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GE Astat Plus Soft start Manual

1. i Control Voltage Bee aia B1B2 4 Control Voltage i LZ 220 I 240V AC T4 DC1 L4 DC3 re 11 14 23 2433 34 SG A1A2 B1 B2 1r 2r 3r Programmable relay Outputs Programmable Inputs 3 13 14 1157 2 57 3 157 4157 516 7 8 Hu Start Stop Permanent Command 2 otor Thermistor 6 2 REMARKS 1 The line contactor DC1 is not required to perform opera tion to the motor Be aware however that DC1 provides galvanic isolation from the mains increasing the safety 2 In this example Start and Stop command is effected by permanent command Push buttons control is allowed as well wiring 1 2 and 57 terminals as shown in page 3 3 3 The output relays allow for direct action on contactors according ratings specified in page 3 2 of this manual 4 The ASTAT Plus is performed with an electronic motor overload protection which may be enough in the most of the applications You should use an external overload protection if required by local rules or to protect the motor against current imbalance 5 DC brake at stopping time is provided by the DC brake function and external contactor DC3 CAUTION The 3 contacts of DC3 must be connected in parallel Mand
2. 1157 2157 22 53 Ge 832 sa ge Se T5 ES E 5 a oo D g bre P 8 5 8 lt S EX a 2 Q lt Start Stop Command by push buttons Notes 1 Control and Mains wiring recommendations are given in chapter 5 2 The programmable inputs 13 14 are not assigned to any function as default Check pages 3 6 before to use these inputs 3 The programmable relay outputs are as default assigned to the following functions Relay 1r RUN RUN status Relay 2r EOR End of Ramp Relay 3r DCBR DC Braking control 3 Technical specifications 3 4 Operating modes Starting and Stopping Initial ramp Initial voltage pedestal 5 main frequncy cycles 30 to 95 Un adjustable Kick start Q 95 Un Enabled by parameter Pxxx to ON Acceleration ramp tmp Voltage ramp up from to 99s adjustable Dual ramp possibility Linear speed ramp by tacho feedback also possible Fastincrease of output voltage when motor gets rated speed Currentlimit 4 1to7 In Permanentstate G Rated voltage Override Rated current 6 Energy savings Enabled by Fxxx to OFF Stopping modes Allselectable Motor power cut off Sxxx to OFF Cxxx to OFF Deceleration ramp 1 to 120s adjustable Secondary ramp 1 to 99 s Ramp dowm modes available are Soft Stop Voltage ramp down Enabled by Sxxx to ON Pump control Selectable
3. 110 120V ac A1 A2 B1 B2 220 240V ac A1 A2 B1 B2 Adaptequipmentratedcurrentto motor setting In motor Factory setting the motor current In NXXX XXX E a x 100 N100 Set overload trip curve as needed oxxx xxx OFF disabled extermal overload relay must be used Factory setting C1 C2 IEC Class 10 or Class 20 N1 N2 N3 Nema 10 20 or 30 o C1 Set starting parameters as needed Factory setting Starting torque T_xx T_ 20 Acceleration ramp time axxx a_20 Kickstart P ON OFF 13 14 P OFF _ Im start p Lxxx en x 100 Kickstarttime p xx x if P enabled P100 Currentlimit Lxxx L300 Set braking parameters as needed Factory setting Softstop S ON OFF I3 I4 S OFF Decceleration ramp time dxxx d 20 DC injection brake B ON OFF 13 14 B OFF DC braking time b xx if B enabled b 5 DC braking current x x x if B enabled 1150 If do you change the default configuration and wish to keep it remember to rewrite the parameters in E2PROM as follows Set parameter K to ON ON 69 All Set parameter W to ON Press parameter W is set to OFF automatically Send run command to equipment and make sure that operation is correct 5 4 Troubleshooting Symptom or Error Possible Cause Measures to be taken No control voltage Check wire harness and control voltage Display OFF F1 fu
4. 630 3150 200 250 200 200 IP 00 QC1UDP 105 0 By fan 500 400 IP 00 QC2UDP 105 0 By fan 850 4250 300 350 300 350 IP 00 QC1VDP 120 0 By fan 700 700 IP 00 QC2VDP 120 0 By fan 2 2 2 Types and ratings 2 3 ASTAT Plus Thermal characteristics The ASTAT Plus allows motor protection according IEC Class 10 or Class 20 and Nema 10 20 or 30 free selectable by parameter o overload IEC Class 10 IEC Class 20 Sec Sec 10000 10000 1000 1000 100 100 1 1 10 15 20 25 30 35 40 45 50 55 60 65 70 10 15 20 25 30 35 40 45 50 55 60 65 7 0 Ir In Ir In Nema 10 Nema 20 Sec Sec 10000 1000075 1000 1000 100 100 HOT HOT 1 1 10 15 20 25 30 35 40 45 50 55 60 65 70 10 15 20 25 30 35 40 45 50 55 60 65 70 Ir In Ir In Nema 30 Thermal memory Sec wg If the control voltage is not removed the unit has a cool down charac teristic being the cool down time 300 sec after the overload trip Ifthe control voltage is removed after tripping you must wait at least 2 minutes before the unit can be restarted 1000 Operations per hour Supposing a cycle T with starting time of t1 running time of T 2t1 at rated current and OFF time of t1 sec at least the ASTAT Plus allows the following operations per hour 100 Operations Hour Operations Hour 1 Overload Starting time t1 10sec Starting time t1 20 sec HOT 21r 18
5. the overload protection curve is automatically ad justed to Class 10 C1 or to Nema 20 N2 Oo X X X Overload Protection oC 1 OFF Selects either the following overload curves N1 N2 N3 OFF Overload protection disabled C1 C2 external overload relay must be used N1 Nema 10 N2 Nema 20 N3 Nema 30 C1 Class 10 C2 Class 20 f x x x Service Factor f 120 100 120 Allows motor service factor Applicable for Nema ratings Voltage calibration procedure When the unit is installed on site or after PCB s replacement the voltage measurements may have accuracy of 10 To improve the Voltage measurement accuracy up to 3 proceed as follow 1 Switch on the ASTAT and measure the RMS voltage on phases 1L1 3L2 using a calibrated voltmeter Search the parameter txxx set the voltage measured and save this value by the enter s keypad key It is not necessary to rewrite the E2PROM to make permanent the new setting the ASTAT plus do this automatically 3 Once the ASTAT has been calibrated this operation does not need to be repeated Note however that the parameter txxx will show the latest entry which may differ of actual voltage value Current calibration procedure When the unit is installed on site or after PCB s replacement the current measurements may have accuracy of 10 To improve the Current measurement accuracy up to 3 proceed as follow 1 Search parameter UF x and enter the right ASTAT s frame type letter ET G
6. 100 In F1 XX according Typower Sicu 660V Fuse Consumpt 2 2 A W A mech design Size In A VA mm QC FDP 17 67 25 6 600 CP URC 14 51 40 00 40 1 18 CLO2 CLO2 4 QC GDP 21 78 32 6 6 URD 30 XX 0063 00 50 1 18 CLO3 CLO3 4 QC _H DP 27 88 40 6 6 URD 30 XX 0080 00 80 1 18 CLO4 CLO3 6 QC I DP 38 116 63 6 6 URD 30 XX 0100 00 100 1 18 CL45 CLO4 10 QC _ JDP 58 208 80 6 6 URD 30 XX 0125 00 125 2 55 CLO7 CL45 16 QC _ KDP 75 277 100 6 6 URD 30 XX 0160 00 160 2 55 CLO8 CLO6 25 QC LDP 86 302 125 6 6 URD 30 XX 0160 00 200 2 55 CLO9 CLO6 35 QC _ MDP 126 389 200 6 6 URD 30 XX 0250 00 250 2 55 CL75 CLO7 50 QC _N DP 187 719 250 6 6 URD 30 XX 0315 00 315 2 78 CK08 CL10 95 QC _ Q DP 288 1097 400 6 6 URD 31 XX 0500 2 550 2 78 CK95 CK85 185 QC _R DP 378 1286 500 6 6 URD 31 XX 0630 2 630 4 118 CK10 CK85 240 QC SDP 444 1374 630 6 6 URD 32 XX 0800 2 800 4 118 CK11 CK95 Bus bar 1 QC TDP 570 2086 800 6 6 URD 33 XX 1000 3 1000 4 118 CK12 CK10 Bus bar 1 QC UDP 732 2352 1000 6 6 URD 33 XX 1250 3 1250 4 248 CK12 CK10 Bus bar 1 QC VDP 1020 3000 1250 6 6 URD 233 XX 2000 4 248 CK13 CK11 Bus bar 1 QC _ X DP 1290 3839 2x800 6 6 URD 233 XX 2000 4 248 CK13 CK12 Bus bar 1 1 As per IEC 947 2 The 3 contacts of DC3 must be connected in parallel IEC Class 20 Ratings TYPE In Total Fuses Fuses Fuses Control voltage Contactor Contactor Conductor losses aM FERRAZ type BUSSMANN type DC 1 DC 3 section 100 In F1 XX according Typower Sicu 660V Fuse Consumpt 2 A W A mech
7. 99 These are a secondary set of ramp up ramp down and 2 dx x Dual Ramp Down 2 d 20 01 99 starting torque parameters which take over the primary 27x x Dual StartingTorque 272 0 10 90 a d and T when the programmable function A is enabled 4 7 4 Programming 4 6 2 Programmable Advanced Functions Display Function Default Range Description Dx x x Linear Ramp DOFF OFF ON 13 14 This function provides linear acceleration and deceleration ramps in a wider range of load conditions A DC Tacho Generator coupled to motor must be used to provide an analog signal feedback of 0 5VDC J XX x Slow Speed J OF F OFF 13 14 This function allows slow speed operation Maximum operation time 120sec j xx Speed changeover j L O LO HI LO Low Speed 7 of rated speed HI High Speed 14 of rated speed r OX X x Reverse r OFF OFF ON 13 14 Reverse dirention is allowed in High slow speed mode only It provides 20 of rated speed Ax x x Dual motor selector A OFF OFF ON 13 14 This function allows dual motor control settings of acceleration deceleration and starting torque and is useful to start or stop a motor in diferent load conditions When this function is enabled the parameters 2a 2d and 2T take over the parameters a d and T It allows dual motor control settings X x x x Remote control selector X OF F OFF ON 13 14 Allows serial commu
8. E02 2 Stalled rotor S x x x SoftStop selection E 0 2 3 Internal error E 0 2 5 Longstarttime 3 E 0 2 6 Longslow speed time L Kx x Lock out E 0 2 7 Lock out E02 8 Undervoltage E 0 2 9 Overvoltage E 030 Undercurrent These are examples Full details in E 0 3 1 Overcurrent sections 4 2 4 3 4 4 4 5 and 4 6 E03 2 Retry Keypad Allows setting of parameters and functions Use with T or J to select the parameter or function code to be D the value ofthe selected t displayed and or modified ecreases the value of the selected parameter C V 4 4 Increases the value ofthe selected parameter Introduces the new parameter value into memory Updates the selected parameter value with the displayed value LJ lt 4 Programming 4 2 Parameter Blocks configuration Mode Selection The ASTAT Plus includes a large number of parameters which are divided in four blocks Monitor Calibration Basic and Advanced The parameters of each group can be displayed or skipped according the selection done in parameter G The monitor parameters are always displayed whichever is the mode selected Settings in parameter G Gxxx The Monitor parameters are always displayed whichever are the settings in parameter G GCAL The Calibration parameters are displayed GBAS The Basic parameters are displayed GADV The Advanced parameters are displayed GALL All parameter
9. H etc Start the motor and measure the rms motor current using a calibrated Ammeter This measurement must be done after complete the starting once the motor current has been stabilized 3 Search the parameter mxxx set the current measured and save this value by the enter s keypad key It is not necessary to rewrite the E2PROM to make permanent the new setting the ASTAT Plus do this automatically 4 Once the ASTAT has been calibrated this operation does not need to be repeated Note however that the parameter mxxx will show the latest entry which may differ of actual current value 4 5 4 Programming 4 5 Basic block Parameteres BAS 4 5 1 Basic Functions Display Function Default Range Unit Description Lxxx Current Limit L350 100 700 Sets Device current Limit Sets motor current limit if pa rameter N is properly adjusted The maximum range setting is automatically calculated by the unit according the following expression Max Limit 450 N max at all 700 N is the motor capacity unit capacity ratio adjusted in parameter Nxxx T xx Starting Torque t 2 0 10 90 Sets the initial voltage applied to the motor a xx Ramp Up time a 20 01 99 sec Sets Voltage ramp up time Motor acceleration time will depend of load conditions dx x x Ramp Down time d 020 001 120 sec Sets Voltage ramp down time Motor dec
10. These two inputs are programmable Can be assigned to the following internal functions 4 Programmable input 14 soft stop DC brake Linear Ramp pump control slow speed control dual ramp selection kick start reverse slow speed bypass function override local remote control Command signal should be provided by one NC dry contact to terminals 57 3 or terminals 57 4 By switching ON OFF this contact is possible to enable or disable the assigned function Digital Outputs Terminal Function Description 11 12 14 Programmable relay1r 11 12 NC 11 14 N O dry contacts This relay can be assigned to several internal output functions p 3 6 As default assigned to function RUN 23 24 Programmable relay 2r 23 24 N O free voltage contact This relay can be assigned to several internal output functions page 3 6 As default assigned to function EOR 33 34 Programmable relay 3r 33 34 N O free voltage contact This relay can be assigned to several internal output functions page 3 6 As default assigned to function DC BRAKE Common for all relay output contacts Maximum usage voltage 380VAC Thermal current 8A AC 15 use 220V 3A 380V 1A DC 15 use 30V max 3 5A Analog I O Terminal Function Description 8 Analog input common This is a common terminal for the analog input terminal number 7 7 TG feedback input 0 5V analog input for speed feedback It should be provided by a DC tacho generator coupled to the motor This speed feedback signal
11. by Sxxx to ON and Cxxx to ON Linear ramp down Tacho feedback needed Evolution of currentin deceleration ramp mode 23 DC brake 0 to 99s adjustable Enabled by Bxxx to ON Starting by voltage ramp Starting by current limitation Override Override U Un l In U Un Energy savings l In 3 4 3 Technical specifications Jog and linear ramp Linearacceleration and deceleration ramp Low slow 7 and High slow 14 speeds Reverse slow speed 20 Slow speed 7 or 14 Acceleration ramp Soft stop deceleration ramp Slow speed 7 or 14 DC Brake Ramp time adjustable Selectable by parameter Dxxx to ON OG Enabled by parameter Jxxx to ON and ixxx to LO or HI Enabled by parameter Jxxx to ON and rxxx to ON Enabled by parameter Jxxx to ON Ramptime adjustable Ramptime adjustable Enabled by parameter Jxxx to ON 90906600 Currentandtime adjustables Linear ramp with T G feedback Slow speed Basic diagram N Nn N Nn Slow speed Full diagram TERMINALS Closed 4 57 Open Closed 1 57 Open Closed 2 57 Open 3 5 3 Technical specifications Programmable Inputs and functions The ASTAT Plus functions like Soft stop kick start and almost all others can be enabled or disabled by setting ON or OFF in their dedicated parameters using the facilities provided by the keypad The most
12. cage motors impossible Traditionally in such cases other types of starting with reduced stator voltage have been resorted to The best known are star delta starters autotransformer starters stator resistance starters or using part winding motors Any reduced starting voltage imposes a current limitation and as a consequence the starting torque is also reduced but there will always be peaks during the change from one point or state to another which can damage the machine being driven In order to analyse the performances offered by each of these different types of starters the following table shows the special characteristics of each of them comparing with the ASTAT system Note that in general all reduced voltage starts produce a reduction in torque in squared proportion to the current in the phases of the motor not on the line and the latter in turn is reduced in linear proportion to the voltage From this it can be deduced that any start with reduced voltage reduces the torque in squared proportion to the voltage per motor phase From this point of view soft starting produces just like any other reduced voltage start a reduction in starting torque according CONVENTIONAL STARTERS to the adjusted parameters The advantage of course is the ease with which this ramp can be controlled to produce a soft start in accordance with the actual requirement of the machine From the comparison table it can be seen that the maximum starting
13. e when the motor is loaded In this case try jumping the bypass terminals 3 57 at the end of acceleration ramp Internal error Microcontroller malfunction Check IC1 and IC8 are correctly inserted in their sockets Long start time Current limit condition present more than 2 x ta sec or 240 sec ta acceleration ramp time Increase current limit and or acceleration ramp time Long slow speed time Equipment has been in slow speed mode more than 120 sec Avoid this condition Lock out The time between startings is less that the adjusted in parameter LKxx Check is settings are correct This protection may be disabled Undervoltage Overvoltage The line voltage exceeds of limit set in parameters UVxx or OVxx Check is settings are correct This protection may be disabled Undercurrent The motor current exceeds of limit set in Check is settings are correct Overcurrent parameters UCxx or OCxx This protection may be disabled Retry The retry feature could not re start the motor Check last message e1xx and correct after a fault Be sure that retry settings are correct as well 5 5 Thyristor check Shortcircuit Use a testing lamp to check the defective power module between input and output phases If the lamp goes on at least one of the thyristors has a shorcircuit Check with a tester the value or the R resistance between input and output of the same phase connector
14. is required when the linear ramp function is used 9 Current Output 0 10V DC analog Output for current measurement purpose Ir correspond to 2V DC Load Impedance 10KQ or higher Motor thermistor terminals Terminal Function 5 6 Motor thermistor input Description This input allows motor thermistor with response value from 2 8 to 3 2KQ and reset value from 0 75 to 1KQ When the motor thermistor is not used a link must be set between those terminals Communications Terminal SG TD RD Function Gr Tx Rx data Description RS232C 3 wires half duplex Maximum cable length 3mts Asynchronous data transmission 9600 Bauds 1 bit start 8 bits data 1 bit stop no parity 3 2 3 Technical specifications 3 3 1 0 Wiring ASTAT Plus s terminal layout and wiring configuration is shown in the diagram of bellow LT L2 13 Control Voltage 1 MOM120VAC e We i SER Serial Comm 1 RS232C A1A2 B1B2 Gr Tx Rx Control Voltage 220 240V AC 12 11 14 423 24 33 34 SGTD RD 1L1 S3L2 513 A1A2 B1B2 ir 2r 3r Programmable relay Outputs 3 Programmable Inputs 2 13 14 57 2 57 3 57 4 57 5 6 7 89 Start Stop T amp ER permanent Command _
15. of these functions can be enabled or disabled remotely as well through the programmable inputs 13 or 14 termi nals board 3 57 and 4 57 Function Parameter SoftStop S x x x 7 Set Value lt Remarks gt due gt z _ O F F The function is permanently disabled ele i 5 _ O N gt The function is permanently enabled d a g SCH i _ 3 The status of the function depends on ASTAT s 13 input Jog nr i UA The status of the function depends on ASTAT s 14 input gt Dual motor 2 A x x x Remote Control X x x x Note One programmable input may enable or disable more than one function Programmable Relay Outputs The ASTAT Plus includes three programmable relay namened tr 2r and 3r dry contacts to ASTAT terminals 11 12 14 23 24 and 33 34 These relays can be assigned to several functions as shown bellow Set Value lt Remarks gt 20 gt EOR Detects end of voltage ramp Only can be asigned to relay 2r 21 gt DC Brake DC Brake command Only can be assigned to relay 3r Relay N Parameter 22 Fault Detects ASTAT s fault status Belair gt 1 r x x 23 Undervoltage Detects limit set in parameter UVxx 24 Overvoltage Detects limit set in parameter OVxx Relay2r ir XX 235 gt RUN Detects ASTAT s run status Paley
16. parameters from the E2PROM to the temporal buffer Qx x x Factory settings QOFF ON OFF Load default factory settings to the temporal buffer Y x Retry Y 0 0 4 Allows up to four tries of automatic restart after a fault Setting 0 disables this function y X X Retry time y 1 0 01 99 sec Time between retries UV x x Undervoltage U VO 0 00 50 The unit trips if the line voltage decreases bellow of the percentage set Setting 0 disables this protection Note Calibrate parameter U before to enable this protection uv xX Xx Undervoltage trip time uv 2 0 00 99 sec Delay trip time OV x x Overvoltage OV O0 0 00 30 The unit trips if the line voltage increases above of the percentage set Setting 0 disables this protection Note Calibrate parameter U before to enable this protection ov xX X Overvoltage trip time ov 2 0 00 99 sec Delay trip time UC x x Undercurrent U CO 00 99 The unit trips if the current decreases bellow of the per centage set Setting 0 disables this protection Note Calibrate parameter U before to enable this protection uc X Xx Undercurrent trip time uc 2 0 00 99 sec Delay trip time Oc x x Overcurrent 0 C0 0 00 50 The unit trips if the current increases above of the per centage set Setting 0 disables this protection Note Calibrate parameter U before to enable this protection oc X X Overcurrent trip time oc 2 0 00 99 sec Delay trip time 2a x x Dual Ramp Up 2 a 2 0 01
17. 0 By fan 40 75 110 55 110 132 IP 00 QC2NDP 45 0 By fan 240 63 110 132 288 80 150 165 IP 00 QC1QDP 45 0 By fan 63 110 132 160 80 150 165 200 IP 00 QC2QDP 45 0 By fan 315 9 160 200 378 110 200 220 IP 00 QC1RDP 55 0 By fan 9 160 200 220 110 200 220 250 IP 00 QC2RDP 55 0 By fan 370 110 200 220 444 132 220 250 IP 00 QC1SDP 55 0 By fan 110 200 220 250 132 220 250 315 IP 00 QC2SDP 55 0 By fan 475 150 250 250 570 160 300 355 IP 00 QC1TDP 80 0 Byfan 150 250 250 335 160 300 355 400 IP 00 QC2TDP 80 0 By fan 610 200 315 400 732 220 400 450 IP 00 QC1UDP 105 0 By fan 200 315 400 400 220 400 450 500 IP 00 QC2UDP 105 0 By fan 850 250 450 530 1020 300 560 600 IP 00 QC1VDP 120 0 By fan 250 450 530 600 300 560 600 750 IP 00 QC2VDP 120 0 By fan 1075 355 600 670 1290 395 715 750 IP 00 QC1XDP 150 0 By fan 355 600 670 750 395 715 750 850 IP 00 QC2XDP 150 0 By fan Notes 1 Ratings in Amps given for ambient temperature up to 40 C and 1000m altitude 2 3 4 5 Derate output current by 1 5 C above 40 C Derate output current by 1 100m above 1000m Heavy duty ratings IEC Class 10 and 20 protections allowed Light duty ratings only IEC Class 10 protection allowed Maximum recommended Motor Power for IEC Class 20 protection Set ASTAT s parameters N and o accordingly Maximum recommended Motor Power for IEC Class 10 protection Set ASTAT s parameters N and o accordin
18. 0 90 3 Ir 160 60 10 15 20 25 30 35 40 45 50 55 60 65 70 a e Ir In 2 3 3 Technical specifications 3 1 ASTAT Plus General specifications Voltage Ratings 3ph AC Systems Up to 440V 10 15 for QC1xDP ASTAT Plus series Up to 500V 10 15 for QC2xDP ASTAT Plus series Freq Range 50 60 Hz Control range of 45 65 Hz Control Control system Digital system with microcontroller Specifications Initial voltage pedestal Starting torque Kick start Motor current Im Current limitation Acceleration ramp time S Energy savings Override Bypass Brake time by ramp S DC braking Slow speed Retry Monitoring Starting ramp with progressive increase in voltage and current limitation 30 95 Un 10 90 Mdirect start 95 Un 90 Mdirect start adjustable 0 to 999 ms 0 4 to 1 2 Ir rated ASTAT current 1to7 In 1 to 99 types standard or linear ramp up Output voltage reduction according to power factor Fixed output voltage permanently equal to supply voltage Direct control of a bypass contactor 1 to 120 1 to 99 in secondary ramp adjustable independently of starting ramp time types standard pump control or linear ramp down 0 to 99s 0 5 to 2 5in Direct torque 7 or 14 of nominal speed reverse torque 20 of nominal speed 0 to 4 attemps and 1 to 99 sec retry time Motor current line voltage power power factor and elapsed time Operation External control Acceler
19. 00 derate output current by 1 100m above 1000m Mounting position Vertical Protection Degree IP00 Standards CE cUL CE Conforming IEC 947 4 2 Conducted amp Radiated emissions Electrostatic discharges Radioelectric interference Immunity to fast trasients Immunity to Surge Voltage Conforming IEC 947 4 2 Class A Conforming to IEC 1000 4 2 level 3 Conforming to IEC 1000 4 6 level 3 and to IEC 1000 4 3 level 3 Conforming to IEC 1000 4 4 level 3 Conforming to IEC 1000 4 5 level 3 3 1 3 Technical specifications 3 2 I O terminal board specifications Power I O terminals Terminal Function Description 1L1 3L2 5L3 Mains Input 3ph input voltage according ASTAT Plus type 271 472 673 Motor output Output terminals to 3ph AC motor A1 A2 B1 B2 Input Control Voltage 110 120V AC 10 15 220 240V AC 10 15 A1jA2 B1 B2 Wlan B1 B2 Digital Inputs Terminal Function Description 57 Common for digital inputs This is a common terminal for the digital input terminals specified below 1 Run Run order Command signal may be provided by one NO free voltage push button to terminals 1 and 57 Stop Stop order Command signal may be provided by one NC free voltage push button to terminals 2 and 57 Note Run Stop permanent command is allowed linking 1 57 and using one dry NO contact to 2 57 terminals 3 Programmable input 13
20. 2 Serial communication 6 Appendix Parameter Parameter Function Read Write Range Comments number name R W 007 p Kick start time msec R W 0 999 008 b DC brake time sec R W 0 99 009 DC brake current In R W 50 250 010 S Soft stop control R W 0 3 0 OFF 1 ON 2 13 3 14 011 C Pump control R W 0 3 0 OFF 1 ON 2 13 3 14 012 P Kick start control R W 0 3 0 OFF 1 ON 2 13 3 14 013 F Override R W 0 3 0 OFF 1 ON 2 13 3 14 014 B DC brake control R W 0 6 0 OFF 1 ON 2 13 3 14 4 PON 5 PI3 6 P14 015 LK Lockout sec R W 0 45 016 o Overload trip curve R W 0 5 0 OFF 1 N1 2 N2 3 N3 4 C1 5 C2 019 R Read EEPROM IW 1 021 v Software version R XXX VXXX 024 1r Programmable relay 11 12 14 R W 22 30 See programmable relays functions in page xx 025 2r Programmable relay 23 24 R W 20 22 30 026 3r Programmable relay 33 34 R W 21 30 027 OC Overcurrent N R W 0 50 0 OFF 028 oc Overcurrent time sec R W 0 99 029 r Reverse slow speed R W 0 3 0 OFF 1 ON 2 13 3 14 030 Y Retry attemps R W 0 4 031 y Retry time sec R W 1 99 032 UV Undervoltage U R W 0 50 0 OFF 033 uv Undervoltage time sec R W 0 99 034 OV Overvoltage U R W 0 30 0 OFF 035 OV Overvoltage time sec R W 0 99 036 UC Undercurrent N R W 0 99 0 OFF 037 uc Undercurrent time sec R W 0 99 038 PF Po
21. 3 Password E2PROM writting P EHEHEH HHEH Parameter Block Selector GBAS GADV GALL GCAL O 4 2 Calibration parameters Line Voltage gt 100 500 Voltage Calibration p Unit frame FH A Current Calibration e m Motor rated current 40 120 Overload Protection 0 N1 N2 N3 C1 C2 HERS Service Factor 100 130 4 Programming Basic Parameters Current Lmit Starting Torque Ramp up time Ramp down time Kick Start DC Brake time DC Brake current Soft Stop switch Pump Control switch Kick Start Switch Override Switch By pass Switch DC Brake Switch 100 700 gt 010 090 01 99 gt 01 120 000 999 gt 000 099 050 250 gt OFF ON 13 14 gt OFF ON 13 14 gt OFF ON 13 14 gt OFF ON 13 14 OFF ON 13 14 gt OFF ON 13 14 PON PIS P14 Lock out E2PROM Reading Factory Settings Retry Retry time Undervoltage Undervoltage trip time Overvoltage Overvoltage trip time Undercurrent Undercurrent trip time Overcurrent Overcurrent trip time Secondary Ramp up Secondary Ramp down Secondary Starting Torque Tacho control switch Slow Speed switch Low High slow speeds Reverse slow speed Dual motor switch Remote control Output relay ir Output relay 2r Output relay 3r 00 45 gt
22. B on main PCB must be previously removed If R lt 50KQ at least one of the thyristor is defective Open thyristor With the simple assembling shown here the lamp should light when the S switch is closed and remain lighting when open If not the thyristor is defective 5 4 1L1 3L2 or 5L3 Testing lamp 3 to 6V 271 4T2 or 6T3 L S 10 ohms 3 to 6V 6 Appendix 6 1 Application diagrams Basic diagram Control Voltage 110 120V AC i Control Voltage A1 A2 B1B2 Control Voltage 1171 DCI 220 240V AC de 11 14 123 24 33 34 SGITDIRD A1A2 B1B2 ir 2r 3r Programmable relay Outputs Programmable Inputs 3 13 14 1157m 2157 3 57 4 57 15 6 7 8 9 FT1 JY A 7 Start Stop Motor Thermistor Push Button 2 REMARKS 1 The line contactor DC1 is not required to perform operation to the motor Be aware however that DC1 provides galvanic isolation from the mains increasing the safety 2 In this example Start and Stop command is effected by push buttons Permanent command is allowed as well wiring 1 2 and 57 terminals as shown in page 3 3 3 The output relays allow for direct action on contactors acc
23. GE Power Controls SOLID STATE SOFT STARTER ASTAT Plus USER MANUAL REMARKS Read this manual throughly before using the ASTAT Plus and store in a safe place for reference Make sure that this manual is delivered to the end user CE MARKING When using ASTAT Plus in the EU compliance with EMC is required ASTAT Plus range comply with the generic EN 50081 2 and EN 50082 2 ASTAT Plus Soft Starters WARNINGS 1 Disconnect power before installing or servicing 2 Hazardous voltages are present in the motor circuit even when the starter is OFF An isolation contactor is recommended configured to provide automatic isolation when the motor is turned OFF 3 Unit may contain more than one live circuit Disconnect both control and main circuits before installing or servicing 4 Soft stop should not be used as an Emergency stop 5 Stopping mode must be set to meet applicable standards for operator safety 6 Separate motor overcurrent protection is required to be provided in accordance with the Canadian Electrical Code Part 1 ASTAT Plus provides separate motor protection CAUTIONS 1 Semi conductor fuses specified may not provide branch circuit protection Refer to local applicable electrical codes 2 Overload relay setting should be properly coordinated with motor 3 Slow speed running will affect the motor thermal characteristic due to reduced cooling Care must be taken when operating motor un
24. NE 26 JOG Detects Jog slow speed status si 27 Undercurrent Detects limit set in parameter UCxx 28 gt Overcurrent Detects limit set in parameter OCxx 29 gt Disables the relay function 30 Future use 3 6 4 Programming 4 1 Keypad and Display description JE C V 4 Display Displays Monitoring Status indications error messages and function set values Display Structure F V V V Status code Function code EE tt EE Sd tFiiVii ViVi Er ee ee ee d np 9 oo TNA VTMA PZCOCO gt PC gt con OO DS ner Sr OO Irr SO 4 mF Oo XV Equipmentis connected tomain supply equipmentis ON Stop Remote stop Kickstart Acceleration ramp Fullconduction Energy saving Softstop Pump control DC braking Override full voltage Inching slow speed Linear ramp tacho FVVV Error code FFVV V function code E 0 1 0 Frequency out of range Mx x x Motor current E 0 1 1 Overload trip vx xX x Software Version E 0 1 3 Loss of synchronism E 0 1 4 Phase U scr A E 0 1 5 Phase V scr P Fx x Power Factor E 0 1 6 Phase W scr E 0 1 7 Heatsinkovertemperature i a E 0 1 8 Motorthermistor Lx x x Limitcurrent E 0 1 9 Phase Ulost Tx x x Starting Torque E 0 2 0 Phase V lost ax x x Ramp uptime E 0 2 1 Phase Wlost d x x x Ramp downtime
25. ON OFF gt ON OFF gt 000 004 001 099 gt 00 50 00 99 00 30 00 99 00 99 gt 00 99 00 50 gt 00 99 01 99 gt 01 99 10 90 gt ON OFF 13 14 OFF 13 14 LO HI gt OFF ON 13 14 gt OFF ON 13 14 gt OFF ON 13 14 22 30 gt 20 22 30 21 22 30 4 Programming 4 3 Monitor block Parameters Display Function Default Range Unit Description ON Status ON ON Switch on time Equipment is connected to main supply STOP Stop LOCK Remote stop Then the control is made thru serial comm PULS Kick start RAMP Acceleration ramp FULL Full conduction SAVE Energy saving SOFT Soft stop PUMP Pump control DCBK DC braking FULL Override full voltage INCH Inching slow speed TACH Linear ramp tacho feedback needed Mxxx Motor Current 000 999 A Displays motor current in Amps 1 0 9 9 kA Current higher than 999A is displayed in kA If parameter UF xx is not calibrated the motor current is displayed in N VOX xx Software Version xxx Version number Vx xx Main Source Voltage V Displays line voltage in Volts P Fx x Power Factor 00 99 Displays line Power Factor wx X X Line Power kW Displays Line Power Ex x x Elapsed time Hrs Displays RUN time in Hours x 1000 exxx Error trace buffer e0xx e3xx Saves the last four err
26. S 1 The line contactor DC1 is not required to perform opera tion to the motor Be aware however that DC1 provides galvanic isolation from the mains increasing the safety 2 In this example Start and Stop command is effected by push buttons Permanent command is allowed as well wiring 1 2 and 57 terminals as shown in page 3 3 3 The output relays allow for direct action on contactors according ratings specified in page 3 2 of this manual 4 The ASTAT Plus is performed with an electronic motor overload protection which may be enough in the most of the applications You should use an external overload protection if re quired by local rules or to protect the motor against current imbalance 5 Slow Speed for Jog forward or reverse using programma ble inputs 13 14 Details given bellow Jog Slow Speed function Programming steps 1 The slow speed function may be enabled by setting Jxxx to 13 In this case Slow Speed is allowed by a push button wired to ASTAT s Plus terminals 3 57 Reverse jog is also possible by setting rxxx to ON As alternative if rxxx is set to programmable input 14 forward or reverse may be controlled by remote push button signal 5 Check section 4 6 3 for more details 2 Slow Speed can be effected with ASTAT Plus in stop status Slow speed and normal run commands are inter nally interlocked Basic diagram with DC brake injection Control Voltage 110 120V AC
27. Tt QC _ JDP QC _ KDP 274 180 QC _ LDP QC _ MDP 6 Appendix 6 3 Dimensions Terminal detail 8 07 28 3 811 S E 20 d 20 y Y Sl CT x QC _ NDP QC _ RDP QC _ QDP QC SDP UI ka gt gt lt lt _ lt gt A D i Term inal details A B c D E F G H l J K L QC_NDP 510 490 305 460 465 9 53 106 54 259 70 168 QC_QDP 510 490 305 460 465 9 53 106 54 259 70 168 QC_RDP 550 540 317 480 495 9 59 118 54 275 78 168 ve QC SDP 550 540 317 480 495 9 59 118 54 275 78 168 be QC TDP 590 685 317 520 640 9 59 118 64 5 270 100 168 N QC UDP 790 850 402 700 805 11 60 120 120 352 120 175 476 QC_VDP 790 850 402 700 805 11 60 120 120 352 120 175 QC_XDP 810 1000 407 720 955 11 70 140 110 357 120 175 6 4 P C B s Supply Control MAIN TRANSFORMER F2 F S PULSE PULSE TRAFO TRAFO tr n I
28. ais de courant de surcharge doit tre proprement coordonn avec la marche du moteur 3 La marche en sous r gime agira sur les caracteristiques thermiques cause de la r duction de refroidessement Op rez le moteur avec pr caution dans en ce cas 4 Ralentissement courant continu peut provoquer la surchauffe de moteur Choisissez le plus foible courant de d c leration et la dur e de ralentissement la plus courte 5 Pour freinage courant continu un contacteur DC3 additional est n cessaire dans le circuit moteur voir le sch ma de raccordement page 6 1 6 Les d lais anormaux de mise en service d une dur e sup rieure 30 secondes ainsi que les mont es descentes en regime les exploitations r gime lent ou les freinages par injection de courant continu r p t s et rapportes sont suseptibles d edommager le moteur Mettez vous en rapport avec votre fabricant en ce qui concerne le choix du moteur ad quat 7 Encas d interruption de l alimentation entre deux demarrages la protection assur e par d marrage froid 8 Le moteur doit tre muni d une protection distincte contre les surintensites et la surchauffe conformement au code de l electricite premiere partie ASTAT Plus le relais de courant de surcharge doit tre proprement coordonne avec la marche du moteur INDEX section 1 Generalities ees EEN EE 1 1 1 1 Comparison of starting systems 20usnnsunssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnsnnnnnnnnnnnn
29. ation phase Permanent phase Start Stop Adjustable time Energy savings Override choice Stop phase Power cut off Ramp DC braking Pump control Inputs Outputs Inputs 4 digital optocoupled Two fixed Start Stop and 2 programmable 13 14 1 Analog 0 5VDC for Tachogenerator input feedback Outputs 3 programmable relays 1r 2r 3r 1 Analog 0 10VDC output for current metering Protections Current limit Adjustable from 1 In to 7 In Overload IEC class 10 and 20 NEMA class 10 20 and 30 all selectable Cool down time after overload trip Loss on input phase Thyristor short circuit ms Radiator overheating ms Motor thermistor ms Loss on output phase S Stalled rotor ms Supply frequency error Hz Overcurrent Undercurrent Overvoltage Undervoltage Error CPU ms Memory Long start time Long slow speed time 300 Trip at 3 Trip at 200 Trip at 200 Trip at 200 if thermistor impedance gt response value Trip at 3 Trip at 200 If f lt 45 or f gt 65 will not start 100 to 150 In trip time adjustable from 0 to 99 sec 0 to 99 In trip time adjustable from 0 to 99 sec 100 to 130 Un trip time adjustable from 0 to 99 sec 0 to 50 Un trip time adjustable from 0 to 99 sec 60 4 former errors 2 x ta ta acceleration ramp time 120 Environmental Temperature C 0 to 55 derate output current by 1 5 C above 40 C conditions Relative humidity 95 without condensation Maximum altitude m 30
30. atory between 2T1 and 4T2 phases otherwise a short circuit can occur DC brake function Programming steps 1 The DC function may be enabled by setting Bxxx to ON 2 Once this function is enabled the relay 3ris automatically assigned to this function This relay must be used to control the DC brake contactor Check section 4 5 1 and 4 5 2 for more details 6 Appendix 6 1 Application diagrams Basic diagram with Linear ramp LT L2 L3 Control Voltage 110 120V AC WD Control Voltage DC A1A2 B1B2 Control Voltage DC1 220 240V AC T4 2 11 14 23 24 33 34 1SG TDIRD amp A1A2 B1B2 Ar Programmable relay Outputs Programmable Inputs 3 2r 3r Push Button 2 13 14 1157 2 57 3 57 4 57 516 718 9 FT1 d 7 1 TAV 5 FA E7 Start Stop Motor Thermistor Gs Linear Ramp 5 REMARKS 1 The line contactor DC1 is not required to perform opera tion to the motor Be aware however that DC1 provides galvanic isolation from the mains increasing the safety 2 In this example Start and Stop command is effected by push buttons Permanent command is allowed as well wiring 1 2 and 57 terminals as shown in page 3 3 3 The
31. d yyy 3 bytes needed is the value to write into the parameter Note the parameters modification is not allowed while the motor is operating Toreada parameter the format commandis the following Request from host Rxxx Response fromthe ASTAT Rxxxyyyyy where xxx 3 bytes needed is the parameter number and yyyyy 5 bytes response is the value of the parameter Examples tostartthe unit the command will be W060000 tostopthe unit the command will be W060001 tosetthe acceleration ramp time to 35sec the command will be W005035 to know which overload curve is selected the command will be R016 iffor instance the response is R01600004 this means that the overload curve selected is IEC class 10 The Table A provides a complete reference as for the parameters that can be controlled by the serial interface Parameter Parameter Function Read Write Range Comments number name R W 000 Status Soft starter status R 0 14 0 ON 1 STOP 2 LOCK 3 Alarm errors 4 PULS 5 RAMP 6 FULL 7 SAVE 8 SOFT 9 DCBK 10 FULL override 11 Not used 12 INCH 13 TACH 14 PUMP 001 M Motor current N or Amps depending on UF parameter R 002 N Nominal motor current Unit current R W 40 120 003 L Limit current In R W 100 700 004 T Starting torque DOL torque R W 10 90 005 a Acceleration ramp time sec R W 1 99 006 d Deceleration ramp time sec R W 1 120 6
32. der these conditions 4 DC braking braking current may cause motor overheating Select the lowest braking current and time 5 DC braking must use additional DC3 in the motor circuit See wiring diagram page 6 1 6 Abnormal starting times in excess of 30 seconds or closely repeated operations of acceleration ramp deceleration ramp slow speed or DC injection braking may cause motor damage Contact motor manufacturer for proper motor selection 7 If control power is lost between starts the overload relay protection is reset to cold start conditions ASTAT Plus Soft Starters PRECAUTIONS 1 _ Debranchez l alimentation en courant lectrique avant de raccorder ou d intervenir 2 Des tensions dangereuses sort pr sente dans le circuit moteur m me si le soft starter indique la position arr t Un contacteur d isolement assurant un isolement automatique quand le moteur est arr te est recommend 3 L appareil peutrenfermer plus d un circuit sous tension de brancher les circuits principaux et les circuits de controle avant de raccorder ou d intervenir 4 D lestage soft stop ne devrait jamais tre utilis en lieu de d lestage d urgence 5 Proc d s de d lestage doivent tre conforme aux normes de s curit des utilisateurs AVERTISSEMENTS 1 Les fusibles semi conducteurs specifies ne prot gent pas obligatoirement les circuits se conformer aux codes locaux d installations lectriques 2 Le rel
33. design Size In A VA mm QC FDP 14 56 20 6 600 CP URC 14 51 40 00 40 1 18 CL01 CL01 4 QC GDP 17 65 25 6 6 URD 30 XX 0063 00 50 1 18 CLO2 CLO2 4 QC_HDP 22 74 32 6 6 URD 30 XX 0080 00 80 1 18 CLO3 CLO3 4 QC I DP 32 99 63 6 6 URD 30 XX 0100 00 100 1 18 CLO4 CLO4 6 QC JDP 48 178 80 6 6 URD 30 XX 0125 00 125 2 55 CL06 CLO4 10 QC_KDP 63 236 80 6 6 URD 30 XX 0160 00 160 2 55 CLD CLO4 16 QC LDP 72 257 100 6 6 URD 30 XX 0160 00 200 2 55 CLO8 CLO6 25 QC_MDP 105 325 160 6 6 URD 30 XX 0250 00 250 2 55 CL10 CLO6 35 QC_NDP 156 591 200 6 6 URD 30 XX 0315 00 315 2 78 CK75 CLO7 70 QC QDP 240 901 315 6 6 URD 31 XX 0500 2 550 2 78 CK85 CK75 120 QC_RDP 315 1063 400 6 6 URD 31 XX 0630 2 630 4 118 CK95 CK85 185 QC SDP 370 1136 500 6 6 URD 32 XX 0800 2 800 4 118 CK10 CK85 240 QC TDP 475 1721 630 6 6 URD 33 XX 1000 3 1000 4 118 CK11 CK95 Bus bar 1 QC UDP 610 1950 800 6 6 URD 33 XX 1250 3 1250 4 248 CK12 CK10 Bus bar 1 Qc_VDP 850 2491 1000 6 6 URD 233 XX 2000 4 248 CK13 CK10 Bus bar 1 QC_XDP 1075 3168 1250 6 6 URD 233 XX 2000 4 248 CK13 CK12 Bus bar 1 1 As per IEC 947 2 The 3 contacts of DC3 must be connected in parallel 5 Installation 5 3 Start up Make sure equipment wiring corresponds to one of the recommended routing diagrams or equivalent If the motor does not have thermal protection sensor a link must be set beetwen terminals 5 and 6 Make sure the control wire harness corre sponds to the control voltage used
34. eleration time will depend of load conditions Enabled only if the parameter Sxxx is ON p xX X Xx Kick start 1 p00 0 000 999 ms During the time adjusted provides 95 of full voltage to motor at starting time Useful for high static friction loads Enabled only if the parameter Pxxx is ON b xx DC Brake time 1 b 00 I x x x DC Brake Current 1 1050 00 99 050 250 sec Provides DC braking at stopping time Enabled only if the parameter Bxxx is ON 1 CAUTION If Pump Control is enabled Function Display Description C ON the Kick Start and DC Brake functions are Load detection px x x default 0 in 50Hz P Source default 15 in 60Hz P Source automatically disabled so the parameters p b and l are Proportional control b x x x default 10 now used to set PID Pump Control algorithm Integral time control Ix x x default 50 4 5 2 Programmable Basic Functions Display Function Default Range Description S x x x Soft Stop selector S OF F OFF ON 13 14 Enables or disables all modes of Soft stop C x x x Pump Control selector COFF OFF ON 13 14 Enables the Pump control function It is usefull to limit hammering The parameter Sxxx must be enabled as well P x x x Kick Start selector P OF F OFF ON 13 14 Enables or disables the Kick start function I
35. f Pump control function P is enabled both Kick start and DC Brake functions are internally disabled Fx xx Override selector FOF F OFF ON 13 14 Enables or disables the energy saving feature providing constant full voltage after starting time Enabling this function the unit produces the lowest harmonic contents 4 6 4 Programming Programmable Basic Functions follow from previous page Z X XX By pass selector z OF F OFF ON 13 14 This function provides control of an external by pass contactor avoiding unit losses and harmonics When the By Pass function z is enabled the programmable relay output 2r is automatically assigned to this function and must be used to control the external by pass contactor Bx x x DC Brake selector BOF F OFF ON 13 14 Enables or disables the DC brake function PON PI3 Pl4 When the DC Brake function B is enabled the programmable relay output 3r is automatically assigned to this function PON PI3 or PI4 settings enable the DC Brake function just before to start the motor This is usefull to stop a fan which is rotating in reverse at the starting time 4 6 Advanced Block Parameters ADV 4 6 1 Advanced Functions Display Function Default Range Unit Description LK x x Lock Out LK 0 0 00 45 min Sets time between consecutive starts Setting 0 disables this function RX X Xx E2PROM reading R OF F ON OFF Load the
36. gly 2 1 2 2 UL Ratings 2 Types and ratings Current Max STANDARD DUTY HEAVY DUTY Degree of Weight Cooled rating starting 200V 230V 460V 200V 230V 460V protection 1 unit current A A HP HP HP HP HP HP Kg 14 70 3 3 3 3 IP 00 QC1FDP 43 Natural 7 5 7 5 IP 00 QC2FDP 4 3 Natural 17 85 3 3 3 3 IP 00 QC1GDP 4 3 Natural 10 10 IP 00 QC2GDP 4 3 Natural 2 110 5 7 5 5 7 5 IP 00 QC1HDP 4 6 Natural 15 15 IP 00 QC2HDP 46 Natural 4 170 7 5 7 5 7 5 7 5 IP 00 QC1IDP 4 6 Natural 2 20 IP 00 QC2IDP 46 Natural 48 240 15 15 10 15 IP 00 QC1JDP 12 5 By fan 30 30 IP 00 QC2JDP 12 5 By fan 63 315 2 20 15 2 IP 00 QC1KDP 12 5 By fan 40 40 IP 00 QC2KDP 12 5 By fan 72 360 2 25 2 2 IP 00 QC1LDP 17 0 By fan 50 40 IP 00 QC2LDP 17 0 By fan 105 525 30 30 30 30 IP 00 QC1MDP 17 0 By fan 75 60 IP 00 QC2MDP 17 0 By fan 156 780 50 60 40 50 IP 00 QC1NDP 45 0 By fan 125 100 IP 00 QC2NDP 45 0 By fan 240 1200 1 75 60 75 IP 00 QC1QDP 45 0 By fan 200 150 IP 00 QC2QDP 45 0 By fan 315 1575 100 125 75 100 IP 00 QC1RDP 55 0 By fan 250 200 IP 00 QC2RDP 55 0 By fan 370 1850 125 150 100 125 IP 00 QC1SDP 55 0 By fan 300 250 IP 00 QC2SDP 55 0 By fan 500 2500 150 200 150 150 IP 00 QC1TDP 80 0 By fan 400 350 IP 00 QC2TDP 80 0 By fan
37. ing devices SMD which increases equipment reliability 5 High level of immunity Design of the unit was closely tied to the conditions of supply lines which handle more disturbance every day The control signals are optoelectronically isolated and various levels of protection have been set up in the circuits to immunize the equipment against external disturbance and its effects 6 Easy to run and adjust This unit can be used for a wide range of applications Adjustments are very easy to make and diverse options may be selected to have equipment capabilities suited to application needs every time 7 Easy maintanence due to full monitoring The signalling code based on alphanumeric display makes the equipment working conditions known at any time and gives a quick diagnosis when protection security is violated 8 Pump control The ASTAT Plus includes a Pump Control function which is more effective than the standard soft stop reducing fluid surges or hammering in a pipe line system This method reduces the motor speed by controlling internal parameters in the motor as well as the output voltage in a close loop system 9 Advanced functions The ASTAT Plus includes advanced functions like linear acceleration ramp forward and reverse jog programmable 1 0 or connection to a computer by serial communication RS 232 all included as standard These performances allo
38. m 8 cm SIGNAL POWER ead Ed CORRECT INCORRECT AC DC Do not install capacitors to correct the power factor between equipment output If the equipment is fed by a line transformer its rated power should be at least 1 5 and motor times but less than 10 times higher than equipment supply Environment When installing equipment keep the following points in mind The equipment should be installed vertically and hang over a platform or bars The vertical position is essential for proper cool air circulation Environmental conditions are in accordance with the following ranges and maximum values Operating temperature 0 C to 55 C Relative humidity without condensation 95 Maximum altitude 3000m Reduce usage intensity by 1 5 C from 40 C and 1 100m from 1000m Donotinstall equipmentin environments containing explosive or flamma ble gases or near important heat sources Equipment should be well ventilated at least keeping clearances as indicated in the following illustration When equipment is to be mounted on a platform subject to strong vibrations there should be an elastic base to protect the equipment 5 1 5 Installation 5 2 Fuses contactors and supply wiring IEC Class 10 Ratings TYPE In Total Fuses Fuses Fuses Control voltage Contactor Contactor Conductor losses aM FERRAZ type BUSSMANN type DC 1 DC 3 section
39. nication control by SG TD and RD terminals Check Appendix section for more details 4 6 3 Programmable Relay Output Functions Display Function Default Range Description Tr x x Output relay 1r 1r 25 22 30 This is a programmable relay with one NO NC dry contacts to ASTAT Plus s terminals 11 12 13 2r x x Output relay 2r 2r20 20 22 30 This is a programmable relay with one NO dry contact to ASTAT Plus s terminals 23 24 This relay is automatically assigned to BY Pass control if the function Z is ON Any other assignment by the user is overwrited in this case 3 r X X Output relay 3r 3 r 2 1 21 22 30 This is a programmable relay with one NO dry contact to ASTAT Plus s terminals 33 34 This relay is automatically assigned to DC Brake control if the function B is ON Any other assignment by the user is overwrited in this case The programmable relays can be set to the functions shown in the following table Range Function Remarks 20 EOR 21 DC Brake 22 FAULT 23 Undervoltage 24 Overvoltage 25 RUN 26 Slow Speed 27 Undercurrent 28 Overcurrent 29 Disabled 30 Future use Detects end of voltage ramp This function only can be assigned to relay 2r DC Brake control command This function only can be assigned to relay 3r Detects unit Fault status Detects Undervoltage according limit adjusted in function UV Detects Overvoltage according limit adjusted in function OV Detects unit RUN status Detects slow speed
40. nnnnnnnnnn nn 1 1 1 2 Advantages of the ASTAT Plus Solid State Soft Starters nen 1 2 Section 2 Types and Ratings eieiei kin 2 1 2 1 IEC ratings 2 2 Ub ut TE 2 2 2 3 Thermal characteristics sense 2 2 Section 3 Technical Specifications sens 3 1 3 1 General Specifications iii 3 1 3 2 W O Terminal Board Specification su 3 2 3 31 VO MWINING Secure tiie ante Aen ieee aces eee lien tite e ees 3 3 3 4 Operating ET 3 4 Section 4 Program mind us EEN sieneueed veteeseecestone 4 1 4 1 Keypad and display description 4 1 4 2 Parameter configuration sise 4 2 4 3 Monitor block parameters ss 4 4 4 4 Calibration block parameters iii 4 5 4 5 Basicblockparameters nn ee en ee nenn 4 6 4 6 Advanced block parameters nn 4 7 Section 5 Installation 4 EES 5 1 5 1 Equipmentinstallation iii 5 1 5 2 Fuses contactors and supply wiring 0 0 2 ee eeeeeeceee sence ee eeeeeaeeeeeeeesaaeeeeseseaaaeeeeeeeeaeeeeeeseaaees 5 2 E STAM Di EEN 5 3 5 4 Troublesh dting rn ee ee dee tiens ENEE 5 3 EI SNE e le 5 4 Section 6 Appendia a aeaea NEE 6 1 6 1 Application Diagrams sise 6 1 6 2 Serial Communications sise 6 4 6 3 DIMENSIONS tn im leur Wheeden eee Mn Es cena Peat eee 6 7 6 4 PCB s Layouts ini ici ihre atleast diate nanan dee 6 8 1 Generalities 1 1 Comparison of starting systems There are numerous applications where soft starting and limited current peak are needed and thereby making direct starting of squirrel
41. on zxxx and external contactor DC2 Details given bel low By pass control Programming steps 1 The by pass function may be enabled by 2 En SCH sl Start Stop LL Permanent By pass 5 Motor Thermistor Command 2 setting zxxx to ON In this case the by pass is automatically done after starting As alternative if zxxx is set to one of the programmable inputs 13 or 14 the by pass may be controlled by one remote signal 5 Check section 4 5 2 for more 6 1 details 2 Once this function is enabled the relay 2r is automatically assigned to this function check section 4 6 3 This relay must be used to control the by pass contactor 6 Appendix 6 1 Application diagrams Basic diagram with jog slow speed function Control Voltage 110 120V AC Control Voltage A1A2 B1 B2 Control Voltage A D I 220 240V AC 1 7 11 14 123 24 33 34 SGITD RD Start Stop Jog Fw Rv Push Button 2 Slow Speed 5 A1A2 B1 B2 1r 2r 3r Programmable relay Outputs Programmable Inputs i3 a H 1 57 2157 357 4 57 5 6 7 819 FT1 7 i 7 A A Motor Thermistor REMARK
42. ording ratings specified in page 3 2 of this manual 4 The ASTAT Plus is performed with an electronic motor overload protection which may be enough in the most of the applications You should use an external overload protection if required by local rules or to protect the motor against current unbalance Basic diagram with By Pass control REMARKS Control Voltage 110 120V AC 1 The line contactor DC1 is not required to perform operation to the motor Be aware however that DC1 provides gal vanic isolation from the mains increasing the safety 2 In this example Start and Stop command is effected by permanentcommand Push Control Voltage A1 A2 B1 B2 Control Voltage LU Lu 220 240V AC _ nel DC2 TE 11 14 23 24 33 34 SG A1A2 B1B2 Ar 2r 3r Programmable relay Outputs Programmable Inputs 3 13 14 157 2 57 3 57 4 57 516 7 8 buttons controlis allowed as well wiring 1 2 and 57 terminals as shown in page 3 3 3 The output relays allow for direct action on contactors according ratings specified in page 3 2 of this manual 4 CAUTION In by pass mode an external overload re DC2 lay protection must be used 5 By pass control using functi
43. ors e0xx Fault 1 Latest fault xx Fault code error e1xx Fault 2 e2xx Fault 3 e3xx Fault 4 Kxxx Password K000 000 999 69 allows E2PROM writing operation 10 key lock enabled 20 Key lock disabled Wx x x E2PROM writting WOFF ON OFF Saves the unit current parameters to the E2PROM This rewrites the last values saved Gx x x Parameter display GBAS CAL BAS ADV CAL Displays Calibration Parameters selection ALL BAS Displays Basic Parameters ADV Displays Advanced Parameters ALL Displays All parameters Note The Monitor block parameters are always displayed 4 4 4 Programming 4 4 Calibration block Parameteres CAL Display Function Default Range Unit Description Ux x x Line Voltage setting U4 0 0 100 500 V Line Voltage from 100 to 500V Set Rated Value t x x x Voltage Calibration t 400 000 600 V Setting of this parameter allows better accuracy in moni toring or voltage protections Check the current calibra tion procedure UF X Unit Frame UF 0 F G H 1 J K L Unit frame rating F G H X M N Q R X Setting 0 disables calibration mx xx Current Calibration m 0 0 0 000 1000 A Setting of this parameter allows better accuracy in moni toring or current protections Check the current calibra tion procedure N x x x Motor Rated Current N10 0 040 120 100 x motor unit ratio When this parameter is adjusted at a value higher than 105
44. output relays allow for direct action on contactors according ratings specified in page 3 2 of this manual 4 The ASTAT Plus is performed with an electronic motor overload protection which may be enough in the most of the applications You should use an external overload protection if re quired by local rules or to protect the motor against current imbalance 5 Linearramp provided by Dxxx function Atacho genera tor must be used as feedback Details given bellow Linear ramp function Programming steps 1 The linear ramp function may be enabled by setting Dxxx to ON In this case linear ramp independent of a wide load range is allowed This function needs the speed feedback provided by an external tacho generator Check section 4 6 2 for more details 6 3 6 Appendix 6 2 Serial communication The ASTAT Plus has the possibility to communicate with a host via a standard RS232C Through this serial communication the ASTAT can be started stopped programmed and checked Request from the host to the ASTAT and response from the ASTAT to the host are a series of bytes in ASCII code sequentially transmitted 6 2 1 RS 232 connection COMPUTER ASTAT Plus RS 232 connector 6 2 2 Data transmission format Towrite data into a parameter the format commandis the following Request from host Wxxxyyy Response fromthe ASTAT Wxxxyyy where xxx 3 bytes needed is the parameter number an
45. s are displayed Searching and Setting Parameters L The ASTAT Plus displays the parameters sequentially while maintain pressed the parameter G is displayed civ Monitoring Parameters Calibration Parameters Basic Parameters Advanced Parameters RS key and pushing repeteadly or keys Proceed in this way untill t There is a quick way to search automatically the parameter G by pressing LI and displayed GIN LI Keys Gxxx will be shown whichever is the actual parameter or Once the parameter G is displayed choose the value desired by pressing P LI Keys The display will sequence GBAS GCAL GADV and 1 GALL values repeatedly The actual value displayed can be stored in a temporal memory buffer by pressing LJ key Values stored in the temporal memory are lost after switch off unless these are saved in the permanent E2PROM memory through parameter W Additional indications are given in page 4 4 The above is an example given for parameter G but all ASTAT Plus parameters can be modified from its default factory value proceeding in similar way Parameter layout Monitor parameters Shown automatically ON STOP LOCK PULS Motor Current Software Version Line Voltage Line Power Elapsed time Fault history Buffer 0 e1 e2 e
46. se blown on power supply PCB Check and change Bad connection of flat wire joining power Verify connectors supply PCB to control PCB Equipment does not respond to F2 fuse blown on power supply PCB Check and change STOP START controls Frequency error admits 45Hz lt f main lt 65Hz No 1L1 phase or frequence is out of range Check 1L1 phase and or mains frequence Overload trip Excesive load or excesive current during starting Verify overload conditions during startingtime and steady state Check settings in parameters Nxxx Lxxx and oxxx 5 3 5 Installation Symptom or Error Possible Cause Measures to be taken Synchronism loss Phase 1L1 lost Check 1L1 phase Phase U V W thyristor Shortcircuited thyristor Check thyristor module No output phases Check 2T1 4T2 and 6T3 phases Heatsink thermostat Heatsink thermostat tripped by overheating or defective Check thermostat and wiring Motor thermistor Motor thermistor tripped by overheating or defective Check thermistor and wiring Phase U V W loss No input output phases Check power wire harness for 1L1 3L2 5L3 271 412 and 6T3 Defective thyristor or bad wire harness Verify gate and cathode wire harness Verify thyristors Stalled rotor Equipment detected stalled motor rotor Restart equipment and check for an appreciable loss in motor speed at any time i
47. status Detects Undercurrent according limit adjusted in function UC Detects Overcurrent limits as adjusted in function OC Disables the relay function 4 8 5 Installation 5 1 Equipment installation CAUTION DISCONNECT POWER BEFORE INSTALLING OR SERVICING ONLY SPECIALIZED PERSONNEL SHOULD INSTALL THE EQUIPMENT AND ONLY AFTER HAVING READ THIS USER S GUIDE THE USER ITSELF IS RESPONSIBLE FOR ANY PHYSICAL INJURY OR MATERIAL DAMAGE RESULTING FROM MISHANDLING THE EQUIPMENT IF YOU HAVE ANY DOUBTS ABOUT ANY PROCEDURE PLEASE CONTACT YOUR DEALER Remarks Supply wire conductors should have the same section as direct starters As 3 xRxLxin R conductor resistance mQ m an indication Vd voltage drop in wires should not be more than 2 Vd 1000 L conductor length m In motor rated current A Conductor section mm 2 5 4 6 10 16 25 35 50 100 150 Resistance R Cu 20 C mQ m 7 5 4 55 3 05 1 85 1 13 0 725 0 528 0 254 0 183 0 122 Resistance R Al 20 C mQ m 1 86 1 188 0 868 0 416 0 3 0 2 Signal wiring should be no longer than 50cm and should be separate from power Relays and contactors located in the same housing as the equipment should wires line motor command relays etc by at least 10cm and if they cross they have an RC suppressor parallel to the coil or a reverse diode if controled by DC should do so at a 90 angle 10 c
48. tarter 1 Increase in productivity and reliability with the use of static soft starters Starting and stopping the motor without steps or transitions lengthens the life of power driven machine mechanical elements greatly reducing stress on trans mission and coupling parts Consequently overhauling times are reduced and machine and facility lifespans are lengthened 2 Improvement in acceleration deceleration characteristics Being able to start by using the voltage ramp or alternatively by limiting current lets acceleration fit the load characteristics Application of a pulse start may also be selected in cases of high static friction load Braking may be made by cutting off power or by stop ramp and itis also possible to brake more energetically by feeding a DC current to the motor stator so there are many ways to obtain the best possible deceleration 3 Protected motor The soft starter protects the motor from overloads as well as from incorrect operating conditions such as loss of an input or output phase blocked rotor thyristor short circuit etc 4 Digital technology The control system is based on the use of a highly specialized microcontroller by which signals are treated digitally thereby avoiding deratings and adjustments common to analogue circuits and obtaining excellent precision and speed of execution The control board is made with the technology of surface mount
49. torque attainable using the soft system is 90 of that which direct starting tends to Bearing in mind that the direct starting torque varies between 1 5 and 2 4 times rated torque it can be deduced that with the soft starter starting torques which are somewhat higher than rated are obtained This area includes the starting of pumps fans conveyor belts etc where a torque in the region of 60 of rated is usually sufficient for correct starting As a general rule it can be guaranteed that soft starter will allow starting of drives which are currently used in conventional starting systems with the advantages outlined and above all the facility to adjust the current peaks and torque at the machine faced with the impossibility or difficulty of varying the steps in conventional systems SOFT STARTER Autotransfo Direct of direct start current in the line 30 40 or 64 Stator Part resistance winding Star delta motor Depending on adjust max 90 of direct start torque 30 40 or 64 Depending on adjust max 90 Starting steps 1 4 30r2 Continuous no steps Connections to motor 3 3 3 Line overload 1 5 2 1or3 2 In 3 3 5 In Depending on adjust approx max 4 7 In Change or NO NO NO starting pause 1 Steps mean sharp changes of speed during the time from rest until rated speed is reached 1 Generalities 1 2 Advantages of the ASTAT Plus Solid State Soft s
50. wer factor R 00 99 039 U Nominal voltage volt R W 100 500 040 V Line voltage volt R 041 w Power KW 10 R 6 Appendix 6 2 Serial communication Parameter Parameter Function Read Write Range Comments number name R W 042 X Local remote control 0 3 0 OFF 1 ON 2 13 3 14 043 D Linear ramp control R W 0 3 0 OFF 1 ON 2 13 3 14 044 J Slow speed control R W 0 2 0 OFF 1 13 2 14 045 j Slow speed type R W 0 1 0 HI 1 LO 046 2a Secondary acceleration ramp time sec R W 1 99 047 2d Secondary deceleration ramp time sec R W 1 99 048 A Dual ramp selection R W 0 3 0 OFF 1 ON 2 13 3 14 049 UF Unit frame R W 0 16 0 not defined 1 to 16 F to X frames 050 E Elapsed time hours R 052 Q Recall factory settings IW 1 053 2T Secondary starting torque DOL torque R W 10 90 056 z Bypass function R W 0 3 0 OFF 1 ON 2 13 3 14 058 f Service factor N R W 100 130 060 RUN STOP RUN STOP order IW 0 RUN 1 STOP 065 e0xx error e0 R xx error code 066 e1xx error e1 R xx error code 067 e2xx error e2 R xx error code 068 e3xx error e3 R xx error code 6 3 Dimensions 6 Appendix A B c QC_FDP 200 160 6 QC_GDP 200 160 6 QC_HDP 200 160 6 QC_IDP 250 200 31 219 10 T 175 300 19 5 180
51. ws the incorporation of the soft starter to a distributed control net in automated plant processes together with other soft starters programmable controllers variable speed drives etc 1 2 2 Types and ratings 2 1 IEC Ratings 1 HEAVY DUTY LIGHT DUTY Degree of Weight Cooled Current 220V 380V 440V 480V Current 220V 380V 440V 480V protection unit rating 2 240V 415V 500V rating 3 240V 415V 500V A WA KW KW 4 Wa A KM KW 5 KW 5 KW Kg 14 3 5 5 7 5 17 4 7 5 75 IP 00 QC1FDP 4 3 Natural 3 5 5 7 5 75 4 75 75 11 IP 00 QC2FDP 4 3 Natural 17 4 75 75 21 5 5 11 11 IP 00 QC1GDP 4 3 Natural 4 7 5 7 5 11 5 5 11 11 13 IP 00 QC2GDP 4 3 Natural 22 5 5 11 11 27 75 13 15 IP 00 QC1HDP 4 6 Natural 5 5 11 11 15 75 13 15 15 IP 00 QC2HDP 4 6 Natural 32 7 5 15 18 5 38 10 18 5 22 IP 00 QC1IDP 46 Natural 75 15 18 5 22 10 18 5 22 2 IP 00 QC2IDP 4 6 Natural 48 13 22 22 58 15 25 30 IP 00 QC1JDP 12 5 By fan 13 22 22 30 15 25 30 37 IP 00 QC2JDP 12 5 By fan 63 15 30 37 75 2 37 45 IP 00 QC1KDP 12 5 By fan 15 30 37 37 22 37 45 45 IP 00 QC2KDP 12 5 By fan 72 20 37 37 86 25 45 50 IP 00 QC1LDP 17 0 By fan 20 37 37 45 25 4 50 50 IP 00 QC2LDP 17 0 By fan 105 30 55 55 126 37 63 75 IP 00 QC1MDP 17 0 By fan 30 55 55 75 37 63 75 80 IP 00 QC2MDP 17 0 By fan 156 40 75 187 55 110 IP 00 QC1NDP 45

GE Astat Plus Soft start Manual

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