GE ASTAT XL Series, Testing, Troubleshooting And Servicing Instructions

Page 1: ...9 0 Hungary GE Hungary Kft Vaci ut 81 83 H 1139 budapest Tel 36 1 447 6050 Italy GE Industrial Solutions Centro Direzionale Colleoni Via Paracelso 16 Palazzo Andromeda B1 I 20864 Agrate Brianza MB Tel 39 039 637 3701 Netherlands GE Industrial Solutions Parallelweg 10 Nl 7482 CA Haaksbergen Tel 31 0 53 573 03 03 Poland GE Power Controls Ul Odrowaza 15 03 310 Warszawa Tel 48 22 519 76 00 8O HV F ħVN...

Page 2: ...3 4 Service Instructions 14 4 1 QLxxB0023D to QLxxB0053D G1B 15 4 2 QLxxB0076D to QLxxB0105D G1B 16 4 3 QLxxB0145D to QLxxB0220D G2B 17 4 4 QLxxB0255D to QLxxB0425D G3B 18 4 5 QLxxX0255D G3C 19 4 6 QLxxB0500D to QLxxB1000D G4B 20 4 7 QLxxX0360D to QLxxX0930D G4C 21 4 8 QLxxX1200D to QLxxX1600D G5C 22 5 Spare Parts 23 5 1 Main Control PCB 23 5 2 Model PCB 25 5 3 Backplane PCB 26 5 4 Bypass Driver P...

Page 3: ...oid the product warranty GROUNDING AND BRANCH CIRCUIT PROTECTION It is the responsibility of the user or person installing the ASTAT XL to provide proper grounding and branch circuit protection according to local electrical safety codes The examples and diagrams in this manual are included solely for illustrative purposes The information contained in this manual is subject to change at any time an...

Page 4: ...as been disconnected If the starter has been energised the AC supply must be isolated at least two minutes before work may continue Normally the capacitors are discharged by an internal resistor Under certain unusual fault conditions the capacitors may fail to discharge Do not assume that the capacitors have discharged To protect the user and the equipment take due care when carrying out any work ...

Page 5: ...ackplane PCB then check for correct operation before replacing the Main Control PCB SCR damage is almost always caused by external influences If the MOVs and or surrounding circuitry on the Backplane PCB show signs of physical damage the most likely cause is overvoltage If the MOVs and or surrounding circuitry on the Backplane PCB do not show signs of physical damage the most likely cause is overc...

Page 6: ... for inside delta connection If the voltage is zero the bypass contactor may be damaged and should be replaced 2 Command the soft starter to start When the Run LED stops flashing you should hear the bypass contactors close If the bypass contactors do not close the bypass contactor Main Control PCB Model PCB or Bypass Driver PCB G2B models only may be faulty or there may be a faulty connection betw...

Page 7: ...FLC Parameter 1A to match the test motor NOTE If the test motor has a current rating which is much lower than that of the soft starter disable Undercurrent Trip Parameter 4C 4 Connect mains supply and motor Test that the soft starter functions as expected 5 Reload the saved parameter set into the ASTAT XL via GE ASTAT Setup Tool ed 3 after servicing work is complete 6 DET 813 ...

Page 8: ...SCR or a short within the bypass contactor Related parameters 15E Battery clock A verification error has occurred on the real time clock or the backup battery voltage is low If the battery is low and the power is off date time settings will be lost The ASTAT XL will continue to soft start and soft stop correctly Reprogram the date and time The battery is not removable In order to replace the batte...

Page 9: ... Run and for 10 minutes after the starter exits the Stop state NOTE Models QLxxB0023D to QLxxB0053D and QLxxB0170D do not have a cooling fan Models with fans will operate the cooling fans from a Start until 10 minutes after a Stop Related parameters 16J High Level This is a name selected for a programmable input See Input A trip High Pressure This is a name selected for a programmable input See In...

Page 10: ...name selected for a programmable input See Input A trip Motor overload Motor 2 overload The motor has reached its maximum thermal capacity Overload can be caused by The soft starter protection settings not matching the motor thermal capacity Excessive starts per hour Excessive throughput Damage to the motor windings Resolve the cause of the overload and allow the motor to cool Related parameters 1...

Page 11: ...communications module Remove and reinstall the module If the problem persists contact your local distributor There is an internal communications error within the soft starter Contact your local distributor Related parameters 16I Starter Disable This is a name selected for a programmable input See Input A trip Thermistor circuit Check that a PT100 RTD is not connected to 64 65 The thermistor input ...

Page 12: ... too hot to permit a start If parameter 4F Motor Temperature Check is set to Check the soft starter will only permit a start when it calculates that the motor has sufficient thermal capacity to complete the start successfully Wait for the motor to cool before attempting another start The starter may be disabled via a programmable input If parameter 6D is set to Starter Disable and there is an open...

Page 13: ...e Control brake jog and PowerThrough functions not working These features are only available with in line installation If the ASTAT XL is installed inside delta these features will not operate After selecting Adaptive Control the motor used an ordinary start and or the second start was different to the first The first Adaptive Control start is actually Constant Current so that the starter can lear...

Page 14: ...ertemperature blocked heatsinks or restricted ventilation inadequate ventilation excessive ambient temperatures bypass relay fails to close during running internally bypassed starters only 3 4 2 Protecting SCRs Modern SCRs are generally rugged and reliable However the risk of SCR damage can be reduced by using semiconductor fuses and or a main contactor 3 4 2 1 Semiconductor Fuses Semiconductor fu...

Page 15: ...lows Frame Size ASTAT XL Models G1B QLxxB0023D QLxxB0043D QLxxB0050D QLxxB0053D QLxxB0076D QLxxB0097D QLxxB0100D QLxxB0105D G2B QLxxB0145D QLxxB0170D QLxxB0200D QLxxB0220D G3B QLxxB0255D QLxxB0350D QLxxB0425D G4B QLxxB0500D QLxxB0580D QLxxB0700D QLxxB0820D QLxxB0920D QLxxB1000D G3C QLxxX0255D G4C QLxxX0360D QLxxX0380D QLxxX0430D QLxxX0620D QLxxX0650D QLxxX0790D QLxxX0930D G5C QLxxX1200D QLxxX1410D...

Page 16: ...023D to QLxxB0053D G1B 11 1 2 3 4 5 6 7 8 9 10 11629 A 1 Main plastic 2 Keypad 3 Main control PCB 4 Model PCB including bypass contactors 5 Backplane PCB 6 SCRs 7 Current transformers 8 Mounting posts 9 Cage clamps 10 Side plastic 11 Base plastic DET 813 15 ...

Page 17: ...D to QLxxB0105D G1B 11630 A 1 2 3 4 5 6 7 8 9 10 11 12 13 1 Main plastic 2 Keypad 3 Main control PCB 4 Backplane PCB 5 Model PCB 6 Bypass contactors 7 SCRs 8 Current transformers 9 Mounting posts 10 Cage clamps 11 Side plastic 12 Base plastic 13 Fan 16 DET 813 ...

Page 18: ...anual 4 3 QLxxB0145D to QLxxB0220D G2B 11631 A 1 2 3 4 5 6 7 8 9 10 1 Main plastic 2 Keypad Main control PCB 3 Bypass driver PCB 4 Support plastic 5 Model PCB 6 Current transformers 7 SCRs 8 Bypass contactors 9 Main chassis 10 Fan DET 813 17 ...

Page 19: ... QLxxB0425D G3B 1 2 5 8 9 11 10 14482 A 4 6 3 7 1 Main plastic 2 Keypad 3 Bypass driver PCB 4 Main control PCB 5 Main chassis 6 Bypass contactors 7 Snubber assembly QLxxB0350D and QLxxB0425D only 8 SCRs 9 Current transformers 10 Heatsink 11 Fan assembly 18 DET 813 ...

Page 20: ...s ASTAT XL Service Manual 4 5 QLxxX0255D G3C 11636 B 1 2 3 4 5 6 7 8 9 1 Cover 2 Main plastic 3 Keypad Main control PCB 4 Support plastic 5 Model PCB 6 Current transformers 7 SCRs 8 Main chassis 9 Fan assembly DET 813 19 ...

Page 21: ... QLxxB1000D G4B 14484 A 9 10 8 11 5 6 4 3 7 2 1 1 Keypad 2 Main cover 3 Main control PCB 4 Support plastic 5 Model PCB 6 Bypass driver PCB 7 Magnetic bypass plate QLxxB0580D QLxxB1000D only 8 Snubber assembly 9 Phase arm 10 Main chassis 11 Fan assembly 20 DET 813 ...

Page 22: ...0D G4C 11640 B 7 1 2 3 4 5 6 8 10 9 11 12 1 Cover 2 Main plastic 3 Keypad Main control PCB 4 Support plastic 5 Model PCB 6 Mounting bracket assembly 7 Snubber assembly 1 per phase 8 Busbar support 9 Power assemblies 10 Fan assembly 11 Main chassis 12 CT assembly DET 813 21 ...

Page 23: ...o QLxxX1600D G5C 5 1 2 3 4 6 7 8 9 10 11 11641 B 1 Cover 2 Main plastic 3 Keypad Main control PCB 4 Support plastic 5 Model PCB 6 Mounting bracket assembly 7 Snubber assembly 1 per phase 8 Power assemblies 9 CT assembly 10 Fan assembly 11 Main chassis 22 DET 813 ...

Page 24: ...XL will return to factory default settings and must be reprogrammed 1 2 V5 V7 V5 V7 QLxxB0023D QLxxB0043D QLxxB0050D QLxxB0053D 995 16148 00 995 16149 00 995 16150 00 995 16151 00 QLxxB0076D QLxxB0097D QLxxB0100D QLxxB0105D QLxxB0145D QLxxB0170D QLxxB0200D QLxxB0220D QLxxB0255D QLxxB0350D QLxxB0425D QLxxB0500D QLxxB0580D QLxxB0700D QLxxB0820D 995 16152 00 995 16153 00 995 16154 00 995 16155 00 QLx...

Page 25: ...ASTAT XL Service Manual Spare Parts 995 16148 00 995 16149 00 995 16150 00 995 16151 00 995 16152 00 995 16153 00 995 16154 00 995 16155 00 24 DET 813 ...

Page 26: ...14 00 QLxxB0255D 995 14866 00 QLxxB0350D 995 14867 00 QLxxB0425D 995 14868 00 QLxxB0500D 995 14869 00 QLxxB0580D 995 14870 00 QLxxB0700D 995 14871 00 QLxxB0820D 995 14872 00 QLxxB0920D 995 14873 00 QLxxB1000D 995 14875 00 QLxxX0255D 995 09415 00 QLxxX0360D 995 09416 00 QLxxX0380D 995 09417 00 QLxxX0430D 995 09418 00 QLxxX0620D 995 09419 00 QLxxX0650D 995 09420 00 QLxxX0790D 995 09421 00 QLxxX0930D...

Page 27: ...LxxB0076D 995 09426 00 QLxxB0097D QLxxB0100D QLxxB0105D QLxxB0145D QLxxB0170D QLxxB0200D QLxxB0220D QLxxB0255D QLxxB0350D QLxxB0425D QLxxB0500D QLxxB0580D QLxxB0700D Not required QLxxB0820D QLxxB0920D QLxxB1000D QLxxX0255D QLxxX0360D QLxxX0380D QLxxX0430D QLxxX0620D QLxxX0650D QLxxX0790D QLxxX0930D QLxxX1200D QLxxX1410D QLxxX1600D 995 09426 00 26 DET 813 ...

Page 28: ...097D QLxxB0100D QLxxB0105D QLxxB0145D QLxxB0170D 995 09427 00 QLxxB0200D QLxxB0220D QLxxB0255D QLxxB0350D QLxxB0425D 995 13448 00 QLxxB0500D QLxxB0580D QLxxB0700D QLxxB0820D 995 10505 00 QLxxB0920D QLxxB1000D QLxxX0255D QLxxX0360D QLxxX0380D QLxxX0430D QLxxX0620D Not required QLxxX0650D QLxxX0790D QLxxX0930D QLxxX1200D QLxxX1410D QLxxX1600D 995 09427 00 995 10505 00 995 13448 00 DET 813 27 ...

Page 29: ...5758 00 QLxxB0105D 995 05759 00 QLxxB0145D QLxxB0170D 995 05760 00 QLxxB0200D 995 05761 00 QLxxB0220D QLxxB0255D 995 05762 00 QLxxX0255D QLxxB0350D 995 14504 00 QLxxB0425D NOTE Spare part kits may include SCRs from different manufacturers SCRs from different manufacturers are fully interchangeable and can be mixed within the same soft starter CAUTION SCR firing loom connections may be different fo...

Page 30: ...0023 0076 7 6 5 4 7 6 5 4 SEMIKRON INFINEON 03297 C Models 0097 0145 5 4 7 6 4 5 6 7 SEMIKRON INFINEON 03298 C Models 0170 0255 7 6 5 4 7 6 5 4 SEMIKRON INFINEON 03299 C Models 0350 0425 14526 A 5 4 7 6 NOTE Unless otherwise indicated spare part kits contain only one of each item All images in this section are indicative DET 813 29 ...

Page 31: ...1000D 995 10141 00 Models QLxxX0360D QLxxX1600D use power assemblies Each soft starter requires two power assemblies QLxxX0360D 995 09431 00 QLxxX0380D 995 09432 00 QLxxX0430D 995 09433 00 QLxxX0620D 995 09434 00 QLxxX0650D 995 09435 00 QLxxX0790D 995 09436 00 QLxxX0930D 995 09437 00 QLxxX1200D 995 09438 00 QLxxX1410D 995 09439 00 QLxxX1600D 995 09440 00 995 09431 00 995 09437 00 995 09438 00 995 ...

Page 32: ...145D QLxxB0170D Not required QLxxB0200D 995 09441 00 1 QLxxB0220D QLxxB0255D QLxxB0350D QLxxB0425D QLxxB0500D QLxxB0580D QLxxB0700D QLxxB0820D 995 00807 00 3 QLxxB0920D QLxxB1000D QLxxX0255D QLxxX0360D QLxxX0380D QLxxX0430D QLxxX0620D QLxxX0650D QLxxX0790D 995 00808 00 2 QLxxX0930D QLxxX1200D QLxxX1410D 995 00808 00 3 QLxxX1600D 995 09441 00 995 00807 00 995 00808 00 NOTE Unless otherwise indicate...

Page 33: ...r assemblies Each soft starter requires three snubber assemblies Each snubber kit includes three snubber assemblies QLxxB0350D QLxxB0425D QLxxB0500D QLxxB0580D 995 11342 00 QLxxB0700D QLxxB0820D QLxxB0920D QLxxB1000D QLxxX0360D QLxxX0380D QLxxX0430D QLxxX0620D 995 11344 00 QLxxX0650D QLxxX0790D QLxxX0930D QLxxX1200D QLxxX1410D 995 11345 00 QLxxX1600D 995 11342 00 995 11344 00 995 11345 00 32 DET 8...

Page 34: ...D 995 02573 00 QLxxB0255D QLxxB0350D QLxxB0425D QLxxB0500D QLxxB0580D QLxxB0700D Not available QLxxB0820D QLxxB0920D QLxxB1000D QLxxX0255D 995 02573 00 QLxxX0360D 995 09442 00 QLxxX0380D 995 09443 00 QLxxX0430D QLxxX0620D 995 09444 00 QLxxX0650D QLxxX0790D 995 09445 00 QLxxX0930D 995 09446 00 QLxxX1200D 995 09447 00 QLxxX1410D 995 09448 00 QLxxX1600D 995 09449 00 995 02571 00 995 02573 00 995 0944...

Page 35: ...e phase arm QLxxB0023D QLxxB0043D Not available QLxxB0050D QLxxB0053D QLxxB0076D QLxxB0097D 995 09450 00 QLxxB0100D QLxxB0105D QLxxB0145D QLxxB0170D QLxxB0200D 995 09451 00 QLxxB0220D QLxxB0255D 995 13449 00 QLxxB0350D QLxxB0425D QLxxB0500D 995 14503 00 QLxxB0580D QLxxB0700D QLxxB0820D Not available QLxxB0920D QLxxB1000D 995 09450 00 995 09451 00 995 13449 00 995 14503 00 NOTE Unless otherwise ind...

Page 36: ...0 00 Not Required QLxxB0076D QLxxB0097D QLxxB0100D QLxxB0105D QLxxB0145D QLxxB0170D QLxxB0200D QLxxB0220D QLxxB0255D QLxxB0350D QLxxB0425D QLxxB0500D QLxxB0580D QLxxB0700D QLxxB0820D 995 11779 00 Not Required 995 11781 00 QLxxB0920D QLxxB1000D QLxxX0255D QLxxX0360D QLxxX0380D QLxxX0430D QLxxX0620D QLxxX0650D QLxxX0790D QLxxX0930D QLxxX1200D QLxxX1410D QLxxX1600D 995 11778 00 995 11779 00 995 11781...

Page 37: ...00D 995 11794 00 995 11795 00 QLxxB0105D QLxxB0145D 995 11796 00 995 11797 00 QLxxB0170D QLxxB0200D 995 11798 00 995 11799 00 QLxxB0220D QLxxB0255D QLxxB0350D QLxxB0425D QLxxB0500D QLxxB0580D Available on request Available on request QLxxB0700D QLxxB0820D QLxxB0920D QLxxB1000D QLxxX0255D 995 11800 00 995 11801 00 set of 6 QLxxX0360D QLxxX0380D QLxxX0430D 995 11802 00 995 11803 00 QLxxX0620D QLxxX0...

Page 38: ...00 995 11792 00 995 11794 00 995 11791 00 995 11795 00 995 11796 00 995 11798 00 995 11797 00 995 11799 00 995 11800 00 995 11801 00 995 11802 00 995 11804 00 995 11806 00 995 11808 00 995 11803 00 995 11805 00 995 11807 00 995 11809 00 DET 813 37 ...

Page 39: ... QLxxB0076D set of 3 QLxxB0097D QLxxB0100D QLxxB0105D QLxxB0145D QLxxB0170D QLxxB0200D 995 11811 00 QLxxB0220D set of 3 QLxxB0255D QLxxB0350D QLxxB0425D QLxxB0500D QLxxB0580D QLxxB0700D QLxxB0820D Not required QLxxB0920D QLxxB1000D QLxxX0255D QLxxX0360D QLxxX0380D QLxxX0430D QLxxX0620D QLxxX0650D QLxxX0790D QLxxX0930D QLxxX1200D QLxxX1410D QLxxX1600D 995 11810 00 995 11811 00 38 DET 813 ...

Page 40: ... assembly 6 1 1 Input Output Busbars to SCRs Model Bolt size Torque Nm QLxxB0023D QLxxB0043D QLxxB0050D M5x12 4 QLxxB0053D QLxxB0076D QLxxB0097D QLxxB0100D M6x16 4 QLxxB0105D QLxxB0145D M6x16 5 QLxxB0170D QLxxB0200D M8x20 9 QLxxB0220D QLxxB0255D QLxxB0350D M10x20 12 QLxxB0425D QLxxB0500D QLxxB0580D QLxxB0700D M8x25 20 QLxxB0820D QLxxB0920D QLxxB1000D QLxxX0255D M8x20 8 QLxxX0360D QLxxX0380D QLxxX0...

Page 41: ...00D QLxxB0105D QLxxB0145D QLxxB0170D QLxxB0200D QLxxB0220D M5x20 5 QLxxB0255D QLxxB0350D M6x30 5 QLxxB0425D QLxxB0500D QLxxB0580D QLxxB0700D Not required Not required QLxxB0820D QLxxB0920D QLxxB1000D QLxxX0255D M5x20 4 QLxxX0360D QLxxX0380D QLxxX0430D QLxxX0620D QLxxX0650D Not required Not required QLxxX0790D QLxxX0930D QLxxX1200D QLxxX1410D QLxxX1600D 40 DET 813 ...

Page 42: ... QLxxB0200D QLxxB0220D M8x20 8 QLxxB0255D QLxxB0350D M10x30 20 QLxxB0425D QLxxB0500D M10x25 20 QLxxB0580D QLxxB0700D QLxxB0820D Not required Not required QLxxB0920D QLxxB1000D QLxxX0255D M8x20 8 QLxxX0360D QLxxX0380D QLxxX0430D QLxxX0620D QLxxX0650D Not required Not required QLxxX0790D QLxxX0930D QLxxX1200D QLxxX1410D QLxxX1600D 6 1 4 Current Transformer Busbar Assembly Model Bolt size Torque Nm Q...

Page 43: ...ASTAT XL Service Manual Appendix 42 DET 813 ...

Page 44: ...9 0 Hungary GE Hungary Kft Vaci ut 81 83 H 1139 budapest Tel 36 1 447 6050 Italy GE Industrial Solutions Centro Direzionale Colleoni Via Paracelso 16 Palazzo Andromeda B1 I 20864 Agrate Brianza MB Tel 39 039 637 3701 Netherlands GE Industrial Solutions Parallelweg 10 Nl 7482 CA Haaksbergen Tel 31 0 53 573 03 03 Poland GE Power Controls Ul Odrowaza 15 03 310 Warszawa Tel 48 22 519 76 00 8O HV F ħVN...