GE Industrial Solutions ASTAT-CD Plus User Manual

ASTAT®-CD Plus

USER MANUAL

DEH-40397B

GE Industrial Systems

SOLID-STATE SOFT STARTER

REMARKS:

1. Read this manual thoroughly before using the AST A T -CD Plus and store in a safe place

for reference.

2. Make sure that this manual is delivered to the end user.

3. CE Marking

When using ASTAT-CD Plus in the EU, compliance with EMC is required. All ASTAT-CD Plus sizes comply with the generic EN 50081-2 and EN 50082-2

4. The policy of GE Industrial Systems is one of continuous improvement. The right is reserved to alter the design on any structural details of the products at any time without giving notice.

ASTAT®-CD 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 configured to provide automatic isolation when the motor is turned OFF is recommended.

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-CD 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 under 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 to ensure proper motor selection has been made for these conditions.

7. If control power is lost between starts, the overload relay protection is reset to cold start conditions.

ASTAT®-CD Plus Soft Starters

PRECAUTIONS

1. Debranchez l'alimentation en courant électrique avant de raccorder ou d'intervenir.

2. Des tensions dangereuses sort présente dans le circuit moteur même si le soft starter

indique la position "arrêt". Un contacteur d'isolement assurant un isolement automatique quand le moteur est arrête, est recommendé.

3. L'appareil peut renfermer plus d'un circuit sous tension de'brancher les circuits principaux et les circuits de controle avant de raccorder ou d'intervenir.

4. Délestage "soft stop" ne devrait jamais être utilisé en lieu de délestage d'urgence.

5. Procédés de délestage doivent être conforme aux normes de sécurité des utilisateurs.

AVERTISSEMENTS

1. Les fusibles semi-conducteurs specifies ne protégent pas obligatoirement les circuits se

conformer aux codes locaux d'installations électriques.

2. Le relais de courant de surcharge doit être proprement coordonné avec la marche du moteur.

3. La marche en sous-régime agira sur les caracteristiques thermiques à cause de la réduction de refroidessement. Opérez le moteur avec précaution dans en ce cas.

4. Ralentissement courant continu peut provoquer la surchauffe de moteur. Choisissez le plus foible courant de décéleration et la durée de ralentissement la plus courte.

5. Pour freinage courant continu, un contacteur (DC3) additional est nécessaire dans le circuit moteur, voir le schéma de raccordement page 6-1.

6. Les délais anormaux de mise en service d'une durée supérieure à 30 secondes, ainsi que les montées/descentes en regime, les exploitations régime lent ou les freinages par injection de courant continu répétés et rapportes sont suseptibles d'edommager le moteur. Mettez-vous en rapport avec votre fabricant en ce qui concerne le choix du moteur adéquat.

7. En cas d'interruption de l'alimentation entre deux dèmarrages, la protection assurée par démarrage à froid.

8. Le moteur doit être muni d'une protection distincte contre les surintensites, et la surchauffe conformement au code de l'electricite, premiere partie. ASTAT-CD Plus le relais de courant de surcharge doit être proprement coordonne avec la marche du moteur.

INDEX

Section 1. Overview ........................................................................................................................ 1-1

1-1 Applications ....................................................................................................................... 1-1

1-2 Features and benefits ........................................................................................................ 1-2

Section 2. T ypes and Ratings........................................................................................................ 2-1

2-1 IEC Ratings........................................................................................................................ 2-1

2-2 UL Ratings ......................................................................................................................... 2-2

2-3 Thermal characteristics...................................................................................................... 2-3

Section 3. Technical Specifications ............................................................................................. 3-1

3-1 General specifications ....................................................................................................... 3-1

3-2 I/O Terminal board specifications....................................................................................... 3-2

3-3 I/O wiring............................................................................................................................ 3-3

3-4 Operating modes ............................................................................................................... 3-4

3-5 Programmable inputs and outputs..................................................................................... 3-6

Section 4. Programming................................................................................................................ 4-1

4-1 Keypad and display description ......................................................................................... 4-1

4-2 Parameter block configuration ........................................................................................... 4-2

4-3 Monitor block parameters .................................................................................................. 4-4

4-4 Calibration block parameters ............................................................................................. 4-5

4-5 Basic block parameters ..................................................................................................... 4-6

4-6 Advanced block parameters .............................................................................................. 4-7

4-7 Application and basic settings ........................................................................................... 4-9

4-8 Saving parameters to E2PROM ........................................................................................ 4-9

Section 5. Installation .................................................................................................................... 5-1

5-1 Equipment installation........................................................................................................ 5-1

5-2 General .............................................................................................................................. 5-1

5-3 Fuses, contactors and supply wiring.................................................................................. 5-2

5-4 Start-up .............................................................................................................................. 5-3

5-5 Troubleshooting ................................................................................................................. 5-3

5-6 Thyristor check .................................................................................................................. 5-4

Section 6. Appendix....................................................................................................................... 6-1

6-1 Application diagrams ......................................................................................................... 6-1

6-2 Serial communications....................................................................................................... 6-4

6-3 Dimensions ........................................................................................................................ 6-9

6-4 PCBs layout ....................................................................................................................... 6-10

i i

1. Overview

1-1. Applications

There are numerous applications where soft starting and limited current peaks are needed for the starting of squirrel cage induction motors. Traditionally reduced voltage starting was accomplished using electromechanical starters such as star delta starters, autotransformer starters, stator resistance starters or by using part winding motors. These methods would provide a two, three or four step torque change by switching the motor voltage from reduced value to full voltage (in steps) after a preset time interval.

ASTAT-CD Plus Solid State Reduced-Voltage Starters (also known as soft starters) use solid state devices to gradually increase the voltage from an initial preset level (initial torque) to full voltage over a selected time period. The same solid state devices may also be used to reduce the voltage for the deceleration of the motor should this be required in the application. This starting and stopping method provides smooth, stepless acceleration and deceleration of AC squirrel-cage induction motors. The ASTAT-CD Plus control circuitry allows many additional functions to be accomplished, such as the monitoring, protection and secondary functions listed.

Versatile Use

ASTAT-CD Plus Solid State Reduced-Voltage Starters offer customer-configurable functions, including pedestal voltage, kick start (selectable), acceleration ramp, current limit, and soft stop (selectable). Typical applications include the following:

• Belted equipment • Centrifugal fans

• Centrifuges • Compressors

• Conveyors • Crushers

• Extruders • Fans and blowers

• Mixers • Packaging equipment

• Pumps • Textile machinery

Advanced Features

The ASTAT-CD Plus incorporates many additional advanced features to insure suitability for most applications.

Monitoring

• Motor Current

• Line Voltage (1)

• Line Power Factor

• Elapsed Time

• Fault History

Protection

• Password

• Lockout

• Undervoltage (1)

• Overvoltage (1)

• Undercurrent

• Overcurrent

• Long Start Time

• Stalled Rotor

Secondary Functions

• Secondary Ramp Up

• Secondary Ramp Down

• Tachometer Feedback

• Dual Motor Switch

• Slow Speed (7&14%)

• Reverse Slow Speed (20%)

• Retry

• DC Injection Braking

• Energy Saving

The ASTAT-CD Plus also features two programmable inputs, three programmable output relays and serial communications control.

1-1

Note: (1) Monitors L1

1-2. Features and benefits

1. Overview

An increase in productivity and reliability with the use of static soft starters.

The ability to start and stop the motor without steps or transitions lengthens the life of power-driven machines’ mechanical parts, and it reduces stress on transmission belts and coupling parts. Consequently, maintenance time is reduced and machine/facility lifespans are lengthened.

Improvement in acceleration / deceleration characteristics

By starting with the voltage ramp or, alternatively, by starting current limitation, the acceleration and deceleration ramp more closely fits the load characteristics. A kick start also may be selected in instances of high static friction load.

Protected motor

The ASTAT-CD Plus protects the motor from overloads and from incorrect operating conditions such as loss of an input or output phase, stalled rotor, thyristor short circuit, etc.

Digital technology

The control system is based upon the use of a highly specialized microcontroller that treats the signals digitally, thereby avoiding deratings and adjustments common to analog circuits. This type of control ensures excellent precision and speed of execution. The control board uses surface-mounted devices (SMD) to increase equipment reliability.

High level of immunity

The control signals are optoelectronically isolated. Various levels of protection have been set up in the circuits to immunize the equipment against external disturbances and their harmful effects.

Easy to run and adjust

The ASTAT-CD Plus can be used for a wide range of applications. A keypad and digital display make it easy to select options that allow the equipment capabilities to be customized to application needs.

Easy maintenance due to full monitoring

Advanced microprocessor technology allows starters to identify 21 different types of fault conditions. The last four errors are retained in memory to facilitate troubleshooting and minimize downtime.

Pump control

The ASTAT-CD Plus includes a pump control function that is more effective in fluid systems than standard soft starting and stopping. The control reduces fluid surges and hammering in a pipeline system. This method controls the motor speed by monitoring the motor parameters with voltage control in a closed-loop system.

Advanced functions

The ASTAT-CD Plus includes advanced functions, such as, linear acceleration ramp, programmable I/O, and connection to a computer by serial communication (RS 232).

1-2

2. Types and Ratings

2-1. IEC Ratings (1)

HEAVY DUTY (2) LIGHT DUTY Degree of Cat. No. Weight Cooled

Current 220V / 380V / 440V 480V / Current 220V / 380V / 440V 480V / protection rating 240V 415V 500V rating (3) 240V 415V 500V

AkW(4) kW(4) kW(4) kW(4) A kW(5) kW(5) kW(5) kW(5) Kg. Lbs. 14 3 5.5 7.5 - 17 4 7.5 7.5 - IP-00 QC1FDP 4.3 9.48 Natural

35.5 7.5 7.5 4 7.5 7.5 11 IP-00 QC2FDP 4.3 9.48 Natural

17 4 7.5 7.5 - 21 5.5 11 11 - IP-00 QC1GDP 4.3 9.48 Natural

47.5 7.5 11 5.5 11 11 13 IP-00 QC2GDP 4.3 9.48 Natural

22 5.5 11 11 - 27 7.5 13 15 - IP-00 QC1HDP 4.6 10.14 Natural

5.5 11 11 15 7.5 13 15 15 IP-00 QC2HDP 4.6 10.14 Natural

32 7.5 15 18.5 - 38 10 18.5 22 - IP-00 QC1IDP 4.6 10.14 Natural

7.5 15 18.5 22 10 18.5 22 25 IP-00 QC2IDP 4.6 10.14 Natural

48 13 22 22 - 58 15 25 30 - IP-00 QC1JDP 12.5 27.56 By fan

13 22 22 30 15 25 30 37 IP-00 QC2JDP 12.5 27.56 By fan

63 15 30 37 - 75 22 37 45 - IP-00 QC1KDP 12.5 27.56 By fan

15 30 37 37 22 37 45 45 IP-00 QC2KDP 12.5 27.56 By fan

72 20 37 37 - 86 25 45 50 - IP-00 QC1LDP 17.0 37.48 By fan

20 37 37 45 25 45 50 50 IP-00 QC2LDP 17.0 37.48 By fan

105 30 55 55 - 126 37 63 75 - IP-00 QC1MDP 17.0 37.48 By fan

30 55 55 75 37 63 75 80 IP-00 QC2MDP 17.0 37.48 By fan

156 40 75 90 - 187 55 90 110 - IP-00 QC1NDP 45.0 99.20 By fan

40 75 90 110 55 90 110 132 IP-00 QC2NDP 45.0 99.20 By fan

240 63 110 132 - 288 80 150 165 - IP-00 QC1QDP 45.0 99.20 By fan

63 110 132 160 80 150 165 200 IP-00 QC2QDP 45.0 99.20 By fan

315 90 160 200 - 378 110 200 220 - IP-00 QC1RDP 55.0 121.3 By fan

90 160 200 220 110 200 220 250 IP-00 QC2RDP 55.0 121.3 By fan

370 110 200 220 - 444 132 220 250 - IP-00 QC1SDP 55.0 121.3 By fan

110 200 220 250 132 220 250 315 IP-00 QC2SDP 55.0 121.3 By fan

475 150 250 250 - 570 160 300 355 - IP-00 QC1TDP 80.0 176.4 By fan

150 250 250 335 160 300 355 400 IP-00 QC2TDP 80.0 176.4 By fan

610 200 315 400 - 732 220 400 450 - IP-00 QC1UDP 105.0 231.5 By fan

200 315 400 400 220 400 450 500 IP-00 QC2UDP 105.0 231.5 By fan

850 250 450 530 - 1020 300 560 600 - IP-00 QC1VDP 120.0 264.5 By fan

250 450 530 600 300 560 600 750 IP-00 QC2VDP 120.0 264.5 By fan

1075 355 600 670 - 1290 395 715 750 - IP-00 QC1XDP 150.0 330.7 By fan

355 600 670 750 395 715 750 850 IP-00 QC2XDP 150.0 330.7 By fan

Notes: (1) = Ratings in Amps. given for ambient temperature up to 40

Derate output current by 1.5% / Derate output current by 1% / 100m above 1000m.

(2) = Heavy duty ratings, IEC Class 10 and 20 protections allowed. (3) =Light duty ratings, only IEC Class 10 protection allowed. (4) = Maximum recommended Motor Power for IEC Class 20 protection. Set ASTAT-CD Plus's parameters "N" and "o" accordingly. (5) = Maximum recommended Motor Power for IEC Class 10 protection. Set ASTAT-CD Plus's parameters "N" and "o" accordingly.

C above 40°C.

C and 1000m altitude.

2-1

2. Types and Ratings

2-2. UL Ratings (1)

Current Max. HEAVY DUTY STANDARD DUTY Degree of Cat. No. Weight Cooled rating starting 200V 230V 460V 200V 230V 460V protection

current AAHP HP HP HP HP HP Kg. Lbs. 14 63 3 3 7.5 3 3 7.5 IP-00 QC2FDP 4.3 9.48 Natural 17 77 3 3 10 3 3 10 IP-00 QC2GDP 4.3 9.48 Natural 22 99 5 7.5 15 5 7.5 15 IP-00 QC2HDP 4.6 10.14 Natural 34 153 7.5 7.5 20 10 10 25 IP-00 QC2IDP 4.6 10.14 Natural 48 216 10 15 30 15 15 30 IP-00 QC2JDP 12.5 27.56 By fan 63 284 15 20 40 20 20 40 IP-00 QC2KDP 12.5 27.56 By fan 72 324 20 20 40 20 25 50 IP-00 QC2LDP 17.0 37.48 By fan 105 473 30 30 60 30 30 75 IP-00 QC2MDP 17.0 37.48 By fan 156 702 40 50 100 50 60 125 IP-00 QC2NDP 45.0 99.20 By fan 240 1080 60 75 150 75 75 200 IP-00 QC2QDP 45.0 99.20 By fan 315 1418 75 100 200 100 125 250 IP-00 QC2RDP 55.0 121.25 By fan 370 1665 100 125 250 125 150 300 IP-00 QC2SDP 55.0 121.25 By fan 500 2250 150 150 350 150 200 400 IP-00 QC2TDP 80.0 176.36 By fan 630 2835 200 200 400 200 250 500 IP-00 QC2UDP 105.0 231.47 By fan 850 3825 250 300 600 300 350 700 IP-00 QC2VDP 120.0 264.54 By fan

Notes: (1) = Ratings in Amps. given for ambient temperature up to 40

Derate output current by 1.5% / Derate output current by 1% / 100m above 1000m.

C above 40°C.

C and 1000m altitude.

2-2

2. Types and Ratings

2-3. AST AT®-CD Plus, Thermal characteristics

The ASTAT-CD Plus allows the user to select motor protection according to IEC Class 10, 20 and NEMA 10, 20 or 30, selectable by "o" -overload- parameter

IEC Class 10 IEC Class 20

Sec. Sec.

COLD

HOT