GE Power Controls. ASTAT Plus. Solid State Soft Starters OVERVIEW OF THE RANGE. Up to 750kW / 500V Heavy Duty Up to 850kW / 500V Light Duty

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1 OVERVIEW OF THE RANGE ASTAT Plus Up to 750kW / 500V Heavy Duty Up to 850kW / 500V Light Duty ASTAT Plus Page # 1, Rev 01

2 PRODUCT DEFINITION ASTAT Plus is a range of, designed to motor soft start and stop without steps, with complete control of starting/stopping current. The ASTAT Plus features in addition, advanced control, monitoring and communication functions r ASTAT Plus advantages Vs conventional starters are, CONVENTIONAL STARTERS ASTAT Plus DOL Autotransfo. Stator Part Star-Delta (Solid State Soft Starter) winding % of direct start current 100% or 64% 58-70% 65% 33% Adjustable, -max 90%- % of direct start torque 100% or 64% 33-49% 48% 33% Adjustable max. 80% ASTAT Plus Page # 2, Rev 01 Starting steps (1) 1 4, 3 or 2 3 or Step-less Connections to motor Line overload 5-7 In 1,5-2,1 or 3,2 In 3-3,5 In 3,25 In 1,65 In Depending on adjust, (approx.) (approx. 2-7 In)

3 PRODUCT DEFINITION r Comparison of starting methods Strong Points Weak Points DOL Ÿ Lowest cost method Ÿ High Starting torque Ÿ Torque may be excessive, causing stress in mechanical moving parts. Ÿ High current during starting -typical 7In- Ÿ Medium or high inertia loads cause excessive loses during starting, and may result in motor burning Star-Delta Ÿ Lowest cost of soft starting systems Ÿ Low starting current -around 2xIn- Ÿ Too low torque for most of applications - only 33% Tn- Ÿ Only two steps starting system. Ÿ Pause between Star to Delta transition, usually cause high current peak ASTAT Plus Page # 3, Rev 01 Auto-transformer Solid State Soft Starter ASTAT Plus Ÿ Higher torque that Star-Delta system Ÿ Starting allowed in several steps Ÿ Step-less and most smooth start system. Ÿ Starting torque and current are easily adjusted, allowing best possible results. Ÿ Good cost /performance ratio. Ÿ Additional functions, like kick star, soft stop, Braking etc. Ÿ Excessive cost, and dimensions depending of starting steps Ÿ Low flexibility system. Auto-transformer characteristics can not be modified Ÿ Losses and Harmonics produced during operation

4 PRODUCT DEFINITION r Typical applications ASTAT Plus is perfect for a variety of customers like industrial users, Process industries, Water and waste water, Equipment Builders... A guide of typical applications is shown below, ASTAT Plus Page # 4, Rev 01 Use Application Pumps Fans Blowers Compressors Belt Comveyors Escalators Mixers Grinders Stone m ills Lifts -Very large inertia Machines- Crane Hoist Positioning Speed Control Adequate Restricted Non-Adequate

5 PRODUCT RANGE CONFIGURATION r IEC Ratings. Derate output current by 1.5% / ºC above 40ºC. Maximum ambient temperature 55ºC Derate output current by 1% / 100m above 1000m. altitude V 500V Current Applicable motor Max. Ratings Applicable motor Max. Ratings Degree Weight Rating Item Heavy Duty Light Duty-Class 10 Item Heavy Duty Light Duty-Class 10 A Amp. KW Amp. KW Amp. KW Amp. KW kg ASTAT Plus Page # 5, Rev QC1FDP 14 5,5 17 7,5 QC2FDP 14 7, IP QC1GDP 17 7, QC2GDP IP QC1HDP QC2HDP IP00 4,6 32 QC1IDP ,5 QC2IDP IP00 4,6 48 QC1JDP QC2JDP IP00 12,5 63 QC1KDP QC2KDP IP00 12,5 72 QC1LDP QC2LDP IP QC1MDP QC2MDP IP QC1NDP QC2NDP IP QC1QDP QC2QDP IP QC1RDP QC2RDP IP QC1SDP QC2SDP IP QC1TDP QC2TDP IP QC1UDP QC2UDP IP QC1VDP QC2VDP IP QC1XDP QC2XDP IP00 150

6 PRODUCT SPECIFICATIONS r Voltage Ratings 3ph systems, up to 440VAC 50/60Hz, by QC1xDP series 3ph systems, up to 500VAC 50/60Hz, by QC2xDP series r Current Output From 14 to 1290 Amps, in 16 ratings. Allowed continuous rating of % r Maximum applicable motor Up to 700KW/400V in Class 10 -Light Duty- Up to 600KW/400V in Class 20 -Heavy Dutyr Current Limit Up to 700%. r Frequency range 45-65Hz r Ambient Temperature 0-55ºC. Ratings derated 1.5%/ºC above 40ºC r Humidity 95% non-condensation ASTAT Plus Page # 6, Rev 01 r Protection / Cooling IP00, Forced cooling from 32 Amps r Display / Keypad Alphanumeric display with four keys. Allows metering, status indications, fault codes and write / reading parameters. r Standards CE, IEC, UL & CSA

7 DIGITAL DISPLAY r Digital Control Panel Description Alphanumeric Display ASTAT Plus Page # 7, Rev 01 Selection Key use with or to select the parameter code to be displayed and or modified C / V Search /Adjustment keys Increases or decreases the value of the selected parameter Entry / Save Key Introduces the new parameter value into memory Updates the selected parameter value with the displayed value

8 DIGITAL DISPLAY r Display Codes F V V V Error code ASTAT Plus Page # 8, Rev 01 Function code F V V V Status code ON (equipment ON) S T O P Stop L O C K Remote stop P U L S Kick start RAMP Acceleration ramp F U L L Full conduction or Override S A V E Energy saving S O F T Soft stop P U M P Pump control DCBK DC braking I N C H Inching / slow speed T A C H Linear ramp (tacho) Data E E E E E E E E E E E E E E E E E E E E E Frequency out of range Overload trip Loss of synchronism Phase U scr Phase V scr Phase W scr Heatsink overtemperature Motor thermistor Phase U lost Phase V lost Phase W lost Stalled rotor Internal error Long start time Long slow speed time Lock-out Undervoltage Overvoltage Undercurrent Overcurrent Retry, attempts exceeded F F/V V V function code M x x x Motor current v x x x Software Version.... P F x x Power Factor.... L x x x Limit current T x x x Starting Torque a x x x Ramp up time d x x x Ramp down time S x x x Soft Stop selection.... L K x x Lock out....

9 DIGITAL DISPLAY r Block Configuration Parameter ASTAT Plus includes a large number of parameters which divided in four blocks: Monitor, Calibration, Basic and Advanced. The parameters of each group can be displayed or skipped according the selection done in parameter "G". Settings in parameter "G" Gxxx The Monitor parameters are always displayed, whichever are the settings in parameter "G". GCAL The Calibration parameters are displayed GBAS The Basic parameters are displayed GADV The Advanced parameters are displayed GALL All parameters are displayed ASTAT Plus Page # 9, Rev 01 Monitoring Parameters CAL BAS ADV ALL Calibration Parameters Basic Parameters Advanced Parameters

10 DIGITAL DISPLAY r Parameter Layout (1/2) Display and description of Monitor, Calibration and Basic Parameters are shown below Monitoring Parameters Calibration Parameters Basic Parameters ASTAT Plus Page # 10, Rev 01 M x x x Motor current v x x x Software Version V x x x Line Voltage P F x x Line Power Factor w x x x Line Power E x x x Elapsed time e x x x Fault history Buffer K x x x Password W x x x E2PROM writting G x x x Parameter Block Selector U x x x Line Voltage t x x x Voltage Calibration U F x x Unit frame m x x x Current Calibration N x x x Motor rated current o x x x Overload Protection f x x x Service Factor L x x x Current Limit T x x x Starting Torque a x x x Ramp up time d x x x Ramp down time p x x x Kick Start b x x x DC Brake time I x x x DC Brake current S x x x Soft Stop switch C x x x Pump Control switch P x x x Kick Start Switch F x x x Override Switch z x x x By-pass Switch B x x x DC Brake Switch

11 DIGITAL DISPLAY r Parameter Layout (2/2) Display and description of Advanced Parameters are shown below Advanced Parameters ASTAT Plus Page # 11, Rev 01 L K x x Lock-out R x x x E2PROM Reading Q x x x Factory Settings Y x x x Retry y x x x Retry time U V x x Undervoltage u v x x Undervoltage trip time O V x x Overvoltage o v x x Overvoltage trip time U C x x Undercurrent u c x x Undercurrent trip time O C x x Overcurrent o c x x Overcurrent trip time 2 a x x Secondary Ramp up 2 d x x Secondary Ramp down 2 t x x Secondary Starting Torque D x x x Tacho control switch J x x x Slow Speed switch j x x x Low / High slow speeds r x x x Reverse slow speed A x x x Dual motor switch X x x x Remote control 1 r x x Output relay 1r 2 r x x Output relay 2r 3 r x x Output relay 3r

12 PRODUCT FEATURES AND FUNCTIONS r I/O Configuration Control Voltage 110 / 120V AC L1 L2 L3 NOTE: (1) The programmable inputs I3, I4 are not assigned to any function as default. Check pages 3-6 prior to using these inputs. A1 A2 A1 A2 B1 B2 Control Voltage 220 / 240V AC B1 B Serial Comm. RS232C Gr Tx Rx SG TD RD 1 L1 3 L2 5 L3 (2) The programmable relay outputs are assigned to the following functions as default: Relay (1r): RUN, (RUN status) Relay (2r): EOR, (End of Ramp) Relay (3r): DCBR, (DC Braking control) 1r 2r 3r Program m able relay Outputs Programmable Inputs I3 I T1 4 T2 6 T3 ASTAT Plus Page # 12, Rev 01 (3) Important: Use dry contacts only for inputs Start /Stop (permanent Command) Start Stop (Command by push-buttons) Programmable Inputs Motor Thermistor Input + - Tacho feedback Analog Input - + V 0-10V Analog output

13 PRODUCT FEATURES AND FUNCTIONS r Programmable Inputs and functions The ASTAT Plus functions like Soft stop, kick start, and etc., can be enabled or disabled by setting ON or OFF in their dedicated parameters. Most of these functions can be enabled or disabled remotely as well, through the programmable inputs I3 or I4 (terminals board 3-57 and 4-57). Function Parameter ASTAT Plus Page # 13, Rev 01 Soft Stop Pump Control Kick Start Override By-pass DC Brake Linear Ramp (Jog). Slow Speed Reverse Jog Dual motor Remote Control S x x x C x x x P x x x F x x x z x x x B x x x D x x x J x x x r x x x A x x x X x x x Set Value _ O F F _ O N _ I 3 _ I 4 The function is permanently disabled The function is permanently enabled The status of the function depends on ASTAT's I3 input The status of the function depends on ASTAT's I4 input Note: <Remarks> One programmable input may enable or disable more than one function

14 PRODUCT FEATURES AND FUNCTIONS r Programmable Relay Outputs The ASTAT Plus includes three programmable relays 1r, 2r and 3r, (dry contacts), which can be assigned to several functions, as shown bellow ASTAT Plus Page # 14, Rev 01 Relay N# Relay 1r Relay 2r Relay 3r Parameter 1 r x x 2 r x x 3 r x x Set Value <Remarks> EOR Detects end of voltage ramp. -Only can be asigned to relay 2r- DC Brake DC Brake command -Only can be assigned to relay 3r- Fault Detects ASTAT's fault status Undervoltage Detects limit set in parameter UVxx Overvoltage Detects limit set in parameter OVxx RUN Detects ASTAT's run status JOG Detects Jog (slow speed) status Undercurrent Detects limit set in parameter UCxx Overcurrent Detects limit set in parameter OCxx Disables the relay function Future use

15 PRODUCT FEATURES AND FUNCTIONS r Thermal Overload Electronic Protection ASTAT Plus includes motor protection according IEC Class 10, 20 and Nema 10, 20, 30, free selectable by the parameter "oxxx", -overload-. Overload curves for IEC C10, 20 are shown below IEC Class 10 Sec. IEC Class 20 Sec. ASTAT Plus Page # 15, Rev 01 HOT COLD Ir / In HOT COLD Ir / In

16 PRODUCT FEATURES AND FUNCTIONS r r Kick Start This is a selectable feature adjustable from 0 to 999ms while maintaining 95% of full line voltage. Useful when high static-friction loads are encountered. Pump control Special acceleration and deceleration cycle, exclusively designed for pump control, may be programmed to limit water hammer, surges, and sudden valve closure. r DC Inject Braking Selectable function which has the capability to inject a DC current to the motor winding, to create a braking torque on the rotor ASTAT Plus Page # 16, Rev 01 r Dual Motor control Dual motor starting torque and ramp time settings are available, to eventually control a secondary motor, or a different load condition.

17 PRODUCT FEATURES AND FUNCTIONS r r By-Pass Selectable function which allows control of a By-Pass external contactor. Communications A RS485 based communication feature is built in the ASTAT Plus as standard. Optional Profibus DP and DeviceNet modules soon available r Retry Allows automatic restart after a fault. Provides up to four programmable retries with programmable time between them ASTAT Plus Page # 17, Rev 01 r Lock-out Selectable function which prevents against consecutive starting

18 PRODUCT FEATURES AND FUNCTIONS r Starting and Stopping diagram Override ASTAT Plus Page # 18, Rev 01 1 Initial ramp 1a Initial voltage (pedestal) 2 Kick start 3 Acceleration ramp 3a The output voltage raises quickly if the motor reaches rated speed. 5 Rated voltage (Override). 6 Voltage in energy saving status. 7 Motor power cut-off (stopped by inertia). 8 Deceleration ramp. 9 DC brake Energy Saving ON

19 PRODUCT FEATURES AND FUNCTIONS r Energy Saving Selectable function which automatically compensates the motor power factor when the motor operates under partial or no-load conditions, thereby obtaining maximum efficiency. ASTAT Plus Page # 19, Rev 01

20 PRODUCT FEATURES AND FUNCTIONS r Slow (jog) Speed Two selectable speed which are 7% or 14% of the nominal speed. Reverse operation is allowed. r Linear Ramp The ASTAT Plus may provide a linear speed ramp regardless of the shape of the load torque. A DC Tacho-generator is used to provide the actual speed feedback ASTAT Plus Page # 20, Rev 01

21 PRODUCT FEATURES AND FUNCTIONS r Protective Features The ASTAT Plus offers all the Protection that you need! The last four errors are saved in an internal buffer. Fixed Protections User selectable Protections ASTAT Plus Page # 21, Rev 01 Ÿ Frequency out of range Ÿ Overload Ÿ Loss of output phases Ÿ SCr fault Ÿ Heatsink overtemperature Ÿ Motor Overtemperature (by thermistor) Ÿ Stalled rotor Ÿ Long start time Ÿ Long jog time operation Ÿ Ÿ Ÿ Ÿ Ÿ Ÿ Undervoltage Overvoltage Undercurrent Overcurrent Retry, attempts exceeded Lock-out

22 APPLICATION EXAMPLES r Basic Diagram L1 L2 L3 C ontrol Voltage 110 / 120V AC REMARKS: (1)The isolation contactor DC1, is not required to perform operation to the motor. Be aware however that DC1 provides galvanic isolation from the incoming line increasing the safety. A1 A2 A1 A2 B1 B2 C ontrol Voltage 220 / 240V AC B1 B2 DC SG TD RD 1 L1 3 L2 5 L3 DC1 (1) ASTAT Plus Page # 22, Rev 01 (4) The ASTAT Plus is provided with an electronic motor overload protection, which should be adequate protection for most of the applications. You should use an external overload protection if required by local codes or to protect the motor against current unbalance. 1r 2r 3r Programmable relay Outputs Programmable Inputs I3 I Start Stop Motor Thermistor Push-Button command (2) 9 2 T1 4 T2 6 T3 M 3 ~ FLT (4)

23 APPLICATION EXAMPLES r By-Pass control L1 L2 L3 Control Voltage 110 / 120 V AC REMARKS: A1 A2 B1 B2 DC1 (1) (1) The isolation contactor DC1, is not required to perform operation to the motor. Be aware however that DC1 provides galvanic isolation from the incoming line increasing the safety. Control Voltage 220 / 240V AC A1 A2 B1 B2 DC1 DC SG TD RD 1 L1 3 L2 5 L3 ASTAT Plus Page # 23, Rev 01 (3) By-pass control requires the use of function "zxxx" and external contactor DC2. Alternativelly, the bypass function can be controlled remotelly if it s assigned to one of the programmable inputs (4) CAUTION: In by-pass mode an external overload relay protection must be used. Start /Stop (2) (permanent Command) 1r 2r 3r Programmable relay Outputs Programmable Inputs I3 I FLT By-Pass (3) Programmable Input Motor Thermistor 9 2 T1 4 T2 6 T3 M 3 ~ FLT (4) DC2

24 APPLICATION EXAMPLES r Normal operation with slow speed control L1 L2 L3 C ontrol Voltage 110 / 120V AC REMARKS: (1) The isolation contactor DC1, is not required to perform operation to the motor. Be aware however that DC1 provides galvanic isolation from the incoming line increasing the safety. A1 A2 A1 A2 B1 B2 C ontrol Voltage 220 / 240V AC B1 B2 DC SG TD RD 1 L1 3 L2 5 L3 DC1 (1) ASTAT Plus Page # 24, Rev 01 (4) The ASTAT Plus is provided with an electronic motor overload protection, which should be adequate protection for most of the applications. You should use an external overload protection if required by local codes or to protect the motor against current unbalance. (5) Slow Speed for Jog forward or reverse using programmable inputs I3, I4. This application requires the use of jog functions "Jxxx" and reverse function "rxxx". Both functions are asigned to programmable inputs I3, I4 Programmable Inputs I3 I Start Stop Push-Button command (2) 1r 2r 3r Programmable relay Outputs Forward Reverse Jog (Slow Speed)(5) Motor Thermistor 9 2 T1 4 T2 6 T3 M 3 ~ FLT (4)

25 INSTALLATION r Fuses, contactors and supply wiring For IEC Class 10 ratings In Total Fuses Fuses Fuses Control voltage Contactor Contactor Conductor losses am FERRAZ type BUSSMANN type DC 1 DC 3 section 100% In (F1) (XX=according (Typower Sicu 660V~) Fuse Consumpt. (2) Cat Number A W A mech. design) Size In A VA mm 2 ASTAT Plus Page # 25, Rev 01 QC _ F DP ,600 CP URC 14.51/ CL02 CL02 4 QC _ G DP ,6 URD 30 XX CL03 CL03 4 QC _ H DP ,6 URD 30 XX CL04 CL03 6 QC _ I DP ,6 URD 30 XX CL45 CL04 10 QC _ J DP ,6 URD 30 XX CL07 CL45 16 QC _ K DP ,6 URD 30 XX CL08 CL06 25 QC _ L DP ,6 URD 30 XX CL09 CL06 35 QC _ M DP ,6 URD 30 XX CK75 CL07 50 QC _ N DP ,6 URD 30 XX CK08 CL10 95 QC _ Q DP ,6 URD 31 XX CK95 CK QC _ R DP ,6 URD 31 XX CK10 CK QC _ S DP ,6 URD 32 XX CK11 CK95 Bus bar (1) QC _ T DP ,6 URD 33 XX CK12 CK10 Bus bar (1) QC _ U DP ,6 URD 33 XX CK12 CK10 Bus bar (1) QC _ V DP ,6 URD 233 XX CK13 CK11 Bus bar (1) QC _ X DP x800 6,6 URD 233 XX CK13 CK12 Bus bar (1)

26 INSTALLATION r Fuses, contactors and supply wiring For IEC Class 20 ratings In Total Fuses Fuses Fuses Control voltage Contactor Contactor Conductor losses am FERRAZ type BUSSMANN type DC 1 DC 3 section 100% In (F1) (XX=according (Typower Sicu 660V~) Fuse Consumpt. (2) Cat Number A W A mech. design) Size In A VA mm 2 ASTAT Plus Page # 26, Rev 01 QC _ F DP ,600 CP URC 14.51/ CL01 CL01 4 QC _ G DP ,6 URD 30 XX CL02 CL02 4 QC _ H DP ,6 URD 30 XX CL03 CL03 4 QC _ I DP ,6 URD 30 XX CL04 CL04 6 QC _ J DP ,6 URD 30 XX CL06 CL04 10 QC _ K DP ,6 URD 30 XX CL07 CL04 16 QC _ L DP ,6 URD 30 XX CL08 CL06 25 QC _ M DP ,6 URD 30 XX CL10 CL06 35 QC _ N DP ,6 URD 30 XX CK75 CL07 70 QC _ Q DP ,6 URD 31 XX CK85 CK QC _ R DP ,6 URD 31 XX CK95 CK QC _ S DP ,6 URD 32 XX CK10 CK QC _ T DP ,6 URD 33 XX CK11 CK95 Bus bar (1) QC _ U DP ,6 URD 33 XX CK12 CK10 Bus bar (1) QC _ V DP ,6 URD 233 XX CK13 CK10 Bus bar (1) QC _ X DP ,6 URD 233 XX CK13 CK12 Bus bar (1))

27 CODES AND CATALOGUE NUMBERS r Cross reference Vs ASTAT CD The ASTAT Plus includes as standard all features which are optional in ASTAT CD One ASTAT Plus Catalog number replaces six of ASTAT CD!! New ASTAT Plus Current ASTAT CD versions Standard + Communications +L. Ramp +Comm+L. Ramp + S. Speed +Comm+S.Speed Catalog # Ref. # Catalog # Ref. # Catalog # Ref. # Catalog # Ref. # Catalog # Ref. # Catalog # Ref. # Catalog # Ref. # ASTAT Plus Page # 27, Rev 01 QC1FDP QC1FDA QC1FCA QC1FEA QC1FFA QC1FGA QC1FHA QC1GDP QC1GDA QC1GCA QC1GEA QC1GFA QC1GGA QC1GHA QC1HDP QC1HDA QC1HCA QC1HEA QC1HFA QC1HGA QC1HHA QC1IDP QC1IDA QC1ICA QC1IEA QC1IFA QC1IGA QC1IHA QC1JDP QC1JDA QC1JCA QC1JEA QC1JFA QC1JGA QC1JHA QC1KDP QC1KDA QC1KCA QC1KEA QC1KFA QC1KGA QC1KHA QC1LDP QC1LDA QC1LCA QC1LEA QC1LFA QC1LGA QC1LHA QC1MDP QC1MDA QC1MCA QC1MEA QC1MFA QC1MGA QC1MHA QC1NDP QC1NDA QC1NCA QC1NEA QC1NFA QC1NGA QC1NHA QC1QDP QC1QDA QC1QCA QC1QEA QC1QFA QC1QGA QC1QHA QC1RDP QC1RDA QC1RCA QC1REA QC1RFA QC1RGA QC1RHA QC1SDP QC1SDA QC1SCA QC1SEA QC1SFA QC1SGA QC1SHA QC1TDP QC1TDA QC1TCA QC1TEA QC1TFA QC1TGA QC1THA QC1UDP QC1UDA QC1UCA QC1UEA QC1UFA QC1UGA QC1UHA QC1VDP QC1VDA QC1VCA QC1VEA QC1VFA QC1VGA QC1VHA QC1XDP QC1XDA QC1XCA QC1XEA QC1XFA QC1XGA QC1XHA

RVS-DN Digital Reduced Voltage Motor Starter

RVS-DN Digital Reduced Voltage Motor Starter Specification Guide Specification Guide Contents 1.0 Introduction 2.0 Specifications 2.1 Standard Performance Features 2.2 Standard Protection Features 2.3