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GE ASTAT XL Series Testing, Troubleshooting And Servicing Instructions

Low voltage soft starters.
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GE
Industrial Solutions
ASTAT
XL
Testing, troubleshooting and servicing instructions
GE imagination at work
Original Instruction
DET-813 ed. 00

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   Summary of Contents for GE ASTAT XL Series

  • Page 1

    Industrial Solutions ASTAT Testing, troubleshooting and servicing instructions GE imagination at work Original Instruction DET-813 ed. 00...

  • Page 2: Table Of Contents

    ASTAT XL Service Manual Contents Contents Caution Statements ..........................2 Electrical Shock Risk ......................................2 Power-up procedure ....................................... 3 Stored charge ........................................3 Short circuit .......................................... 3 Disposal Instructions ....................................... 3 Functional Tests ............................4 Power Circuit Test ......................................4 Start Performance Test ....................................

  • Page 3: Caution Statements

    ASTAT XL Service Manual Caution Statements Caution Statements WARNING - ELECTRICAL SHOCK HAZARD The ASTAT XL contains dangerous voltages when connected to mains voltage. Only a qualified electrician should carry out the electrical installation. Improper installation of the motor or the ASTAT XL may cause equipment failure, serious injury or death. Follow this manual and local electrical safety codes.

  • Page 4: Power-up Procedure

    Caution Statements ASTAT XL Service Manual Power-up procedure Always apply control voltage before (or with) mains voltage. QLxxB0023D to QLxxB0105D: After transportation, mechanical shock or rough handling there is a possibility that the bypass contactor may have latched into the on state. To prevent the possibility of the motor starting immediately, on first commissioning or operation after transportation, always ensure that the control supply is applied before the power, so that the contactor state is initialised.

  • Page 5: Functional Tests

    Use the tests in this section to identify the cause of problems with the soft starter. NOTE Before changing any parameter settings, save the current parameter set to a file using GE ASTAT Setup Tool ed.3 or the soft starter's Save User Set function (see the soft starter user manual for more information).

  • Page 6: Run Performance Test

    Functional Tests ASTAT XL Service Manual Run Performance Test This procedure tests for correct operation of the ASTAT XL during Run mode. This test is performed using an AC voltmeter. Measure the voltage across each phase (L1-T1, L2-T2, L3-T3). This should be close to the nominal mains voltage (phase voltage for in-line connection and line voltage for inside delta connection).

  • Page 7

    If the test motor has a current rating which is much lower than that of the soft starter, disable Undercurrent Trip (Parameter 4C). Connect mains supply and motor. Test that the soft starter functions as expected. Reload the saved parameter set into the ASTAT XL via GE ASTAT Setup Tool ed.3 after servicing work is complete. DET-813...

  • Page 8: Troubleshooting

    Troubleshooting ASTAT XL Service Manual Troubleshooting Protection Responses When a protection condition is detected, the ASTAT XL will write this to the event log and may also trip or issue a warning. The soft starter's response depends on the Protection Action setting (parameter group 16).

  • Page 9

    ASTAT XL Service Manual Troubleshooting Display Possible cause/Suggested solution Where 'X' is phase 1, 2 or 3. Firing Fail Px The SCR did not fire as expected. The SCR may be faulty or there may be an internal wiring fault. This trip is not adjustable.

  • Page 10

    Troubleshooting ASTAT XL Service Manual Display Possible cause/Suggested solution During pre-start checks the starter has detected a shorted SCR or a short L1-T1 shorted within the bypass contactor as indicated. If the starter is connected in-line L2-T2 shorted L3-T3 shorted with the motor, consider using PowerThrough to allow operation until the starter can be repaired.

  • Page 11

    ASTAT XL Service Manual Troubleshooting Display Possible cause/Suggested solution This is a name selected for a programmable input. See Input A trip. No Flow • A parameter value is outside the valid range. Parameter out of range The starter will load the default value for all affected parameters. Press RESET to go to the first invalid parameter and adjust the setting.

  • Page 12: General Faults

    Troubleshooting ASTAT XL Service Manual General Faults This table describes situations where the soft starter does not operate as expected but does not trip or give a warning. Symptom Probable Cause Starter "Not Ready" • Check Input A (53, 55). The starter disable function may be active.

  • Page 13

    ASTAT XL Service Manual Troubleshooting Symptom Probable Cause Motor does not reach full speed. • If the start current is too low, the motor will not produce enough torque to accelerate to full speed. The soft starter may trip on excess start time.

  • Page 14: Scrs

    Troubleshooting ASTAT XL Service Manual SCRs SCR damage is generally caused by overcurrent, overvoltage or overtemperature. To prevent future damage, check that the soft starter has been installed properly. Common causes of SCR problems include: Overcurrent: • cable fault on soft starter output •...

  • Page 15: Service Instructions

    ASTAT XL Service Manual Service Instructions Service Instructions The physical layout and spare parts for ASTAT XL vary according to the size of the starter. ASTAT XL starters can be grouped into seven "frame sizes" as follows: Frame Size ASTAT XL Models QLxxB0023D QLxxB0043D QLxxB0050D...

  • Page 16: Qlxxb0023d To Qlxxb0053d (g1b)

    Service Instructions ASTAT XL Service Manual QLxxB0023D to QLxxB0053D (G1B) Main plastic Keypad Main control PCB Model PCB (including bypass contactors) Backplane PCB SCRs Current transformers Mounting posts Cage clamps Side plastic Base plastic DET-813...

  • Page 17: Qlxxb0076d To Qlxxb0105d (g1b)

    ASTAT XL Service Manual Service Instructions QLxxB0076D to QLxxB0105D (G1B) Main plastic Keypad Main control PCB Backplane PCB Model PCB Bypass contactors SCRs Current transformers Mounting posts Cage clamps Side plastic Base plastic DET-813...

  • Page 18: Qlxxb0145d To Qlxxb0220d (g2b)

    Service Instructions ASTAT XL Service Manual QLxxB0145D to QLxxB0220D (G2B) Main plastic Keypad/Main control PCB Bypass driver PCB Support plastic Model PCB Current transformers SCRs Bypass contactors Main chassis 10 Fan DET-813...

  • Page 19: Qlxxb0255d To Qlxxb0425d (g3b)

    ASTAT XL Service Manual Service Instructions QLxxB0255D to QLxxB0425D (G3B) Main plastic Keypad Bypass driver PCB Main control PCB Main chassis Bypass contactors Snubber assembly (QLxxB0350D and QLxxB0425D only) SCRs Current transformers 10 Heatsink 11 Fan assembly DET-813...

  • Page 20: Qlxxx0255d (g3c)

    Service Instructions ASTAT XL Service Manual QLxxX0255D (G3C) Cover Main plastic Keypad/Main control PCB Support plastic Model PCB Current transformers SCRs Main chassis Fan assembly DET-813...

  • Page 21: Qlxxb0500d To Qlxxb1000d (g4b)

    ASTAT XL Service Manual Service Instructions QLxxB0500D to QLxxB1000D (G4B) Keypad Main cover Main control PCB Support plastic Model PCB Bypass driver PCB Magnetic bypass plate (QLxxB0580D~QLxxB1000D only) Snubber assembly Phase arm Main chassis Fan assembly DET-813...

  • Page 22: Qlxxx0360d To Qlxxx0930d (g4c)

    Service Instructions ASTAT XL Service Manual QLxxX0360D to QLxxX0930D (G4C) Cover Main plastic Keypad/Main control PCB Support plastic Model PCB Mounting bracket assembly Snubber assembly (1 per phase) Busbar support Power assemblies Fan assembly Main chassis CT assembly DET-813...

  • Page 23: Qlxxx1200d To Qlxxx1600d (g5c)

    ASTAT XL Service Manual Service Instructions QLxxX1200D to QLxxX1600D (G5C) Cover Main plastic Keypad/Main control PCB Support plastic Model PCB Mounting bracket assembly Snubber assembly (1 per phase) Power assemblies CT assembly 10 Fan assembly 11 Main chassis DET-813...

  • Page 24: Spare Parts

    Spare Parts ASTAT XL Service Manual Spare Parts NOTE Unless otherwise indicated, spare part kits contain only one of each item. All images in this section are indicative. Main Control PCB Each soft starter requires one Main Control PCB. NOTE Programmable parameters are stored in the Main Control PCB.

  • Page 25

    ASTAT XL Service Manual Spare Parts 995-16148-00, 995-16149-00, 995-16150-00, 995-16152-00, 995-16153-00, 995-16154-00, 995-16151-00 995-16155-00 DET-813...

  • Page 26: Model Pcb

    Spare Parts ASTAT XL Service Manual Model PCB Each soft starter requires one Model PCB. QLxxB0023D 995-09399-00 QLxxB0043D 995-09400-00 QLxxB0050D 995-09401-00 QLxxB0053D 995-09402-00 QLxxB0076D 995-09404-00 QLxxB0097D 995-09408-00 QLxxB0100D 995-09409-00 QLxxB0105D 995-09410-00 QLxxB0145D 995-09411-00 QLxxB0170D 995-09412-00 QLxxB0200D 995-09413-00 QLxxB0220D 995-09414-00 QLxxB0255D 995-14866-00 QLxxB0350D 995-14867-00...

  • Page 27: Backplane Pcb

    ASTAT XL Service Manual Spare Parts Backplane PCB Models QLxxB0023D~QLxxB0105D require one Backplane PCB. QLxxB0023D QLxxB0043D QLxxB0050D QLxxB0053D QLxxB0076D 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...

  • Page 28: Bypass Driver Pcb

    Spare Parts ASTAT XL Service Manual Bypass Driver PCB Models QLxxB0145D~QLxxB1000D require one Bypass Driver PCB. QLxxB0023D QLxxB0043D QLxxB0050D QLxxB0053D Not required QLxxB0076D QLxxB0097D 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...

  • Page 29: Scrs And Scr Connections

    ASTAT XL Service Manual Spare Parts SCRs and SCR Connections Models QLxxB0023D ~ QLxxB0425D use SCRs. Each soft starter requires three SCRs. QLxxB0023D 995-05753-00 QLxxB0043D 995-05754-00 QLxxB0050D 995-05755-00 QLxxB0053D 995-05756-00 QLxxB0076D QLxxB0097D 995-05757-00 QLxxB0100D 995-05758-00 QLxxB0105D 995-05759-00 QLxxB0145D QLxxB0170D 995-05760-00 QLxxB0200D 995-05761-00 QLxxB0220D...

  • Page 30

    Spare Parts ASTAT XL Service Manual Connect the coloured firing looms to the numbered gates according to the diagrams below: Models 0023~0076 7 6 5 4 7 6 5 4 SEMIKRON INFINEON Models 0097~0145 SEMIKRON INFINEON Models 0170~0255 SEMIKRON INFINEON Models 0350~0425 NOTE Unless otherwise indicated, spare part kits contain only one of each item.

  • Page 31: Power Assemblies

    ASTAT XL Service Manual Spare Parts Power Assemblies Models QLxxB0500D ~ QLxxB1000D use phase arms. Each soft starter requires three phase arms. QLxxB0500D 995-14501-00 QLxxB0580D 995-14502-00 QLxxB0700D 995-10136-00 QLxxB0820D 995-10139-00 QLxxB0920D 995-10140-00 QLxxB1000D 995-10141-00 Models QLxxX0360D ~ QLxxX1600D use power assemblies. Each soft starter requires two power assemblies.

  • Page 32: Fans

    Spare Parts ASTAT XL Service Manual Fans Certain models include a fan. The number of fans required differs between units and is shown in the table below. Part number Quantity QLxxB0023D QLxxB0043D Not required QLxxB0050D QLxxB0053D QLxxB0076D QLxxB0097D QLxxB0100D 995-09441-00 QLxxB0105D QLxxB0145D QLxxB0170D...

  • Page 33: Snubber Assemblies

    ASTAT XL Service Manual Spare Parts Snubber Assemblies NOTE These parts are only required for models with mains voltage 380~690 VAC. Models QLxxB0350D ~ QLxxB1000D and QLxxX0360D ~ QLxxX1600D use snubber assemblies. Each soft starter requires three snubber assemblies. Each snubber kit includes three snubber assemblies. QLxxB0350D QLxxB0425D QLxxB0500D...

  • Page 34: Current Transformers

    Spare Parts ASTAT XL Service Manual Current Transformers Each soft starter requires three current transformers. The current transformers for models QLxxB0500D ~ QLxxB1000D are included in the phase arm. QLxxB0023D QLxxB0043D QLxxB0050D QLxxB0053D 995-02571-00 QLxxB0076D QLxxB0097D QLxxB0100D QLxxB0105D QLxxB0145D QLxxB0170D QLxxB0200D QLxxB0220D 995-02573-00...

  • Page 35: Bypass Contactors

    ASTAT XL Service Manual Spare Parts 5.10 Bypass Contactors Some models are internally bypassed. Each soft starter requires three bypass contactors. The bypass contactors for models QLxxB0023D ~ QLxxB0053D are included in the Model PCB. The bypass contactors for models QLxxB0700D ~ QLxxB1000D are included in the phase arm. QLxxB0023D QLxxB0043D Not available...

  • Page 36: Plastics

    Spare Parts ASTAT XL Service Manual 5.11 Plastics The following body plastic components are available for ASTAT XL. Main plastic Mounting posts Model PCB support QLxxB0023D QLxxB0043D QLxxB0050D QLxxB0053D 995-11778-00 995-11780-00 Not Required QLxxB0076D QLxxB0097D QLxxB0100D QLxxB0105D QLxxB0145D QLxxB0170D QLxxB0200D QLxxB0220D QLxxB0255D QLxxB0350D...

  • Page 37: Busbars

    ASTAT XL Service Manual Spare Parts 5.12 Busbars Each soft starter requires a total of six busbars (three input and three output). Each kit contains three busbars (unless otherwise stated) and fixing accessories if applicable. Input Output QLxxB0023D QLxxB0043D 995-11790-00 QLxxB0050D 995-11791-00 QLxxB0053D...

  • Page 38

    Spare Parts ASTAT XL Service Manual 995-11790-00 995-11792-00, 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, 995-11803-00, 995-11805-00, 995-11807-00, 995-11808-00 995-11809-00 DET-813...

  • Page 39: Other Spare Parts

    ASTAT XL Service Manual Spare Parts 5.13 Other Spare Parts The following spare parts are also available. Cage Clamps Connector Plugs QLxxB0023D QLxxB0043D QLxxB0050D QLxxB0053D 995-11810-00 QLxxB0076D (set of 3) QLxxB0097D QLxxB0100D QLxxB0105D QLxxB0145D QLxxB0170D QLxxB0200D 995-11811-00 QLxxB0220D (set of 3) QLxxB0255D QLxxB0350D QLxxB0425D...

  • Page 40: Appendix

    Appendix ASTAT XL Service Manual Appendix Bolt Tightening Torques When assembling soft starter components, each bolt should be tightened using a calibrated torque driver set to the appropriate assembly torque. The following tables indicate the different types of bolts and bolt tightening torques for each assembly. 6.1.1 Input/Output Busbars to SCRs Model...

  • Page 41

    ASTAT XL Service Manual Appendix 6.1.2 SCRs to Heatsink Model Bolt size Torque (Nm) QLxxB0023D QLxxB0043D QLxxB0050D QLxxB0053D QLxxB0076D M5x16 QLxxB0097D QLxxB0100D QLxxB0105D QLxxB0145D QLxxB0170D QLxxB0200D QLxxB0220D M5x20 QLxxB0255D QLxxB0350D M6x30 QLxxB0425D QLxxB0500D QLxxB0580D QLxxB0700D Not required Not required QLxxB0820D QLxxB0920D QLxxB1000D QLxxX0255D...

  • Page 42

    Appendix ASTAT XL Service Manual 6.1.3 Bypass Contactor Connections Model Bolt size Torque (Nm) QLxxB0023D QLxxB0043D M5x12 QLxxB0050D QLxxB0053D QLxxB0076D QLxxB0097D M6x12 QLxxB0100D QLxxB0105D QLxxB0145D M5x12 QLxxB0170D QLxxB0200D QLxxB0220D M8x20 QLxxB0255D QLxxB0350D M10x30 QLxxB0425D QLxxB0500D M10x25 QLxxB0580D QLxxB0700D QLxxB0820D Not required Not required QLxxB0920D QLxxB1000D...

  • Page 43

    ASTAT XL Service Manual Appendix DET-813...

  • Page 44

    Industrial Solutions GE is a first class global supplier of low and medium voltage products, including wiring devices, residential and industrial electrical distribution components, automation products, enclosures and switchboards. Demand for the company’s products comes from wholesalers, installers, panel builders, contractors, OEMs and utilities worldwide.

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