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ASTATplus - Gepowercontrols.com

1. a aaa ivetsexteenecsteeseticene A 5 Section 2 Types and Rn e TEE A 6 6 e 7 e DN Kee an lege tre A 8 Section 3 Technical specifications E A 9 3 1 General specifications 9 32 specifications UP REIR DURS REOR eee SE HONI 12 Egide mm A 13 Section 4 Te au Du ue E A 16 4 1 Keypad and display description A 16 4 2 Parameter blocks configuration EE A 17 4 3 Monitor block parameters EE A 19 4 4 Calibration block parameters CAL A 20 45 Basic block parameters BS EE 21 4 6 Advanced block parameters ADV EN A 23 5 EE E ooo A 26 5 1 Equipment installation RR 26 5 2 Fuses contactors and supply wiring EE 27 SEE eg gt EE 28 OF 29 e Er e eg ent A 20 CONS APPENA E A 31 6 1 Application diagrams EE A 31 62 COIN MONG S DNO TUR A 34 MTS SIONS 42 m mt 43 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 cage motors impossible Traditionally in such cases other types of star
2. Start Stop Push button command 2 thermistor Basic diagram with By Pass control Control Voltage 110 120V AC Control SC 220 240V 12 11 23124 3334 bi 1r 2r 3r Programmable relay Outputs Programmable Inputs 3 I3 l4 s s T7 s 9 o gt 1 i L j TU 513 FLT Tot Start Stop 2 d permanent EE Programmable Motor Input thermistor By pass control Programming steps FLT 4 ASTATplus Remarks 1 The isolation contactor DC1 is not required to perform operation to the motor Be aware however that DC1 provides galvanic isolation from the incoming line increasing the safety 2 In this example Start and Stop command is enabled by push buttons Permanent command is allowed as well wiring 1 2 and 57 terminals as shown on page A12 3 The output relays allow for direct action on contactors according ratings specified on page A11 of this manual 4 The ASTATplus is provided with an electronic motor overload protection which should be adequate protection for most of the applications You should use an external overload protection if required by local codes or to protect the motor against current unbalance Remarks 1 The isolation contactor DC1 is not required to perform operation to the motor Be aware however that DC1 provides galvanic isolation from the incoming line
3. ASTATplus Sets time between consecutive starts Setting 0 disables this function Loads the parameters from the E2PROM to the temporal buffer Loads default factory settings to the temporal buffer Allows up to four tries of automatic restart after a fault Setting 0 disables this function Time between retries The unit trips if the line voltage decreases be low the percentage set Setting 0 disables this protection Note Calibrate parameter U before ena bling this protection Delay trip time The unit trips if the line voltage increases above the percentage set Setting O disables this protection Note Calibrate parameter U before ena bling this protection Delay trip time The unit trips if the current decreases below the percentage set Setting O disables this protection Note Calibrate parameter U before ena bling this protection Delay trip time The unit trips if the current increases above the percentage set Setting O disables this pro tection Note Calibrate parameter U before ena bling this protection Delay trip time These are a secondary set of ramp up ramp down and starting torque parameters which take over the primary d and when the programmable function A is enabled 4 6 2 Programmable advanced functions Dx x x Linear Ramp Slow Speed Speed changeover Revers
4. Ot 20 25 30 35 40 45 50 55 60 65 70 Ir In Thermal memory If the control voltage is not removed the unit has a cool down characteristic being the cool down time 300 sec after the overload trip If the control voltage is removed after tripping you must wait at least 2 minutes before the unit can be restarted Operations per hour Supposing a cycle T with starting time of t1 running time of T 2t1 at rated current and OFF time of sec at least the ASTATplus allows the following operations per hour Starting Operations Hour Operations Hour current Starting time ti 10sec Starting time t1 20 sec 2 x Ir 180 90 3 x Ir 160 60 10 15 20 25 30 35 40 45 50 55 60 65 70 4 x Ir 30 10 Ir In ASTATplus 3 Technical specifications 3 1 General specifications Voltage ratings 3ph AC systems Up to 440V 10 15 for QC1xDP ASTATplus series Up to 500V 10 15 for QC2xDP ASTATplus series Freq range 50 60 Hz Control range of 45 65 Hz Control Digital system with microcontroller specifications Starting ramp with progressive increase in voltage and current limitation Initial voltage pedestal 96 30 95 Un Starting torque 10 90 Ma irect start 95 Un 9096 Mairect start adjustable to 999 ms Motor current Im 0 4 to 1 2 Ir rated ASTAT current Current limitation 1 to 7 In Acceleration ramp time 1 to 99 s types standard or linear ramp up Energy savings Ou
5. 09 09 QS _VDP Notes GE Power Controls GE Power Controls GE Power Controls France Hornhouse Lane 7 rue Nicolas Robert Knowsley Business Park 32 2 1 La Garenne Liverpool L33 7YQ F 93601 Aulnay sous Bois United Kingdom GE Power Controls Nederland GE Power Controls Belgium Maanlander 45 Axxes Business Park NL 3824 MN Amersfoort Guldensporenpark 30 Postbus 127 aS B 9820 Merelbeke Gent NL 3800 AC Amersfoort EE GE Power Controls Germany GE Power Controls 3 Ernst Weyden StraBe 7 Export Department D 51105 K ln Guldensporenpark 30 SE B 9820 Merelbeke Gent 26 Belgium
6. M r Serial Comm 1 5 RS232C 8182 bg Gr Tx Rx Control Voltage 220 240V AC MEM Se 1r 2r 3r Programmable relay Outputs 3 Programmable Inputs 2 Start Stop permanent Command 4 7 m 1187 CIF on OO gt 25 5 5 5 5 5 Q Aa 2 ER Gg E lt TD 5 oc ri FE E O o di lt 2 lt I I i Li bd 4 Start Stop Command by push buttons 4 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 page A15 prior to using these inputs 3 The programmable relay outputs are assigned to the following functions as default Relay 10 RUN RUN status Relay 20 EOR End of Ramp Relay 3r DCBR DC Braking control 4 Important Use dry contacts only 3 4 Operating modes Starting and Stopping Initial ramp Initial voltage pedestal Kick start Acceleration ramp tramp Current limit Permanent state Stopping modes All selectable Starting by voltage ramp Override U Un Energy savings U Un OO OOOO ASTATplus 5 main frequency cycles 30 to 95 Un adjustable 95 Un Enabled by parameter Pxxx to ON Voltage ramp up from1 to 99s adjustable Dual ramp possibi
7. 170 37 48 QC2LDP 170 37 48 105 _ 525 QCiMDP 17 0 37 48 75 QC2MDP 170 3748 156 6 ____ INDE 45 0 99 20 QC2NDP __ 45 0 9920 240 1200 o s m QCiQDP 450 99 20 QC2QDP 450 99 20 315 1575 QCIRDP 55 0 121 25 DEE QC2RDP 550 121 25 370 1850 QCiSDP 550 121 25 QC2SDP 550 12125 500 2500 QCiTDP 80 0 176 36 630 3150 HE o O QCiUDP 1050 23147 105 0 231 47 850 4250 fo QCiVDP 120 0 264 54 700 QC2VDP 120 0 264 54 ASTATplus 2 3 Thermal characteristics The ASTATplus allows motor protection according IEC Class 10 or Class 20 and Nema 10 20 or 30 free selectable by parameter overload IEC Class 10 IEC Class 20 e H et J 1 10 15 20 25 30 35 40 45 50 55 60 65 70 10 Sec 10000 EE ut Lut LA I L CL al IL 10 15 20 25 30 35 40 45 50 55 60 65 70
8. 100m from 1000m Do not install equipment in environments containing explosive or flammable gases or near important heat sources Equipment should be well ventilated with minimum keeping clearances as indicated in the illustration When equipment is to be mounted on a platform subject to strong vibrations there should be an elastic base to protect the equipment zs a s we e s conductor resistance mQ m L conductor length m In motor rated current A V3 xRxLxln 1000 1 86 11 188 0 868 10 416 0 3 0 2 Relays and contactors located in the same housing as the equipment should have an RC suppressor parallel to the coil or a reverse diode if controled by DC AC DC If the equipment is fed by a line transformer its rated power should be at least 1 5 times but less than 10 times higher than equipment supply 63 ASTATplus 5 2 Fuses contactors and supply wiring IEC Class 10 ratings Cat No Total losses Fuses Fuses Control voltage Contactor Contactor Conductor Jean Muller BUSSMANN type DC 1 100 In type Typower Sucu 660V Fuse Consumpt W Size In A VA mm FDP 17 67 25 S00C Uf01 40A 690V_ 00 40 1 18 CLO2 CLO2 4 21 78 32 S00C Uf01 50A 690V_ 00 50 1 18 CLO3 CL03 4 QC _ 27 88 40 S00C Uf01 80A 690V_ 00 80 1 18 CLO4 CLO3 6 QC DP 38 116 63 S1 f01 110 1004 690V 00 100 1 18 CL45 CLO4 1
9. 55 where is a char to indicate the command start ss is the station address xxx 3 bytes needed is the parameter number and yyyyy chars response is the value of the parameter The lt 1 is the return key to indicate the command stop Examples If we are trying to communicate with station 2 to start the unit the command will be 02W060000 lt to stop the unit the command will be 02W060001 lt to set the acceleration ramp time to 35sec the command will be 02W005035 lt to know which overload curve is selected the command will be 02R016 lt if for instance the response is 02R01600004 lt this means that the overload curve selected is IEC class 10 The table shown in 6 2 5 provides a complete reference for the parameters that can be controlled by the serial interface 6 2 3 MODBUS RTU Protocol Modbus RTU is an standard communication protocol It is completely predefined so any Modbus RTU master device will be able to send and receive data from ASTATplus To select this communications protocol XP must be set to 1 The communication begins with a master request which is answered by the slave ASTATPlus Each message from master to slave and viceversa is transmitted asynchronously as follows Quiet time Slave address Data field Quiet time It is required to give different address to each slave A Modbus master is able to handle up to 248 different
10. Data field as a read command the data requested is the starting address and the quantity to read As this is also a write command the data requested is the number of parameters to be written number of chars starting address and the value to write Quiet time Slave address Data field Quiet time starting address to read of parameters to read 3 5 chars slave 17 starting address to write 2 chars 3 5 chars of parameters to write of chars to write values to write ASTATplus The response from the ASTATplus will contain the same slave address and function code but the data field will include the total number of chars read and the value of the requested parameters Quiet time Slave address Data field Quiet time of chars 3 5 chars slave 17 parameters read 2 chars 3 5 Chars Examples Supposing we are trying to communicate with slave 17 note that 17 is 11h read parameters 3 4 5 and 6 Quiet time Slave address Data field Quiet time 0003 3 5 chars 11 03 0004 2 chars 3 5 chars To read values 1 2 and 3 in parameters 9 10 and 11 Quiet time Slave address Data field Quiet time i B i To execute the above 2 commands in one Quiet time Slave address Data field Quiet time ASTATplus 6 2 4 Profibus DeviceNet It is possible to connect ASTATplus to an industrial fieldbus Only a communications adapter is required It is also necessary to set XP to 2 2 di
11. Status code Equipment is connected to main supply equipment is Stop Remote stop Kick start Acceleration ramp Full conduction or Override Energy saving Soft stop Pump control DC braking Inching slow speed Linear ramp tacho function code to be displayed and or modified SEARCH ADJUSTMENT Increases the value of the selected parameter rn rn rn m m rn rn rn rn rn rn rn rn rn rn rmn rmn rm rm rm rm CO PO POP D D D D D sch sch sch sch sch sch sch sch D J C BR Error code Frequency out of range Overload trip Loss of synchronism Phase U scr Phase V scr Phase W scr Heatsink overtemperature Motor thermistor Phase U lost Phase V lost Phase W lost Stalled rotor Internal error Long start time Long slow speed time Lock out Undervoltage Overvoltage Undercurrent Overcurrent Retry attempts exceeded ASTATplus function code Motor current Software Version Power Factor Limit current Starting Torque Ramp up time Ramp down time Soft Stop selection Lock out These are examples Full details in sections 4 2 on page A17 4 3 on page A19 4 4 on page A20 4 5 on page A21 and 4 6 on page A23 SEARCH ADJUSTMENT Decreases the value of the selected parame ter ENTER SAVE Introduces the new parameter value into memory Updates the selected parameter value with the displayed va
12. the programmable relay output 3r is automatically assigned to this function PON or settings enable the DC Brake function just before starting the motor This is usefull to stop a fan which is rotating in reverse at the starting time Curve 0 both STOO SP00 Standard voltage ramp up starting and ramp down soft stop Curve 1 both ST01 01 Pump Algorithm based on estimated average PF power factor with large sampling period Curve 2 both STO2 02 Pump Algorithm based on instantaneous PF with short sampling period Curve both STO3 SP03 Pump Algorithm based on estimated average PF with short sampling period Curve 4 SP04 As Curve 3 but with high accuracy on PF average estimation Curve 5 SP05 Pump Algorithm based on former ASTAT CD 4 6 Advanced block parameters ADV 4 6 1 Advanced functions L K x x Rx x x N N N gt gt 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 Dual ramp up Dual ramp down Dual starting torque L KO 0 N N N NO 00 45 0 4 01 99 00 50 00 99 00 30 00 99 00 99 00 99 00 50 00 99 01 99 01 99 10 90 Sec sec sec sec sec
13. 1 2 Control Voltage de 220 240V 12 11 14 23 24 33 34 SGITDRD TU 312 513 2 8182 BCEE ele Outputs Programmable Inputs 8 13 4 21i aie 503 3 57 4 516 L e Motor Start Sto thermistor Push button D s 2 5 Linear ramp function Programming steps ASTATplus Remarks 1 The isolation contactor DC1 is not required to perform operation to the motor Be aware however that DC1 provides galvanic isolation from the incoming line increasing the safety In this example Start and Stop command is provided by push buttons Permanent command is allowed as well wiring 1 2 and 57 terminals as shown on page 12 The output relays allow for direct action on con tactors according ratings specified on page 11 of this manual The ASTATplus is provided with an electronic motor overload protection which should be ad equate protection for most of the applications You should use an external overload protection if required by local codes or to protect the motor against current unbalance Linear ramp provided by function A tacho generator must be used as feedback Details given bellow The linear ramp function may be enabled by setting Dxxx to ON In this case linear ramp is independent of the load This function needs the speed feedback provided by an external tacho generator Check s
14. Line voltage 0400 100 500 Line Voltage from 100 to 500V Set rated value setting t x x Voltage t 400 000 600 V Setting of this parameter allows better accuracy calibration in monitoring or voltage protections Check the voltage calibration procedure 1 x frame 0 G H J L Unit frame rating F G H X a Setting 0 disables calibration m x x Current mO 0 0 000 1000 A Setting of this parameter allows better accuracy calibration in monitoring or current protections Check the current calibration procedure 2 N x x Motor rated N 1 0 0 040 120 100 x motor unit ratio current When this parameter is adjusted at a value higher than 105 the overload protection curve is automatically adjusted to Class 10 C1 or to Nema 20 N2 x x x Overload C 1 Selects either the following overload curves protection N1 N2 OFF Overload protection disabled C1 C2 external overload relay must be used N1 10 20 30 C1 Class 10 C2 Class 20 f x x x Service factor f 100 100 130 Allows motor service factor Applicable for Nema ratings 1 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
15. addresses but as address 0 is reserved for broadcast command only 247 slaves are allowed The CRC is an error detection code Although Modbus protocol defines up to 24 different functions only 3 of them will be useful to ASTATplus Read Write Read Write ASTATplus Read parameters from ASTATplus The function code assigned to Read is 3 3h The request message from master must contain the following information Slave address the master must indicate which slave has been selected The non addressed slaves will receive the message but will not execute the command Only the slave with the corresponding address will send a response message Function code as related above Read command is number 3 Data field as this is a read command the data requested is the number of parameters to be read and the starting address to begin to read Quiet time Slave address Data field Quiet time starting address 3 5 Chars slave 3 of parameters 2 chars 3 5 chars The response from the ASTATplus will contain the same slave address and function code but the data field will include the total number of chars read and the value of the requested parameters Quiet time Slave address Data field Quiet time of chars read 3 5 Chars slave 3 parameters value 2 chars 3 5 chars Write Parameters to ASTATplus The function code assigned to Write is 16 10h The request message from master must contain the fo
16. 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 Error CPU 60 ms Memory 4 former errors Long start time 2 5 x ta ta acceleration ramp time Long slow speed time 120s ASTATplus Environmental Temperature to 55 derate output current by 1 5 C above 40 C conditions 95 without condensation 3000 m derate output current by 1 100m above 1000m Standards CE Conforming IEC 947 4 2 UL cUL conforming to UL508 Conducted amp Conforming IEC 947 4 2 Class A Radiated emissions Electrostatic discharges Conforming to IEC 1000 4 2 level 3 Radioelectric interference Conforming to IEC 1000 4 6 level 3 and to IEC 1000 4 3 level 3 Immunity to fast trasients Conforming to IEC 1000 4 4 level 3 Immunity to Surge Voltage Conforming to IEC 1000 4 5 level 3 3 2 1 0 terminal board specifications Power I O terminals Terminal Description 121 92 5163 3ph input voltage according ASTATplus type 211 412 613 Motor output Output terminals to 3ph AC motor A1 A2 B1 B2 Input Control 110 120V AC 10 15 220 240V AC 10 15 Voltage Digital inputs Terminal Description 57 Common for digital This is common terminal for the digital input terminals specified below inputs 1 Run Run order Command signal ma
17. feedback Slow speed Basic diagram Slow speed Full diagram TERMINALS Closed 4 57 Open Closed 1 57 Open Closed 2 57 Open ASTATplus Programmable inputs and functions The ASTATplus functions like Soft stop kick start and etc can be enabled or disabled by setting ON or OFF in their dedicated parameters using the facilities provided by the keypad Most of these functions can be enabled or disabled remotely as well through the programmable inputs 13 14 terminals board 3 57 and 4 57 Function Parameter Soft Stop gt S x x x Set Value lt Remarks gt ik ee i The function is permanently disabled See i ON The function is permanently enabled 2 j nos Gem i i i _ 3 The status of the function depends on ASTAT s 13 input i i _ 4 The status of the function depends on ASTAT s 14 input Dual motor x x Remote Control gt X x x x Note One programmable input may enable or disable more than one function More than one function can be enabled in the ASTATplus either by the keypad or through the programmable inputs 13 and 14 but there are some functions which may not work as expected during stopping when are simultaneously enabled The priority when two or more of the below functions are simultaneously enabled is defined in the following table Condition Acti
18. voltmeter 2 Search the parameter txxx set the voltage measured and save this value by the LI key lt It is not necessary to rewrite the E2PROM to make permanent the new setting the ASTATplus does 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 from the actual voltage value 2 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 F G H etc 2 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 ASTATplus do this automatically Note Setreal current measured while motor is running DO NOT enter motor nameplate current rating 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 from the actual
19. 0 JDP 58 208 80 1001 110 125 690 00 125 2 55 CL07 CL45 16 QC 75 277 100 S1 f01 110 160A 660V 00 160 2 55 CL08 CL06 25 QC 86 302 125 S10f01 110 200A 690V 00 200 2 55 CL09 CL06 35 QC 126 389 200 1001 110 250 690 00 250 2 55 75 CLO7 50 QC 187 719 250 M2 f02 315A 690V 00 315 2 78 CK08 CL10 95 QC 288 1097 400 M3 f02 500A 690V 2 550 2 78 CK95 CK85 185 378 1286 500 S8Uf02 110 630A 690V 2 630 4 118 CK10 CK85 240 QC _ SDP 444 1374 630 S3 f02 110 8004 690V 2 800 4 118 CK11 CK95 Busbar 2 QC 570 2086 800 S3 f02 110 10004 690V 1000 4 118 12 10 Busbar 2 QC 732 2352 1000 S3Uf02 110 1250A 690V 3 1250 4 248 CK12 CK10 Busbar 2 _ V DP 1020 3000 1250 S3Uf02 110 800A 690V 4 248 CK13 CK11 Busbar 2 _ 1290 3839 2x800 S3 f02 110 10004 690V 8 4 248 CK13 CK12 Busbar 2 IEC Class 20 ratings QC 14 56 20 S00C Uf01 40A 690V_ 00 40 1 18 CLO1 CLO1 4 QC 17 65 25 S00C f01 50A 690V 00 50 1 18 CLO2 CLO2 4 QC _H DP 22 74 32 S00C f01 80A 690V 00 80 1 18 CLO3 CL03 4 _1 DP 32 99 63 S1 f01 110 100A 690V 00 100 1 18 CL04 CL04 6 QC JDP 48 178 80 S1 f01 110 125A 690V 00 125 2 55 CLO6 CLO4 10 QC KDP 63 236 80 S1 f01 110 160A 660V 00 160 2 55 CLO7 CLO4 16 QC _ L DP 72 257 100 S1 f01 110 200A 690V 00 200 2 55 CL08 CL06 25 QC _ 105 325 160 S1
20. 70 55 0 121 3 32 315 QC2SDP 55 0 121 3 475 150 T 570 QCITDP 800 1764 QC2TDP 800 1764 610 732 220 400 e actube 1050 231 5 200 315 400 QC2UDP 105 0 231 5 850 1020 300 560 600 QCIVDP 1200 2645 250 450 530 600 QC2VDP 120 0 264 5 1075 1290 1500 330 7 355 600 670 750 QC2XDP 150 0 330 7 1 Ratings in Amps given for ambient temperature to 40 C 1000 altitude 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 and o accordingly 5 Maximum recommended Motor Power for IEC Class 10 protection Set ASTAT s parameters N and o accordingly ASTATplus 2 2 UL ratings Current Max HEAVY DUTY STANDARD DUTY Type Weight rating starting 200V 230V 460V 200V 230V 460V current A _ Im mm P H H Im Ls Cooling with convection IP00 14 43 948 QC2FDP 43 948 17 38 8 3 43 948 QC2GDP 43 9 48 22 46 10 14 E 8 QC2HDP 46 10 14 34 170 QCilDP 46 10414 QC2IDP 4 6 10 14 Cooling with fan IPOO 48 MEI ex 1 12 5 27 56 CE QC2JDP 12 5 27 56 63 5 290 o 20 12 5 2756 QC2KDP 125 27 56 72 360 QCiLDP
21. AKE Common for all relay output contacts Maximum usage voltage 380VAC B300 UL Thermal current 8A AC 15 use 220V 3A 380V 1A DC 15 use 30V max 3 5A Analog input common TG feedback input Current Output Motor thermistor terminals Description Terminal 5 6 Communications Terminal SG TD RD Motor thermistor input This is a common terminal for the analog input terminal number 7 0 5 analog input for speed feedback It should be provided by a DC tacho gen erator coupled to the motor This speed feedback signal is required when the linear ramp function is used 0 10V DC analog Output for current measurement purpose Ir correspond to 2V DC Load Impedance 10KQ or higher This input allows a motor thermistor with a response value from 2 8 to 3 2KQ and a reset value from 0 75 to 1KQ to control motor temperature When the motor thermistor is not used a link must be used in terminals 5 6 Gr Tx Rx data RS232C 3 wires half duplex Maximum cable length 3mts 10 feet Asynchronous data transmission 9600 Bauds 1 bit start 8 bits data 2 bits stop No parity ASCII and ModBus RTU protocols selectable from keypad as standard Check appendix 6 2 Profibus DP and DeviceNet by external optional accessory ASTATplus 3 3 wiring ASTATplus s terminal layout and wiring configuration is shown in the diagram of bellow L1 2 L3 Control Voltage u 1 110 120V AC Sg d
22. GE Power Controls AS TAT plus t Ed 02 nthe ne able 9 m 150 d ww Softstarter User s guide D marreur progressif Manuel d utilisation Softstarter Gebruikershandboek Sanft Anlasser Benutzerhandbuch ASTAT Soft Starters USER S GUIDE ASTATplus MANUEL D UTILISATION ASTATplus GEBRUIKERSHANDBOEK ASTATplus BENUTZERHANDBUCH ASTATplus Notes Power Controls SOLID STATE SOFT STARTER ASTATplus USER S MANUAL Remarks Read this manual throughly before using the soft starter ASTATplus and store it in a safe place for reference Make sure that this manual is delivered to the end user CE marking When using ASTATplus in the EU compliance with EMC is required ASTATplus range comply with the generic EN 50081 2 and EN 50082 2 The policy of GE Power Controls is one of continuous improvement The right is reserved to alter the design or any structural details of the products at any time without giving notice ASTATplus WARNINGS Disconnect power before installing or servicing 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 Unit may contain more than one live circuit Disconnect both control and main circuits before installing or servicing Soft stop should not be used as an Emergency stop Stopping mode m
23. RDP 2 500 in parallel delivering not more than 65KA RMS _ SDP 2x600A in parallel symetrical amperes for 208V 240V and QC 2 1000 in parallel up to 480V maximum when used with UDP 2x1200A in parallel contactors isolation or by pass that QC V DP 2 1600 in parallel are also rated for 65KA withstand Note When ASTATplus reduced voltage starters are used in conjunction with semi conductor fuses type 2 co ordination to IEC 947 4 is attained These fuses are recommended for best overall short circuit protection The semiconductor fuse specified may provide branch circuit protection Refer to local applicable electrical codes ASTATplus 5 3 Start up Make sure equipment wiring If the motor has thermal protection sensor remove the link corresponds to one of the recommended between terminals 5 and 6 prior to wire the sensor routing diagrams or equivalent Make sure the control wire harness 110 120V ac 220 240V ac corresponds to the control voltage used k ECCE mjel eTe Adapt equipment rated current to motor In motor Factory setting setting the motor current In Ir unit x 100 N100 Set overload trip curve as needed xxx OFF disabled Factory setting external overload relay must be used C1 C2 IEC Class 10 or Class 20 o C1 N1 N2 N3 10 20 or 30 Set starting parameters as needed Factory setting Starting torque Xxx T _ 20 Accelerati
24. Uf01 110 250A 690V 00 250 2 55 CL10 CLO6 35 QC _ 156 591 200 M2 f02 315A 690V 00 315 2 78 CK75 CLO7 70 QC _ 240 901 315 M3 f02 500A 690V 2 550 2 78 CK85 CK75 120 QC _ RDP 315 1063 400 53002 110 630 690 2 630 4 118 CK95 CK85 185 QC 370 1136 500 S3 f02 110 8004 690V 2 800 4 118 CK10 CK85 240 QC 475 1721 630 S3 f02 110 10004 690V 1000 4 118 CK11 CK95 Busbar 2 QC _ 610 1950 800 S3 f02 110 12504 690V 1250 4 248 CK12 CK10 Busbar 2 QC _ 850 2491 1000 S3Uf02 110 800A 690V 4 248 CK13 CK10 Busbar 2 QC 1075 3168 1250 S3Uf02 1 10 1000A 690V e 4 248 CK13 CK12 Busbar 2 1 The 3 contacts of DC3 must be connected in parallel 2 As per IEC 9471 Branch circuit protection UL Gould Shawmut semi conductor fuses Short circuit rating max 480V Cat Nr Max Fuse Max circuit Non Type rating class breaker combi Combi size nation nation Remarks QC FDP 50A 3 Suitable for use on a circuit capable of QC _ G DP 60A delivering not more than 100KA RMS QC _ H DP 80A symetrical amperes for 208V 240V and _1 DP 100A up to 480V maximum when used with QC _JDP 150A the semi conductor fuse for short QC _ K DP 200A circuit protection Listed with Gould QC 225A Shawmut Form 101 Type A5QS or _ 350A _ 450A QC 600 4 Suitable for use on a circuit capable of QC _
25. ctions like linear accel eration ramp forward and reverse jog programmable or connection to a computer by serial communication RS 232 all included as standard These performances allows 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 ASTATplus 2 Types and powers 2 1 IEC ratings 1 HEAVY DUTY LIGHT DUTY Current 220V 380V 440V 480V Current 220V 380V 440V 480V rating 2 240V 415V 500V rating 3 240V 415V 500V kW kW 4 kW 5 kW 5 kW 5 kW 5 Cooling with natural convection IP20 14 55 p s Seren 43 9 48 QC2FDP 43 9 48 17 Se irme 43 9 48 a 55 11 11 13 0 2 43 948 22 5 5 11 11 7 5 T QC1HDP 46 10 14 55 11 11 15 QC2HDP 46 10 14 32 75 15 185 38 u 10 14 75 15 18 5 22 QC2IDP 6 10 14 Cooling with fan IP00 48 13 2 2 58 125 27 56 SS 2 QC2JDP 125 27 56 63 enr 12 5 27 56 TE A 22 37 45 45 QC2KDP 125 27 56 72 as as 5 lt 17 0 37 48 20 7 a 45 E QC2LDP 170 37 48 105 so 55 55 Jm 87 _ 63 75 QCIMDP 170 3748 Bo e e e m x QC2MDP 170 37 48 156 1450 99 20 110 132 2 45 0 99 20 240 288 QCiQDP 45 0 99 20 110 T 160 QC2QDP 450 99 20 315 20 160 200 378 QCIRDP 55 0 1213 QC2RDP _ 55 0 1213 3
26. ctual value displayed be stored in a temporal memory buffer by pressing L key Values stored the temporal memory lost upon control power loss unless these are saved the permanent E2PROM memory through parameter W Additional indications are given on page 4 4 The above is an example given for parameter G but all ASTATplus parameters can be modified from its default factory value proceeding in similar way Parameter layout Monitor parameters Shown automatically ON STOP LOCK PULS see page A 16 Motor Current Software Version CH lt GBAS GADV GALL GCAL Line Voltage Calibration parameters Line Power Factor RS L Line Power E Elapsed time e Fauit history Buffer 0 el e2 ei Password 1 W E2PROM writting Parameter Block Selector x x Lo Line Voltage 100 500 Voltage Calibration Unit frame ED H A Current Calibration m Motor rated current v 40 120 Overload Protection 0 1 2 N3 C1 C2 Service Factor 100 130 0 ASTATplus Basic parameters Current Limit Starting Torque Ramp up time Ramp down time Kick Start DC Brake time DC Brake current Soft Stop switch Pump Control switch Pump curve se
27. current value ASTATplus 4 5 Basic block parameters BAS 4 5 1 Basic functions L x x x Current limit L350 100 700 Sets Device current limit Sets motor current limit if parameter is properly adjusted The maximum range setting is automatically calculated by the unit according the following expression Max Limit 450 N max allowed is 700 N is the motor capacity unit capacity ratio adjusted in parameter Nxxx T X X Starting torque t 2 0 10 90 Sets the initial voltage applied to the motor a x Ramp up 2 0 01 99 sec Sets Voltage ramp up time Motor acceleration time will depend of load conditions d x x x Ramp downtime 4020 001 120 Sets Voltage ramp down time Motor decelera tion time will depend of load conditions Enabled only if the parameter Sxxx is ON x x x Kick start p 00 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 is ON b x x DC brake time b 0 0 00 99 Sec Provides DC braking at stopping time Enabled only if the parameter Bxxx is ON I DC brake 1050 050 250 current 4 5 2 Programmable basic functions ASTATplus S x x Soft stop selector S OF F OFF ON 13 14 Enables or disables all modes of Soft stop xx Pump control C OF F OFF 13 14 Enables the Pump control function Usefull to limit fluid
28. e Dual motor selector Remote control selector Communication protocol Station number DOFF J A OF F OFF 13 14 OFF 13 14 LO HI OFF ON 13 14 OFF ON 13 14 OFF ON 13 14 00 02 001 247 ASTATplus This function provides linear acceleration and deceleration ramps in a wider range of load conditions using tachogenerator feedback A DC Tacho Generator coupled to motor must be used to provide an analog signal feedback of 0 5VDC to terminals 7 and 8 This function enables slow speed operation Maximum operation time 1205 LO Low Speed 7 of rated speed HI High Speed 14 of rated speed Reverse dirention is allowed in High slow speed mode only It provides 20 of rated speed This function allows dual motor control settings of acceleration deceleration and starting torque and is useful to start or stop a motor in diferent load conditions When this function is enabled the parameters 2a 2d and 2T take over the parameters a d and T It allows dual motor control settings Allows serial communication control by SG TD and RD terminals Check Appendix section for more details Sets serialcommunications protocol 0 ASCII 1 Modbus RTU 2 External modules DeviceNet ProfibusDP ASCII protocol allows a maximum of 90 stations only ASTATplus 4 6 3 Programmable relay output functions 1r x x Output relay ir Tr 2 5 22 30 This is a programmable relay
29. ection 4 6 2 on page A 24 for more details ASTATplus 6 2 Serial communication ASTATplus is able to send and receive data trough a serial RS232 port Within this port ASTATplus communicates with a host which can be either with a PC PCL or an industrial fieldbus system to be started stopped programmed or checked Three different communication possibilities are available Connection to a PC PLC using ASCII protocol PC Windows communication software tool available Connection to a PC PLC using Modbus RTU protocol Connection to industrial fieldbus systems Profibus DP DeviceNet In this case it is necessary to use an external communications module ASTATplus communicates with this module using Modbus RTU protocol and the module acts as a gateway to the fieldbus system In order to select the disired procedure the user must change the value of the parameter XP Protocol XP setting ASCII 0 Modbus RTU 1 Profibus DeviceNet 2 6 2 1 RS232 port wiring and communication settings RS232 is an operating standard of communication only in terms of electrical characteristics voltage timing etc while the communication procedure are defined by different protocols Modbus ASCII Profibus DeviceNet etc The maximum allowed RS232 cable length is 3 meters ASTATplus uses a connector with only 3 pins TD RD SG Astat Terminal Name TD Transmit data Receive data SG Signal common The follo
30. esign 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 maintenance 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 ASTATplus Pump control The ASTATplus 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 nominal motor Initial tension 0 Acceleration 4 Fast increase of tension when motor reaches its nominal speed 2 Constant tension when motor current reaches its limit value 6 Soft stop non linear prevents water hammering in pump control 5 Nominal tension 3 Acceleration 9 Advanced functions The ASTATplus includes advanced fun
31. fferent modules are available Profibus DP and DeviceNet Profibus DP Cat Nr QCPPDP Reference Nr 129769 DeviceNet Cat Nr QCPDNT Reference Nr 129768 ASTATplus communicates with this module using Modbus protocol Modbus RTU Communications Fieldbus adapter system Profibus DP DeviceNet p max length 3m Note Detailed information of communication modules QCPPDP and QCPDNT is described in their specific manuals 63 ASTATplus 6 2 5 List of 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 P 002 003 004 005 Accelerationramptime sec __ DI 119 006 d Deceleration ramp time sec 11120 007 p Kickstarttime msec RA 099 008 b brake time sec 099 009 HET DC brake current 96 In 010 S Soft stop control R W 0 3 0 OFF 1 ON 2 13 3 011 Pump control R W 0 3 OFF 1 ON 2 13 3 14 012 Kick start control R W 0 3 OFF 1 ON 2 13 3 14 013 Override R W 0 3 1 2 3 14 014 DC brake control R W OFF 1 ON 2 13 3 14 4 5 6 015 Lockout 016 Overload
32. increasing the safety 2 In this example Start and Stop command is enabled by permanent command Push buttons control is allowed as well wiring 1 2 and 57 terminals as shown on page 12 3 The output relays allow for direct action on contactors according ratings specified on page 11 of this manual 4 CAUTION In by pass mode an external overload relay protection must be used 5 By pass control using function ZXxx and external contactor DC2 Details given bellow 1 The by pass function may be enabled by setting zxxx to ON In this case the by pass is automatically done after starting An alternative if zxxx is set to one of the programmable inputs I3 or 14 the by pass may be controlled by one remote signal 5 Check section 4 5 2 on page A22 for more details Once this function is enabled the relay 2r is automatically assigned to this function check section 4 6 3 on page A24 This relay must be used to control the by pass contactor Basic diagram with jog slow speed function Cntrol Voltage 110 120V AC 2 8182 Control Voltage 220 240V AC 1r 2r 3r Programmable relay Outputs Programmable Inputs 3 Start Stoo Forward Reverse Motor Push Button Jog thermistor command 2 Slow Speed 5 Jog Slow Speed function Programming steps ASTATplus Remarks 1 The isolation contactor DC1 is not required to perform operation to the
33. k settings in parameters Nxxx LXXX and Synchronism loss Ex13 Phase 1L1 lost Check 1L1 phase Phase U V W thyristor Ex14 Shortcircuited thyristor Check thyristor module Ex15 Ex16 No output phases Check 2T1 4T2 and 6T3 phases Heatsink thermostat Ex17 Heatsink thermostat tripped by Check thermostat and wiring overheating or defective Motor thermistor Ex18 Motor thermistor tripped by overheating Check thermistor and wiring or defective Phase U V W loss Ex19 No input output phases Check power wire harness for 1L1 3L2 Ex20 5L3 2T1 4T2 and 6T3 EE Defective thyristor or bad wire harness Verify gate and cathode wire harness Verify thyristors Stalled rotor Ex22 Equipment detected stalled motor rotor Restart equipment and check for an appreciable loss in motor speed at any time i e when the motor is loaded In this case try jumping the bypass terminals 3 57 at the end of acceleration ramp Internal error Ex23 Microcontroller malfunction Check IC1 and IC8 are correctly inserted in their sockets Long start time Ex25 Current limit condition present more than Increase current limit and or 2 x ta sec or 240 sec acceleration ramp time ta acceleration ramp time Long slow speed time Ex26 Equipment has been in slow speed Avoid this condition mode more than 120 sec Lock out Ex27 The time between startings is less that Check is settings are correct the adjusted in parameter LKxx Thi
34. lection starting Pump curve selection stopping Kick Start Switch Override Switch By pass Switch DC Brake Switch MEME Sec Sec Range 100 700 010 090 01 99 01 120 000 999 000 099 050 250 OFF ON 13 4 OFF ON 13 4 00 03 00 05 OFF ON 13 4 OFF ON 13 4 OFF ON 13 4 OFF ON 13 4 PON Advanced parameters lt OV lt O D 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 Comm Protocol selection Station number Output relay 1r Output relay 2r Output relay 3r MERECE Unit minutes n attempts sec sec sec Range 00 45 ON OFF ON OFF 000 004 001 099 00 50 00 99 00 30 00 99 00 99 00 99 00 50 00 99 01 99 01 99 10 90 ON OFF 13 4 OFF 13 4 LO HI OFF ON 13 4 OFF ON 13 4 OFF ON 13 4 00 02 001 247 22 30 20 22 30 21 22 30 4 3 Monitor block parameters Display ON Status ON STOP LOCK PULS RAMP FULL SAVE SOFT PUMP DCBK INCH Mo
35. lity Linear speed ramp by tacho feedback also possible Fast increase of output voltage when motor gets rated speed 1 to 7 In Rated voltage Override Rated current Energy savings Enabled by Fxxx to OFF Motor power cut off Sxxx to OFF Cxxx to OFF Deceleration ramp 1 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 by Sxxx to ON and Cxxx to ON Linear ramp down Tacho feedback needed Evolution of current in deceleration ramp mode DC brake 0 to 99s adjustable Enabled by Bxxx to ON Starting by current limitation Override Energy savings In ASTATplus Jog and linear ramp Linear acceleration and deceleration ramp Ramp time adjustable Selectable by parameter Dxxx to ON Low slow 7 and High slow 14 speeds Enabled by parameter Jxxx to ON and jxxx to LO or HI Reverse slow speed 20 Slow speed 7 or 14 Enabled by parameter Jxxx to ON and rxxx to ON Enabled by parameter Jxxx to ON Acceleration ramp Ramp time adjustable Soft stop deceleration ramp Slow speed 7 or 14 Ramp time adjustable Enabled by parameter Jxxx to ON 7 Current and time adjustables Enabled by parameter Bxxx to ON and bxx Ixxx adjustments Linear ramp with T G
36. llowing information Slave address the master must indicate which slave has been selected The non addressed slaves will receive the mes sage but will not execute the command Only the slave with the corresponding address will send a response message Function code as related above Write command is number 10h Data field as this is a write command the data requested is the number of parameters to be written number of chars starting address and the value to write Quiet time Slave address Data field Quiet time starting address 3 5 chars slave 10 of parameters 2 chars 3 5 chars of chars values to write The response from the ASTATplus will contain the same slave address and function code but the data field will include the total number of chars read and the value of the requested parameters Quiet time Slave address Data field Quiet time starting address 3 5 chars slave 10 of parameters 2 chars 3 5 chars Read Write parameters to ASTATplus The function code assigned to Read and Write is 23 17h The request message from master must contain information to perform both operations Slave address the master must indicate which slave has been selected The non addressed slaves will receive the mes sage but will not execute the command Only the slave with the corresponding address will send a response message Function code as related above write command is number 17h
37. lue 4 2 Parameters blocks configuration Mode selection Monitoring The ASTATplus includes a large number of parameters which are parameters divided in four blocks Monitor Calibration Basic and Advanced The parameters of each group can be displayed or skipped according the selection done in parameter G The monitor parameters are always displayed regardless of the mode selected Settings in parameter G 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 parameters are displayed Searching and setting parameters ASTATplus Calibration parameters Basic parameters Advanced parameters The ASTATplus displays the parameters sequentially while depresing the key and pushing repeteadly or LI keys Proceed in this way untill the parameter G is displayed CIV Y 1 There is a quick way to search automatically the parameter by pressing and Keys Gxxx will be shown on the display CIV lt Once the parameter G is displayed choose the value desired by pressing or Keys The display will sequence GBAS GCAL GADV and 4 GALL values repeatedly The a
38. mmable Inputs 3 Start Stop permanent Command thermistor DC brake function Programming steps 1 The DC function may be enabled by setting Bxxx to ON Remarks 1 The isolation contactor DC1 is not required to perform operation to the motor Be aware however that DC1 provides galvanic isolation from the incoming line increasing the safety 2 In this example Start and Stop command is enabled by permanent command Push buttons control is allowed as well wiring 1 2 and 57 terminals as shown on page A 12 3 The output relays allow for direct action on contactors according ratings specified on page A11 of this manual 4 The ASTATplus is provided with an electronic motor overload protection which should be adequate protection for most of the applications You should use an external overload protection if required by local codes or to protect the motor against current unbalance 5 DC brake at stopping time is provided by the DC brake function and external contactor DC3 CAUTION The 3 contacts of DC3 must be connected in parallel Mandatory between 2T1 and 4T2 phases otherwise a short circuit can occur 2 Once this function is enabled the relay 3r is automatically assigned to this function This relay must be used to control the DC brake contactor Check section 4 5 1 and 4 5 2 on A 21 and A 22 for more details Basic diagram with linear ramp Control Voltage 110 120V 2
39. motor Be aware however that DC1 provides galvanic isolation from the incoming line increasing the safety 2 In this example Start and Stop command is enabled by push buttons Permanent command is allowed as well wiring 1 2 and 57 terminals as shown on page 12 3 The output relays allow for direct action on contactors according ratings specified on page 11 of this manual 4 The ASTATplus is provided with an electronic motor overload protection which should be adequate protection for most of the applications You should use an external overload protection if required by local codes or to protect the motor against current unbalance 5 Slow Speed for Jog forward or reverse using programmable inputs 13 14 Details given bellow 1 The slow speed function may be enabled by setting Jxxx to I3 In this case Slow Speed is allowed by a push button wired to ASTATplus 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 on page A24 for more details 2 Slow Speed can be effected with ASTATplus in stop status Slow speed and normal run commands are internally interlocked Basic diagram with DC brake injection Control Voltage 110 120V AC 2 81 82 Control Voltage Z pc1 220 240V AC 3r Programmable relay Outputs Progra
40. nal starters ASTATplus Bearing in mind that the direct starting torque varies be tween 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 al 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 Part Star delta winding motor Direct Autotransfo Stator resistance 100 30 40 or 64 58 70 65 33 Depending on adjust max 90 30 40 or 64 33 49 48 33 Depending on adjust max 90 toe s k 1 of direct start current in the line of direct start torque Starting steps 1 Connections to motor Line overload approx Change or starting pause EE SOS no steps 1 5 or 2 1 or 3 2 In 3 3 5 In 3 25 In 1 65 adjust 4 7 gm 1 Steps means sharp changes of speed during the time from rest until rated speed is reached 1 2 Advantages of the ASTATplus 1 Increase in productivity and reliabili
41. on DC Brake B ON The Unit stops by Linear Ramp m A 7 2 n x b The unit stops by DC brake after the Soft Stop is completed Linear Ramp S D ON a The unit stops by Pump Control Soft Stop S ON b a Pump Control S C ON Programmahble relay outputs The ASTATplus includes three programmable relays 1r 2r and 3r dry contacts ASTAT terminals are 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 EOR Detects end of voltage ramp Only can be asigned to relay 2r 21 DC Brake DC Brake command Only can be assigned to relay 3r Relay N Parameter 22 Fault Detects ASTAT s fault status Relay 1r gt 1 r x x 23 Undervoltage Detects limit set in parameter UVxx 24 gt Overvoltage Detects limit set in parameter OVxx Relay 2r 1r xx 25 RUN Detects ASTAT s run status Hive ce gw 26 JOG Detects Jog slow speed status 27 gt Undercurrent Detects limit set in parameter UCxx 28 Overcurrent Detects limit set in parameter OCxx 29 Disables the relay function 30 Future use 4 Programming 4 1 Keypad and display description Keypad 2 Allows setting of parameters and functions SELECTION Use with T or J to select the parameter or Cc c O gt c OO gt
42. on ramp time _20 Im start 100 Kickstart P ON OFF I3 l4 P OFF In motor Kickstart time p x x x if P enabled P100 Current limit L x x X L300 Set braking parameters as needed Factory setting Soft stop S ON OFF 13 14 S OFF Deceleration ramp time 20 DC injection brake B ON OFF 13 14 B OFF DC braking time b _ if enabled D 5 DC braking current Ixxx if B enabled 1150 If you change the default configuration and _ wish to keep it remember to rewrite the Set parameter to ON ON 69 441 parameters in E2PROM as follows Set parameter W to ON Press lt 4 parameter W is set to OFF automatically Send run command to equipment and make sure that operation is correct ASTATplus 5 4 Troubleshooting Symptom or Error Possible Cause Measures to be taken Display OFF Equipment does not respond to STOP START controls Frequency error admits 45Hz lt f main lt 65Hz Overload trip No control voltage F1 fuse blown on power supply PCB Bad connection of flat wire joining power supply PCB to control PCB F2 fuse blown on power supply PCB No 1L1 phase or frequency is out of range Excessive load or excessive current during starting Check wire harness and control voltage Check and change page 6 8 Verify connectors Check and change page 6 8 Check 1L1 phase and or mains frequence Verify overload conditions during starting time and steady state Chec
43. plus Parameter Parameter Read Write Range Comments number name R W 060 RUN STOP RUN STOP order AN mE 0 RUN 1 STOP 061 NENNEN 062 063 064 065 066 HEN 067 068 sss 069 070 Pump Control selection curve R W 0 3 0 standard voltage ramp 1 3 Pump algorithms 071 Internal use 072 m 073 SP Pump Control selection curve R W 0 5 0 standard voltage ramp 1 5 Pump algorithms 074 NENNEN 075 076 aa 077 078 NENNEN 079 Ss 080 SS 081 082 KCK lt a s 083 Communication protocol R W 0 2 0 ASCII 1 Modbus RTU 2 others with external module 1 247 084 5 Station number for communication W 085 0 error 0 086 1 error 1 error code 087 2 error 2 088 e3xx error e3 error code XX error code DIDID 7 E x d lt 6 3 Dimensions Weight kg Weight kg WE S N or Al Weight kg ASTATplus m I l l L3 H gt px a Terminal D details Terminal details dis Control MAIN TRANS FORMER PULSE PULSE PULSE TRAFO TRAFO TRAFO Weight kg
44. s 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 RESPONSABLE 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 an indication Vd Vd voltage drop in wires should not be more than 2 Conductor section mm R Cu 20 C mQ m Al 20 C m Signal wiring should be no longer than 3mts up to 25mts when using screened cable and should be separate from power wires line motor command relays etc by at least 10cm and if they cross they should do so at a 90 angle 8 cm SIGNAL ee POWER INCORRECT CORRECT Do not install capacitors to correct the power factor between equipment output and motor 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 to 55 Relative humidity without condensation 9596 Maximum altitude 3000m Reduce rating by 1 596 from 40 and 196
45. s protection may be disabled Undervoltage Ex28 The line voltage exceeds of limit set in Check is settings are correct overvoltage Ex29 parameters UVxx OVxx This protection may be disabled Undercurrent Ex30 The motor current exceeds of limit set in Check is settings are correct overcurrent Ex31 parameters UCxx or This protection may be disabled Retry Ex32 The retry feature could not re start the Check last message e1xx and correct motor after a fault Be sure that retry settings are correct as well 5 5 Thyristor check Short circuit Use a testing lamp to check the defective power module between input and output phases If the lamp goes on at least one of the thyristors has a short circuit Check with a tester the value or the R resistance between input and output of the same phase connector B on main PCB must be previously removed If lt 50KQ at least one of the thyristor is defective 1L1 3L2 or 5L3 211 4 2 6T3 Open thyristor With the simple assembly shown the lamp should light when the S switch is closed and remain lite when open If not the thyristor is defective ASTATplus Testing lamp 6 Appendix 6 1 Application diagrams Basic diagram Control Voltage 110 120V A1 A2 1 2 Control Voltage 220 240V AC 312 513 Progr riimable relay Outputs Programmable Inputs 3 2 2 4T2 SE
46. selector hammering The parameter Sxxx must also be enabled NOTE Parameters b are disabled while C is ON S T xx Pump curve ST O0 O 00 03 Choice of various pump control algorithms for starting selection at phase starting phase 00 Voltage ramp up 01 03 Various pump algorithms SPxx Pumpcurve S 2 00 05 Choice of various pump control algorithms for stopping selection at phase stopping phase 00 Voltage ramp down 01 05 Various pump algorithms P x x x Kick start selector P OF F OFF 13 14 Enables or disables the Kick start function If Pump control function P is enabled both Kick start and DC Brake functions are internally disabled F x x Override selector F OFF 13 14 When this function is enabled the unit provides constant full voltage after starting producing the lowest harmonic distortion Note that the energy saving function is disabled when Override is enabled z x x x By pass selector z OF F OFF ON 13 14 This function provides control of an external by pass contactor significantly lowering heating losses and eliminating harmonics When the By Pass function z is enabled the programmable relay output 2r is automatically assigned to this function and must be used to control the external by pass contactor B x x x DC Brake selector BOF F OFF 13 14 Enables or disables the DC brake function PON When the DC Brake function is enabled
47. ting 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 reduced voltage starts produce a reduction in torque in squared proportion to the current in the phases of the motor not 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 to the adjusted parameters The avantage 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 torque attainable using the soft system is 90 of that which direct starting tends to Conventio
48. tor current 000 999 A 1 0 9 9 kA Software version Main Source voltage V Power factor 00 99 Line power kW Elapsed time S Hrs Error trace buffer eOxx e3xx Password K000 000 999 B E2PROM writing Parameter display GBA S CAL BAS selection ADV ALL EWEN ON ASTATplus Switch on time Equipment is connected to main supply Stop Remote control through serial port Kick start Acceleration ramp Full conduction Override full voltage Energy saving Soft stop Pump control DC braking Inching slow speed Linear ramp tacho feedback needed Displays motor current in Amps Current higher than 999A is displayed in kA If parameter UFxx is not calibrated the motor current is displayed in N xxx Version number Displays line voltage in volts Displays line power factor Displays line power Displays RUN time in hours x 1000 Saves the last four errors eOxx Fault 1 Latest fault e1xx Fault 2 e2xx Fault 3 e3xx Fault 4 xx Fault code error 69 allows E2PROM writing operation 10 Key lock enabled 20 Key lock disabled Saves the unit current parameters to the E2PROM This rewrites the last values saved CAL Displays calibration parameters BAS Displays basic parameters ADV Displays advanced parameters ALL Displays all parameters Note The monitor block parameters are always displayed 4 4 Calibration block parameters CAL ASTATplus Ux x x
49. tput voltage reduction according to power factor Override Fixed output voltage permanently equal to supply voltage Bypass Direct control of a bypass contactor Brake time by ramp 1 to 120s 1 to 99 in secondary ramp adjustable independently of starting ramp time types standard pump control or linear ramp down DC braking to 99 0 5 to 2 5in Slow speed Direct torque 796 or 1496 of nominal speed reverse torque 2096 of nominal speed 0 to 4 attemps and 1 to 99 sec retry time Monitoring Motor current line voltage power power factor and elapsed time Operation External control Start Stop Acceleration phase Adjustable time Permanent phase Energy savings Override choice Stop phase Power cut off Ramp DC braking Pump control Inputs Outputs Inputs 4 digital optocoupled Two fixed Start Stop and 2 programmable I3 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 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 300 s JJ D Loss on input phase Trip at 3 s Thyristor short circuit Trip at 200 ms Radiator overheating Trip at 200 ms Motor thermistor Trip at 200 ms if thermistor impedance gt response value Loss on output phase at 3 s Stalled rotor Trip at 200 ms Supply frequency error Hz If f lt 45 or
50. trip curve R W 0 5 OFF 1 N1 2 2 3 4 C1 5 C2 017 018 019 R Lead EEPROM LW ___ SS Parameter number 020 021 022 023 024 025 026 027 028 029 030 031 032 033 034 035 036 037 038 039 040 041 042 043 044 045 046 047 048 049 050 052 053 054 055 056 057 058 059 ASTATplus Parameter Read Write Range Comments name R W __ ll VXXX jhtemduse ll ___ o ll functions on page xx 0 OFF Overcurrent time se DW 109 r Reverse slow speed R W 0 3 0 OFF 1 ON 2 13 3 14 0 fw 099 030 ____ 0 OFF Overvoltagetime Sec ______________ e ue Undercurent N RW 099 oo uc ______ Undercurrent time sec _ 1099 Line voltage volt Power KW 10 R X Local remote control 0 3 0 OFF 1 ON 2 13 3 14 Linear ramp control R W 0 3 OFF 1 2 13 3 14 J Slow speed control R W 0 2 OFF 1 13 2 4 Slow speed type 0 1 0 HI 1 LO 1 99 RW 1 99 Dual ramp selection R W 0 3 1 2 13 3 14 1 to 16 to X frames E _____ Elapsed time hours TR Q Recall factory settings Current calibration LUrtemgd use LI 2 Bypass function R W 0 3 OFF 1 ON 2 13 3 14 htemaluse Service factor N t Voltage calibration R 63 ASTAT
51. ty 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 transmission 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 it is 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 mounting devices SMD which increases equipment reliability 5 High level of immunity D
52. ust be set to meet applicable standards for operator safety Separate motor overcurrent protection is required to be provided in accordance with the Canadian Electrical Code Part 1 ASTATplus provides separate motor protection CAUTIONS Semi conductor fuses specified may not provide branch circuit protection Refer to local applicable electrical codes Overload relay setting should be properly coordinated with motor Slow speed running will affect the motor thermal characteristic due to reduced cooling Care must be taken when operating motor under these conditions DC braking braking current may cause motor overheating Select the lowest braking current and time DC braking must use additional DC3 in the motor circuit See wiring diagram page A 12 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 If control power is lost between starts the overload relay protection is reset to cold start conditions ASTATplus CONTENTS SECTION 1 ET io 4 Comparison Oe Stall SNS EE A 4 1 2 Advantages of the ASTATPIUS
53. wing table indicates the communication settings used by ASTATplus to perform data communication via its serial port Name Seting Description Baud Rate 9600 bps Bits per second transmission rate Parity None Data error checking method Data Bits Number of data bits in each transmission Start Bits Number of bits to indicate beginning of transmission Stop Bits Number of bits to indicate ending of transmission Data ASCII RTU Communications protocol used Handshaking None No need to request to send or clear to send ASTATplus 6 2 2 ASCII Protocol To select this communications protocol XP must be set to 0 It is possible to operate the ASTATplus from a host using standard ASCII characters Two functions are available to be able to READ and WRITE parameters Write Parameters to ASTATPlus To write data into a parameter the command format is the following Request from host SSWxxxyyy Response from the ASTAT SSWxxxyyy where is a char to indicate the command start ss is the station address 3 bytes needed is the parameter number and bytes needed is the value to write into the parameter The lt is the return key to indicate the command stop Note the parameters modification is not allowed while the motor is operating Read Parameters from ASTATplus To read a parameter the command format is the following Hequest from host ssRxxx Response from the ASTAT
54. with one NO NC dry RUN contacts to ASTATplus s terminals 11 12 13 2 r x x Output relay 2r 2r20 20 22 30 This is a programmable relay with one NO dry contact EOR to ASTATplus 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 1 overwrited in this case 3r xx Output relay 3r 3r 2 1 21 22 30 This is a programmable relay with one NO dry contact DC Brake to ASTATplus 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 Detects end of voltage ramp This function only can be assigned to relay 2r 21 DC Brake DC Brake control command This function only can be assigned to relay 22 FAULT Detects unit Fault status 23 Undervoltage Detects Undervoltage according limit adjusted in function UV 24 Overvoltage Detects Overvoltage according limit adjusted in function OV 25 RUN Detects unit RUN status 26 Slow Speed Detects slow speed status 27 Undercurrent Detects Undercurrent according limit adjusted in function UC 28 Overcurrent Detects Overcurrent limits as adjusted in function OC 29 Disabled Disables the relay function 30 Future use 5 Installation 5 1 Equipment installation ASTATplu
55. y be provided by one NO free voltage push button to terminals 1 and 57 2 Stop Stop order Command signal may be provided by one NC free voltage push but ton 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 Programmable These two inputs are programmable Can be assigned to the following internal input 13 functions 4 Programmable soft stop DC brake Linear Ramp input 14 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 11 12 14 23 24 33 34 Analog 1 0 Terminal 8 Description Programmable 1 Programmable relay 2r Programmable relay 3r ASTATplus 11 12 NC 11 14 N O dry contacts This relay can be assigned to several internal output functions page A 12 As default assigned to function RUN 23 24 free voltage contact This relay can be assigned to several internal output functions page A 12 As default assigned to function EOR 33 34 N O free voltage contact This relay can be assigned to several internal output functions page A 12 As default assigned to function DC BR

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