ABB Crane motion controller ASTAT® 25-2000 A 380-690 V

ABB Crane motion controller ASTAT® 25-2000 A 380-690 V

ASTAT® for industry!

ASTAT, with slip-ring motors, has become the

leading technology for new heavy industrial

cranes in the growth regions of the world.

In Europe, ASTAT is mostly used for retrofit

installations or when normal industrial drives

are unable to fulfil the requirements.

We supply ASTAT solutions for applications up

to 4000 A or 4700 kVA.

The ASTAT Digital Crane Motion Controller has

better control and information properties

compared to earlier controllers. Equally

important is the focus on quality of hardware

components. The digital controller can be

mounted on a steel plant crane in hot countries

such as India without extra cooling or air

conditioning. This capability provides additional

benefits to worldwide industrial crane users.

i.e. The crane control system must withstand

dirty, hot and cold environments in addition to

difficult power supply systems. This has forced

us to integrate functions like brake control, time

relays, logic control and thermistor relays into

the ASTAT controller. Generic products with the

same robustness as the ASTAT controller are

difficult to find. With this level of integration we

offer a complete, fully tested motion control

system.

Slip-ring motors may be produced with small

internal rotor losses. This is important in crane

applications with multiple motors and a high

demand for good motion control. As well as

being ideal for crane applications, slip-ring

motors are low on maintenance with brushes

being exchanged only every 5 to 10 years.

ASTAT uses the slip-rings for measurement of

the rotor frequency and from this calculates the

speed. In most cases no tachometer or pulse

encoder is necessary.

The operator controls the crane motion, while

all rotor contactors are optimized by ASTAT, as

an integrated part of the current control. This

results in dramatically reduced wear of

contactors and crane mechanical parts. Crane

maintenance costs will therefore be reduced.

Advantages with ASTAT®:

• Fewer and better components result in more up-time.

• Operational diagnostics will speed-up fault tracing.

• Multipurpose spares will reduce parts in stock.

• The PC-program for maintenance can be installed in

a ground level computer. Nobody has to visit the crane

first to find the problem.

Digital ASTAT motion control is superior to other

techniques and it increases the operational results to the

limits of the crane itself. For you as a user it will create:

• Increased productivity. The operator moves the

crane without jogging, i.e. with one single movement.

• Prolonged lifetime. Smooth acceleration and

retardation decreases torque peaks.

• Special functions reduce rope and brake wear.

• Satisfied operators. Motion control is possible down

to increments of only one cm. Try to do such a small step

without the ASTAT system!

• Excellent control features permit higher speed

during automatic control.

When to select ASTAT® ?

ASTAT is suitable for crane control in demanding

environments, when larger motor powers must be

handled, for retrofits or when automating one or more

cranes.

Operation limits

Voltage: Nominal -30% ...+10%.

Current: See below.

Frequency: 50 Hz ±10 Hz, 60 Hz ±10 Hz

Temperature: -25(-40)ºC w/o heating

+70 (+85)ºC w/o cooling

continuously (short)

Isolation: EN60664, Pollution degree 4

Over voltage Protection DASG

5 Voltages: 380-400 V AC, 415 V,

440-480 V, 500-575 V, 690 V

Thyristor Modules DASD

3 Voltages: max. 530 V,

max. 600 V, max. 690 V (50 / 60 Hz)

8 Currents: 25 A ... 1000 A

crane motor rated current

The continuous current (AC-1) is higher than

the rated current.

3 Frame sizes: 25-100 A, 200-355 A, 630-1000 A

Functions

22 Main groups

I/O units and Factory test Selectable DO

Supply information Load functions

Motor information Limit switch function

ASTAT configuration Rotor system

Brake information Positioning system

Speed feedback Master-Follower

Speed reference Motion control logic

Speed regulator Shared motion

Speed supervision Two operators stations

Current/Torque regulator Different parameter sets

Rotor resistor Fault handling system

Set-up: With PC. Windows and COM1/ USB port

required.

Indication Two digits, 00 - 99.

Readable -40 ... + 85ºC

Control System Modules

Control System Module DARA 1001

2 Voltages 115/230 V

50/60 Hz. Single phase.

2 Thyristor Modules each max. 1000 A

(Totally max. 2000 A)

1 RS 232 interface for

programming/supervision PC

1 RS 232 for overriding control

1 Opto interface for Master-Follower

1 Opto interface for Optional Control

1 Opto interface for I/O-connection

17 Digital in, 110 V DC (supplied internally)

8 Digital out, relay (for 110 - 230 V AC)

4 Motor PTC inputs

4 Analog in, +/- 20 mA or +/- 10 V

2 Analog out, +/- 10 V

2 RS 232 for intelligent transducers

1 Incremental pulse encoder

4 Rotors for speed feedback /

rotor monitoring

0 - 3 Remote I/O "Cabin I/O"

Remote I/O DAPM 100 "Cabin I/O"

8 Digital in, 24 V DC

8 Digital out, 24 V DC, transistor

2 Analog in, +/- 20 mA or +/- 10 V

2 Analog out, +/- 10 V

Feedback Module DADT

1 Rotor, max. 600 V rated rotor voltage

Control data

Reversible stator voltage control, with 0 - 3 rotor contactors.

2 Modes: Scalar speed control or vector

based torque control

3 Speed feedback options:

Rotor frequency, tachometer, and pulse encoder

10 ms Speed reference generation and closed speed

regulator loop execution

3 ms Current regulator execution (interrupt controlled)

100 μs Resolution rotor frequency measurement

Optional Control

Sway Control System

Positioning system for TCP/IP commands

Four-rope grab crane