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Soft start units

Altistart soft start-stop units

Contents

Torque and current curves pages 8 to 11

Presentation, description page 12

Operation pages 13 to 15

Characteristics pages 16 and 19

References pages 20 to 23

Options

Dialogue and communication pages 24 to 26

Line chokes page 27

Dimensions pages 28

Schemes pages 30 to 33

Compatibility pages 34 and 35

Spare parts pages 36 and 37

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Soft start units

Conventional starting of 3-phase asynchronous motors

Torque and current curves

Direct on line starting

i Starting current4 to 8 times the nominal current.

i Starting torque0.5 to 1.5 times the nominal torque.

i Characteristics- 3-terminal motor, low to medium power.- On-load starting.- High starting current peak and voltage drop- Simple equipment.

i No parameter adjustment.

Star-delta starting

i Starting current1.8 to 2.6 times the nominal current.

i Starting torque0.5 times the nominal torque.

i Characteristics- 6-terminal motor.- No-load starting or starting with low resistive torque.- High current and torque peaks at "star-delta"

changeover.- Equipment requires maintenance.

i No parameter adjustment

Presentation, description :page 12Characteristics :pages 16 to 19References :pages 20 to 27Dimensions :pages 28 and 29

6

5

4

3

2

1

0 0 0,25 0,5 0,75 1 N/Ns

I/In

2,5

2

3

1,5

1

0,5

0

0 0,25 0,5 0,75 1

N/Ns

C/Cn

Cr

6

5

4

3

2

1

00 0,25 0,5 0,75 1

N/Ns

I/In

2,5

2

3

1,5

1

0,5

00 0,25 0,5 0,75 1

N/Ns

C/Cn

Cr

T/Tn

T/Tn

Tr

Tr

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Soft start units

Conventional starting of 3-phase asynchronous motors


Primary resistance starting

i Starting current4.5 times the nominal current.


i Characteristics- 3-terminal, high power motor.- Increasing resistive torque during starting.- High current peak.- Bulky equipment, which requires maintenance.


T/Tn

Autotransformer starting

i Starting current1.7 to 4 times the nominal current.


i Characteristics- 3-terminal, high power motor.- Large voltage drop and high current peak when starting

at the instant of transition.- Bulky, complex equipment, requiring maintenance.


Presentation, description :page 12Characteristics :pages 16 to 19References :pages 20 to 27Dimensions :pages 28 and 29:

6

5

4

3

2

1

00 0,25 0,5 0,75 1

N/Ns

I/In

2,5

2

3

1,5

1

0,5

00 0,25 0,5 0,75 1

N/Ns

C/Cn

Cr

6

5

4

3

2

1

00 0 ,25 0,5 0,75 1 N/Ns

I/In

2,5

3

2

1,5

1

0,5

0

0 0,25 0,5 0,75 1

N/Ns

C/Cn

Cr

T/Tn

T/Tn

Tr

Tr

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00 0,25 0 ,5 0 ,75 1

N/Ns

Cr

U

0,85 U

0,6 U

C

0

0 0,25 0,5 0,75 1N/Ns

Cr

Cd1

Cd

Id1

Id

3

M

T

Is

Td1

Soft start units

Soft-starting 3-phase asynchronous motors


Electronic starting by varying the voltage and the current limit

The voltage of the 3-phase supply to the motor is steadily increased by the use of a thyristor bridge. The bridge consistsof back to back pairs of thyristors connected in each phase of the a.c. supply.

By varying the firing angle of the thyristors, the motor can be fed with a steadily increased voltage at fixed frequency.

The output voltage can be controlled either by an acceleration ramp or by the current limit or by a combination of bothparameters.

Is

Figure 1 illustrates the development of the torque as afunction of the starting current.Limiting the starting current ls to a present value ls1 has theeffect of reducing the starting torque Ts1 which is practi-cally equal to the ratio of the square of currents ls and ls1.

Example :For a motor with Ts = 2 Tn for ls = 6 ln, limiting the currentto ls1 = 3 ln, or 0.5 ls, gives a starting torque :Ts1 = Ts x (0.5)2= 2 Tn x 0.25 = 0.5 Tn.

Figure 1

Figure 2 illustrates the torque/speed characteristic of asquirrel cage motor as a function of the supply voltage.At fixed frequency the torque varies as the square of thevoltage. The steady rise of the voltage limits the torque andthe current during starting, and prevents instantaneouscurrent peaks.

Figure 2

Tr

Ts1

Is1Ts

Tr


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Soft start units

Soft-starting 3-phase asynchronous motors


Soft-starting using the Altistart 46 (torque control)

Altistart 46 is a 6-thyristor soft start - soft stop unit for the controlled starting and stopping of 3-phase asynchronous squirrelcage motors.

It provides :

i control of the operating characteristics, during starting and stopping periods,

i thermal overload protection of both the motor and the starter,

i mechanical protection of the driven machine, by the elimination of torque surges and reduction of the inrush current,

i control of accelerating torque in all of zone 1for true control of starting phases,

i adaptation of motor torque profile to the application,

i reduction of losses in the motor.

i Starting currentAdjustable from 2 to 5 times the nominal current.

i Starting torqueVariable from 0.15 nominal torque to nominal torque.

i Characteristics- 3-terminal motor, nominal 2.2 to 800 kW,- Independently adjustable acceleration and

deceleration ramps.- d.c. injection braking possible.- Equipment needs no maintenance.

Note:Altistart 46 soft start units are motor starters.They cannot be used to supply resistors or transformers.


6

5

4

3

2

1

00 0,25 0,5 0,75 1

N/Ns

I/In

2,5

2

3

1,5

1

10,5

00 0,25 0,5 0,75 1

N/Ns

Cr

C/CnT/Tn

Tr

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Soft start units

Altistart 46 soft start - soft stop units

Presentation, description

Presentation

All the dialogue functions are accessible on the front panelof the unit via :

1 a dialogue option2 the LED display3 the removable terminal block.

The Altistart 46 is designed to meet the needs of both thesupply and the motor. It is supplied factory set and ready touse. By adding one of the two dialogue options, the factorysettings, configuration and display parameters can bemodified.

Altistart 46 soft start - soft stop units are recommended when the following features are required :i limitation of supply voltage drop and reduction of current peaks during startingi limitation of starting torque to protect the driven mechanismi smooth acceleration, deceleration or braking, to protect both equipment and personneli gradual starting of high inertia machinesi ability to easily adapt the starter for special machinesi highly sophisticated motor protection.

i The Altistart 46 can control motors with standard 3-phase voltages between 208 and 500 V and with power ratingbetween 2.2 and 800 kW.

Description

The Altistart 46 comprises a control module mounted on a power assembly. Local or on-line communication options (PLCor PC) complete the product.

Microprocessors can be used to control the torque during starting and stopping, without any need for a tachogenerator.

Schematic diagram

(1) Torque feedback(2) Etimation of torque(3) Calculation of the torque reference(4) Power stage(5) Asynchronous motor(6) Measurements

The products are supplied factory set and can be put into service without any further adjustment for use as starters. Theconfiguration, factory settings and monitoring parameters can however be modified by means of an adjustment-displayoption that plugs into the Altistart, or a PC connection option.

1

Characteristics :pages 16 to 19References :pages 20 to 29Dimensions :pages 28 and 29Schemes :pages 30 to 35

3

2

(6)

(3)

(2)

(1) (4) (5)

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Soft start units


Operation

Torque control

The Altistart 46 uses a Schneider patent to control the torque during starting and stopping. This allows:i constant acceleration and deceleration, without a tachogenerator, even when the motor load varies,i optimization of losses in the motor during transitional phases (gain of at least 10 to 15 % ),i factory setting which requires no further adjustment for the majority of applications.

Self-adjustment

There is an Altistart model for each standard motor. The product is factory set for its corresponding motor, for standardduty applications. For severe duty applications, a switch adapts the start unit to the characteristics of the derated motor.

The Altistart 46 is factory set for the most common applications.

The dialogue or communication option is required for the following functions :i use of functions which are not preset (boost, deceleration, braking, etc)i adjustment of the thermal overload protectioni display of status and parameter.

Protective devices and thermal memory

A microprocessor-controlled surveillance system continuously monitors the temperature rise of the motor and of thestarter unit, based on the motor operating current defined by the product, or set by the user, and the actual motor current.

The product is supplied with class 10 protection, but can be adapted for other starting classes (10 A, 20, 30).An early warning signal indicates that the motor has exceeded its nominal temperature rise threshold. This informationis saved even after a break in the power supply.After a stoppage due to a thermal fault, the control circuit prevents restarting if the temperature of the motor is still toohigh.

Integrated protection of the motor against overloads

The Altistart 46 is factory set. It can be put into service without adjusting the settings (when it is used without options).Motor manufacturers indicate the period during which the motor will withstand 7.2 times its nominal current (ln). From thisstandard data, the Altistart 46 calculates the overload time according to the starting current.

Note: the motor is protected if its nominal current does not exceed 5 % of the nominal current of the starter unit. In anyother case it will be necessary to adjust the current with the options.

Hierarchical access: dialogue and communication

Dialogue and the modification of settings and of the configuration are possible by means of:i either a plug-in dialogue option,i

or a PC,i or a PLC.

Once adjustment and configuration have been completed, the options can either be removed with the Altistart poweredup, or locked in order to obtain a display during operation.The display is coded in 4 languages on the dialogue option or on the PC (French, English, German, Spanish).

The PC connection also enables settings to be saved to disk or hard disk and to be subsequently downloaded to anynumber of Altistart 46.

Also designed for use in simple automated systems, the Altistart 46 can be controlled via an AS-i bus.


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Soft start units


Operation

Starting class for motor protection

With an Altistart 46, the tripping class (IEC 947-4-1) can be adapted to all the standard starting classes.The tripping times for each starting class are given in the table below.The product is set to class 10 for standard duty and to class 20 for severe duty.

Starting Tripping Trippingclass time time

at 7.2 In (1) at 3 In

2 1.5 s 9 s

10 A 3.7 s 22 s

10 7.4 s 45 s

15 11.1 s 67 s

20 14.8 s 89 s

25 18.5 s 112 s

30 22.2 s 134 s

Standard duty for the starter unit is one which does not exceed 230 s at 3 times the motor nominal current perhour, or 6.3% of operating time including starting, stopping or braking.

For example, within one hour the Altistart 46 could perform :- 38 starts of 6 secs or 10 starts of 23 secs- 19 starts of 6 secs and 19 decelerated or braked stops of 6 secs- 5 starts of 23 secs and 5 decelerated or braked stops of 23 secsAbove these levels, the duty will be considered as being severe.

Special uses

i Cascaded starting of several identical motorsThe Altistart 46 starts all of the motors without any special precautions. As motor protection is not provided, externalthermal protection must be added to each motor.

i Cascaded starting of several different motorsThis case is identical to the former if the ratio between the lowest and highest power is between 0.5 and 1. If the ratiois greater, there is a risk that the acceleration ramp will not be optimum.

i Starting identical or different motors connected in parallelFor this application, the Altistart 46 is an intelligent solid state contactor. The current supplied by the starter is dividedbetween each motor according to its load. Motor protection is not provided.

Note: in all of these uses, in standard duty, the total starting time of all motors must not exceed 230 s per hour andall motors are controlled without boost, underload or overload protection, and using the same stopping time.

i Use of special motorsIf the motor is to be protected, it is necessary to modify the factory settings of the starter. However, if the motor isprotected externally to the Altistart unit, the factory settings will be suitable without modification.

i Use on AS-i busThe Altistart 46 can be controlled via an As-i bus by using an interface, reference ABE-8S44SBB0.

(1) Conforming to IEC 947-4-1.


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Soft start units


Operation

Application areas

The Altistart 46 meets the most severe duty requirements for the associated machines.This table is for information only.

Type of machine Duty Functions performed Starting Startingby the Altistart 46 current time

(In%) (secs)

Centrifugal pump Standard Slow-down (elimination of waterhammer) 300 5 to 15Protection against underload or inversionof direction of phase rotation

Piston pumps Standard Monitoring of running dry and direction of 350 5 to 10pump rotation

Ventilation fans Standard Detection of overload caused by clogging 300 10 to 40or severe or underload (damaged transmission(> 30 s) chain)

Braking torque at stop

Cold Standard Protection, even for special motors 300 5 to 10compressor

Screw-type Standard Protection against inversion of direction 300 3 to 20compressor of phase rotation

Contact for automatic emptying at stop

Centrifugal Standard Protection against inversion of direction 350 10 to 40compressor or severe of phase rotation

(> 30 s) Contact for automat ic emptying a t stop

Piston Standard Protection against inversion of direction 350 5 to 10compressor of phase rotation

Contact for automatic emptying at stop

Conveyor, Standard Control of overload for detection of breakdown 300 3 to 10transporter or of underload for detection of break

Lifting screw Standard Control of overload for detection of hard spot 300 3 to 10or of underload for detection of break

T-bar ski lifts Standard Control of overload for detection of jamming 400 2 to 10or of underload for detection of break

Lift (elevator) Standard Control of overload for detection of jamming 350 5 to 10or of underload for detection of breakConstant starting with variable load

Circular saw, Standard Braking for fast stop 300 10 to 60band saw or severe

(> 30 s)

Pulper, butchery Severe Control of starting torque 400 3 to 10knives

Agitator Standard Display of current gives the density 350 5 to 20of the material

Mixer Standard Display of current gives the density 350 5 to 10of the material

Grinder Severe Braking to limit vibrations during 450 5 to 60stopping, control of overload for detectionof jamming

Crusher Severe Braking to limit vibrations during 400 10 to 40stopping, control of overload for detection

of jamming

Refiner Standard Control of starting and stopping torque 300 5 to 30

Press Severe Braking to increase the number of cycles 400 20 to 60


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Soft start units


Characteristics

Electrical characteristics (continued)

Current adjustment The motor nominal current ln is adjustable from 0.5 to 1.3 times the product ratingAdjustment of maximum starting current from 2 to 7 times the motor nominal current, limited to5 times the starter current limit

Starting method By torque control (1), the starter current limited to 5 InFactory setting : 3 In for standard duty on torque ramp of 10 s and 3.5 In for severe duty on torque rampof 15 s

Method of stopping

Freewheel Freewheel stop by default

Stop contro lled by torque ramp Adjustab le by programming f rom 0.5 to 60 s

Braked stop Automatically controlled by the flux

LED display Off On Flashing

Locking (red) Fault Automatic reset

Supply on (green) Supply on

Output relays(2 relays) R1 R2

Contacts 1 N/O + 1 N/C (2 separate contacts) 1 N/C

Factory setting Safety relays, End of start relayOnly R1

can be reassigned (for isolation on stopping)

Maximum operating power VA Inrush 1200, maintained 120with c220 V

Minimum switching capacity 100 mA - 24 V

Nominal operating current A 0.5. Categories AC-14, AC-15 (c240 V) and DC-13 (a48 V)

Nominal thermal current A 5

Maximum operating voltage V c400

Mechanical durability 50 million operating cycles

Analog output AO Current output 0-20 mA or voltage output 0-10 V with 500 impedance, can be reassigned to 4-20 mAMaximum load impedance : 800 Precision 3 %, linearity 3 %

Logic outputs LO 2 logic outputs LO1 and LO2 with 0V commonMaximum voltage 40 V, minimum voltage 10 VMaximum output current : 200 mA

Available internal power supply 1 isolated output + 24 V (PL)Precision 20 %Maximum 100 mA

Logic inputs LI 3 logic inputs with 3.5 kimpedancePower supply + 24 VState 0 if < 5 V, state 1 if > 11 V

Protection Integrated thermal protection for motor and starter unit

Mains supply protection Phase failure and imbalance, indicated by output relay

Thermocontacts On fan-cooled units, 75 to 1200 A ratings

Short circuits Protection against short circuits less than 13I cL

Selection of starter unit The Altistart 46 must be selected according to the nominal power of the motor and the duty

One starter power can be used for standard or severe dutyFor severe duty, the starter and the motor are deratedThe Altistart 46 can be overrated if the product is by-passed at the end of starting.

(1) Schneider patent.

Presentation, description :page 12References :pages 16 to 19Dimensions :pages 20 and 27Schemes :pages 30 to 35

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Soft start units


Characteristics

Electrical characteristics (continued)

ATS-46 start units D17N D22N D32N D38N D47N D62N D75N D88N C11N C14N C17N

Total power dissipated W 72 91 104 121 161 206 265 310 342 426 566at nominal load

ATS-46 start units C21N C25N C32N C41N C48N C59N C66N C79N M10N M12N

Total power dissipated W 670 817 973 1404 1452 1800 2022 2680 3040 3640at nominal load

Electromagnetic characteristics (1)

Standards Test levels Examples (elements causing interference)

Summary of immunity IEC 1000-4-2 level 3tests performed withthe Altistart 46 Electrostatic discharges :

- by contact 6 kV discharge Contact of an electrically charged item

- in the air 8 kV discharge

IEC 1000-4-3 level 3

Radiated electromagnetic 10 V/m Equipment transmitting radio frequenciesfields


Rapid electrical transients : Opening/closing of a contactor

- power cables 4 kV

- control cables 2 kV


Shock wave :

- phase/phase 1 kV Lighting circuit

- in the air 2 kV

IEC 1000-4-12 level 3

Damped oscillating waves 1 kV - 1MHz Oscillating circuit on the mains supply

EMC IEC 947-4-2, class A : for all productsRadiated and IEC 947-4-2, class B : for products up to 140 A (Sizes 1 and 2). Necessary to by-pass the Altistart at the end of rampconducted emissions and add recommended line chokes.

(1) The start units conform to standard IEC 947-4-2 relating to electromagnetic compatibility. This standard guarantees a level of immunity of the products anda level of interference emitted.In steady state, the interference emitted is lower than the requirement of the standard on electromagnetic compatibility. It may however cause interference on lowlevel loads during acceleration and deceleration. Interference is mainly low frequency interference (harmonics). It can be reduced by using chokes (see page 27)

wired between the mains supply and the Altistart.Note:Power factor correction is only possible upstream of the Altistart, only being brought into circuit at the end of the starting period.The filters used on the Altistart 46 generate 1 mA earth leakage currents; residual current devices must therefore be sized accordingly.Injection braking currents generate frequencies which can interfere with protection devices, in particular insulation monitors.It is recommended that d.c. devices be used.

Presentation, description :page 12References :pages 16 to 19Dimensions :pages 20 and 27Schemes :pages 30 to 35

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