GE Industrial Solutions ASTAT-IBP Plus User Manual
ASTAT®-IBP Plus
USER MANUAL
DEH-40396B
GE Industrial Systems
SOLID-STATE SOFT STARTER
REMARKS:
1. Read this manual thoroughly before using the ASTAT-IBP Plus and store in a safe
place for reference.
2. Make sure that this manual is delivered to the end user.
3. 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®-IBP 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-IBP 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. Abnormal starting times in excess of 30 seconds or closely repeated operations
of acceleration ramp/deceleration ramp may cause motor damage. Contact motor
manufacturer to ensure proper motor selection has been made for these conditions.
4. If control power is lost between starts, the overload relay protection is reset to cold
start conditions.
ASTAT®-IBP 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. Les délais anormaux de mise en service d'une durée supérieure à 30 secondes,
ainsi que les montées/descentes en regime, sont suseptibles d'edommager le
moteur. Mettez-vous en rapport avec votre fabricant en ce qui concerne le choix
du moteur adéquat.
4. En cas d'interruption de l'alimentation entre deux dèmarrages, la protection
assurée par démarrage à froid.
5. Le moteur doit être 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 être proprement coordonne avec la marche du
moteur.
INDEX
Page
Section 1. Overview......................................................................................................... 1-1
1-1 Applications ....................................................................................................................... 1-1
1-2 Features and benefits ........................................................................................................ 1-2
Section 2. Types and Ratings............................................................................................. 2-1
2-1 Ratings............................................................................................................................... 2-1
2-2 Thermal characteristics...................................................................................................... 2-2
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..................................................................................... 3-5
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 ........................................................................................... 4-8
4-8 Saving parameters to E2PROM ........................................................................................ 4-9
4-9 Lockout .............................................................................................................................. 4-10
Section 5. Installation ..................................................................................................... 5-1
5-1 Equipment installation........................................................................................................ 5-1
5-2 General .............................................................................................................................. 5-1
5-3 Branch circuit protection .................................................................................................... 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....................................................................................................... 6-2
6-3 Dimensions ........................................................................................................................ 6-6
i i
1-1. Applications
1. Overview
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-, threeor four-step torque change by switching the motor voltage from
reduced value to full voltage (in steps) after a preset time interval.
ASTAT-IBP 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-IBP Plus control
circuitry offers many additional functions, such as the monitoring,
protection and secondary functions listed.
Integral Bypass
The ASTAT-IBP Plus provides acceleration and deceleration control
using back-to-back SCRs. When the motor reaches the end of the
ramp, a bypass contactor is energized and the SCRs are switched
off. This allows the ASTAT-IBP Plus to run cooler than conventional
soft starters.
Advanced Features
The ASTAT-IBP Plus incorporates many additional advanced
features to ensure 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
Versatile Use
ASTAT-IBP Plus Solid State Reduced-Voltage Starters offer
customer-configurable functions, including pedestal voltage, kick
start (selectable), acceleration ramp, starting 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
The ASTAT-IBP Plus also features two programmable inputs, two
programmable output relays and serial communications control.
Note: (1) Monitors L1
1-1
1-2. Features and benefits
1. Overview
An 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 machines’ mechanical parts and
reduces stress on transmission belts and coupling parts.
Consequently, maintenance time is reduced and machine/facility
lifespans are lengthened.
Improvement in acceleration / deceleration characteristics
Starting with the voltage ramp or, alternatively, by starting current
limitation, the acceleration and deceleration ramp more closely fits
load characteristics. A kick start may also be selected in instances
of high static friction load.
Protected motor
The ASTAT-IBP Plus protects the motor from overloads as well as
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 on 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 is designed using surface mounted devices (SMD)
to increases equipment reliability.
Easy to run and adjust
The ASTAT-IBP Plus can be used for a wide range of applications.
A keypad and a 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
20 different types of fault conditions. The last four errors are
retained in memory to facilitate trouble-shooting and to minimize
downtime.
Pump control
The ASTAT-IBP 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 pipe line
system. This method controls the motor speed by monitoring the
motor parameters with voltage control in a closed-loop system.
Advanced functions
ASTAT-IBP Plus includes advanced functions, such as linear
acceleration ramp, programmable I/O and connection to a computer
by serial communication (RS 232).
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 disturbance and their harmful effects.
1-2
2. Types and Ratings
2-1. Ratings (1)
Ratings for Standard Duty Applications (300% Current for 30 sec) for low inertia loads such as centrifugal pumps.
Catalog Frame Maximum Horsepower kW
Number Rating, A
QI3KDP 55 15 20 40 50 17 30 37 40
QI3LDP 68 20 25 50 60 20 37 40 45
QI3YDP 80 25 25 60 75 22 37 45 50
QI3MDP 105 30 40 75 75 30 55 63 75
QI3ZDP 130 40 50 100 125 37 63 75 80
QI3NDP 156 50 60 125 150 40 75 80 90
QI3PDP 192 60 75 150 200 55 90 100 110
QI3QDP 248 75 100 200 250 63 110 132 147
QI3RDP 302 100 100 250 300 90 160 185 220
QI3SDP 361 125 150 300 350 110 200 220 250
200 V 230 V 460 V 575 V 220 V
380 V/
415 V 500 V
440 V
480 V/
Ratings for Heavy Duty Applications (450% Current for 30 sec) for medium loads such as belted conveyors.
Catalog Frame Maximum Horsepower kW
Number Rating, A
QI3KDP,LP,YP 55 15 20 40 50 17 30 37 40
QI3MDP 105 30 30 75 75 22 50 63 63
QI3ZDP 130 40 50 100 125 37 63 75 80
QI3NDP 156 50 60 125 150 40 75 80 90
QI3PDP,QP,RP 192 60 75 150 200 50 90 100 110
QI3SDP 361 75 100 200 250 63 110 132 132
200 V 230 V 460 V 575 V 220 V
380 V/
415 V 500 V
440 V
480 V/
Notes: (1) = Ratings in Amps given for ambient temperature of up to 40°C and 1000m altitude. Temperatures inside the
enclosure must be kept within a 0°-45°C range. Derate output current by 1.5% per degree C above 40°C. Derate
output current by 1% per 100m above 1000m.
2-1
2. Types and Ratings
2-2. ASTAT®-IBP Plus, Thermal characteristics
The ASTAT-IBP Plus allows the user to select motor protection according IEC Class 10, 20 and NEMA 10, 20 or 30, selectable by "o" -overload- parameter
IEC Class 10 IEC Class 20
Sec. Sec.
COLD
COLD
HOT
Multiples of motor FLA Rating In
NEMA 10 NEMA 20
Sec.
COLD
HOT
Multiples of motor FLA Rating In
Sec.
HOT
Multiples of motor FLA Rating In
COLD
HOT
Multiples of motor FLA Rating In
NEMA 30
Sec.
Thermal memory:
If the control voltage is not removed, the unit has a cool down
characteristic. The time for cool down is 300 sec. after the
overload trip.
If the control voltage is removed after tripping, you must wait at
least 5 minutes before the unit can be restarted. See Section 4-10
for restart limitations.
COLD
HOT
Multiples of motor FLA Rating In
2-2
3. Technical Specifications
3-1. ASTAT®-IBP Plus, General specifications
Voltage Ratings 3ph AC Systems Up to 600V, +10%, -15% for QI3xDP ASTAT-IBP
Plus series
Freq. Range 50/60 Hz Control range of 45-65 Hz
Control Control system Digital system with microcontroller
Specifications Starting ramp with progressive increase in voltage and
current limitation
Initial voltage (pedestal) % 30 - 95 U
Starting torque % 10 - 90 M
Kick start % 95 Un (90% M
Motor unit ratio (N) 0.4 - 1.2
Current limit (starting) 1 to 4.5 (Ir/In) Max 4.5 I
Acceleration ramp time s 1 to 45 (standard or linear ramp up)
Bypass Direct control of a bypass contactor
Brake time by ramp s 1 to 60 (1 to 60 in secondary ramp) adjustable independently of starting
ramp time (types: standard, pump control or linear ramp down)
Monitoring Motor current, line voltage (1), power, power factor and elapsed time
Running External control Start - Stop
Acceleration phase Adjustable time
Stop phase Power cut-off / Ramp / Pump control
Inputs / Outputs Inputs 4 digital optocoupled. Two fixed (Start , Stop), and 2 programmable (I3, I4)
1 Analog 0-5VDC for Tachogenerator input feedback
Outputs 2 Programmable relays (1r, 3r); 1 fixed relay (2r)
1 Analog 0-10VDC output for current metering
Protections Current limit Adjustable 1 to 4.5 (I
Overload IEC class 10 and 20 ; NEMA class 10, 20 and 30 all selectable
Cool-down time after
overload trip See Restart Times on page 4-10
Loss on input phase s Trip at 3
Thyristor short circuit ms Trip at 200
Heatsink overheating ms Trip at 200
Motor thermistor ms Trip at 200 if thermistor impedance > response value
Loss on output phase s Trip at 3
Stalled rotor ms Trip at 200
Supply frequency error Hz If f < 45 or f > 65, will not start
Overcurrent 100 to 150% In; trip time adjustable from 0 to 99 sec.
Undercurrent 0 to 99% In; trip time adjustable from 0 to 99 sec.
Overvoltage (1) 100 to 130% Un; trip time adjustable from 0 to 99 sec.
Undervoltage (1) 0 to 50% Un; trip time adjustable from 0 to 99 sec.
Error (CPU) ms 60
Memory 4 former errors
Long start time s 2 x ta (ta = acceleration ramp time)
n
direct start
direct start
), adjustable 0 to 999 ms
n
/I
) Max 4.5 I
r
n
n
I Actual measured motor current
I
m
I
n
I
r
L Current limit for starting Im/I
L
max
M
direct start
NI
SF Service factor
U
n
Abbreviations
Maximum starting current desired
Nominal motor nameplate FLA
ASTAT rated nameplate FLA
450/N
Full voltage starting torque
n/Ir
Full line voltage
r
Environmental Temperature °C0 to +55 (derate output current by 1.5% / °C above 40°C)
conditions Relative humidity % 95% without condensation
Maximum altitude m 3000 (derate output current by 1% / 100m above 1000m)
Mounting position Vertical
Protection Degree IP00, UL Open
Standards cUL, UL UL, cUL conforming to UL508
Conducted & radiated emissions Conforming IEC 947 -4-2, Class A
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
Note: (1) Monitors L1
(
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.
2T1, 4T2, 6T3 Motor output Output terminals to 3ph AC motor
TBA1, TBA2 Input Control Voltage 110/120V AC, +10%, -15%
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 dry momentary contact to terminals 1 and 57.
2 Stop Stop order. Command signal may be provided by one NC dry momentary contact 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 I3 These two inputs are programmable. Can be assigned to the following internal functions:
4 Programmable input I4
-soft stop -linear ramp
-pump control -dual ramp selection
-kick start -local / remote control
Command signal should be provided by one NC dry contact to terminals 57-3 or terminals 57-4.
By switching this contact ON / OFF it is possible to enable or disable the assigned function.
Digital Outputs
Terminal Function Description
11, 12, 14 Programmable relay 1r
23, 24 Fixed relay 2r 23-24 = N.O. dry contact. This relay is assigned to function EOR for bypass contactor control
33, 34 Programmable relay 3r 33-34 = N.O. dry contact. This relay can be assigned to several internal output functions (page 3-5).
Analog I/O
Terminal Function Description
8 Analog input common (-) This is a common terminal for the analog input terminal number 7 and analog output terminal number 9.
7 TG feedback input (+) 0-5V analog input for speed feedback. It should be provided by a DC tacho-generator coupled to the motor.
9 Current output (+) 0-10V DC analog Output for current measurement purpose. (1 x I
Motor thermistor terminals
Terminal Function Description
5 , 6 Motor thermistor input This input allows a motor thermistor with a response value from 2.8 to 3.2KΩ , and a reset value from 0.75 to
11-12 = NC, 11-14 = N.O. dry contacts. This relay can be assigned to several internal output functions (p. 3-5).
As default assigned to function RUN
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
This speed feedback signal is required when the "linear ramp" function is used.
= 2V DC output)
Load Impedance 10KΩ or higher.
1KΩ to control motor temperature.
When the motor thermistor is not used, a link must be used between terminals 5-6.
r
Communications
Terminal Function Description
SG, TD, RD Gr, Tx, Rx data RS232C, 3 wires, half duplex. Maximum cable length 3 meters (10 feet)
Asynchronous data transmission, 9600 Bauds, 1 bit start, 8 bits data, 2 bits stop, no parity.
3-2
3. Technical Specifications
3-3. I/O wiring
ASTAT-IBP Plus terminal layout and wiring configuration is shown in the diagram below.
Control Voltage
110 / 120V AC
TBA2TBA1
M2
Bypass
Serial Comm.
RS232C
Tx
Gr
Rx
L1 L2 L3
A1A2 B1 B2
57 57 57 6 8
12
(Permanent Command)
(Command by push-buttons)
Start /Stop
57 57
1
Start Stop
12 11 14
1r 2r 3r
Programmable Relay Outputs
Programmable Inputs
I3 I4
23
3457
24
33
34
TD
+-
RDSG
9
-+
V
1 L1 3 L2 5 L3
2 T1 4 T2 6 T3
M
3 ~
M2
Bypass
2
Programmable
Inputs
Input
Motor Thermistor
Analog Input
Tacho feedback
0-10V
Analog Output
Notes: (1) Control and Mains wiring recommendations are given in chapter 5.
(2) The programmable inputs I3, I4 are not assigned to any function as default. Check pages 3-5 prior to using these
inputs.
(3) The programmable relay output is assigned to the following functions as default:
Relay (1r): RUN, (RUN status)
(4) Important: Use dry contacts only
3-3
3. Technical Specifications
p
3-4. Operating modes
Operating Mode Key Description
Initial ramp
Initial voltage (pedestal)
Kick start
Acceleration ramp
Running mode
Soft stop mode
Current limit
Ramp continue
Stop mode
Starting by voltage ramp
U/Un
1a
1
2
3
4
5
6
7
8
9
5 main frequency cycles
30 to 95% Un (adjustable via initial torque setting T)
95% Un. Enabled by parameter "Pxxx" to ON, 0-999 ms (adjustable)
1-45 sec (adjustable). Dual ramp option.
Fast ramp (if motor is up to speed before end of normal ramp time)
Nominal voltage (bypass mode)
Deceleration ramp 1-60 sec (adjustable). Secondary ramp 1-60 sec.
Ramp down 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)
Current limiting set point (100 to 450% x (Ir/In) Max 450% In)
Accelerating ramp (continuation of acceleration after motor amps drop below current limit)
Standard stopping (coast to rest)
100%
2
Starter
Output
Voltage (%)
1a
1
Starting by current limitation
Current to Motor
Out
100%
Starter
Output
Voltage (%)
1a
3
3
ut Voltage
7
5
6
4
8
Time
Motor Current
Max
450%
5
4
Current
Limit
8
9
Set Point
FLA
Ramp Current Limit
Ramp At Speed Coast Stop Time
(Voltage Hold)
3-4
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