GE Industrial Solutions ASTAT-IBP Plus User Manual

DEH-40396B

GE Industrial Systems

SOLID-STATE SOFT STARTER

ASTAT®-IBP Plus

USER MANUAL

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. 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-, 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.

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

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

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

Note: (1) Monitors L1

1-1

1. Overview

1-2. Features and benefits

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.

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.

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).

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			200 V	230 V	460 V	575 V	220 V	380 V/	440 V	480 V/
													415 V		500 V
	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

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			200 V	230 V	460 V	575 V	220 V	380 V/	440 V	480 V/
													415 V		500 V
	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

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
	HOT
						Multiples of motor FLA Rating In
Multiples of motor FLA Rating In
NEMA 10						NEMA 20
Sec.						Sec.

COLD

COLD

HOT

HOT

Multiples of motor FLA Rating In

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

Abbreviations

Plus series

I

Actual measured motor current

Freq. Range

50/60

Hz

Control range of 45-65 Hz

Im

Maximum starting current desired

In

Nominal motor nameplate FLA

Control

Control system

Digital system with microcontroller

Ir

ASTAT rated nameplate FLA

Specifications

Starting ramp with progressive increase in voltage and

L

Current limit for starting I /I

r

current limitation

m

Lmax

450/N

Initial voltage (pedestal)

%

30 - 95 Un

Starting torque

%

10 - 90

Mdirect start

Mdirect start

Full voltage starting torque

Kick start

%

95 U

n

(90% M

direct start

), adjustable 0 to 999 ms

N

In/Ir

Motor unit ratio (N)

0.4 - 1.2

SF

Service factor

Current limit (starting)

1 to 4.5 (Ir/In) Max 4.5 In

U

Full line voltage

Acceleration ramp time

s

1 to 45 (standard or linear ramp up)

n

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 (Ir/In) Max 4.5 In

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)

Environmental

Temperature

°C

0 to +55 (derate output current by 1.5% / °C above 40°C)

conditions

Relative humidity

%

95% without condensation

Maximum altitude

m

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	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
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).
		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 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.
		This speed feedback signal is required when the "linear ramp" function is used.
9	Current output (+)	0-10V DC analog Output for current measurement purpose. (1 x Ir = 2V DC output)
		Load Impedance 10KΩ or higher.
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
		1KΩ to control motor temperature.
		When the motor thermistor is not used, a link must be used between terminals 5-6.
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.

L1

L2

L3

Control Voltage

110 / 120V AC

Serial Comm.

RS232C

TBA1 TBA2

M2

Tx

Rx Gr

Bypass

12 11 14

23 24

33 34

TD RD SG

3 L2

5 L3

A1 A2

B1 B2

1 L1

M2

1r

2r

3r

Bypass

Programmable Relay Outputs

Programmable Inputs

I3

I4

2 T1

4 T2

6 T3

1 57

2 57

3

57

4

5

6

7

8

9

Start /Stop

-

+

(Permanent Command)

V

M

+

-

3 ~

1 57

2 57

Programmable Inputs

Motor Thermistor

Input

Tacho feedback

Analog Input

0-10V

Analog Output

Start

Stop

(Command by push-buttons)

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

3-4. Operating modes

Operating Mode

Key

Description

Initial ramp	1
Initial voltage (pedestal)	1a
Kick start	2
Acceleration ramp	3
	4
Running mode	5
Soft stop mode	6
Current limit
Ramp continue
Stop mode

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)

Starting by voltage ramp

	U/Un
100%		5	6
	2	4
Starter
		8
Output		3
Voltage (%)
1a	1
			Time

Starting by current limitation

				Max	Motor Current
	Current to Motor					450%
	Output Voltage		5
100%
			4
Starter				Current
						Set Point
Output				Limit
Voltage (%)	7	8		9
1a	3					FLA
Ramp	Current Limit	Ramp	At Speed	Coast Stop	Time
	(Voltage Hold)
			3-4