22 23 24 31
16 17 18 19 32 33

Parameter Set 2

001, 002, 003, 004, 006,

Figure 42: Connection of external control inputs
011, 012, 013, 014, 016,
017, 020, 021, 022, 023,
024, 025, 030, 031, 032,
Parameter Set PS1 (16-18) PS2 (17-18)
033, 034, 035, 036, 037, 1 Open Open
038, 039, 040, 041, 042, 2 Closed Open
043, 044, 045, 055, 056, 3 Open Closed
057, 058, 074, 075, 081, 4 Closed Closed
082, 083, 084, 085, 086,
091, 092, 093, 094, 095,
096, 097, 098, 099, 101,
102, 103, 104
Common for all parameter set
007, 008, 046, 051, 052, 061, 071, 072,
088, 089, 105, 111, 112, 113, 114, 199,
206

Figure 41: Parameter overview

When ’Parameter set’ in menu 061 is set to 0 (external

selection), only parameters in menu 006 (Control mode)
and 061 (Parameter set) can be changed. All other
parameters are not allowed to change.
It is possible to change parameter set at stop and at full
voltage running.

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7.21 Motor protection, overload (F2 alarm) Internal motor thermal

072 protection
In many cases it is convenient to have a complete
starter. The soft starter have a possibility to use either an
input PTC signal from the motor, an internal thermal
10
model of the motor for thermal protection or both togeth- Default: 10
er at the same time. Slight overload for long time and Range: oFF, 2-40 sec
several overloads of short duration will be detected with oFF Internal motor protection is disabled.
both methods.
2-40 Selection of the thermal curve
Motor PTC input according to Fig. 43
071 - Check that menu 042 is set to the
proper motor current (see § 7.16,
no page 51).
- If the current exceeds the 100% level
an F2 alarm is activated.
Default: no - The motor model thermal capacity
Range: no, YES must cool down to 95% before reset
no Motor PTC input is disabled. can be accepted.
- Used thermal capacity in menu 073 in
YES Motor PTC input is activated: § 7.21, page 57.
- Connect the PTC to temrinals 69 and
70, see table 9, page 34 and § Fig.
18, page 36. NOTE! If ’Bypass’ is used check that the current
- A too hot motor will give an F2 alarm. trans-formers are placed and connected
The alarm can only be reset after correctly.
cooling down of the motor.
NOTE! Open terminals will give an F2 alarm CAUTION! Used thermal capacity is set to 0
immediately. Make sure the PTC is always
connected or the terminals are shorted. ! if the control board loses its supply (termi-
nal 01 and 02). This means that the internal
thermal model starts with a ’cold’ motor,
NOTE! The internal motor thermal protection will which perhaps in reality is not the case. This means
still generate an alarm if it is not selected that the motor can be overheated.
oFF.
Overload time sec

Current (x I nom)

Figure 43: The thermal curve

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7.22 Mains protection
Used thermal capacity
073 081 Voltage unbalance alarm

0 10
Default: - Default: 10
Range: 0-150% Range: 2-25% Un
Read-out of the used thermal capacity. If menu 072 Insert limit in % of nominal motor voltage. Max unbal-
‘Internal motor thermal protection’ is selected oFF, the ance in voltage between the 3 input phases is com-
capacity is shown as if the default class 10 was pared with the selected value. This is a category 2
selected. alarm.

Starts per hour limitation Response delay voltage

074 082 unbalance alarm
oFF oFF
Default: oFF Default: oFF
Range: oFF, 1-99 / hour Range: oFF, 1-60 sec
oFF Starts per hour limitation is disabled. oFF Unbalance voltage alarm is disabled
1-99 Sets the start per hour limitation alarm. 1-60 Set the response delay time for
If the selected number is exceeded, unbalanced voltage alarm F8.
alarm F11 occurs.

Over voltage alarm

083
Locked rotor alarm
075
115
oFF Default: 115
Range: 100-150% Un
Default: oFF
Insert limit in % of nominal motor voltage. Max voltage
Range: oFF, 1.0-10.0 sec of the 3 input phases is compared with the selected
oFF Locked rotor alarm is disabled. value. This is a category 2 alarm.
1.0-10.0 An F5 alarm is given when the rotor
locks. The alarm is active during starting
Response delay over
and running. 084 voltage alarm

oFF
Default: oFF
Range: oFF, 1-60 sec
oFF Overvoltage alarm is disabled
1-60 Set the response delay time for over
voltage alarm F9.

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7.23 Application protection (load monitor)

Under voltage alarm
085 7.23.1 Load monitor max and min/protection
(F6 and F7 alarms)
oFF AS6 has a built in load monitor based on the output
shaftpower. This is a unique and important function
Default: 85 which enables protection of machines and processes
Range: 75-100% Un driven by the motor connected to the soft starter. Both a
Insert limit in % of nominal motor voltage. Min voltage Min and Max limit is possible to select.
of the 3 input phases is compared with the selected In combination with the pre-alarm function, see
value. This is a category 2 alarm.
§ 7.23.2, page 59, this create a powerful protection. An
auto set function is also included for an automatic setting
of the alarm limits. A start-up delay time can be selected
Response delay under to avoid undesired alarms at start-up, see Fig. 44 on
086 voltage alarm page 61.

oFF NOTE! The load monitor alarms are all disabled

during a stop ramp.
Default: oFF
Range: oFF, 1-60 sec
Auto set power limits
oFF Under voltage alarm is disabled 089
1-60 Set the response delay time for under
voltage alarm F10. no
Default: no
Phase sequence Range: no, YES
087
no Auto set is disabled.

- -- - YES Auto set is activated if ENTER is

pressed.
Default: -
Range: L123, L321 Output shaftpower in %.
090
L123 is the direct phase sequence.
L321 is the reverse phase sequence.
no
Default: -
Phase reversal alarm Range: 0-200%
088
Measured output shaftpower in % of nominal motor

oFF power.

Default: oFF NOTE! System must be in full voltage running before

Range: oFF, on an auto set is permitted.
oFF Phase reversal alarm is disabled.
The actual power is regarded as 1.00xPact.
on Set the phase reversal Alarm. The set levels are:
- Switch on the power supply first. Power max alarm limit [092]: 1.15xP actual
The phase sequence is stored as the
Power max pre-alarm limit [094]: 1.10xP actual
correct sequence.
- Set the menu 088 to “on”.
Power min pre-alarm limit [096]: 0.90xP actual
- Any reversal of phase sequence will Power min alarm limit [098]: 0.85xP actual
cause alarm F16.
A successful auto set shows a message ’Set’ for 3 s and
NOTE! The actual phase sequence can be
if something goes wrong a message ’no’ will be showed.
viewed in menu 87.

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7.23.2 Pre-alarm
Start delay power limits It could be useful to know if the load is changing towards
091 a load alarm limit. It is possible to insert both a Max and
Min pre-alarm limit based on the motor output shaft
10 power. If the load exceeds one of these limits, a pre-
alarm condition occurs.
Default: 10 sec It should be noted that it is not normal alarms. They will
Range: 1-250 sec not be inserted in the alarm list, not activating the alarm
relay output, not displayed on the display and they will
From start command during selected delay time, all
not stop operation. But it is possible to activate relay K1
power load monitor alarms and pre-alarms are
disabled.
or K2 if a pre-alarm condition occurs. To have pre-alarm
status on any of these relays, select value 3 in menu 051
or 052 (see § 7.17, page 52).
Max power alarm limit A start-up delay time can be selected in menu 091 to
092 avoid undesired pre-alarms at start-up. Note that this
time is also shared with power Max and Min alarms.
115 NOTE! The pre-alarm status is always available on
Default: 115 the serial communication.
Range: 5-200% Pn
Insert limit in % of nominal motor power. The actual Max power pre-alarm
power in % of nominal motor power, could be read 094 limit
out in menu 090. If output shaft power exceeds
selected limit, an F6-alarm occurs after the response
delay time. The ‘Auto set’ function in menu 089, affect 110
this limit even if the alarm is set “oFF” in menu 093.
This is a category 1 alarm. Default: 110
Range: 5-200% Pn
Insert limit in % of nominal motor power. The actual
Response delay max
093 alarm
power in % of nominal motor power, could be read
out in menu 090. If output shaft power exceeds
oFF selected limit, a pre-alarm occurs after the response
delay time. The ‘Auto set’ function in menu 089, affect
selected limit even if the pre-alarm is set “oFF” in
Default: oFF menu 095.
Range: oFF, 0.1-25.0 sec
oFF Max Alarm is disabled.
Max pre-alarm response
0.1-25.0 Sets the response delay of the Max 095 delay
Alarm level.
oFF
Default: oFF
Range: oFF, 0.1-25.0 sec
oFF Max Pre-Alarm is disabled.
0.1-25.0 Sets the response delay of the Max
Pre-Alarm level.

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Min power pre-alarm limit Min alarm response delay

096 099

90 oFF
Default: 90% Default: oFF
Range: 5-200% Pn Range: oFF, 0.1-25.0 sec
Insert limit in % of nominal motor power. The actual oFF Min Alarm is disabled.
power in % of nominal motor power, could be read 0.1-25.0 Sets the response delay of the Min
out in menu 090. If output shaft power goes below Alarm level. The Min alarm is dis-
selected limit, a pre-alarm occurs after the response abled during a stop ramp down.
delay time. The ‘Auto set’ function in menu 089, affect
selected limit even if the pre-alarm is set “oFF” in
menu 097.

Min pre-alarm response

097 delay

oFF
Default: oFF
Range: oFF, 0.1-25.0 sec
oFF Min Pre-Alarm is disabled.
0.1-25.0 Sets the response delay of the Min
Pre-Alarm level. The Pre-alarm is dis
abled during a stop reamp down.

Min power alarm limit

098

85
Default: 85
Range: 5-200% Pn
Insert limit in % of nominal motor power. The actual
power in % of nominal motor power, could be read
out in menu 090. If output shaft power goes below
selected limit, an F7-alarm occurs after the response
delay time. The ‘Auto set’ function in menu 089, affect
this limit if the alarm is set “oFF” in menu 099. This is
category 1 alarm.

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[Link]
Start ramp Underload situation Overload situation

92 Max Alarm (115%)

94 Max Pre-Alarm (110%)
100%
Default: PNOM or
Figure 44: Load monitor alarm functions

Autoset: PMOMENTARY
96 Min Pre-Alarm (90%)
98 Min Alarm (85%)

Max Alarm
93 Response Delay (1s) 93 Response Delay (1s)
Max Pre-Alarm
95 Response Delay (1s) 95 Response Delay (1s)

AS6 Instruction Manual

Min Alarm
97 Response Delay (1s)

SET-UP MENU
Min Alarm
91 Response Delay (10s) 99 Response Delay (1s)
61
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7.24 Resume alarms 7.25 Slow speed with JOG

7.24.1 Phase input failure F1 Slow speed with "JOG" is possible from the "JOG" keys,

Multiple phase failure. but also from terminals, see menu 57 page 54 and serial
Shorter failure than 100ms is ignored. If failure duration comm. The "JOG" is ignored if the soft starter is running.
time is between 100 ms and 2 s, operation is temporary The slow speed "JOG" function has to be enabled for
stopped and a soft start is made if the failure disappears both forward and reverse directions in menus 103 and
before 2 s. If failure duration time is longer than 2 s, an 104, see below.
F1 alarm is given in cat. 2.

Single phase failure. NOTE! The enable functions is for all control modes.
During start up (acceleration) the behaviour is like multi-
ple phase failure below. When full voltage running there JOG forward enabled
is a possibility to select the behavior. 103

1 01 Run at single phase loss oFF

Default: oFF
no Range: oFF, on
Default: no oFF JOG forward disabled.
Range: no, YES on JOG forward enabled.
no Soft starter trips if a single phase loss is detect
ed. Alarm F1 (category 2) will appear after 2 s.
JOG reverse enabled
Soft starter continues to run after a single 104
phase loss.
YES - Alarm F1 appears after 2 sec.
- If the loose phase is reconnect the alarm is oFF
reset automatically.
- If running on 2 phases, a stop command will Default: oFF
give a Direct on line stop (freewheel). Range: oFF, on
oFF JOG reverse disabled
7.24.2 Run at current limit time-out F4
In modes ’Current limit at start’ and ’Voltage ramp with
on JOG reverse enabled.
current limit at start’ an alarm is activated if still operating
at current limit level when selected ramp time exceeds. If
an alarm occurs there is a possibility to select the
behaviour.
JOG JOG
Run at current limit time-out
1 02

no Figure 45: The 2 Jog keys

Default: no
Range: no, YES
no Soft starter trips if the current limit time-out is
exceeded. Alarm F4 (category 2) appears.
Soft starter continues to run after the current
limit time-out has exceeded:
YES - Alarm F4 appears
- The current is no longer controlled and the
soft starters ramps up to full voltage with a 6s
ramp time.
- Reset the alarm with either ENTER/RESET
key or by giving a stop command.

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7.26 Automatic return menu Serial comm parity
113
Often it is desirable to have a specific menu on the dis-
play during operation, i.e. RMS current or power con-
sumption. The Automatic return menu function gives the
0
possibility to select any menu in the menu system. Default: 0
The menu selected will come up on the display after 60 Range: 0.1
sec. if no keyboard activity. The alarm messages (F1- This parameter will select the parity.
F16) have a priority over menu 105 (as they have for all 0 No parity.
menus). 1 Even parity.

Automatic return menu

105 Serial comm. broken alarm
If control mode is ’Serial comm. control’ and no contact
oFF is established or contact is broken the Soft starter con-
sider the contact to be broken after 15 sec, the soft
Default: oFF starter can act in three different ways:
1 Continue without any action at all.
Range: oFF, 1-999 2 Stop and alarm after 15 sec.
1-999 Pressing “+” / “-” will lead through the 3 Continue and alarm after 15 sec.
menu system.
If an alarm occurs, it is automatically reset if the com-
7.27 Communication option, related munication is re-established. It is also possible to reset
Parameters the alarm from the soft starter keyboard.
The following parameters have to be set-up:
- Unit address.
- Baud rate. Serial comm contact
114 interrupted
- Parity
- Behaviour when contact broken.
1
Setting up the communication parameter must be made
Default: 1
in local ’Keyboard control’ mode. See § 7.2, page 39.
Range: oFF, 1, 2
This parameter will control the bahavior in the soft
Serial comm unit address starter when the serial comm. is interrupted.
111 oFF No alarm and continue operation.
1 Alarm and stop operation.
1 2 Alarm and continue operation.

Default: 1
Range: 1-247
This parameter will select the unit address.

Serial comm baudrate

112

9.6
Default: 9.6
Range: 2.4, 4.8, 9.6, 19.2,38.4 kBaud
This parameter will select the baudrate.

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7.28 Reset to factory setting [199] RMS main voltage

202
When selecting reset to factory settings:

All parameters in all parameter sets will have default
factory settings.
0.0

Menu 001 will appear on the display. Default: -

Note that the alarm list, the power consumption and Range: 0 - 720V
the operation time will not have default settings. The RMS input main voltage.

Reset to factory settings

199
Output motor shaftpower
203
no
Default: no 0.0
Range: no, YES Default: -
no No reset. Range: -9999 - +9999HP
YES Reset all functions to the factory Viewing will show negative value if generator
defaults incl. all 4 Parameter Sets. mode.
NOTE! Reset to factory settings is not allowed at
run.
Power factor
7.29 View operation 204

General
The soft start includes as standard numerous metering
0.0
functions which eliminate the need of additional trans- Default: -
ducers and meters. Range: 0.00-1
Viewing the actual power factor.
Measured values
- Current RMS 3-phase current and per phase
- Voltage RMS 3-phase voltage and per phase NOTE! The power factor viewing will not work at
- Output shaft power /torque HP/[Link]. bypass even if the current transformers are
- Power factor mounted outside the soft start.
- Power consumption in kWh
- Operation time in hours
Total power consumption
Viewing of the measured values
205
After setting motor data and extended functions one can
set menu 008 in oFF and will then automatically move to 0.0 0 0
menu 201, the first menu viewing the measured values
and thus eliminate to scroll through menu 011 to menu Default: -
199. Range: 0.000-2000MWh
View the total power consumption.
RMS current
201

0.0
Default: -
Range: 0.0 - 9999Amp
Read-out of the RMs motor current.

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Reset of power RMS current in phase L2
206 consumption
212

no 0.0
Default: no Default: -
Range: no, YES Range: 0.0 - 9999Amp
no No reset of power consumption. View the current in phase L2.
YES Reset power consumption in menu
205 to 0.000.
RMS current in phase L3
213

207 Motor shaft torque

0.0
0.0 Default:
Range:
-
0.0 - 9999Amp
Default: - View the current in phase L3.
Range: -9999 - +[Link].
Viewing will show negative value of generator
mode. Main voltage L1-L2
214

Operation time
0
208
Default: -
0.0 Range: 0-720V
View main voltage L1-L2.
Default: -
Range: Hours
Operation tme is calculated when the soft starter Main voltage L1-L3
is in RUN mode. After 9999 hours the display will
215
show two values.
Example: 12467 hours shows 1 1 sec 0
2467 5 sec
Default: -
Range: 0-720V
View main voltage L1-L3.
RMS current in phase L1
21 1

0.0 216 Main voltage L2-L3

Default: -
Range: 0.0 - 9999Amp 0
View the current in phase L1. Default: -
Range: 0-720V
View main voltage L2-L3.

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7.30 Keyboard lock

The keyboard can be locked to prohibit operation and

parameter setting by an unauthorised. Lock keyboard by
pressing both keys "NEXT " and "ENTER
" for at
least 2 sec. The message ’- Loc’ will display when
locked. To unlock keyboard press the same 2 keys
"NEXT " and "ENTER
" for at least 2 sec. The mes-
sage ’unlo’ will display when unlocked.
In locked mode it is possible to view all parameters and
read-out, but it is forbidden to set parameters and to
operate the soft starter from the keyboard.
The message ’-Loc’ will display if trying to set a parame-
ter or operate the soft starter in locked mode.
The key lock status can be read out in menu 221.

Locked keyboard info

221

no
Default: no
Range: no, YES
no Keyboard is not locked.
YES Keyboard is locked.

7.31 Alarm list

The alarm list is generated automatically. It shows the
latest 15 alarms (F1 - F16). The alarm list can be useful
when tracing a failure in the soft starter or its control cir-
cuit. Press key “NEXT ” or “PREV ” to reach the
alarm list in menus 901-915 (menu 007 has to be ON).

Alarm
901

F1
Default: -
Range: F1-F6
View actual alarm.

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[Link] PROTECTION & ALARM
8.0 PROTECTION AND ALARM
The soft starter is equipped with a protection system for the motor, the machine and for the soft starter itself.
Three categories of alarm are available:

Category 1
Alarm that stops the motor and needs a separate reset before a new start can be accepted.

Category 2
Alarm that stops the motor and accepts a new start command without any separate reset.

Category 3
Alarm that continues to run the motor.

All alarm, except pre-alarm, will activate the alarm relay output K3, flash a red fault number on the display and it will
also be placed in the alarm list. As long as the alarm is active, the display is locked in the alarm indication.
The relay output K3 can be used in the control circuit for actions needed when alarm occurs.
If more than one alarm is active, it is the last alarm that is presented on the display.

8.1 Alarm description

8.1.1 Alarm with stop and requiring a separate reset

Operation will stop for a category 1 alarm. A separate reset is needed before a new start command is accepted. It is
possible to reset from keyboard (pushing "ENTER/RESET") regardless of selected control mode. It is also possible
to reset the alarm from the actual control mode (i.e. if control mode is serial communication, a reset is possible to do
from serial communication).
A reset is accepted first when the alarm source goes back to normal.
When a reset is made, the alarm relay output K3 is deactivated, the alarm indication on the display disappear and
the original menu shows.
After a reset is made the system is ready for a new start command.

8.1.2 Alarm with stop and requiring only a new start command
Operation will stop for a category 2 alarm. A restart can be done and at the same time the alarm relay output K3 is
deactivated, the alarm indication on the display disappear and the original menu shows.
It is still possible to reset the alarm in the same way as for category 1 alarms (see 8.1.1), if a start is not required at
the time.

8.1.3 Alarm with continue run

Operation will continue run for a category 3 alarm. Some different reset behaviour is possible (see remarks for the
specific alarms in § 8.2, page 68).

Automatic reset when the alarm source goes back to normal.

Automatic reset when a stop command is given.

Manual reset during run.

When the reset occurs, the alarm relay output K3 is deactivated, the alarm indication on the display disappear and
the original menu shows.

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8.2 Alarm overview

Display Protective
Alarm category Remark
indication function
Single phase failure when full voltage running if menu
Cat 3. Run with auto reset. 101 'Run at phase loss' = YES. If the fault phase
comes back, an automatic reset is made.
F1 Phase input failure
Multiple phase failure or single phase failure when not
Cat 2. Stop with reset in
full voltage running or if menu 101 'Run at phase loss'
start.
= no.
If menu 071 'Motor PTC input' = YES, cool down the
Motor protection, Cat 1. Stop with manual
F2 motor. If menu 071 'Motor PTC input' = no, the
overload. reset.
internal model has to 'cool' down.
Soft start Cat 1. Stop with manual
F3 If not cooled down, a reset will not be accepted.
overheated reset.
If menu 102 'Run at current
limite time-out' = no. Cat 2. The current limit start is not completed.
Full speed not Stop with reset in start.
reached at set
F4
current limit and When start time expired, a 6 sec ramp is used to
If menu 102 'Run at current
start time. reach full voltage, without control of the current.
limite time-out' = YES. Cat
Reset the alarm with either a manual reset or a stop
3. Run with manual reset.
command.
Cat 1. Stop with manual
F5 Locked rotor. Motor and/or machine protection.
reset.
Above max power Cat 1. Stop with manual
F6 Machine protection.
limit. reset.
Below min power Cat 1. Stop with manual
F7 Machine protection.
limit. reset.
Cat 2. Stop with reset in
F8 Voltage unbalance. Motor protection.
start.
Cat 2. Stop with reset in
F9 Over voltage Motor protection.
start.
Cat 2. Stop with reset in
F10 Under voltage Motor protection.
start.
Starts / hour Cat 2. Stop with reset in
F11 Motor and/or machine protection.
exceeded. start.
When stop command comes, the stop will be a
'Direct On Line' stop, and the soft starter will be
Cat 3. Run with manual
F12 Shorted thyristor resetted. After this fault it is possible to start only in
reset.
'Direct On Line' mode. One or more thyristors
probably damaged.
Cat 1. Stop with manual
F13 Open thyristor One or more thyristors probably damaged.
reset.
Motor terminal Cat 1. Stop with manual
F14 Motor not correctly connected.
open. reset.
If menu 114 Serial comm.
Serial communication broken will stop operation. Run
Contact broken = 1. Cat 2.
Serial from keyboard if necessary.
Stop with reset in start.
F15 communication
If menu 114 Serial comm.
broken Serial communication broken will not stop operation.
Contact broken = 2. Cat 3.
Run from keyboard if necessary.
Run with auto reset.
Phase reversal Cat 1. Stop with manual
F16 Incorrect phase order on main voltage input.
alarm. reset.

68 © 2002 Saftronics, Inc.

 AS6 Instruction Manual
[Link] TROUBLESHOOTING
9.0 TROUBLESHOOTING
9.1 Fault, cause and solution

Observation Fault Indication Cause Solution

The display is not
None No control voltage. Switch on the control voltage.
illuminated
F1 Fuse detective Renew the fuse.
(Phase input failure) No mains supply. Switch the main supply on.
Perhaps PTC connection. Check the PTC input if PTC protection is used.
F2 Perhaps incorrect nominal If internal protection is used, perhaps another class
(Motor protection, overload) motor current inserted (menu could be used (menu 072).
042). Cool down the motor and make a reset.
Check ventilation of cabinet.
Abient temperature too high.
Check the size of the cabinet.
F3 Soft starter duty cycle
Clean the cooling fans.
(Soft start overheated) exceeded.
If the fan(s) is not working correctly, contact your local
Perhaps fan failure.
distributor.
F4 Current limit parameters are
(Full speed not reached at set perhaps not matched to the Increase the starting time and/or the current limit level.
current limit and start time) load and motor.
Something stuck in the
F5 Check the machine and motor bearings. Perhaps the
machine or perhaps motor
(Locked rotor) alarm delay time can be set longer (menu 075).
bearing failure.
The motor does not F6 Overload. Check the machine. Perhaps the alarm delay
run Overload
(Above max power limit) time can be set longer (menu 093).
F7 Under load. Check the machine. Perhaps the alarm
Underload
(Below min power limit) delay time can be set longer (menu 099).
F8 Main supply voltage
Check mains supply.
(Voltage unbalance) unbalance.
F9
Main supply over voltage. Check mains supply.
(Over voltage)
F10
Main supply under voltage. Check mains supply.
(Under voltage)
F11 Number of starts exceeded Wait and make a new start. Perhaps the number of
(Starts / hour exceeded) according to meny 074. starts / hour could be increased in menu 074.
F13 Make a reset and a restart. If the same alarm appears
Perhaps a damaged thyristor.
(Open thyristor) immediately, contact Saftronics Technical Support.
If the fault is not found, reset the alarm and inspect the
alarm list. If alarm F12 is found, a thyristor is probably
F14 Open motor contact, cable or
shorted.
(Motor terminal open) motor winding.
Make a restart. If alarm F14 appears immediately,
contact Saftronics Technical Support.

© 2002 Saftronics, Inc. 69

AS6 Instruction Manual
TROUBLESHOOTING [Link]

Observation Fault Indication Cause Solution

Make a reset and try to establish contact. Check contacts,

cables and option boards.
Verify
F15 - System address (menu 111).
Serial communication broken.
(Serial Communication broken) - Baudrate (menu 113).
- Parity (menu 113).
If the fault is not found run the motor with keyboard control
if urgent, see also manual for serial communication.
The motor does not
run. F16 Incorrect phase sequence on
Switch L2 and L3 input phases.
(Phase reversal) main supply.
Start command comes perhaps
from incorrect control source.
---- Give start command from correct source (menu 006).
(I.e. start from keyboard when
remote control is selected.

Unlock keyboard by pressing the keys 'NEXT' and

-Loc System in keyboard lock.
'ENTER' for at least 3 sec.
Check fuses and mains supply. Deslect 'Run at single
F1 Failure in one phase. Perhaps
phase input failure' in menu 101, if stop is desired at
(Phase input failure) fuse defective.
single phase loss.

F4 Current limit parameters are Increase the starting time and / or the current limit level.
(Full speed not reached at set perhaps not matched to the Deselct 'Run at current limit time-out' in menu 102, if stop
current limit and start time) load and motor. is desired at current limit time-out.

When stop command is given, a free wheel stop is made.

Perhaps a damaged thyristor. Make a reset and a restart. If alarm F14 appears
F12 immediately, contact Saftronics Technical Support.
The motor is
(Shorted thyristor)
running but an Bypass contactor is used but
alarm is given. meny 032 'Bypass' is not set to Set meny 032 'Bypass' to "on".
"on".

Make a reset and try to establish contact. Check contacts,

cables and option boards.
Verify
F15 - System address (menu 111).
Serial communication broken.
(Serial Communication broken) - Baudrate (menu 113).
- Parity (menu 113).
If the fault is not found run the motor with keyboard control
if urgent, see also manual for serial communication.

70 © 2002 Saftronics, Inc.

 AS6 Instruction Manual
[Link] TROUBLESHOOTING

Observation Fault Indication Cause Solution

Input nominal motor data in menus 041-046. Select the
If 'Torque control' or "Pump
proper load characteristic in menu 025. Select a correct
control' is selected, it is
initial and end torque at start in menus 016 and 017. If
necessary to input motor data
'Bypass' is selected, check that the current transformers
into the systems.
are correctly connected.
Starting time too short. Increase starting time.
When starting, motor reaches
Starting voltage incorrectly set. Adjust starting voltage.
full speed but it jerks or vibrates.
The motor jerks Motor too small in relation to
Use a smaller model of the soft starter.
etc. rated current of soft starter.
Motor too large in relation to
Use larger model of soft starter.
load of soft starter.
Starting voltage not set Readjust the start ramp.
correctly. Select the durrent limit function.

Ramp times not set correctly. Readjust the start and/or stop ramp time.
Starting or stopping time too
long, soft does not not work. Motor too large or too small in
Change to another motor size.
relation to load.
Input nominal motor data in menus 041-046. Adjust
The monitor It is necessary to input nominal
alarm levels in menus 091-099. If 'Bypass' is selected,
function does not No alarm or pre-alarm. motor data for this function.
check that the current transformers are correctly
work. Incorrect alarm levels.
connected.
Unexplainable Adjust the response delay times for the alarms in menus
FF5, F6, F7, F8, F9, F10 Alarm delay tome is too short.
alarm. 075, 082, 084, 086, 093, and 099.
PTC input terminal could be
open. PTC input terminal should be short circuit if not used.
F2 Motor could still be too warm. If Wait until motor PTC gives an OK (not overheated)
(Motor protection, overload) internal motor protection is signal. Wait until the internal cooling is done. Try to reset
The system seems used, the cooling in the internal the alarm after a while.
locked in an alarm. model take some time.
Check that cables from power part are connected in
F3 Ambient temperature too high. terminals 073, 074, 071 and 072. MSF-071 to MSF-145
(Soft start overheated) Perhaps fan failure. should have a short circuit betweem 071 and 072. Check
also that the fan(s) is rotating.
If the menu number is one of
020 - 025, only one can be Deselect the other main mode before selecting the new
selected, i.e. only one main one.
mode is possible at a time.
If menu 061, 'Parameter set' is
set to "0", the system is in a
remote parameter selection Set the menu 061, 'Parameter set' to a value between
mode. It is now impossible to "1" - "4" and then it is possible to change any parameter.
change most of the
parameters.
During acceleration,
----
Parameter will not deceleration, slow speed, DC
be accepted. brake and power factor control Set parameters during stop or full voltage running.
mode, it is impossible to
change parameters.
If control source is serial
comm., it is impossible to
Change parameters from the actual control source.
change parameters from
keyboard and vice versa.
Read-out values can not be altered. In table 13, page
Some menus include only read
35, read-out menus has '---' in the factory setting
out values and not parameters.
column.
Unlock keyboard by pressing thekeys 'NEXT' and
-Loc Keyboard is locked.
'ENTER' for at least 3 sec.

© 2002 Saftronics, Inc. 71

AS6 Instruction Manual
MAINTENANCE [Link]

10.0 MAINTENANCE
In general the soft starter is maintenance free. There are however some things which should be checked regularly.
Especially if the surroundings are dusty the unit should be cleaned regularly.

!
WARNING! Do not touch parts inside the enclosure of the unit when the control and motor voltage
is switched on.

Regular maintenance

Check that nothing in the soft starter has been damaged by vibration (loose screws or connections).

Check external wiring, connections and control signals. Tighten terminal screws and busbar bolts if
necessary.

Check that PCB boards, thyristors and cooling fin are free from dust. Clean with compressed air if
necessary. Make sure the PCB boards and thyristors are undamaged.

Check for signs of overheating (changes in colour on PCB boards, oxidation of solder points etc.). Check
that the temperature is within permissible limits.

Check that the cooling fan/s permit free air flow. Clean any external air filters if necessary.

In the event of fault or if a fault cannot be cured by using the fault-tracing table in chapter 9. page 69.

72 © 2002 Saftronics, Inc.

 AS6 Instruction Manual
[Link] OPTIONS
11.0 OPTIONS
The following option are available. Please contact your supplier for more detailed information.

11.1 Serial communication

For serial communication the MODBUS RTU

(RS232/RS485) option card is available.

Figure 46: Option RS232/485

11.2 Field bus systems

Various option cards are available for the following bus systems:

PROFIBUS DP

Device NET

LONWORKS

FIP IO

INTERBUS-S

Each system has it’s own card. The option is delivered with
an instruction manual containing the all details for the set- Figure 47: Option Profibus
up of the card and the protocol for programming.

11.3 External PPU

The external PPU option is used to move the PPU (key-

board) from the soft starter to the front of a panel door or
control cabinet.
The maximum distance between the soft starter and the
external PPU is 3 m.
The option can be factory mounted (01-2138-01) or it can
be built in later (01-2138-00). For both versions instruction
/data sheet are available.

(03-F62)

Figure 48: Shows an example of the External

PPU after it has been built in

© 2002 Saftronics, Inc. 73

AS6 Instruction Manual
SET-UP MENU LIST [Link]

12.0 SET-UP MENU LIST

Menu Factory
Function/Parameter Range [Link] Value Page
number Setting
001 Initial voltage at start 25-90% of U 1-4 30 38
002 Start time ramp 1 1-60 sec 1-4 10 38
003 Step down voltage at stop 100-40% U 1-4 100 38
004 Stop time ramp 1 oFF, 2-120 sec 1-4 oFF 38
005 Current 0.0-9999 Amp ----- ---- 38
006 Control mode 1, 2, 3 1-4 2 39
007 Extended functions & metering oFF, on ----- oFF 40
008 Extended functions oFF, on ----- oFF 40

011 Initial voltage start ramp 2 30-90% U 1-4 30 40

012 Start time ramp 2 oFF, 1-60 sec 1-4 oFF 40
013 Step down voltage stop ramp 2 100-40% U 1-4 40 40
014 Stop time ramp 2 oFF, 2-120 sec 1-4 oFF 40

016 Initial torque at start 0-250% Tn 1-4 10 40

017 End torque at start 50-250% Tn 1-4 150 41
018 End torque at stop 0-100% Tn 1-4 0 41
020 Voltage ramp with current limit at start oFF, 150-500% In 1-4 oFF 41
021 Current limit at start oFF, 150-500% In 1-4 oFF 42
022 Pump control oFF, on 1-4 oFF 42
023 Remote analogue control oFF, 1, 2 1-4 oFF 43
024 Full voltage start D.O.L. oFF, on 1-4 oFF 43
025 Torque control oFF, 1, 2 1-4 oFF 44

030 Torque boost active time oFF, 0.1-2.0 sec 1-4 oFF 45
031 Torque boost current time 300-700% In 1-4 300 45
032 Bypass oFF, on 1-4 oFF 45
033 Power Factor Control PFC oFF, on 1-4 oFF 47
034 Brake active time oFF, 1-120 sec 1-4 oFF 47
035 Braking strength 100-500% 1-4 100 48

036 Braking methods 1, 2 1-4 1 48

037 Slow speed torque 10-100 1-4 10 49
038 Slow speed time at start oFF, 1-60 sec 1-4 oFF 50
039 Slow speed time at stop oFF, 1-60 sec 1-4 oFF 50
040 DC-Brake at slow speed oFF, 1-60 sec 1-4 oFF 50

041 Nominal motor voltage 200-700 V 1-4 400 51

042 Nominal motor current 25-150% Insoft in Amp 1-4 Insoft in Amp 51
043 Nominal motor power 25-300% of Pnsoft in kW 1-4 Pnsoft in kW 51
044 Nominal speed 500-3600 rpm 1-4 Nnsoft in rpm 51
045 Nominal power factor 0.50-1.00 1-4 0.86 51
046 Nominal frequency 50, 60 Hz ----- 50 51

74 © 2002 Saftronics, Inc.

 AS6 Instruction Manual
[Link] SET-UP MENU LIST
Menu Factory
Function/Parameter Range [Link] Value Page
number Setting

051 Programmable relay K1 1, 2, 3, (4), 5 1 52

052 Programmable relay K2 1, 2, 3, 4, 5 ---- 2 52

054 Analogue output oFF, 1, 2 1-4 oFF 53

055 Analogue output value 1, 2, 3 1-4 1 53
056 Scaling analogue output 5-150% 1-4 100 53
057 Digital input selection oFF, 1, 2, 3, 4 1-4 oFF 54
058 Digital input pulses 1-100 1-4 1 54

061 Parameter set 0, 1, 2, 3, 4 ---- 1 55

071 Motor PTC input no, YES ---- no 56

072 Internal motor thermal protection class oFF, 2-40 sec ---- 10 56
073 Used thermal capacity 0-150% ---- ---- 57
074 Starts per hour limitation oFF, 1-99/hour 1-4 oFF 57
075 Locked rotor alarm oFF, 1.0-10.0 sec 1-4 oFF 57

081 Voltage unbalance alarm 2-25% Un 1-4 10 57

082 Response delay voltage unbalance alarm oFF, 1-60 sec 1-4 oFF 57
083 Over voltage alarm 100-150% Un 1-4 115 57
084 Response delay over voltage alarm oFF, 1-60 sec 1-4 oFF 57
085 Under voltage alarm 75-100% Un 1-4 85 58
086 Response delay under voltage alarm oFF, 1-60 sec 1-4 oFF 58
087 Phase sequence L123, L321 ---- ---- 58
088 Phase reversal alarm oFF, on ---- oFF 58
089 Auto set power limits no, YES ---- no 58
090 Output shaft power 0.0-200.0% Pn ---- ---- 58
091 Start delay power limits 1-250 sec 1-4 10 59
092 Max power alarm limit 5-200% Pn 1-4 115 59
093 Max alarm response delay oFF, 0.1-25.0 sec 1-4 oFF 59
094 Max power pre-alarm limit 5-200% Pn 1-4 110 59
095 Max pre-alarm response delay oFF, 0.1-25.0 sec 1-4 oFF 59
096 Min pre-alarm power limit 5-200% Pn 1-4 90 60
097 Min pre-alarm response delay oFF, 0.1-25.0 sec 1-4 oFF 60
098 Min power alarm limit 5-200% Pn 1-4 85 60
099 Min alarm response delay oFF, 0.1-25.0 sec 1-4 oFF 60

101 Run at single phase input failure no, YES 1-4 no 62

102 Run at current limit time-out no, YES 1-4 no 62
103 Job forward enable oFF, on 1-4 oFF 62
104 Job reverse enable oFF, on 1-4 oFF 62
105 Automatic return menu oFF, 1-999 ---- oFF 63

111 Serial comm. unit address 1-247 ---- 1 63

112 Serial comm. baudrate 2.4-38.4 kBaud ---- 9.6 63

© 2002 Saftronics, Inc. 75

AS6 Instruction Manual
SET-UP MENU LIST [Link]

Menu Factory
Function/Parameter Range [Link] Value Page
number Setting
113 Serial comm. Parity 0, 1 ---- 0 63
114 Serial comm. Contact broken oFF, 1, 2 ---- 1 63

199 Reset to factory settings no, YES ---- no 64

201 Current 0.0-9999 Amp ---- ---- 64

202 Line Main Voltage 0-720 V ---- ---- 64
203 Output shaft power -9999 - 9999 kW ---- ---- 64
204 Power factor 0.00-1.00 ---- ---- 64
205 Power consumption 0.000-2000 MWh ---- ---- 64
206 Reset power consumption no, YES ---- no 65
207 Shaft torque -9999 - 9999 Nm ---- ---- 65
208 Operation time Hours ---- ---- 65

211 Current phase L1 0.0 - 9999 Amp ---- ---- 65

212 Current phase L2 0.0 - 9999 Amp ---- ---- 65
213 Current phase L3 0.0 - 9999 Amp ---- ---- 65
214 Line main voltage L1-L2 0 - 720 V ---- ---- 65
215 Line main voltage L1-L3 0 - 720 V ---- ---- 65
216 Line main voltage L2-L3 0 - 720 V ---- ---- 65

221 Locked keyboard info no, YES ---- no 66

901 Alarm list, Latest error F1 - F16 ---- ---- 66

Explanation of units:

U Input line voltage

Un Nominal motor voltage.
In Nominal motor current.
Pn Nominal motor power.
Nn Nominal motor speed.
Tn Nominal shaft torque.
Insoft Nominal current soft starter. (AS6 rated current)
Pnsoft Nominal power soft starter. (AS6 HP at selected voltage)
Nnsoft Nominal speed soft starter.

Calculation shaft torque

Tn = Pn

(60N x 2 π
n (

NOTE! The six main functions for motor control,

menus 020–025, can only be selected one at
a time.

76 © 2002 Saftronics, Inc.

 AS6 Instruction Manual
[Link] INDEX
13.0 INDEX
Numerics Current limit time-out . . . . . . . . . . . . . . . . . . . . . .62
2-wire start/stop . . . . . . . . . . . . . . . . . . . . . . . . . .39 Current transformer . . . . . . . . . . . . . . . . . . . . . . .46
3-wire start/stop . . . . . . . . . . . . . . . . . . . . . . . . . .39 D
A D.O.L start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Above max power limit . . . . . . . . . . . . . . . . . . . . .68 DC-brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Alarm category . . . . . . . . . . . . . . . . . . . . . . . . . . .68 DC-Brake at slow speed . . . . . . . . . . . . . . . . . . . .50
Alarm list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 Decrease value . . . . . . . . . . . . . . . . . . . . . . . . . .27
Alarm reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 Decrease value of setting . . . . . . . . . . . . . . . . . . .27
Ambient temperatures . . . . . . . . . . . . . . . . . . . . .23 Device connections . . . . . . . . . . . . . . . . . . . . . . .31
analogue control . . . . . . . . . . . . . . . . . . . . . . . . . .34 different operation situation . . . . . . . . . . . . . . . . . .26
Analogue input . . . . . . . . . . . . . . . . . . . . . . . .34, 43 Digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Analogue output . . . . . . . . . . . . . . . . . . . . . . .34, 53 Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Analogue output gain . . . . . . . . . . . . . . . . . . . . . .53 DIN VDE 0100 . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Analogue output value . . . . . . . . . . . . . . . . . . . . .53 Direct On Line start . . . . . . . . . . . . . . . . . . . . . . .43
Auto set power limits . . . . . . . . . . . . . . . . . . . . . .58 Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
automatic reset . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Display next window . . . . . . . . . . . . . . . . . . . . . . .27
Automatic return menu . . . . . . . . . . . . . . . . . . . . .63 Display previous window . . . . . . . . . . . . . . . . . . . .27
B Dual voltage ramp . . . . . . . . . . . . . . . . . . . . . . . .40
Basic parameter setting . . . . . . . . . . . . . . . . . . . .13 E
Below min power limit . . . . . . . . . . . . . . . . . . . . . .68 Electrical characteristic . . . . . . . . . . . . . . . . . . . . .31
Brake method . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Braking Strenght . . . . . . . . . . . . . . . . . . . . . . . . . .48 End torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Braking time . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 F
Busbars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Factory settings . . . . . . . . . . . . . . . . . . . . . . . . . .64
Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
C Forward/reverse . . . . . . . . . . . . . . . . . . . . . . . . . .36
Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 Free circulation of air . . . . . . . . . . . . . . . . . . . . . .28
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Clickson thermistor . . . . . . . . . . . . . . . . . . . . . . .334 Full speed not reached . . . . . . . . . . . . . . . . . . . . .68
Combination matrix . . . . . . . . . . . . . . . . . . . . . . .22 Full voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Complaint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Full voltage start . . . . . . . . . . . . . . . . . . . . . . . . . .43
Confirm setting . . . . . . . . . . . . . . . . . . . . . . . . . . .27 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Connections . . . . . . . . . . . . . . . . . . . . . . . . . .31, 34 G
Control mode . . . . . . . . . . . . . . . . . . . . . . . . .28, 39 General description . . . . . . . . . . . . . . . . . . . . . . .25
Control voltage . . . . . . . . . . . . . . . . . . . . . . . . . . .34 H
Control voltage connection . . . . . . . . . . . . . . . . . .31 Heat dissipation . . . . . . . . . . . . . . . . . . . . . . . . . .24
Cooling fins . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 High ambient temperatures . . . . . . . . . . . . . . . . . .45
cos phi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 I
Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 Increase value . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Current in phase L1 . . . . . . . . . . . . . . . . . . . . . . .65 Increase value of setting . . . . . . . . . . . . . . . . . . . .27
Current in phase L2 . . . . . . . . . . . . . . . . . . . . . . .65 Initial torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Current in phase L3 . . . . . . . . . . . . . . . . . . . . . . .65 Initial voltage at start ramp 1 . . . . . . . . . . . . . . . . .38
Current limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 Initial voltage at start ramp 2 . . . . . . . . . . . . . . . . .40

© 2002 Saftronics, Inc. 77

AS6 Instruction Manual
INDEX [Link]

INSPECTION AT DELIVERY . . . . . . . . . . . . . . . . .8 020 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 021 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Insulation test . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 022 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
J 023 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
JOG Forward . . . . . . . . . . . . . . . . . . . . . . . . .27, 62 024 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
JOG fwd/rev . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 025 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
JOG Reverse . . . . . . . . . . . . . . . . . . . . . . . . .27, 62 030 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Jumper J1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 031 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Jumper J2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 032 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
K 033 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 034 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Keyboard lock . . . . . . . . . . . . . . . . . . . . . . . . .27, 66 035 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 036 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
L 037 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
LED display . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 038 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Live circuit components . . . . . . . . . . . . . . . . . . . .28 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Load monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 040 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Locked rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 041 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14, 51
Low load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 042 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14, 51
M 043 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14, 51
Main functions . . . . . . . . . . . . . . . . . . . . . . . . . . .75 044 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14, 51
Mains contactor . . . . . . . . . . . . . . . . . . . . . . . . . .13 045 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15, 51
Mains supply . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 046 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15, 51
Mains voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 051 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . .72 052 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 054 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Max power alarm limit . . . . . . . . . . . . . . . . . . . . .59 055 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Max power pre-alarm limit . . . . . . . . . . . . . . . . . .59 056 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Max pre-alarm response delay . . . . . . . . . . . . . . .59 057 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Menu 058 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 061 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
002 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15, 38 071 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 072 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15, 38 073 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16, 38 074 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16, 39 075 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 081 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 082 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 083 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 084 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 085 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
014 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 086 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
016 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 087 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
017 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 088 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
018 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 089 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

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 AS6 Instruction Manual
[Link] INDEX
090 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 Motor data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
091 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59 Motor power . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
092 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59 Motor power supply . . . . . . . . . . . . . . . . . . . . . . .31
093 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59 Motor protection, overload . . . . . . . . . . . . . . .56, 68
094 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59 Motor shaft torque . . . . . . . . . . . . . . . . . . . . . . . .65
095 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59 Motor speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
096 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 Motor terminal open . . . . . . . . . . . . . . . . . . . . . . .68
097 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 Motor voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
098 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
099 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 MOUNTING/WIRING . . . . . . . . . . . . . . . . . . . . . .28
101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 N
102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 Next . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 Nominal frequency . . . . . . . . . . . . . . . . . . . . .15, 51
104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 Nominal motor cos phi . . . . . . . . . . . . . . . . . .15, 51
105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 Nominal motor current . . . . . . . . . . . . . . . . . .14, 51
111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 Nominal motor power . . . . . . . . . . . . . . . . . . .14, 51
112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 Nominal motor speed . . . . . . . . . . . . . . . . . . .14, 51
113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 NTC thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . .31
114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 O
199 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 Open thyristor . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 Operation time . . . . . . . . . . . . . . . . . . . . . . . .64, 65
203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 Operation/Set-up . . . . . . . . . . . . . . . . . . . . . . . . .28
204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 Operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . .25
205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 Output motor shaftpower . . . . . . . . . . . . . . . . . . .64
206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 Output shaftpower . . . . . . . . . . . . . . . . . . . . .54, 64
207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 Over voltage . . . . . . . . . . . . . . . . . . . . . . . . . .57, 68
208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 P
211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 Parallel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 Parallel cables . . . . . . . . . . . . . . . . . . . . . . . . . . .74
213 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 Parameter Set . . . . . . . . . . . . . . . . . . . . . . . .31, 55
215 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 PFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 Phase input failure . . . . . . . . . . . . . . . . . . . . . . . .68
221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27, 66 Phase loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
901 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 Phase reversal alarm . . . . . . . . . . . . . . . . . . . . . .68
RMS current read-out . . . . . . . . . . . . . . . . . . . . . .16 Phase sequence . . . . . . . . . . . . . . . . . . . . . . . . .58
Menu expansion . . . . . . . . . . . . . . . . . . . . . . . . . .40 Pole-changing contactor . . . . . . . . . . . . . . . . . . . .23
Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Min alarm response delay . . . . . . . . . . . . . . . . . . .60 Power consumption . . . . . . . . . . . . . . . . . . . . . . .64
Min power alarm limit . . . . . . . . . . . . . . . . . . . . . .60 Power factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Min power pre-alarm limit . . . . . . . . . . . . . . . . . . .60 Power Factor Control . . . . . . . . . . . . . . . . . . . . . .47
Min pre-alarm response delay . . . . . . . . . . . . . . . .60 Power Factor Correction Capacitor . . . . . . . . . . . . .23
Minimum free space . . . . . . . . . . . . . . . . . . . .29, 29 Power loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Motor current . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 PPU unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

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AS6 Instruction Manual
INDEX [Link]

Pre-alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . .52, 59 Softbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Prevent damage to the thyristors . . . . . . . . . . . . .28 Softstart overheated . . . . . . . . . . . . . . . . . . . . . . .68
Previous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Programmable relay . . . . . . . . . . . . . . . . . . . . . . .52 Standard wiring . . . . . . . . . . . . . . . . . . . . . . .13, 35
Programming and presentation unit (PPU) . . . . . .25 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Protective earth . . . . . . . . . . . . . . . . . . . . . . . . . .31 Start command . . . . . . . . . . . . . . . . . . . . . . . . . . .26
PTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 Start delay power limits . . . . . . . . . . . . . . . . . . . .59
PTC Thermistor input . . . . . . . . . . . . . . . . . . . . . .34 Start ramp 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Pump control . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 Start ramp 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Q Start the motor . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Quick Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Start time ramp 1 . . . . . . . . . . . . . . . . . . . . . .15, 38
R Start/Stop . . . . . . . . . . . . . . . . . . . . . . . . .16, 17, 27
Rating plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Start/stop combination . . . . . . . . . . . . . . . . . . . . .22
Recyclable material . . . . . . . . . . . . . . . . . . . . . . . .2 Start/stop/reset from keyboard . . . . . . . . . . . . . . .17
Regular maintenance . . . . . . . . . . . . . . . . . . . . . .72 Start/stop-LED . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Relay K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .31, 52 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Relay K2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 Starting/Operating . . . . . . . . . . . . . . . . . . . . . . . .75
Relay K3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 Starts per hour . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Remote . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 Starts per hour limitation . . . . . . . . . . . . . . . . . . . .57
Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 Step down voltage in stop ramp 2 . . . . . . . . . . . . .40
reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 Step down voltage stop ramp 1 . . . . . . . . . . . . . . .38
Response delay max alarm . . . . . . . . . . . . . . . . .59 Stop command . . . . . . . . . . . . . . . . . . . . . . . . . . .26
RMS current . . . . . . . . . . . . . . . . . . . . . . .16, 38, 64 Stop ramp 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
RMS main voltage . . . . . . . . . . . . . . . . . . . . . . . .64 Stop ramp time 2 . . . . . . . . . . . . . . . . . . . . . . . . .40
Rotating loads . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Stop time ramp 1 . . . . . . . . . . . . . . . . . . . . . . . . .15
Running motors . . . . . . . . . . . . . . . . . . . . . . . . . .24 storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Running-LED . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Supply voltage . . . . . . . . . . . . . . . . . . . . . . .32, 734
S switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2, 7 Switch the device off . . . . . . . . . . . . . . . . . . . . . . .2
Safety measures . . . . . . . . . . . . . . . . . . . . . . .7, 13 Switch-off procedures . . . . . . . . . . . . . . . . . . . . . . .2
Scrapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 T
Selection of control mode . . . . . . . . . . . . . . . .15, 38 Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Semiconductor fuses . . . . . . . . . . . . . . . . . . . . . .35 Thermal capacity . . . . . . . . . . . . . . . . . . . . . . . . .57
Serial communication . . . . . . . . . . . . . . . . . . . . . .28 Thermal protection . . . . . . . . . . . . . . . . . . . . . . . .56
Serial communication broken . . . . . . . . . . . . . . . .68 Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . .30
Shaftpower . . . . . . . . . . . . . . . . . . . . . . . . . . .58, 64 Torque boost active time . . . . . . . . . . . . . . . . . . . .45
Shielded motor cable . . . . . . . . . . . . . . . . . . . . . .23 Torque boost current limit . . . . . . . . . . . . . . . . . . .45
Shorted thyristor . . . . . . . . . . . . . . . . . . . . . . . . . .68 Torque booster . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Simple soft start and soft stop . . . . . . . . . . . . . . .13 Torque control . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Slip ring motors . . . . . . . . . . . . . . . . . . . . . . . . . .23 Trained personnel . . . . . . . . . . . . . . . . . . . . . . .2, 13
Slow blow fuses . . . . . . . . . . . . . . . . . . . . . . . . . .35 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Slow speed time at start . . . . . . . . . . . . . . . . . . . .50 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . .69
Slow speed time at stop . . . . . . . . . . . . . . . . . . . .50 Two speed motor . . . . . . . . . . . . . . . . . . . . . . . . .23
Slow speed torque . . . . . . . . . . . . . . . . . . . . . . . .49 U
Small motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Under voltage . . . . . . . . . . . . . . . . . . . . . . . . .58, 68

80 © 2002 Saftronics, Inc.

 AS6 Instruction Manual
[Link] INDEX

V
VIEW OPERATION . . . . . . . . . . . . . . . . . . . . . . . .64
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Voltage unbalance . . . . . . . . . . . . . . . . . . . . .57, 68
W
Wiring circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Wiring example . . . . . . . . . . . . . . . . . . . . . . . . . .36

© 2002 Saftronics, Inc. 81