GE Industrial Solutions ASTAT-XT RVSS PANEL User Manual

ASTAT-XT RVSS PANEL

sufficiently for the purchaser’s purposes, the matter should be referred to the nearest

GE ED&C sales office.

DEH 40621 Instruction

Table of Contents

Section Topic

Thanks information – DEH40627 Installation and Start-up Instructions for ASTAT-XT RVSS Bypass & Non Bypass Panels –

DEH40620

Operating and Troubleshooting Instructions for ASTAT-XT RVSS Bypass and Non

Bypass Panels – DEH40622

ASTAT-XT User’s Guide (ED230209) – DEH40625 Appendices – Table of Contents (Current Ratings and Fuse Sizes) – DEH40624 In-Warranty Information Form – DEH40626

7 Appendices – Table of Contents (Wire Sizes, Torque and Estimated Watt loss Details) –

DEH40623

8 Product Drawings – Electrical and Mechanical (To be inserted)

GE Consumer & Industrial

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DEH 40627 Instruction

GE wishes to thank you for choosing our Soft Starter product. We are committed to being the world’s leading supplier of RVSS Panel by providing the highest quality products as well as the best documentation and product support available in the industry.

Compiled in this manual is a comprehensive set of documentation for your purchase. The manual is designed to provide you installation, commissioning, preventative maintenance, trouble-shooting and proper operating instructions for your RVSS Panel product. We suggest complete review of the manual by your personnel prior to installation and subsequent operation of the product.

Before proceeding to the instructions note that throughout this manual there are several warnings, cautions and notes, which are highlighted in, shadowed boxes as shown below. Please take time to read these special instructions because they contain important information regarding protection and safety of personnel and equipment.

WARNING: Denotes operating procedures and practices that may result in personal injury or loss of life if not correctly followed

CAUTION: Denotes operating procedures and practices that, if not strictly

observed, may result in damage to, or destruction of equipment.

NOTE: Notes call attention to information that is especially significant in understanding and operating the equipment.

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with the installation, operation, or maintenance. Should further problems arise which are not covered sufficiently for the purchaser’s purposes, the matter should be referred to the nearest GE ED&C sales office.

GE Consumer & Industrial

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CAUTION: Care should be taken when unpacking the panel; improper

use of tools could damage equipment.

WARNING: Improper lifting of enclosure could result in a fatal or

serious injury.

WARNING: Failure to comply with this instruction could result in a fire and/or explosion, thus resulting in a fatal or serious injury.

CAUTION: On enclosures the panel doors can swing more than 90+

degrees and there are no stops to inhibit the door from hitting equipment located next to the panel. This could result in damage to the door mounted switches and indicator lights on the panel door.

DEH 40620 Instruction

INSTALLATION AND START-UP INSTRUCTIONS FOR ASTAT-XT RVSS BYPASS & NON-BYPASS PANELS

The following information is provided for reference used during the installation of your Astat-xt RVSS Bypass and Non-Bypass Panels. Please note that all equipment shall be installed in accordance with the 2008 edition of NFPA 70 (National Electric Code) along with applicable local codes. This document provides information pertaining to: inspections, environment, installation, and wiring. The ASTAT-XT User’s Guide (ED230209) and the Astat-xt RVSS Panel Operating Instructions contained in this notebook have additional information and will be referenced through out this document.

INSPECTION #1 After unpacking your control panel inspect it for damage that may have

occurred during shipment.

If any damage is found please report it to the distributor from which the panel

was purchased.

PREPARING FOR Remove and discard desiccant / drying / silica packs, if included. INSTALLATION Before you begin to install the Astat-xt RVSS panel, make sure the proper

equipment for lifting is available. Refer to the appropriate Outline drawing for the dimensions, estimated weight, and required clearances for installation.

Review the Layout and Elementary diagrams before wiring your stat-xt RVSS

panel.

ENVIRONMENT Astat-xt RVSS Non-Bypass and Bypass Panels are available in different

NEMA types of enclosures. These types of enclosures consist of NEMA 1, 12 & 3R. The environment must also be totally free from flammable or combustible vapors and/or dust.

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The environments for NEMA Type 1 enclosures shall be indoor where the

CAUTION: Damage to equipment will result if panel is operated or

stored below or above stated ambient temperature range.

WARNING: The temperature of the starter heat sink fins may reach 90 C (194 F). Thus if not mounted on a heat resistant or a nonflammable surface a fire may occur resulting in a fatal or serious injury,

following condition may exist; falling dirt. The environments for NEMA type 12 enclosures shall be located indoors

where the following conditions may exist; dust, falling dirt, and/or noncorrosive dripping liquids.

The environments for NEMA Type 3R enclosures shall be indoor or outdoor where the following conditions may exist; falling dirt, rain, sleet and snow and undamaged by the external formation of ice on the enclosures. It is recommended that outdoor enclosures should not be mounted in direct sun light to avoid tripping over temperature & possible damage to equipment.

For all enclosure types the ambient temperature must remain in the range

from -10 C (14 F) to 40 C (104 F). Never store or operate panel below or above ambient range. All wall-mounted enclosures must be mounted on a non-flammable or heat resistant surface

Some enclosure configurations of Astat-xtRVSS Panels require ventilation to

keep the components and Starter unit within their thermal recommendations. The enclosure door and sides contains grilles at the bottom and top to allow for air to circulate through the enclosure. Ventilation is accomplished by the cooling fan(s) mounted at the bottom grille(s) pulling air into the enclosure and forcing it out the top grille(s).

The air used for ventilating the enclosure must be free from condensation,

moisture, dirt, dust, and flammable or combustible vapors and/or dust

The recirculation of air leaving the enclosure should be avoided. Air forced

out of the enclosure should not be allowed to circulate back into the enclosure. All enclosures shall be installed where the doors are able to completely open. Do not mount enclosure where the air-flow into or out of it may be restricted.

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INSTALLATION Determine conduit entry and exit locations on the enclosure before mounting.

CAUTION: Failure to cover components from metal shavings may result

in damage to equipment.

See the appropriate Outline drawing for recommended conduit locations. Allow for input and output power wiring to be located in separate conduit.

No conduit holes are provided in the enclosure except knockouts for Type-1

Enclosures; therefore the customer must install all conduit holes. Place a protective covering over the components of the panel while installing the conduit holes to prevent metal shavings or chips from landing on part or electronic boards.

For NEMA 12 and 3R enclosure types, liquid tight conduit (UL listed rain tight conduit hubs) and fittings must be installed to maintain the enclosure integrity.

GROUNDING

All panels/enclosures must be grounded. Each panel contains a grounding lug with provisions for connecting a field-

grounding conductor.

All field wiring shall be copper and have a minimum insulation rating of 75C

(167 F). Size grounding conductors according to local and national codes. Grounding methods must comply to local and national codes.

POWER WIRE

(Greater than 120 VAC)

All field wiring shall be copper and have a minimum insulation rating of 75 C

(167 F). Size all wire based on panel nameplate current ratings in accordance with

local and national codes. Does not use the cable sizes list ED230209 in

manuals.

All power wiring must be routed away from other wiring. Avoid running power

wiring parallel to other wiring without a minimum separation distance of four

(4) inches. Power wiring should only cross perpendicular to other wiring. Input and output power shall be connected as per the wiring diagram.

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Incoming power cables should be terminated at line side of the lugs provided

CAUTION: Do not connect power supply voltage greater than panel

rated voltage, or damage will occur to equipment.

WARNING: Never connect or disconnect input wiring with voltage

applied, a serious or fatal injury may result.

WARNING: Never connect or disconnect output wiring with voltage

applied, a serious or fatal injury may result.

with the Circuit breaker or Disconnect switch.

Locate terminals (T1, T2, and T3) in the panels and use these terminals to

connect the motor wires. Depending on actual panel configuration, motor

cables should be terminated on the load side lugs provided with the core

Softstater (non-bypass panel), Power Distribution blocks (AC1 Bypass panel)

and Overload relay (AC3 Bypass contactor configurations).

For Softstater panels of certain HP ratings & panel configuration, no lugs are

provided with the overload relay. Use appropriate size UL listed ring or fork or

suitable ferrule to terminate the cables on busbars terminals of overload

relay. Refer to Appendices for details for units with bus bar terminals for

motor connections.

Refer tables for Torque values for customer input and output power

connections, which are shown in pages in later part of this document

All field wiring shall have a minimum insulation rating of 75 C (167 F).

Size wire according to local and national codes.

All control wiring must be routed away from power wiring. If control wiring is

routed parallel to signal wiring (24 Vdc or less), isolation of the signal wiring

must be maintained. A minimum of four (4) inches is needed to adequately

separate signal and control wiring. If signal wire is UL recognized shielded

cable, separation can be minimized to a one (1) inch separation.

SIGNAL WIRING (24 VDC or less)

All field wiring shall have a minimum insulation rating of 75 C (167 F).

CONTROL WIRING (120 VAC)

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Size wire according to local and national codes.

CAUTION: Do not over-tighten terminal board connectors, damage to

the equipment may occur.

All field signal wiring must be twisted and shielded. All shields must be

grounded at one point ONLY. It is recommended to terminate the shield

drains at the signal’s source. Avoid routing signal wiring with power wiring. If

signal wiring is routed with control wiring a minimum separation of one (1)

inch is required.

Astat-xt RVSS Panels require no additional control wiring to operate properly.

Additional control interfacing to your Bypass & Non Bypass panels can be

accomplished through the panel mounted customer terminal board “CTB”.

Please reference the appropriate wiring diagram. Torque values for

connecting to “CTB” are located in the Appendices. If your application requires wiring to the Astat-xtRVSS Starter I/O control

terminal board, use 20 to 28 AWG wire. Connections on the inverter I/O terminal board should be tight enough such

that a slight tug on the wire will not result in the wire coming partially or

completely out of the terminal board.

MISCELLANEOUS INFORMATION If your enclosure is equipped with forced ventilation for keeping the starter

and other components within their thermal recommendations, the cooling

fan(s) used to ventilate your enclosure also need to be cleaned periodically.

Cleaning the cooling fan(s) is recommended to keep the proper amount of air

circulating through the enclosure. GE recommends that all power connections be checked for proper tightness

every 6 months due to thermal cycling that may occur during normal

operation. INSPECTION #2 Prior to start-up of your Astat-xtRVSS panel inspect the following:

 The mechanical installation for any safety and local or national code

violation.

 The electrical installation for proper connections and any violation of local

or national code.

 Proper grounding of equipment.

 All field wiring for tight and proper connections (no split wire ends that

may come in contact with adjacent connection points).

 No loose hardware, metal shavings, or wiring chips.

 All factory wiring for proper tightness that may have became loose due to

shipping vibration.

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ASTAT-XT RVSS PANEL

sufficiently for the purchaser’s purposes, the matter should be referred to the nearest

GE ED&C sales office.

GE Consumer & Industrial

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ASTAT

XT RVSS PANEL

DEH 40622 Instruction

Your Solid State RVSS Bypass and Non Bypass Panel comes with an ASTAT-XT Soft Starter from GE mounted in an enclosure and may contain the following equipment to control the motor from the Soft Starter and , if included, manually or automatically allow motor operation across-the-line.

FERRAZ SHAWMUT

GE Spectra RMSTM Mag-Break Solid State Circuit Breaker w/through-the-door lockable handle GE C-2000 GE C-2000TM Class 20/30 Fixed Heater Motor Overload Relays GE C-2000TM Selector Switches GE P9TM Indicating Lights GE P9TM Push Buttons GE C-2000TM MCR Series Control relays GE Type IP Encapsulated or Vacuum Impregnated 115 VAC Control Power Transformer w/fuses FERRAZ SHAWMUT Phoenix Control Terminal blocks (or Equivalent)

These instructions are intended as a supplement to the User’s Guide for the ASTAT-XT Soft Starter. For programming, operating and troubleshooting instructions for the Soft Starter please refer to the User’s Guide, which is included with your Bypass and Non Bypass panel documentation package.

ED230209 ASTAT-XT User’s Guide

Also included with your Bypass and Non Bypass panel documentation package are installation instructions, electrical and mechanical drawings of your Bypass and Non Bypass panel.

OPERATING AND TROUBLESHOOTING INSTRUCTIONS FOR

ASTAT-XT RVSS BYPASS AND NON-BYPASS PANELS

FERRAZ SHAWMUT equivalent)



Non-Fused Disconnect w/through-the-door lockable handle (optional) (or



Fused Disconnect w/through-the-door lockable handle (optional) (or equivalent)

3-Pole Non-Reversing Contactors



or Bussmann Amp-trap Time-Delay Class J Fuses (or equivalent)

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XT RVSS PANEL

1. Operator Devices page 3

2. Customer Terminal Board page 5

3. RVSS Soft Starter Terminal Board I/O page 6

4. Adjustments page 8

5. ASTAT-XT Soft Starter Function Code Changes page 11

6. Troubleshooting page 12

Table of Contents

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XT RVSS PANEL

1. Operator Devices

Your Bypass and Non-Bypass panel is equipped with several panel door mounted operator devices, which may include the following: one (1) through-the-door, lockable, input device disconnect handle; two (2) operator selector switches; two (2) push buttons; three (3) meters; one(1) door mounted keypad and three (3) indicator lights. Based on the selection, these components may or may not present in the panel. The operations of these devices are explained in this section. Refer to the Soft Starter Terminal Board I/O section of this manual and wiring diagrams for specifics on wiring connections.

Input Disconnect The purpose of the panel-mounted input disconnects with through-the-door

handle is to provide a local, lockable method of removing all AC input power from the Bypass and Non-Bypass panel and ASTAT-XT Soft Starter.

If your panel includes a circuit breaker, in addition to providing a manual method of applying and removing AC input power from the BYPASS AND NON BYPASS panel, the circuit breaker also provides short circuit protection for the panel components and the motor.

ASTAT - OFF - BYPASS (A-O-B) Selector Switch: This Switch is available only with AC3 (Bypass

Starter) configurations, AC3 configurations allow the unit to make and break rated motor current in the bypass mode and run the motor independent of the Solid State RVSS., an external overload relay is provided with this configuration to provide protection in Bypass operation.

The setting of this selector switch determines whether power to the motor

is controlled from the Soft Starter (“ASTAT” position) or directly from the AC line (“BYPASS” position). When started in Soft Starter mode the unit automatically changes over to the Bypass Contactor after the EOR (End of Ramp) signal is available from starter unit. On a stop command control reverts to the Soft Start. When the A-O-B switch is in the Bypass position, full voltage power is be fed to motor through Bypass contactor.

In the case of AC1 configurations, the Bypass Contactor is always

energized and de-energized through soft starter. Additionally, the contactor is not rated to for full voltage starting of the motor and no external overloads are provided

WARNING: Although Disconnect or Breaker Handle is in the “OFF” position, this does not guarantee that dangerous voltage levels are absent at the line side of disconnect or breaker. Always make sure to disconnect the upstream breaker or disconnect to remove power to the panel before working on it.

WARNING: Since an improper setting of the circuit breaker trip level can result in code violations or inadequate short circuit protection possibly resulting in a fire or safety hazard; refer to the “Adjustments” section of this manual for further instructions on setting the trip level.

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XT RVSS PANEL

HAND-OFF-AUTO Selector Switch: This selector is also referred to as the H-O-A switch. In the “Off”

In “Hand” mode, power will be applied to the motor from either the Soft

In “Auto” mode, power will be applied to the motor only when a

START-STOP Push Button This operator is used to Energize and de-energize panel, In some panels

RUN Indicator This Red/Green light on the panel door indicates that the Soft Starter and

OFF Indicator This Green light on the panel door indicates that the Soft Starter and

FAULT Indicator This red light on the panel door indicates that the soft starter is reporting

position power will be removed from the motor in both Bypass and Soft Starter modes of operation. It should be noted that this will not cause AC input power to be removed from the Soft Starter. To remove Soft Starter input power the Disconnect or breaker should be placed in the “OFF” position or a Line Isolation contactor should be used.

Starter or the AC line according to the A-O-B selector switch

connection is made between the two remote run contacts (CTB1-14 and CTB1-15) on the customer terminal board inside the panel enclosure

Start and / or Stop pushbutton are used along with H-O-A based on the selection.

Isolation Contactor (If present) and Bypass Contactor (If Present) are energized and the Soft Starter or Bypass Contactor are powering to the motor. Note that this light only means that the Soft Starter or Bypass contactor are energized and the panel is operating in “Soft Starter” or “Bypass” mode. This light will be OFF during fault and stop conditions

Isolation Contactor (If present) and Bypass Contactor (If Present) are not controlling the motor and the conditions that will cause this light to become energized are – ASTAT-Off-Bypass or Hand-Off-Auto switches are in the “OFF” and “OFF” positions without the Soft Starter reporting a fault condition. Note that this light only means that the Soft Starter or Bypass contactor are not operating the motor but the panel is energized (Disconnect or Breaker are in “ON” position)

a fault condition. Refer to Section 7, Trouble shooting and the ASTAT-XT users guide for fault codes, descriptions and trouble shoot on the same.

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XT RVSS PANEL

2. Customer Terminal Board – “CTB”

Inside the panel enclosure there are terminal boards for customer connections. The wiring diagram provides a reference of the terminal board connection and refer the ASTAT-XT users guide for details on each of the functionality and programming, the brief descriptions are as follows:

CTB1-1 Wire this Dual Set / Reverse / Reset Input This terminal allows for

activating the Dual Adjustment / Reversing / Reset Contact functionality on the ASTAT-XT 8 as required

CTB1-2 External Fault Input. Wire this for External Fault Input on ASTAT-XT as

required. When the input from a N.O. contact that is connected between terminals is closed, the ASTAT-XT will trip 2 seconds after the contact closes

CTB1-3 through CTB1-5 Thermistor Input. Thermistor input is programmable as a PTC or NTC

type thermistor. The trip value is adjustable between 1-10Kohm, preset delay of 2 Sec. Connect thermistor and/or Analog output shield to ground Terminal. User programmable Analog output (0-10VDC or 0-20mA or 420mA)

CTB1-6 and CTB1-7 Analog Output. User Programmable Analog output (0 - 10V DC or 0 -

20mA or 4-20mA)

CTB1-8, CTB1-9, CTB1-10 Customer Safety Interlocks Input. Put normally closed contacts between and CTB-19 CTB1-8 and CTB1-9 and between CTB1-10 and CTB1-19. An

open circuit between these positions will cause the Soft Starter to drop out resulting in power being removed from the motor. These positions come jumpered together from the factory and require removal of the factory jumpers prior to connecting customer normally closed contacts.

WARNING: When the circuit breaker/disconnect handle is turned to the “On” position, terminal board points can be at 115 VAC with respect to ground. Therefore, prior to making any connections to these points lock the disconnect handle in the “Off” position. In fact, good safety practice dictates that prior to servicing any electrical equipment that all sources of electrical energy be disconnected and “locked out” to avoid reconnection by a third party unaware of the maintenance efforts

WARNING: Do not use this for phase rotation correction and ensure application support the reverse rotation before using this functionality

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