GE Industrial Solutions ASTAT-SD Solid-State Reduced Voltage Starter User Manual

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Page 1

ASTAT-SD™Solid-State Reduced Voltage Starter

DEH-036 Instructions

Page 2

Page 3

DEH-036

WARNINGS, CAUTIONS, AND NOTES

AS USED IN THIS PUBLICATION

WARNINGS: Warning notices are used in this publication to emphasize that hazardous

voltages, currents, or other conditions that could cause personal injury exist in this equipment or may be associated with its use.

Warning notices are also used for situations in which inattention or lack of equipment knowledge could cause either personal injury or damage to equipment.

CAUTIONS: Caution notices are used for situations in which equipment might be damaged

is care is not taken.

NOTES: Notes call attention to information that is especially significant to

understanding and operating the equipment.

This document is based on information available at the time of its publication. While efforts have been made to ensure accuracy, the information contained herein does not cover all details or variations in hardware and software, nor does it provide for every possible contingency in connection with installation, operation, and maintenance. Features may be described herein that are not present in all hardware and software systems. GE Electrical Distribution & Control assumes no obligation of notice to holders of this document with respect to changes subsequently made.

GE Electrical Distribution & Control makes no representation or warranty, expressed, implied, or statutory, with respect to, and assumes no responsibility for the accuracy, completeness, sufficiency, or usefulness of the information contained herein. No warranties of merchantability or fitness for purpose shall apply.

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ASTAT-SD™Solid-State Reduced Voltage Starters

Table of Contents

Chapter 1. Technical Specifications

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

1-2 UL Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1-3 Technical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

1-4 Recommended Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Chapter 2. Installation & Start-up

2-1 Mounting Position/Required Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2-2 Installation Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2-3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

2-4 ASTAT-SD Total Losses at 100% Rated Current . . . . . . . . . . . . . . . . . . . . . .8

2-5 Isolation Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

2-6 Motor Starting and Duty Cycle Conditions . . . . . . . . . . . . . . . . . . . . . . . . . .9

2-7 Terminal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

2-8 Control Panel Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

2-9 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

2-10 Error Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Troubleshooting Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

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ASTAT-SD™Solid-State Reduced Voltage Starters

Chapter 1. Technical Specifications

1-1 IEC Ratings

450% nominal current for 30 sec. max.

Catalog

Current HP KW

No.

Rating 220/ 380/

440V

480V/ 220/ 380/

440V

480V/

Amps 240V 415V 500V 240V 415V 500V

QS2BNA 5 1.5 3 3 4 1.1 2.2 2.2 3 QS2DNA 9 3 5.5 5.5 7.5 2.2 4 4 5.5 QS2FNA 12 4 7.5 7.5 10 3 5.5 6.3 7.5 QS2GNA 16 5 7.5 10 13.5 3.7 6.3 7.5 10 QS2HNA 22 7.5 13.5 14.5 17.5 5.5 10 12 13 QS2INA 34 10 20 20 25 7.5 15 17 20 QS2INA* 34 10 20 25 25 7.5 15 18.5 20

*300% nominal current for 30 sec. max.

1-2 UL Ratings

450% nominal current for 30 sec. max.

Catalog

Current Max. HP

No.

Rating Starting

200V 230V 460V

Amps Current

QS2BNA 5 25 1 1 3 QS2DNA 9 45 2 2 5 QS2FNA 12 60 3 3 7.5 QS2GNA 16 80 3 5 10 QS2HNA 22 110 5 7.5 15 QS2INA 34 160 7.5 10 20 QS2INA* 34 160 10 10 25

*300% nominal current for 30 sec. max.

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ASTAT-SD™Solid-State Reduced Voltage Starters

Chapter 1. Technical Specifications

1-3 Technical Characteristics

Environmental

Temperature 0 to 45°C

Storage temperature -20 to +70°C Relative humidity 95% without condensation Maximum altitude 3300 feet (1000m)

Mounting positions Vertical

Electrical characteristics

Three phase supply voltage 500VAC +10% maximum Frequency 48-62 Hz Rated current 6 ratings, 5-34A Motor horsepower (KW) 3-25hp at 460V (3-20 KW at 500V) Motor voltages 200V, 230V, 460V (220V, 380/415V, 440V, 500V for IEC) Control voltages 110/120VAC or 220/240VAC, 50/60Hz

Control characteristics

Control system Digital system with microcontroller

Starting ramp with progressive increase in voltage and current limitation

Loss of control voltage 3 cycle ridethru

Starting

Initial (starting) torque 15 to 80% full voltage starting torque Kick start 90% line voltage (80% full voltage starting torque), 400ms Current limit 200 to 500% starter current Acceleration ramp time .5 to 60 sec.

Running

Energy savings Output voltage reduction based on power factor of running

motor to optimize system energy consumption

Override - energy savings Energy saving mode turned OFF

Stopping

Coasting With no soft stop, power removed from motor Stop time by ramp Soft stop time fixed at 2 x t

ramp

Inputs/Outputs

Starter control Start/Stop or remote contact Inputs 2 isolated inputs for Start/Stop Input ratings 12VDC supplied by ASTAT to solid state optoisolators Output auxiliary relays Run/End of Ramp (at speed), DIP switch selectable

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ASTAT-SD™Solid-State Reduced Voltage Starters

Chapter 1. Technical Specifications

Inputs/Outputs (continued)

Relay output ratings 5A maximum

120VAC 360 VA pilot duty B300 & 1/3hp 45LRA 7.2FLA 240VAC 470VA pilot dutyB300 & 1/2hp 30LRA 5.0FLA General purpose DC ratings: 24VDC 8A

48VDC 0.8A 240VDC 0.1A

Protections

Current limit Adjustable from 200 to 500% starter rating Loss of input phase Trip at 3 sec Thyristor short circuit Trip at 200ms Loss of output phase Trip at 3 sec Supply frequency error If frequency <48Hz or >62Hz, will not start Error (CPU) 60ms Overload protection Separate overload relay required

Description of terminals

1L1, 3L2, 5L3 Power supply inputs +10%, -15% 2T1, 4T2, 6T3 Outputs to motor A1/A2, B1/B2 Command supply inputs (110/120 - 220/240V AC), +10%, -15% 11, 14 Run/End of ramp internal relay output (1NO) 1, 57 Run command input 2, 57 Stop command input 3, 4 Not used

Features

SCR repetitive peak inverse voltage (PIV) 1600V

Transient protection - QC2B through QC2I: 120 joules metal oxide varistors

Standards and listings UL 508, File E 153901

CSA 22.2/14, File LR30821 IEC 947-4-2

In conformity with EN500B-1, EN500B2-2, EN 53001, EN 60801-2, ENV 50140,

EN 61000-4-4, EN 610004-5 Complies with Electromagnetic Compatibility Directives

89/336/EEC 5/3/89

Reduce rated controller current (Ir) by 1.5%°C above 45°C, maximum 55°C.

Reduce rated controller current (Ir) by 1%/330 feet above 3300 feet, maximum 10,000 feet (1%/1000m above 1000m, 3000m maximum).

See page 9 for start time limitations.

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1-3 Technical Characteristics (continued)

Operating modes

Initial ramp 5 main frequency cycles Initial voltage (pedestal) 40% - 90% V (adjustable by torque setting) Kick start 90% V (DIP switch selectable) Acceleration ramp 0.5 to 60 seconds (adjustable)

Fast ramp (if motor is up to speed prior to end of

normal ramp time) Current limit 2 to 5 In Permanent state choice Nominal voltage (override)

Nominal current

Energy savings Stop mode Motor power cutoff (stopped by inertia)

Deceleration ramp (Max. time 2x t

ramp

)

Evolution of current in deceleration ramp mode

ASTAT-SD™Solid-State Reduced Voltage Starters

Chapter 1. Technical Specifications

100%

Override

Starter output voltage

100%

Energy savings

100%

Motor current %

Override

Energy savings

Starting by current limitation

Starting by voltage ramp

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ASTAT-SD™Solid-State Reduced Voltage Starters

Chapter 1. Technical Specifications

1-4 Recommended Diagrams

220/240 VAC

3 PHASE

LINE VOLTAGE

EOR/RUN

OUTPUT (PROGRAMMABLE)

START STOP CONTACT FROM CONTROL CIRCUIT

JUMPER

A1 B1 B2A2

A1 1 2 3 457 57 11 14

1 L1 5 L33 L2

2 T1 6 T34 T2

MOTOR

B1 B2A2

CONTROL 110/120

VOLTAGE VAC

220/240 VAC

3 PHASE

LINE VOLTAGE

CONTROL 110/120

VOLTAGE VAC

120V

CONTROL VOLTAGE

EOR/RUN

OUTPUT (PROGRAMMABLE)

START

STOP

COIL

A1 B1 B2A2

A1 1 2 3 457 57 11 14

1 L1 5 L33 L2

2 T1 6 T34 T2

MOTOR

B1 B2A2

Fig. 1

Start/stop by remote contact

Fig. 2

Start/stop by push button control

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ASTAT-SD™Solid-State Reduced Voltage Starters

Chapter 2. Installation & Start-up

Warnings

1. Disconnect power before installing or servicing.

2. Hazardous voltages are present in the motor circuit even when the soft starter is OFF. An isolation contactor is recommended, configured to provide automatic isolations when motor is turned off.

3. Unit may contain more than one live circuit. Disconnect both control and main circuits before installing or servicing.

4. SOFT STOP should not be used as an EMERGENCY STOP.

5. Stopping mode must be set to meet applicable standards for operator safety.

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 coordinator with motor.

Précautions

1. Débranchez l’alimentation en courant électrique avant de raccorder ou d’intervenir.

2. Des tensions dangereuses sont 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 arrêté, est recommandé.

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

4. Délestage “Softstop” 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 specifiés ne protègent pas obligatoirement les circuits se conformer aux codes locaux d’installations électriques.

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

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ASTAT-SD™Solid-State Reduced Voltage Starters

Chapter 2. Installation & Start-up

2-1 Mounting Position/Required Clearances

When installing the equipment, the following criteria must be observed:

• The equipment should be installed in a vertical position to ensure proper cool air circulation.

• Do not install equipment in environments containing explosive or flammable gases.

• Equipment should be well ventilated, with minimum clearances as indicated in the following illustration:

Minimum Clearances

2-2 Installation Recommendations

It is recommended that all signal wiring be shielded wiring or twisted pairs.

Do not

install capacitors to correct the power factor between the reduced voltage starter output and

the motor.

Relays and contactors located in the same housing as the reduced voltage starter should have an RC suppressor parallel to the coil (or a reverse diode, if controlled by DC).

ASTAT-S D

2 in

50mm

6 in

150mm

4 in

100mm

2 in

50mm

AC DC

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ASTAT-SD™Solid-State Reduced Voltage Starters

Chapter 2. Installation & Start-up

2-4 ASTAT-SD total losses at 100% rated current

Type

Power losses at 100% Control circuit Total losses,

rated current (W) losses (W) power & control (W)

QS2BNA 15 2 17 QS2DNA 29 2 31 QS2FNA 35 2 37 QS2GNA 47 2 49 QS2HNA 59 2 61 QS2INA 90 2 92

2-3 Dimensions

5.51

[140.0]

3.62

[92.0]

5.06

4.65

[80.0]

3.15

[14.2]

.56

[14.2]

4.72

[120.0]

[128.5]

[118.0]

.56

6.30

[160.0]

4.15

[105.5]

1.58

[40.0]

Dual Dimensions

(For Estimating Only)

TYPE A

5.91

QS-BNA

[150.0]

QS-DNA

5.91

[150.0]

7.09

QS-FNA

[180.0]

7.09

QS-GNA

[180.0]

Inches

Millimeters

6.70

[170.0]

4.55

[115.5]

1.97

[50.0]

Dual Dimensions

(For Estimating Only)

TYPE B

QS-HNA

7.87

[200.0]

QS-INA

9.84

[250.0]

7.87

[200.0]

6.70

[170.0]

[155.0]

5.06

[128.5]

.56

[14.2]

.56

[14.2]

6.10

4.65

[118.0]

Inches

Millimeters

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ASTAT-SD™Solid-State Reduced Voltage Starters

Chapter 2. Installation & Start-up

2-5 Isolation contactors

Type Isolation

QS2BNA CL00 QS2DNA CL00 QS2FNA CL01 QS2GNA CL02 QS2HNA CL25 QS2INA CL45

2-6 Motor Starting and Duty Cycle Conditions

The following illustration shows allowable motor starting currents according to the starting time.

The OFF TIME is the minimum amount of time between the motor stop and motor start. The duty cycle is the start time + stop time + off time. This graphic will enable the user to develop a duty cycle within the capabilities of the motor starter ratings.

Maximum Starting Time

For standard duty For heavy duty

Ir HP rating HP rating

500% 1 sec. 3 sec. 450% 5 sec. 30 sec. 300% 20 sec. 55 sec. 200% 120 sec. 120 sec.

1234567891020406080100

Off Time = 2 Minutes

Cold State Current

Starting Time (Seconds)

Motor Starting

current (Is)

Starter current

rating (Is)

Off Time = 3 Minutes

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ASTAT-SD™Solid-State Reduced Voltage Starters

Chapter 2. Installation & Start-up

2-7 Terminal connections

Use minimum 75°C copper wire only. Minimum wire size must conform to 75°C table per electrical codes. Tighten connections with following torque:

• QS2B-QS2I, wire range #14-#8 AWG, torque 20 in lb.

Output Relay

Run mode: Contact 11-14 closes when the run order is given to start the unit. Contact 11-14 opens if

either the stop order is given or an error is found, and the unit turns off. If soft stop is programmed, contact opens when the soft stop ramp is complete.

End-of-ramp (at speed) mode: Contact 11-14 closes when the starting ramp voltage reaches the end of ramp (i.e., full voltage). Contact 11-14 opens if either the stop order is given or an error is found, and the unit turns off. If soft stop is programmed, contact opens prior to the beginning of soft stop ramp.

Branch Circuit Protection

Semi-conductor Maximum Fuses

Maximum

Catalog Fuses

Circuit

No. Gould Shawmut Class RK5 & J Breakers

Type A50QS

QS2BNA 40A 10A 15A QS2DNA 40A 20A 25A

QS2FNA 50A 30A 35A

QS2GNA 60A 35A 40A QS2HNA 80A 40A 50A

QS2INA 100A 70A 80A

Note: When ASTAT-SD reduced voltage starters are used in conjunction with semi-conductor fuses,

Type 2 Coordination to IEC 947-4 is attained. These fuses are recommended for best overall short-circuit protection. The semi-conductor fuse specified may provide branch circuit protection. Refer to local applicable electrical codes.

Suitable for use on a circuit capable of delivering not more than 100KA rms symmetrical amperes, for 208V, 240V and up to 480V maximum, when used with the semi-conductor fuse

for short-circuit protection. Listed with Gould Shawmut Form

101, Type A50QS.

Suitable for use on a circuit capable of delivering not more than 25KA rms symmetrical amperes, for 208V, 240V and up to 480V maximum, when used with Class RK5 and J fuse.

Suitable for use on a circuit capable of delivering not more than 25KA rms symmetrical amperes, for 208V, 240V and up to 480V maximum, when used with circuit breakers.

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ASTAT-SD™Solid-State Reduced Voltage Starters

Chapter 2. Installation & Start-up

2-8 Control panel description

Potentiometers

RAMP Acceleration ramp time, in seconds ILT/TORQUE Current limit 2-5 starter current rating/Starting torque

(15-80% DOL), selected by DIP switch ILT/TORQUE

DIP Switches* Position Function

HD/SD 1 Not used

0 Not used

ILT/TORQUE 1 Select ILT/TORQUE potentiometer for current limit

0 Select ILT/TORQUE potentiometer for initial torque

KICK START 1 Kick start function ON. When started, a 90% voltage pulse is

applied for 400 ms duration. Subsequently, the ramp continues with the preselected starting torque and ramp time.

0 Kick start function OFF.

SOFT STOP 1 Soft stop. On receiving stop command, equipment stops by

decreasing voltage ramp over a maximum of 2 x t (acceleration ramp).

0 No soft stop. Equipment coasts to stop after receiving stop command.

EOR/RUN 1 Select internal relays (terminals 11-14) as end of ramp relay; contact

11-14 closes when the starting ramp voltage reaches end of ramp. If soft stop is programmed, contact closes prior to the beginning of soft stop ramp.

0 Select internal relay (terminals 11-14) as RUN relay; contact 11-14

closes when the RUN order is given to the unit, and opens after the STOP order is given (coast), when the soft stop ramp is completed, or an error is found.

OVERRIDE 1 Override function ON. The energy-saving feature is disabled.

0Override function OFF. The energy-saving feature is enabled.

*Factory default setting is DIP switches off.

5010

0.5 60

4/603/40

7030

2/15 5/80

RAMP(s)

WHEN BLINKING SEE ERROR CODE

ILT/TORQUE

A B C

B C

RUN

FULL SAVE

ILT/TORQUE

HD/SD

KICK START SOFT STOP

EOR/RUN OVERRIDE

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ASTAT-SD™Solid-State Reduced Voltage Starters

Chapter 2. Installation & Start-up

2-9 Start-up

Make sure equipment wiring corresponds to one of the recommended wiring diagrams or equivalent.

Make sure the control wiring corresponds to the control voltage used.

Set starting parameters according to your application.

Set stopping parameters according to your application.

Set the rest of the parameters as needed.

Start motor and make sure that operation is correct.

110/120V ac

A2 B1 B2 A1

220/240V ac

A2 B1 B2

0.5 60

RAMP(s)

ILT/TORQUE

HD/SD

KICK START SOFT STOP EOR/RUN OVERRIDE

ILT/TORQUE

HD/SD

KICK START SOFT STOP EOR/RUN OVERRIDE

Voltage ramp or current limit Acceleration ramp time Kick start feature

4/603/40

7030

2/15 5/80

ILT/TORQUE

HD/SD

KICK START SOFT STOP EOR/RUN OVERRIDE

ILT/TORQUE

HD/SD

KICK START SOFT STOP EOR/RUN OVERRIDE

Select relay output (contact 11-14) as RUN or End of Ramp (at speed) relay

ILT/TORQUE

HD/SD

KICK START SOFT STOP EOR/RUN OVERRIDE

Select full voltage or energy saving at steady state

Page 17

2-10 Error detection

LEDs

●● OFF

● ON

BLINKING

OA BC OPERATION CODE

● ●● ●● ●● Equipment is connected to main supply

●● ●● ●● Run

●● ● ●● End of ramp

●● ● ● Effective energy saving

● ●● ● ●● Stop order

ASTAT-SD™Solid-State Reduced Voltage Starters

Chapter 2. Installation & Start-up

5010

0.5 60

4/603/40

7030

2/15 5/80

RAMP(s)

WHEN BLINKING SEE ERROR CODE

ILT/TORQUE

A B C

B C

RUN

FULL SAVE

ILT/TORQUE

HD/SD

KICK START SOFT STOP

EOR/RUN OVERRIDE

LEDs

ABC Symptom or Error Possible Cause Measures to be Taken

LED “O” off No control voltage Check wire harness and control voltage

Defective control PCB,s Change control PCB,s

Equipment does not Defective control PCB,s Change control PCB,s respond to STOP/ START controls

● ●● Frequency error No 1L1 phase of frequency Check 1L1 phase and/or main

48Hz <f main < 62 Hz) is out of range frequency

●●Phase sequence loss Disturbance in supply voltage Check notches or dropouts in power line

Defective thyristor Check thyristors No input phases Check 1L1, 3L2 and 5L3 phases

●● ●● Synchronism loss Phase 1L1 lost Check 1L1 phase, ground connection

and/or output voltage to ground

● ●● A Phase A, B, C Short-circuited thyristor Check thyristor module

●● ● B thyristor No output phases Check 2T1, 4T2 and 6T3 phases

●●C

● ●●

A Phase A, B, C lost No input/output phases Check power wire harness for

●● ● B 1L1, 3L2, 5L3, 2T1, 4T2 and 6T3

●● C Defective thyristor or bad Verify gate and cathode wire

wire harness harness and verify thyristors

● Internal failure Microcontroller malfunction Check that IC2 is correctly inserted

in socket

Page 18

ASTAT-SD™Solid-State Reduced Voltage Starters

Chapter 2. Installation & Start-up

Troubleshooting Checklist

To assist you in troubleshooting, the following information is required in order to evaluate the cause and avoid further failures.

Item Circle correct choice or fill in the blank

Catalog No. (located on right side of ASTAT) Date code: Startup date: RGA No.: Failure date:

Contact name: Company: Address: Telephone: Fax:

Application type/characteristics: Motor hp: RPM: Service factor: NEMA design:

Observations and comments:

Power system data: 3-phase volts: Frequency, Hz:

System grounding: kVA: Transformer data: Yes No NP Data: KVA Engine generator: Yes No NP Data: KW

Power factor correction: Yes No NP Data: µf

Page 19

ASTAT-SD™Solid-State Reduced Voltage Starters

Chapter 2. Installation & Start-up

Troubleshooting Checklist (continued)

Item Circle correct choice or fill in the blank

Line (V) A-B phase: B-C phase: C-A phase: Line-Ground (V) A: A: B: C: Bypass contactor: Yes No NEMA enclosure type: 1 12/3R

Motor overload relay Cat. No.:

Setting: Amps:

Application description:

Status when failure occurred: Power up Running Starting Stopping

Last 4 error codes:

●ON ●● OFF BLINKING

●● ●● ●● 2 ●● ●● ●● 3 ●● ●● ●● 4 ●● ●● ●●

Parameters: (Enter indicators on potentiometer controls)

DIP switch settings (circle setting for each):

HD/SD 1 0 Soft Stop 1 0 ILT/Torque 1 0 EOR/Run 1 0 Kick Start 1 0 Override 1 0

5010

0.5 6 0

4/603/40

7030

2/15 5/80

RAMP(s)

ILT/TORQUE

Page 20

GE Electrical Distribution & Control

General Electric Company 41 Woodford Avenue, Plainville, CT 06062

DEH-036 0297