GE Industrial Solutions ASTAT XT User Manual
GE Consumer & Industrial
ASTAT XT
User Manual
2 •Warnings
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 IS RECOMMENDED, CONFIGURED TO PROVIDE AUTOMATIC ISOLATION WHEN
THE 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.
6. SEPARATE MOTOR OVERCURRENT PROTECTION IS REQUIRED TO BE PROVIDED IN ACCORDANCE WITH
THE CANADIAN ELECTRICAL CODE, PART 1. ASTAT-XT 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. ABNORMAL STARTING TIMES IN EXCESS OF 30 SECONDS, OR CLOSELY REPEATED OPERATIONS OF
ACCELERATION RAMP/DECELERATION RAMP, SLOW SPEED, MAY CAUSE MOTOR DAMAGE. CONTACT
MOTOR MANUFACTURER FOR PROPER MOTOR SELECTION.
5. IF CONTROL POWER IS LOST BETWEEN STARTS, THE OVERLOAD RELAY PROTECTION IS RESET TO COLD
START CONDITIONS.
REMARKS:
1. Read this manual thoroughly before using the ASTAT-XT 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.
3 • Table of Contents
ASTAT-XT User Manual
1.
Generalities..................................................................................................................................................... 7
1.1 Squirrel-Cage Motor Starting.................................................................................................................................................... 7
1.2 Advantages of the ASTAT-XT Solid State Soft Starters ................................................................................................. 7
2. Types and Ratings ......................................................................................................................................... 8
2.1 IEC Ratings. Recommended Motor and Type Unit Ratings........................................................................................ 8
2.2 NEMA Ratings . Recommended Motor and Type Unit Ratings................................................................................. 9
2.3 Thermal Characteristics ............................................................................................................................................................10
3. Technical Specifications .............................................................................................................................11
3.1 General Specifications ...............................................................................................................................................................11
3.2 Weight................................................................................................................................................................................................13
3.3 I/O Terminal Board Specifications........................................................................................................................................13
3.4 I/O Wiring..........................................................................................................................................................................................17
3.5 Ordering Information..................................................................................................................................................................18
3.5.1 Ordering Accessories .................................................................................................................................................18
3.6 Operating Modes ..........................................................................................................................................................................19
4. Control Keypad.............................................................................................................................................20
4.1 LCD Arrangement.........................................................................................................................................................................20
4.2 Push-Buttons..................................................................................................................................................................................21
4.3 Status LEDs......................................................................................................................................................................................21
4.4 Reviewing and Modifying Parameters...............................................................................................................................21
4.5 Special Actions Performed in Test/Maintenance Mode .............................................................................................22
4.5.1 Run Self Test ...................................................................................................................................................................22
4.5.2 View Software Version...............................................................................................................................................22
4.5.3 Obtain Default Parameters ..................................................................................................................................... 22
4.5.4 Reset Statistical Data .................................................................................................................................................22
4.5.5 Calibrate Voltage and Current (Factory Use Only!) .....................................................................................23
4.6 Mode Pages.....................................................................................................................................................................................23
4.7 Overview of All Mode Pages and Factory Defaults......................................................................................................24
4.7.1 Display Mode – Page 0 ..............................................................................................................................................26
4.7.2 Main Settings – Page 1 ..............................................................................................................................................27
4.7.3 Start Settings – Page 2 ..............................................................................................................................................29
4.7.3.1 Soft Start Parameters.......................................................................................................................................32
4.7.4 Stop Settings – Page 3 ...............................................................................................................................................34
4.7.4.1 Soft Stop Parameters ....................................................................................................................................... 35
4.7.5 DUAL Settings Parameters – Page 4...................................................................................................................36
4.7.6 Slow Speed & Energy Save Parameters – page 5........................................................................................37
4.7.7 Fault Settings – Page 6 ..............................................................................................................................................38
4.7.8 I/O Settings Parameters – Page 7........................................................................................................................ 40
4.7.8.1 Terminal 7 and 8 Programming ..................................................................................................................41
4.7.9 COMM. Parameters – Page 8 – With the Modbus standard PCB ..........................................................42
4.7.10 Comm. Parameters – Page 8 – With the Profibus optional PCB............................................................42
4.7.11 Comm. Parameters – Page 8 – With the DeviceNet Optional PCB ......................................................43
4.7.12 Statistical Data – page 9...........................................................................................................................................44
4.8 Non Adjustable Protection and Fault Reset.....................................................................................................................45
4.8.1 Under/Over Frequency .............................................................................................................................................45
4.8.2 Phase Loss.......................................................................................................................................................................45
4.8.3 Phase Sequence ...........................................................................................................................................................45
4.8.4 Wrong Connection ......................................................................................................................................................45
4.8.5 Shorted SCR ....................................................................................................................................................................45
4.8.6 Heat-Sink Over Temperature .................................................................................................................................45
4.8.7 External Fault .................................................................................................................................................................45
4.8.8 Fault and Reset .............................................................................................................................................................45
4.8.9 Auto Reset........................................................................................................................................................................46
4.9 Timing Occurrence Table..........................................................................................................................................................46
4 • Table of Contents
5. Installation .................................................................................................................................................... 47
5.1 Prior to Installation.......................................................................................................................................................................47
5.2 Mounting...........................................................................................................................................................................................47
5.3 Temperature Range & Heat Dissipation............................................................................................................................47
5.3.1 Forced Ventilation........................................................................................................................................................48
5.4 Main PCB and Optional PCBs..................................................................................................................................................48
5.5 Dip Switch Settings on the Main PCB..................................................................................................................................49
5.5.1 Switch # 1 – Display Modes ....................................................................................................................................49
5.5.2 Switch # 2 – Not used ................................................................................................................................................50
5.5.3 Switch # 3 – Main/ D.Set: Generator Parameters.........................................................................................50
5.5.4 Switches # 5, 6 – Language Selection................................................................................................................50
5.5.5 Switch # 7 – Expanded Settings............................................................................................................................ 50
5.5.6 Switch # 8 – Software Lock .....................................................................................................................................50
5.6 Internal Fan Control ....................................................................................................................................................................51
5.7 Analog I/O (Terminals T1, T2, Gnd, Out (-), Out (+)) ........................................................................................................51
5.8 Remote Key-Pad Installation..................................................................................................................................................52
6. Starting Procedure ...................................................................................................................................... 53
6.1 Standard Starting Procedure..................................................................................................................................................54
Examples of Starting Curves...................................................................................................................................................55
6.2
6.2.1 Light Loads - Pumps, Etc. .........................................................................................................................................55
6.2.2 High Inertia Loads: Crushers, Centrifuges, Mixers, Etc...............................................................................55
6.2.3 Special Starting Using DUAL Settings ................................................................................................................56
6.2.3.1 Special Starting – Using DUAL Settings – Wiring Diagram ............................................................57
6.2.4 Choosing a Suitable Pump Curve (Centrifugal Pumps)..............................................................................57
6.2.4.1 Starting Curve ......................................................................................................................................................57
6.2.4.2 Stopping Curve ....................................................................................................................................................58
6.2.4.3 End Torque During Soft-Stopping a Pump Motor...............................................................................58
7. Trouble Shooting.......................................................................................................................................... 59
8. Application diagrams.................................................................................................................................. 62
8.1 Terminal 21 Connections With Various Mains................................................................................................................62
8.2 Control Supply, Control Input and Mains are From the Same Source, Neutral Connected to Terminal 21
63
8.3 Control Supply and Control Input From the Same Source, Neutral not Connected to Terminal 21 ....63
8.4 Control Supply and Control Input from Separate Sources ......................................................................................64
8.5 Soft Start, Soft Stop and Stop, Control Supply and Control Input from the Same Source........................64
8.6 Soft Start, Soft Stop and Stop, Control Supply and Control Input from Separate Sources ......................64
8.7 Soft Start and Immediate Stop (no Soft Stop) .................................................................................................................65
8.8 Soft Start and Soft Stop .............................................................................................................................................................65
8.9 Soft Start, Soft Stop and Immediate Stop.........................................................................................................................65
8.10 Energy Save, Slow Speed or Reset.................................................................................................................................66
8.11 Slow Speed and Slow Speed Reverse ...........................................................................................................................66
8.12 External Fault............................................................................................................................................................................67
8.13 Line Contactor..........................................................................................................................................................................67
8.14 Bypass Contactor...................................................................................................................................................................68
8.15 Reversing with Two Line Contactors .............................................................................................................................69
8.16 Operating via Communication Links.............................................................................................................................70
8.17 D.Set: Generator Parameters Wiring.............................................................................................................................71
8.18 Short Circuit Protection........................................................................................................................................................72
8.19 Transient Protection ..............................................................................................................................................................73
8.20 Inside Delta Configuration..................................................................................................................................................74
8.18.1 Type 1 Coordination ................................................................................................................................................... 72
8.18.1.1 Type 1 Coordination with GE Circuit Breakers: ....................................................................................72
8.18.1.2 Type 1 Coordination with Type aM Siba Fuses:................................................................................... 72
8.18.2 Type 2 Coordination ................................................................................................................................................... 72
8.20.1 General Information ...................................................................................................................................................74
8.20.2 Notes on Inside Delta Connection .......................................................................................................................74
8.20.3 Motor Connection and Terminals......................................................................................................................... 75
5 • Table of Contents
8.20.4 ASTAT-XT Connected Inside Delta w/Bypass Contactor and Inside Delta Contactor ................76
8.20.5 ASTAT-XT Connected Inside Delta - Reverse Speed....................................................................................77
9. Dimensions....................................................................................................................................................78
9.1 UL cUL Approved Models..........................................................................................................................................................78
9.2 Non UL cUL Approved Models................................................................................................................................................82
Appendix A - MODBUS RTU Protocol......................................................................................................................86
A.1. Introduction.....................................................................................................................................................................................86
A.2. Basic Structure of the Serial Link Frame ...........................................................................................................................87
A.3. SYNC (Silent Interval) ...................................................................................................................................................................87
A.4. Serial Link No. (Slave Address)...............................................................................................................................................87
A.5. Function ............................................................................................................................................................................................87
A.6. List of Functions Supported By The ASTAT-XT ...............................................................................................................87
A.7. Actual Data (3X References & 4X References)................................................................................................................89
A.8. Parameter Settings (4X References) ....................................................................................................................................91
A.9. Control Register Write (4X Reference) ................................................................................................................................94
A.10. Discrete Commands (Coils, 0x References)...............................................................................................................95
A.11. Discrete Hardwired Inputs (1x References)...............................................................................................................97
A.12. Diagnostics ................................................................................................................................................................................98
A.13. Exception Responses ............................................................................................................................................................99
Appendix B - Profibus..............................................................................................................................................101
B.1. Operation Mode in PROFIBUS:.............................................................................................................................................101
B.1.1. Structure of the ASTAT-XT Receiving Frame ................................................................................................ 101
B.1.2. Structure of the ASTAT-XT Transmitting Frame ......................................................................................... 101
B.1.2.1. Selection of the DPV0 Registers through Data Request (DPV1)................................................ 101
B.1.3. Read and Write from Random Registers via Data Request .................................................................102
B.2. Configure the PROFIBUS in the ASTAT-XT......................................................................................................................103
B.3. Watch Dog Definition ..............................................................................................................................................................103
B.4. Actual Data Register Numbers (decimal) ....................................................................................................................... 104
B.5. Setting Parameters Registers for Data Request......................................................................................................... 106
Appendix C - DeviceNet™ to Modbus™ Gateway..............................................................................................108
C.1. Introduction.................................................................................................................................................................................. 108
C.1.1. Overview........................................................................................................................................................................ 108
C.1.2. Definitions..................................................................................................................................................................... 108
C.1.3. Reference Documents............................................................................................................................................ 108
C.1.4. Open DeviceNet Vendor Association, Inc. (ODVA) ..................................................................................... 108
C.1.5. Rotary Switch Configuration ............................................................................................................................... 109
C.1.6. LED Indicators............................................................................................................................................................. 109
C.2. Identity Object (01
1 Instance) ..................................................................................................................................... 111
HEX -
C.2.1. Class Attributes (Instance 0)................................................................................................................................. 111
C.2.2. Instance Attributes (Instance 1) ......................................................................................................................... 111
C.2.3. Common Services..................................................................................................................................................... 111
C.3. Message Router Object (02
C.4. DeviceNet Object (03
HEX -
1 Instance) ...................................................................................................................111
HEX -
1 Instance)................................................................................................................................111
C.4.1. Class Attributes (Instance 0)................................................................................................................................. 111
C.4.2. Instance Attributes (Instance 1) ......................................................................................................................... 111
C.4.3. Common Services..................................................................................................................................................... 111
C.5. Assembly Object (04
– 4 Instances) ............................................................................................................................112
HEX
C.5.1. Class Attributes (Instance 0)................................................................................................................................. 112
C.5.2. Output (O2T) Instance Attributes – Register 40752 .................................................................................. 112
C.5.2.1. Output Instance 112 (0x70) – Control Output.................................................................................... 112
C.5.3. Input (T20) Instance Attributes – Register 40257....................................................................................... 112
C.5.3.1. Input Instance 60 (0x3C) – Basic Softstart Input .............................................................................. 112
C.5.3.2. Input Instance 61 (0x3D) – Extended Softstart Input ..................................................................... 112
C.5.3.3. Input Instance 100 (0x64) – Status .........................................................................................................112
C.5.4. Common Services..................................................................................................................................................... 113
C.6. Connection Object (05
2 Instances) ..........................................................................................................................113
HEX –
C.6.1. Class Attributes (Instance 0)................................................................................................................................. 113
C.6.2. Instance Attributes (Instances 1-2) Explicit, Polled I/O............................................................................ 113
C.6.3. Common Services..................................................................................................................................................... 115
C.7. Softstart Object (2D
1 Instance)...................................................................................................................................115
HEX -
C.7.1. Class Attributes (Instance 0)................................................................................................................................. 115
C.7.2. Instance Attributes (Instance 1) ......................................................................................................................... 115
C.7.2.1. Extended AtReference Values................................................................................................................... 115
C.7.2.2. Extended StartMode Values....................................................................................................................... 115
C.7.3. Common Services..................................................................................................................................................... 115
C.8. Control Supervisor Object (29
1 Instances)............................................................................................................ 115
HEX -
C.8.1. Class Attributes (Instance 0)................................................................................................................................. 115
C.8.2. Instance Attributes (Instance 1) ......................................................................................................................... 115
C.8.3. Common Services..................................................................................................................................................... 116
C.9. Modbus / Serial Object (65
1 Instance).................................................................................................................... 116
HEX –
C.9.1. Class Attributes (Instance 0)................................................................................................................................. 116
C.9.2. Instance Attributes (Instance 1) ......................................................................................................................... 116
C.9.3. Common Services..................................................................................................................................................... 117
C.10. Input Object (70
1 Instance) ....................................................................................................................................117
HEX –
C.10.1. Class Attributes (Instance 0) ............................................................................................................. 117
C.10.2. Instance Attributes (Instance 1) ...................................................................................................... 117
C.10.3. Common Services.................................................................................................................................. 118
C.11. Main Parameter Object (71
1 Instance)............................................................................................................. 118
HEX –
C.11.1. Class Attributes (Instance 0) ............................................................................................................. 118
C.11.2. Instance Attributes (Instance 1) ...................................................................................................... 118
C.11.3. Common Services.................................................................................................................................. 119
C.12. Start Settings Object (72
1 Instance)................................................................................................................... 119
HEX –
C.12.1. Class Attributes (Instance 0) ............................................................................................................. 119
C.12.2. Instance Attributes (Instance 1) ...................................................................................................... 119
C.12.3. Common Services.................................................................................................................................. 119
C.13. Stop Settings Object (73
1 Instance) ...................................................................................................................119
HEX –
C.13.1. Class Attributes (Instance 0) ............................................................................................................. 119
C.13.2. Instance Attributes (Instance 1) ...................................................................................................... 119
C.13.3. Common Services.................................................................................................................................. 119
C.14. Dual Settings Object (74
1 Instance)................................................................................................................... 119
HEX –
C.14.1. Class Attributes (Instance 0) ............................................................................................................. 119
C.14.2. Instance Attributes (Instance 1) ...................................................................................................... 120
C.14.3. Common Services.................................................................................................................................. 120
C.15. Slow SP & Saving Parameters Object (75
C.15.1. Class Attributes (Instance 0) ............................................................................................................. 120
C.15.2. Instance Attributes (Instance 1) ...................................................................................................... 120
C.15.3. Common Services.................................................................................................................................. 120
C.16. Fault Settings Object (76
1 Instance) ..................................................................................................................120
HEX –
C.16.1. Class Attributes (Instance 0) ............................................................................................................. 120
C.16.2. Instance Attributes (Instance 1) ...................................................................................................... 120
C.16.3. Common Services.................................................................................................................................. 121
C.17. I/O Settings Object (77
1 Instance) ......................................................................................................................121
HEX –
C.17.1. Class Attributes (Instance 0) ............................................................................................................. 121
C.17.2. Instance Attributes (Instance 1) ...................................................................................................... 121
C.17.3. Common Services.................................................................................................................................. 121
C.18. Communication Parameter Object (78
C.18.1. Class Attributes (Instance 0) ............................................................................................................. 121
C.18.2. Instance Attributes (Instance 1) ...................................................................................................... 121
C.18.3. Common Services.................................................................................................................................. 122
6 • Table of Contents
1 Instance)................................................................................. 120
HEX –
1 Instance) .....................................................................................121
HEX –
1. GENERALITIES
1.1 Squirrel-Cage Motor Starting
7 • Generalities
There a
re numerous applications where soft starting and limited current peak are needed, thereby making direct
starting of squirrel-cage motors impossible. Traditionally in such cases other types of starting 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, thus reducing the starting torque, but there will always
be peaks during the change from one point or state to another which can damage the machine being driven.
Note that in general, all reduced voltage starts reduce torque in squared proportion to the current in the phases of
the motor (not on 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 advantage is the ease with which this ramp can be controlled to
produce a soft start in accordance with the actual requirement of the machine.
1.2 Advantages of the ASTAT-XT Solid State Soft Starters
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 machine mechanical elements, greatly reducing stress on
transmission and coupling parts.
Consequently, overhauling times are reduced and machine and facility
lifespans are lengthened.
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.
Stopping may be made by cutting-off power or by soft stop ramp.
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.
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.
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 maybe selected for
have equipment capabilities suited to application needs every time.
Easy maintenance due to full monitoring
The alphanumeric display and the LEDs on its front overlay makes the
equipment working conditions known at any time.
Pump control
The ASTAT-XT includes several soft stop curves 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.
Advanced functions
The ASTAT-XT includes advanced functions, like linear acceleration ramp,
forward and reverse jog, programmable I/O or connection to a control system
via Modbus protocol included as standard and other optional protocols.
These functions allow 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.
High level of immunity
Design of the unit was closely tied to the conditions of supply lines, which
handle more disturbances every day. The control signals are
opto-electronically isolated and various levels of protection have been set up
in the circuits to immunize the equipment against external disturbance and its
effects.
8 • Types and Ratings
2. TYPES AND RATINGS
2.1 IEC Ratings
1
. Recommended Motor and Type Unit Ratings.
Light
Duty
Max
Current
Rating
17 17 4 7.5 7.5 15 15 12 3 5.5 5.5 10 8 QTx0017Uxxxx
34 31 8 15 18.5 15 22 31 8 15 18.5 25 22 QTx0031Uxxxx
54 44 11 22 30 40 37 44 11 22 30 40 37 QTx0044Uxxxx
65 58 15 30 37 50 55 55 15 30 37 50 45 QTx0058Uxxxx
72 72 22 37 45 60 55 66 18.5 37 45 60 55 QTx0072Uxxxx
104 85 22 45 55 75 75 80 22 45 55 75 75 QTx0085Uxxxx
130 105 30 55 55 100 90 99 30 55 55 100 90 QTx0105Uxxxx
156 145 45 75 90 150 132 130 37 55 90 125 90 QTx0145Uxxxx
170 170 55 90 110 150 160 134 37 75 90 125 132 QTx0170Uxxxx
248 210 55 110 132 200 200 203 55 110 132 200 200 QTx0210Nxxxx
361 310 90 160 200 300 250 310 75 160 200 300 250 QTx0310Nxxxx
390 390 110 200 250 300 355 344 110 160 250 350 315 QTx0390Nxxxx
480 460 132 250 315 450 400 432 132 250 315 450 400 QTx0460Nxxxx
480 460 132 250 315 450 400 432 132 250 315 450 400 QTx0460Uxxxx
610 580 160 315 400 500 560 488 160 250 355 500 400 QTx0580Nxxxx
610 580 160 315 400 500 560 552 160 315 400 560 QTx0580Uxxxx
820 650 200 355 400 630 552 160 315 400 560 QTx0650Nxxxx
820 820 250 400 560 800 690 200 400 500 710 QTx0820Uxxxx
1180 950 315 560 630 900 950 315 560 630 900 QTx0950Nxxxx
1375 1100 355 630 800 1000 1076 355 630 800 1000 QTx1100Nxxxx
1750 1400 400 800 1000 1400 400 800 1000 QTx1400Nxxxx
Normal Duty (IEC Class 10)
Recommended Motor Ratings
Current
rating
A A kW kW kW HP kW A kW kW kW HP kW
8 8 2 3.0 4 5 5.5 8 1.5 3.0 4 5 5.5 QTx0008Uxxxx
230V 400V
2
415V
480V
500V
575V 690V Current
Heavy Duty (IEC Class 20)
Recommended Motor Ratings
rating3
230V 400V
415V
480V
500V
Type Unit
575V 690V
Note:
Select the appropriate ASTAT-XT, according to the main power supply and motor voltage rating.
Use QT1xxxx units for power supply and motors rated at 230V-500V
Use QT2xxxx units for power supply and motors rated at 460V-600V
Use QT3xxxx units for power supply and motors rated at 690V
1
Ratings in Amps. given for ambient temperature up to 40°C and 1000m altitude.
For higher ambient temperature between 40°C and 50°C, derate the current by 2.5% for each °C that is above 40°C.
2
Normal duty ratings, only IEC Class 10 protection is allowed.
3
Heavy duty ratings, IEC Class 10 and 20 protections are allowed.
9 • Types and Ratings
2.2 NEMA Ratings4 . Recommended Motor and Type Unit Ratings.
Light Duty
Nema 10
Current
rating
A HP HP HP A HP HP HP A HP HP HP
8 2 5 5 8 2 5 5 8 2 5 5 QTx0008Uxxxx
17 5 10 15 17 5 10 15 12 3 7.5 10 QTx0017Uxxxx
34 10 25 30 31 10 20 25 31 10 20 25 QTx0031Uxxxx
54 20 40 50 44 15 30 40 44 15 30 40 QTx0044Uxxxx
65 20 50 60 58 20 40 50 55 20 40 50 QTx0058Uxxxx
72 25 50 60 72 25 50 60 66 20 50 60 QTx0072Uxxxx
104 40 75 100 85 30 60 75 80 30 60 75 QTx0085Uxxxx
130 50 100 125 105 40 75 100 99 40 75 100 QTx0105Uxxxx
156 60 125 150 145 50 100 150 130 50 100 125 QTx0145Uxxxx
170 60 125 150 170 60 125 150 134 50 100 125 QTx0170Uxxxx
262 100 200 250 210 75 150 200 203 75 150 200 QTx0210Uxxxx
387 150 300 400 310 100 250 300 310 100 250 300 QTx0310Uxxxx
414 150 350 400 390 150 300 400 361 150 300 300 QTx0390Uxxxx
480 200 400 500 460 150 350 400 432 150 350 400 QTx0460Uxxxx
610 250 500 580 200 400 400 552 200 400 500 QTx0580Uxxxx
820 820 250 500 500 690 250 500 QTx0820Uxxxx
230V 460V 575V Current
5
Normal Duty
Nema 20
rating6
Heavy Duty
Nema 30
230V 460V 575V Current
rating7
Type Unit
230V 460V 575V
Note:
Select the appropriate ASTAT-XT, according to the main power supply and motor voltage rating.
Use QT1xxxxUxxxx units for power supply and motors rated at 230V-500V
Use QT2xxxxUxxxx units for power supply and motors rated at 460V-600V
4
Ratings in Amps. given for ambient temperature up to 40°C and 1000m altitude.
For higher ambient temperature between 40°C and 50°C, derate the current by 2.5% for each °C that is above 40°C.
5
Light duty ratings, only NEMA Class 10 protection is allowed.
6
Normal duty ratings, NEMA Class 10 and 20 protections are allowed.
7
Heavy duty ratings, NEMA Class 10, 20 and 30 protections are allowed
2.3 Thermal Characteristics
10 • Types and Ratings
The ASTAT-X
T allows the user to select motor protection according IEC Class 10, 20 and NEMA 10, 20 or 30,
selectable by Overload Class parameter (refer to section
4.7.2 page 27)
3. TECHNICAL SPECIFICATIONS
3.1 General Specifications
11 • Technical Specifications
General Info
rmation:
Supply Voltage: Line to line 230-690V (to be specified) + 10%-15%
Frequency: 45 – 65 Hz (fixed or variable frequency source)
Control Supply: Either 110VAC or 230VAC (to be specified) +10% - 15%
Control Inputs: Either 90-230VAC or 24VDC (to be specified)
Load: Three phases, three/six wires, squirrel cage induction motor
Connection type: Standard 3 wire U, V, W connection, or 6 wire Inside Delta (programmable)
Rated Insulation Voltage: 1,000V
Rated Impulse Voltage: 4kV
Form designation: Form 1
This product was tested for compliance with IEC 60947-4-2 for class A equipment.
Start-Stop Parameters:
Starter Current: ASTAT-XT’s rated current according to its nameplate.
Motor Current: Motor Full Load Ampere (Im) 50-125%8 of Starter Current.
Start/Stop Curve 0
2 standard starting and stopping curves
(Standard)
Pump Control Curves (1!,
2!, 3!)
6 field selectable curves preventing over-pressure during start and water hammer
during stop
Torque Control Curve (4) 2 selectable curves preventing over-pressure during start and water hammer during
stop. In addition, these curves may be used for torque control starting of constant
torque applications.
Kick Start Duration: A pulse of 80% Un, for an adj. time 0.1-1 Sec, for starting high friction loads
Starting Voltage: 10-50% Un (5-80%9)
Initial Current:
100-400% In. A single current control starting curve. It appears when Starting
Voltage is displayed, the up arrow is pressed and Starting Voltage has
reached its max.
Current Limit: 100-700% of Motor Current
Ramp UP Time: 1-30 Sec (1-90 sec9)
Ramp DOWN Time: 1-30 Sec (1-90 sec9)
DUAL Settings Parameters: Secondary start stop characteristic for: Starting Voltage, Starting Current, Current
Limit, Ramp UP, Ramp DOWN and Motor Current.
Energy Saving: Energy save for lightly loaded motors
Slow Speed Torque: Torque while motor is at 1/6 nominal speed
Motor Protection:
Too Many Starts: Maximum number of starts, range: Off or 1-10, during a time period 1-60 min.
Starts Inhibit: Time period 1-60 min, when starting is prevented, after too many starts fault
Long Start Time (stall
Maximum allowable starting time 1-30 sec. (1-250 Sec9)
protection):
Over Current (JAM Fault): Three trip functions:
At all time
- If I > 850% of Starter Current it trips the ASTAT-XT within 1 cycle
(overrides the value of the O/C – JAM Delay setting).
At starting process
- If I > 850% of Motor Current it trips the ASTAT-XT after O/C
JAM Delay (see here after)
At run time
- If I > O/C – JAM Fault setting of Im it trips the ASTAT-XT after O/C
JAM Delay
Electronic Overload: Can be set as IEC Class 10, 20 or NEMA Class 10, 20 or 30.
Can be set to operate at all times, disabled or operate during Run only.
Under Current: Trips when current drops below 20-90% of Motor Current, time delay 1-40 sec.
Optional auto reset after time delay.
Under Voltage: Trips when main voltage drops below 120-600V, time delay 1-10 Sec. Optional Auto
Reset.
Over Voltage: Trips when main voltage increase above 250-750V, time delay 1-10 sec.
8
Refer to sections 2.1 page 8 and 2.2 page 9 for detailed information.
9
Refer to section 5.5.5 page 50 for expanded setting.
12 • Technical Specifications
Phase Loss, Under/over
Frequency:
Phase Sequence: Trips when phase sequence is wrong
Long Slow Speed Time: Trips if operating at slow speed TRQ for more than 1-30 sec (1-250 sec9)
Wrong Connection: Prevents starting, trips if motor is not connected / incorrectly connected to the
Shorted SCR: Trips if one or more SCRs have been shorted
Heat Sink Over
Temperature:
External Fault: Trips when an external contact closes for 2 sec.
Motor Thermistor: Trip level setting 1-10KΩ, trips when resistance decreases below the level set
Control:
Displays: LCD in 4 – Field selectable languages and 8 LEDs
Keypad: 6 keys for easy setting
Aux Contact – Immediate: 1 C/O, 8A, 250VAC, 2000VA
Aux Contact – End Of
Ramp:
Fault Contact: 1 C/O, 8A, 250VAC, 2000VA
Communication: RS 485 with Modbus protocol for full control and supervision
Communication (optional): Profibus DPV1 for full control and supervision
Communication (optional): DeviceNettm for full control and supervision
Temperatures Operating: -10° to 50°C
Storage: -20° to 70°C
Standards:
Dielectric Test: 2500VAC
Degree of Protection: IP 20 for QTx0008 - QTx0072 ; IP 00 for QTx0085 – QTx1400
Pollution Degree: 3
EMC Emissions: EN 61000-6-4 CISPR 11 Class A
Immunity: EN 61000-6-2 ESD 8KV air, IEC 801-2;
Safety: EN IEC 600947-4-2 and EN IEC 60947-1 Related to safety requirements.
Rated Operational Current AC:53a:4-30: 50-4
Normal Service Conditions:
Altitude: Up to 1000m.
Humidity: 95% at 50°C or 98% at 45˚C
Fan and Control Consumption Ratings:
QTx0008 to QTx0031: No fan Total approximate consumption: 150VA
QTx0044 to QTx0072: Fan 35 VA Total approximate consumption 185VA
QTx0085 to QTx0170 :Fan 60 VA Total approximate consumption 210VA
QTx0210 to QTx0390 : Fans 105 VA (35VA x 3) Total approximate consumption 255VA
QTx0460 to QTx1400A : Fans 150 VA (50VA x 3) Total approximate consumption 300VA
Trips when one or two phases are missing, or frequency is < 40Hz or > 65Hz.
Optional auto reset.
ASTAT-XT (not active in D.Set: Generator Parameters)
(not active in D.Set: Generator Parameters)
Trips when heat-sink temperature rises above 85°C
1 C/O, 8A, 250VAC, 2000VA
Electric RF field 10 V/m, 20-1000Mhz, IEC 801-3
Fast transients 2KV, IEC 801-4
UL508C
13 • Technical Specifications
3.2 Weight
Model Weight
Kg Lbs
QTx0008Uxxxx 4.2 9.3
QTx0017Uxxxx 4.2 9.3
QTx0031Uxxxx 5.3 11.7
QTx0044Uxxxx 6.7 14.8
QTx0058Uxxxx 6.7 14.8
QTx0072Uxxxx 6.7 14.8
QTx0085Uxxxx 15.2 33.5
QTx0105Uxxxx 15.2 33.5
QTx0145Uxxxx 15.2 33.5
QTx0170Uxxxx 15.2 33.5
QTx0210Nxxxx 32.7 72.1
QTx0210Uxxxx 46.5 102.5
QTx0310Nxxxx 32.7 72.1
QTx0310Uxxxx 46.5 102.5
QTx0390Nxxxx 32.7 72.1
QTx0390Uxxxx 46.5 102.5
QTx0460Nxxxx 58.4 128.7
QTx0460Uxxxx 61.8 136.2
QTx0580Nxxxx 63.2 139.3
QTx0580Uxxxx 69.5 153.2
QTx0650Nxxxx 64.8 142.9
QTx0820Uxxxx 69.5 153.2
QTx0950Nxxxx 86.7 191.1
QTx1100Nxxxx 169.8 374.3
QTx1400Nxxxx 175.5 386.9
3.3 I/O Terminal Board Specifications
Refer to dra
wing on page 17.
Terminal Function Description
1L1, 3L2, 5L3 Connection to mains voltage up
to 690V
A, B, C Preparation for bypass
connection
2T1, 4T2, 6T3 Connection to motor
G Connection to ground For proper operation and for safety reasons soft ASTAT-XT
Terminal L Control phase The control voltage operates the electronic circuitry and the
Terminal N Control neutral (return) Two control voltages are available:
Thyristor’s PIV rating, internal circuitry and insulation defines
three voltage levels:
QT 1 x : for 230-500V +10%/ -15% 50/60Hz
QT 2 x: for 460-600V +10% /-15% 50/60Hz
QT 3 x: for 690V +10% /-15% 50/60Hz
Each ASTAT-XT is suitable for one of the above levels & for
50/60 Hz.
Bypass preparation is standard in all models.
All models from ASTAT-XT 950A and up must
be operated
with a bypass contactor.
Refer to section
5.3 page 47 for more details.
Connect motor’s terminals to these terminals/busbars.
must be properly grounded.
fans (when they exist).
QT x xxxx x 1 x x S for 110V +10%/-15% 50/60Hz
QT x xxxx x 2 x x S for 230V +10%/-15% 50/60Hz
14 • Technical Specifications
Terminal Function Description
Terminal F Fan control An internal jumper, connected between the fan and
terminal 2 enables three modes of operation (refer to section
5.6 page 51).
For fan power consumption, see technical specification in
section
Terminal 4 Input – STOP command.
• Input from a N.C. contact
• To stop the motor, disconnect
Control Input voltage from
• Control Input voltage (STOP, SOFT STOP, START, terminal
• The Control Inputs are opto-coupled and isolated from the
terminal 4 for at least
250mSec. (no SOFT STOP)
Terminal 5 Input – SOFT STOP command10.
• Input from a N.C. contact
• To SOFT STOP the motor
Control Input voltages available:
QT x xxxx x x 1 x S for 90-230V +10%/-15% 50/60Hz.
QT x xxxx x x 2 x S for 24VDC +10%/-15%.
disconnect Control Input
voltage from terminal 5 for at
least 250mS
Terminal 6 Input – START command11.
• Input from a N.O. contact.
• To SOFT START the motor,
connect Control Input voltage
to terminal 4 for at least
250mSec.
Terminal 7 Programmable input – Energy
Refer to section 4.7.8.1 page 41.
Save / Slow Speed / Reset
Terminal 8 Programmable input – Dual Set
/ Reverse / Reset
Terminal 9 12 Common to terminals 4-8.
This terminal is a reference for terminals 4, 5, 6, 7 &
8.
Terminal 10 Immediate Relay (N.O.) Immediate Relay (RUN relay) is the immediate output relay.
• Voltage free 8A, 250VAC, 2000VA max.
Terminal 11 Immediate Relay (N.C.) • The relay is energized upon the START signal.
Terminal 12 Immediate Relay (Common) • The relay is de-energized when one of the following occurs:
• When SOFT STOP is operated - the relay is de-energized at
• The Immediate Relay (RUN relay) can be used for the
• The relay incorporates ON and OFF delays of 0-3600 sec.
Terminal 13 Programmable Fault Output
relay (N.O.)
Terminal 14 Programmable Fault Output
relay (N.C.)
Voltage free 8A, 250VAC, 2000VA max. changes its position
upon fault.
The contact is programmable to function as At Fault
Close or At Fault Open.
10
If SOFT STOP is not required, connect a jumper between terminals 4 and 5.
11
Motor will start only if STOP (terminal 4) and SOFT STOP (terminal 5) terminals are connected to Control Input voltage.
To reset a fault the START command must be removed.
12
When Control Supply and Control Input voltage are from the same source, connect a jumper between terminals 3 and 9.
3 page 11.
inputs 7 and 8) can be the same as Control Supply
(terminals 1, 3) or voltage from a different source.
microprocessor circuitry.
Fault, Control Supply outage or STOP signal.
the end of the SOFT STOP process.
following purposes: Release a brake of a motor, Interlock
with other systems, Signalling, Delay the opening of a line
contactor at the end of SOFT STOP, thus allowing current to
decrease to zero before opening the contactor or to switch
to / from DUAL settings with a time delay from the START
signal (see Special Starting section
each. Refer to section
4.7.8 page 40 for Relay ON Delay
6.2.3.1 page 57).
programming.
15 • Technical Specifications
Terminal Function Description
Terminal 15 Programmable Fault Output
relay (Common)
Terminal 16 Programmable EOR (End Of
Ramp) Output relay (N.O.)
Terminal 17 Programmable EOR (End Of
Ramp) Output relay (N.C.)
Terminal 18 Programmable EOR (End Of
Ramp) Output relay (Common)
Terminal 19 External Fault input Input from a N.O. contact that is connected between
Terminal 21 Neutral connection When a mains neutral wire is available, connect terminal 21
When the At Fault Close function is selected, the relay
is energized upon fault. The contact returns to its original
position when one of the following occurs:
• The fault has been removed and ASTAT-XT was reset.
• Disconnection of Control Supply
When the At Fault Open function is selected, the relay is
energized immediately when the Control Supply is connected
and de-energizes when one of the following occurs:
• Fault
• Control Supply disconnection
Refer to section
4.7.8 page 40 for PROG. Fault Relay
programming.
Voltage free 8A, 250VAC, 2000VA max. changes its position at
the end of ramp, after an adjustable time delay (Contact
Delay), 0 – 120 sec.
The contact returns to its original position when Energy
Save is operated, on Soft Stop or Stop signals, on Fault
condition, or upon voltage outage.
The EOR (End Of Ramp) contact can be used for:
• Closing a bypass contactor
• Activating a valve after compressor has reached full speed
• Loading a conveyor after motor reached full speed.
Refer to section
4.7.3 page 29 for EOR Relay Delay
programming
terminals 19 and 21. The ASTAT-XT will trip 2 seconds after
the contact closes.
Notes:
• Wires connecting the External Fault contact to terminal 19
should not exceed 1 meter in length.
• External Fault can be used only when terminal 21 is
connected to neutral or ground.
• Only potential free contacts may be connected to terminal
19.
• Do not connect any voltage to terminal 19.
• Any connection of voltage to this terminal may disrupt
ASTAT-XT operation, and cause ASTAT-XT or motor damage.
• Refer to section 8.12 page 67 for the External Fault wiring
diagram.
to neutral. Terminal 21 serves only as a voltage reference to
the control circuitry.
Caution
• ASTAT-XT circuitry incorporates an internal artificial neutral,
:
which should only be used, when the mains system is not
grounded and mains neutral connection is not available.
• Only potential free contacts may be connected to terminal
21.
• Do not connect any voltage to terminal 21.
Any connection of voltage to this terminal may disrupt
ASTAT-XT operation, and cause ASTAT-XT or motor damage.
• Refer to section 8.1 on page 62 for terminal 21 connection.
16 • Technical Specifications
Terminal Function Description
Terminal SG No connection • Standard RS485, half duplex with Modbus protocol, baud
rate 1200, 2400, 4800, 9600 BPS.
Terminal D- RS-485 communication (-) • Twisted shielded pair should be used.
Connect shield to ground on the PLC/Computer side.
Terminal D+ RS-485 communication (+) • Terminals 4 & 5 must be wired to Control Supply for
operation in communication mode (refer to section
page 70 for wiring diagram).
• Up 32 units can be connected for Modbus RS485
communication. For reliable communication, units should
be installed in the vicinity of 200m maximum, from the first
to the last unit.
• Refer to section 4.7.9 page 42 for programming.
• Refer to Appendix A of this manual for Modbus protocol
manual.
Terminal 28 Thermistor input (T1) Thermistor input is programmable as a PTC or NTC type
thermistor. The trip value is adjustable between 1-10Kohm,
preset delay of 2 Sec.
Terminal 29 Thermistor input (T2)
Connect thermistor and/or Analog output shield to ground
terminal.
Terminal 30 Ground Analog output (0-10VDC or 0-20mA or 4-20mA)
8.16
Terminal 31 Analog output (-) Reflects motor current and is related to 2xIm. i.e., Full scale
(10VDC or 20mA) is related to 2xIm.
Terminal 32 Analog output (+) Note:
Refer to section
5.7 page 51 for analog output PCB dip switch
setting.
• Refer to section 4.7.8 page 40 for Analog Output
programming.
• Refer to section 4.7.7 page 38 for Thermistor Type and
Thermistor Trip programming.
D-9 connector Profibus communication
(optional)
• Profibus DPV0 and DPV1, up to 12 MBPS.
• D type 9 pin connector is applied.
• Control, monitoring and setting parameters can be achieved
via the Profibus connection.
• Setting is possible only when DPV1 is implemented.
• Refer to section 4.7.10 page 42 for programming.
• Refer to Appendix B of this manual for Profibus protocol
manual.
Terminal V- 0 Volt external power supply
Terminal CL Negative data line
DeviceNet communication
(optional)
Terminal Dr Cable shield
Terminal CH Positive data line
Terminal V+
+24V external power supply
3.4 I/O Wiring
17 • Technical Specifications
18 • Technical Specifications
3.5 Ordering Information
Notes:
cUL Certification
(*1) – ASTAT-XT up to 600V, and up to 170A (Cat Numbers up to to QT10170_ or QT20170) are always cUL
Control and Inputs Voltage
(*2) ASTAT XT standard Control Voltage configuration is option 2, Voltage 230VAC, +10%, -15%
(*3) ASTAT XT standard configuration for Inputs is option 1, Voltage 90-230VAC, +10%, -15%
3.5.1 Ordering Accessories
certified. Option “N” not available
- Units QT1 or QT2 from QTx0950_ up to QTxx1400 are not UL certified. Option “U” not available.
- Units QT3x, rated to 690V, are not UL certified. Option “U” not available
Catalog Number
QTAKPADKIT1 Keypad mounting kit for ASTAT-XT up to 72A
QTAKPADKIT2 Keypad mounting kit for ASTAT-XT above 72A
Description
19 • Technical Specifications
3.6 Operating Modes
Operating Mode
Key Description
Starting Voltage 1 5 to 80% Un. Adjustable via Starting Voltage parameter.
Kick Start 2
Fixed level of 80% Un with an adjustable time, 0-1 sec., via Kickstart
Time parameter.
13
1-30 sec. (1-90
Secondary ramp 1-30sec. (1-90
sec.). Adjustable via Ramp UP Time.
13
sec.). Adjustable via Ramp UP-2
parameter.
Acceleration Ramp 3
Ramp up modes available are:
Soft Start Curve 0 (Standard)
Soft Start Curve 1!!-3!!
Soft Start Curve 4(Torque) for linear torque control
4 Fast ramp (if the motor is up to speed before the end of normal ramp time)
Running mode 5 Nominal voltage
13
Deceleration ramp 1-30sec. (1-90
Secondary ramp 1-30sec. (1-90
sec.). Adjustable via Ramp DOWN Time.
13
sec.). Adjustable via Ramp DOWN-2
parameter.
Soft stop mode 6
Ramp down modes available are:
Soft Stop Curve 0 (Standard)
Soft Stop Curve 1!!-3!!
Soft Stop Curve 4(Torque) for linear torque control
7 Current limiting set point (100-500%xMotor Current)
8
Acceleration ramp (continuation after motor amps drop below the current
limit).
9 Standard stopping (coast to rest)
Starting by voltage ramp:
Starting by current limitation:
13
Refer to section 5.5.5 page 50 for expanded setting.
20 • Control Keypad
4. CONTROL KEYPAD
The control keypad is the interface between the ASTAT-XT and the user.
The ASTAT-XT control keypad features:
Eight indication LEDs (On, Start, Run, Soft Stop, Stop, Save/Slow Speed, Dual Set/Reverse, Fault)
Two lines of 16 alphanumeric characters each with selectable languages – English, Italian, German, and Spanish.
Six push-buttons - Mode, Reset, Select, Set, Up (▲) and Down (▼) keys.
(1)
(2)
(3)
ASTAT-XT control keypad
4.1 LCD Arrangement
Starting Voltage
30%
Upper line displays the function.
Lower line displays the setting and\or measured values.
4.2 Push-Buttons
Mode
Select
Scrolls throu
When a mode name is displayed, pressing this button drills down to the parameters for that mode.
When a parameter is displayed, pressing this button scrolls to the next parameter.
Allows the operator to increment adjusted values shown in the display. Operator should press this
▲
button once to increment one value, or continuously to rapidly increment values up to the maximum
value.
Allows the operator to decrement adjusted values shown in the display. Operator should press this
▼
button once to decrement one value, or continuously to rapidly decrement values up to the minimum
value.
Stores modified parameters only
Set
Settings Xxxxxx Parameters is displayed. After you store a parameter successfully Data
Saved OK will display.
21 • Control Keypad
gh the display and programming menus of the ASTAT-XT.
when you have scrolled through all parameters and Store
15
14
Reset
Resets the ASTAT-XT after a fault has been dealt with and the start command has been removed. This
cancels the fault displayed and allows you to restart the motor.
4.3 Status LEDs
Green
On Lights when the control supply voltage is connected to the ASTAT-XT.
Yellow Start Lights during soft start, indicating that motor supply voltage is ramping up.
Green Run
Lights after completion of the starting process, indicating that motor is receiving
full voltage. This LED flashes during slow speed operation.
Yellow Soft Stop Lights during soft stop, indicating that the motor supply voltage is ramping down.
Red Stop Lights when the motor is stopped.
Yellow
Green
Save/Slow
Speed
Dual
set/Reverse
Lights when Energy Saving is in operation.
Flashes when the motor is running in Slow Speed.
Lights when Dual Settings is in operation.
Flashes when the motor is running in Slow SP Reverse.
Red Fault Lights upon operation of any of the built-in protections.
4.4 Reviewing and Modifying Parameters
Press the Mode key several times until you reach the required mode page.
Press the Select key to review parameters for this mode.
Once you reach the required parameter, use the ▼ or ▲ keys to modify its value.
To store the new parameters, press the Select key until the Store Settings Xxxxxx Parameters message
displays and then press the Set key. The Data Saved OK message will display for 2 seconds.
Note:
After completing parameter settings:
• Turn control voltage OFF
• Wait 3 seconds
• Reconnect control voltage
14
Pressing Mode continuously increases the speed at which the parameters change.
15
Pressing the Set button at any other time has no effect.
22 • Control Keypad
• Verify that all parameters are set correctly.
4.5 Special Actions Performed in Test/Maintenance Mode
4.5.1 Run Self Test
Press
the Mode and ▼ keys simultaneously. The LCD will display:
Test/Maintenance
Statistics
Press the Select key. The LCD will display:
Auto Test.
Press UP Key
Press the ▲ key. The LCD will display:
Self Test Passed
And after a few seconds the LCD will display:
Motor Current
0
4.5.2 View Software Version
Press
the Mode and ▼ keys simultaneously. The LCD will display:
Test/Maintenance
Statistics
Press the Select key twice. The LCD will display:
Firmware Version
STRT.GE-031208
Press the Mode and ▼ keys simultaneously to exit the Test/Maintenance mode. The LCD will display:
Motor Current
0
4.5.3 Obtain Default Parameters
Press the Mode and ▼ keys simultaneously. The LCD will display:
Test/Maintenance
Statistics
Press the Select key three times. The LCD will display:
Store Settings
Default data
Press the Set + Mode keys simultaneously. The LCD will display:
Data Saved OK
And after a few seconds the LCD will display:
Motor Current
0
CAUTION! Obtaining Default Data erases all previously modified settings and requires the
operator to reprogram all parameters that differ from the factory default.
Note: It is especially important to reprogram the Starter Current (as shown
on the name plate of the ASTAT-XT), Motor Current and voltage protection
values again.
4.5.4 Reset Statistical Data
Press
the Mode and ▼ keys simultaneously. The LCD will display:
Test/Maintenance
Statistics
Press the Select key four times. The LCD will display:
Reset Statistics
Press the Reset + Set keys simultaneously. The LCD will display:
Data Saved OK
And after a few seconds the LCD will display:
Statistical Data
- **** -
23 • Control Keypad
Press the Mode and go back to:
Motor Current
0
4.5.5 Calibrate Voltage and Current (Factory Use Only!)
the Mode and ▼ keys simultaneously. The LCD will display:
Press
Test/Maintenance
Statistics
Press the Select key five times. The LCD will display:
Calibration VOLT
0 VOLT
Press the Select key. The LCD will display:
Calibration CURR
5% of Ir
Press the Mode and ▼ keys simultaneously to exit the Test/Maintenance mode.
4.6 Mode Pages
Upon init
iation of the ASTAT-XT, the LCD displays motor’s operating current:
Motor Current
0
You can review all mode pages by pressing the Mode key:
Main Settings
- **** Start Settings
- **** Stop Settings
- **** DUAL Settings
Parameters
Slow SP & Saving
Parameters
Fault Settings
- **** -
These pages are skipped if ASTAT-XT is programmed to Minimized
Mode and are shown only in Maximized Mode. Refer to section
on page 49 for changing mode from Minimized
Mode.
I/O Settings
Parameters
COMM. Parameters
- **** Statistical Data
- **** -
5.5.1
Mode to Maximized
24 • Control Keypad
4.7 Overview of All Mode Pages and Factory Defaults
Appears only in
Maximized
Display Page
Main Settings
- **** -
Start Settings
- **** -
Stop Settings
- **** -
DUAL Settings
16
Parameters
Function & Default Function & Default Function & Default Function & Default Function & Default
Motor Current
0
Starter Current
58 AMP.
Soft Start Curve
0(Standard)
Soft Stop Curve
0(Standard)
Starting VOLT-2
30%
Line Voltage
0 Volt
Motor Current
58 AMP.
Kickstart Time
0 SEC.
Ramp DOWN TIME
10 SEC.
Starting CURR-2
100%
Thermistor Input.
3.1 Kohm
LINE/DELTA Conf.
Line
Starting Voltage
30 %
End Torque
0 (MIN.)
Current Limit-2
300% of Im
Undercurrent FLT
0% of Im
Starting Current
100 %
Store Settings
Stop Settings
Ramp UP-2
10 SEC.
Undercurrent DLY
10 SEC.
Current Limit
400% OF Im
Ramp DOWN-2
10 SEC.
O/C JAM Fault
850% OF Im
Ramp UP Time
10 SEC.
Motor Current-2
31 AMP.
O/C JAM Delay
0.5 Sec.
Max. Start Time
30 SEC.
Store Settings
Dual Settings
Overload Class
IEC CLASS 10
Number of Starts
10
Overload Protect
Enabled
Duty Cycle Time
30 Min.
Undervoltage FLT
300 Volt
Start Lockout
15 Min.
Undervoltage DLY
5 SEC.
EOR Relay Delay.
5 Sec.
Overvoltage FLT
480 Volt
Store Settings
Start Settings
Overvoltage DLY
2 SEC.
Store Settings
Main Settings
16
Refer to section 5.5.1 on page 49 for changing mode from Minimized Mode to Maximized Mode.
25 • Control Keypad
Only in Max. Mode
Slow SP & Saving
Parameters
16
Only in Max. Mode
Fault Settings
- **** -
16
Only in Max. Mode
16
I/O Settings
Parameters
Only in Max. Mode
COMM. Parameters
- **** -
16
Statistical Data
- **** -
Function & Default Function & Default Function & Default Function & Default Function & Default
Energy Saving
0 (MIN)
Slow Speed TRQ.
8
Max Slow SP Time
30 SEC.
Store Settings
Slow SP & Saving
Phase Loss
Enabled
Phase Sequence
Disabled
Auto Reset
Disabled
Thermistor Type
PTC
Thermistor Trip
Disabled
Undercurrent RST
Disabled
Store Settings
Fault Settings
Appears when in
Test/Maintenance
Test/Maintenance
***Statistics***
Display and default
values
Auto Test
Press UP Key
Firmware Version
STRT-GE-270508
Store Settings
Default Data
Reset Statistics
Calibration VOLT
0 VOLT
Calibration CURR
5% of Ir
PROG. Input #7
Reset
PROG. Input #8
Dual Settings
PROG. Fault Relay
At Fault Close
Relay ON Delay
0 SEC.
Relay OFF Delay
0 SEC.
Analog Output
I, 0...200% OF Im
Store Settings
I/O Settings
COMM. Protocol
Modbus
Baud Rate
9600 (MODBUS)
Parity Check
EVEN
Station Number.
OFF
S. Link Par. Set
DISABLED
Ser. Link Control
DISABLE
Store Settings
COMM. Parameters
COMM. Protocol
Profibus
Baud Rate
AUTO (Profibus)
Parity Check
AUTO (Profibus)
PROFI. Network ID
OFF
S. Link Par. Set
Disabled
Ser. Link Control
Disabled
Store Settings
COMM. Parameters
COMM. Protocol
DeviceNet
Baud Rate
Set Manually
Parity Check
AUTO (DeviceNet)
DeviceNet ID
Set Manually
S. Link Par. Set
Disabled
Ser. Link Control
Disabled
Store Settings
COMM. Parameters
Last Start Time
No Data
Last Start Curr.
No Data
Elapsed Run Time
0 Hours
Number Of Starts
0
Last Fault
No Data
Motor FLT Current
0 % of Im
Fault Counter
0
Previous Fault -1
No Data
PREVIOUS Fault -9
No Data
Note: There are three different groups of COMM. Protocol parameters. Each group of COMM. Protocol parameters
are only valid when its corresponding optional PCB is installed.
26 • Control Keypad
4.7.1 Display Mode
Function &
17
– Page 018
Unit Description
Default
Motor Current
0
A Displays operating current of the motor.
ASTAT-XT’s Default Display. After pressing the Mode or Select keys, a time
delay is initiated. Following the delay the LCD returns to display Motor
Current.
If current is lower than 0.1 of the rated current of the ASTAT-XT, the display
will show: I < 0.1 Ir
Line Voltage
0 Volt
Thermistor Input
3.1 Kohm
V Displays the mains voltage.
Kohm Displays the resistance level of the motor’s thermistor.
17
Displays in MINIMIZED MODE and MAXIMIZED MODE.
18
Parameters cannot be programmed in page 0.
27 • Control Keypad
4.7.2 Main Settings
Function &
Default
Starter Current
58 Amp.
Motor Current
58 Amp.
LINE/DELTA Conf.
Line
19
– Page 1
Range Unit Description
8 – 1400 A Sets ASTAT-XT’s Rated Current (Type Unit)
Check the name plate on the soft starter and make sure that
digits 4 to 7 of the model name are the same as the
Starter Current setting. For example the setting for
model QTx0008Uxxx must be 8 Amp. Refer to section
page 47.
4-175020
Based on % of
Starter
Current
A Sets the motor’s Full load Ampere
Should be programmed as shown on the motor’s name
21
plate.
Note:
When setting Motor Current to a higher level than
Starter Current, Overload Class parameter (see
below) is automatically set to NEMA Class 10.
Line, Inside
Delta
Sets ASTAT-XT’s connection type.22
Factory preset - features and functions not
DELTA Conf. is configured:
Kickstart.
Soft Start Curve selection (Curve 0!! only)
Slow Speed
Phase Sequence Disabled mode
Refer to section
8.20 on page 74 for further information.
5.1 on
active when
Undercurrent FLT
0% of Im
0%=OFF;
20-90
% of
Motor
Current
Sets Undercurrent protection.
Trips the ASTAT-XT when the motor current drops below the
level that was set for a time period longer than
Undercurrent Dly.
Undercurrent DLY
10 SEC.
1-40 sec. Sets the time delay for Undercurrent FLT protection.
Note:
Operational when the motor is running (the RUN LED is lit).
O/C JAM Fault
850% of Im
100-850 % of
Motor
Current
Sets O/C JAM Fault protection.
Operational when ASTAT-XT is energized and has three trip
functions:
At all time
- If I > 850% of Starter Current it trips the
ASTAT-XT within 1 cycle (overrides the value of the O/C JAM
Fault setting).
O/C JAM Delay
0.5 Sec.
0.0 – 5 sec. At starting process - If I > 850% of Motor Current it trips
the ASTAT-XT after O/C JAM Delay
At run time
- If I > O/C JAM Fault setting of Motor
Current it trips the ASTAT-XT after O/C JAM Delay.
Caution:
The O/C JAM Fault is not intended to replace the fast
acting fuses, required to protect the thyristors. Refer to
section
8.18 on page 72.
19
Displays in MINIMIZED MODE and MAXIMIZED MODE.
20
The lower limit can be set as low as 50% of Starter Current. The upper limit is automatically set by the ASTAT-XT and is
between 100 and 126% of Starter Current.
The Motor Current can be set as high as indicated in columns “Current Rating” for Light Duty applications in the tables in
section
21
When the ASTAT-XT is installed in the Inside Delta configuration set:
Motor Current = <rated motor current>/1.73.
22
When the ASTAT-XT is installed in DELTA Conf. set Motor Current = <rated motor current>/1.73.
2.1 page 8 and in section 2.2 page 9.
28 • Control Keypad
Function &
Default
Overload Class
IEC CLASS 10
Overload Protect
Enabled
Undervoltage FLT
300 Volt
Undervoltage DLY
5 SEC.
Range Unit Description
IEC CLASS 10;
IEC CLASS 20;
NEMA CLASS
10;
NEMA CLASS
20;
NEMA CLASS
30;
Sets Overload CLASS.
Overload Class is operational as programmed in the
Overload Protect parameter. (see next parameter)
The O/L circuitry incorporates a thermal memory register
that calculates heating minus dissipation of the motor. The
ASTAT-XT trips when the register fills up.
The time constant for cool down after overload trip is:
For IEC/NEMA Class 10 – 320seconds
For IEC/NEMA Class 20 – 640seconds
For NEMA Class 30 – 960seconds
Refer to section
2.3 on page 10 for thermal characteristic.
Note:
When setting Motor Cu
rrent to a higher level than
Starter Current, Overload Class parameter is
automatically set to NEMA Class 10.
Enable after
EOR;
Enabled;
Disabled;
Sets Overload Protection operation.
Enable after (End Of Ramp) will set the overload
protection to be operative after starting process is completed
and (End Of Ramp) relay is energized.
Enabled will set the overload protection to be operative at
all time.
Disabled will set the overload protection not to be
operative at all time.
ATTENTION!
When Overload Protect is set to Disabled the motor
is not protected for Overload!!
120-600
V Sets Undervoltage Fault level.
Trips the ASTAT-XT when mains voltage drops below the level
that was set for a time longer than Undervoltage DLY.
1 –10 sec. Sets Undervoltage Fault delay23
Overvoltage FLT
480 Volt
250-750
V Sets Overvoltage Fault level.
Trips the ASTAT-XT when mains voltage increases above the
level that was set for a time longer than Overvoltage
DLY. Can not be set lower than the Undervoltage FLT
setting.
Overvoltage DLY
2 SEC.
Store Settings
Main Settings
1 –10 sec. Sets Overvoltage Fault delay.24
Storing modified parameters25
To store selected parameters scroll through all parameters
until you reach Store Settings Main Settings, then
press the Set key.
After you store a parameter successfully the Data Saved
OK message will display.
If ASTAT-XT fails to store the parameter the LCD Will display
the Storage Error message (refer to section
7 on page
59 for more details).
23
Becomes operational only after the start signal.
When voltage drops to zero (voltage outage) the ASTAT-XT will trip immediately, thus overriding the delay.
24
Becomes operational only after the start signal.
25
Pressing the Set key when the Store Settings Xxxxx Settings message does not appear on the display has no
effect.
4.7.3 Start Settings
26
– Page 2
29 • Control Keypad
Function &
Default
Soft Start Curve
0(Standard)
Kickstart Time
0 Sec.
Range Unit Description
0
(Standard)
Sets ASTAT-XT’s Soft Start Curve.
Refer to section
4.7.3.1 on page 32.
27
1 !!
2 !!
3 !!
4 (Torque)
0 –1.0 sec. Sets ASTAT-XT’s Kickstart Time.28
Kickstart level is 80% Un.
Intended to start high friction loads that require high starting
torque for a short time.
A pulse of 80% Un without Current Limit is initiated to break the
load free.
Kickstart Time is adjustable, 0.1–1sec. After this pulse the
voltage is ramped down to Starting Voltage setting
before ramping up again to full voltage according to the Start
Settings.
26
Displays in MINIMIZED MODE and MAXIMIZED MODE.
27
When ASTAT-XT is connected in DELTA Conf. only Soft Start Curve 0 (Standard) is applied.
28
There is no Kickstart function when ASTAT-XT is connected in DELTA Conf.
30 • Control Keypad
Function &
Default
Starting Voltage
30 %
Starting Current
100 %
Range Unit Description
10-50%
After
reaching
50% the
display
changes to:
Starting
Current
100-400%
29
% of
mains
voltage
Sets the motor’s Starting Voltage.
The motor’s torque
is directly proportional to the square of the
voltage.
This adjustment also determines the inrush current and
mechanical shock. A setting that is too high may cause high
initial mechanical shock and high inrush current. This can occur
even if Current Limit is set low because the Starting
Voltage setting overrides the Current Limit setting.
A setting that is too low may result in prolonged time until the
motor starts to turn. In general, this setting should ensure that
the motor starts turning immediately after start signal.
Note:
When Starting Voltage is set its maximum value, this
displays changes to Starting Current.
When Starting Current is set the ASTAT-XT causes current
ramp instead of voltage ramp.
29
The range of the Starting Voltage can be extended to 5-80% by using the EXPANDED SETTING as described in section 5.5.5
page 50.
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