ABB ASTAT Manual AST10_054 Crane motion controller

ABB ASTAT Manual  AST10_054 Crane motion controller

Basic Operating Parameters

Voltage range: The rated voltage of the control and thyristor modules is allowed to fluctuate within the range of -30% to +10% of the nominal value, and there are various operating voltages, such as 380 - 690V AC, etc., and different voltages are applicable to different models of modules.

Frequency range: The supported frequency is from -10Hz to +10Hz nominal, commonly 50Hz or 60Hz.

Temperature range: Control system modules can be operated continuously from -25°C (unheated) to +70°C, thyristor modules can be operated at +85°C (short periods without cooling), but the permissible current needs to be reduced at temperatures above +40°C or +55°C.

Isolation requirements: EN 60664, pollution class 4, 250V AC for control system modules and 630V AC for thyristor modules.

Control System Module Specifications

Models and characteristics: DARA 1000, DARA 1001, DARA 1010 and other models, some of which support different types of feedback (such as rotor frequency feedback, pulse encoder feedback, etc.), and integrated with a variety of interfaces, such as the RS232 interface for programming/monitoring, optocoupler interfaces for master-slave control, and so on.

Electrical parameters: the operating voltage is 115V or 230V AC 50/60Hz single phase, the power and current consumption of different models are different, such as the power of DARA 1000 is 100VA, and the current consumption of DARA 1010 is different under different loads.

Thyristor Module Specifications

Voltage and current rating: Covering a wide range of voltage, such as maximum 530V, 600V, 690V, etc.; current rating from 25A to 1000A, different models are suitable for different motor current ratings.

Other parameters: Thyristor modules are IP20 rated, come in different sizes and weights, and perform differently at different temperatures, e.g. need to be derated for high temperature environments.

Other module specifications

Overvoltage Protection Modules: Various models are available for different voltage levels, e.g. DASG 218 - DASG 223, for protection against voltage spikes, monitoring of voltage levels and phase sequence, with different sizes, weights and power consumption.

Cabin I/O modules: The DAPM 100 and DAPM 101 models are available for analogue and digital signal interfaces, respectively, with protection class IP20 and an operating temperature range of max. +55°C (plastic housing) or +70°C (metal housing).

Speed feedback modules: the DADT 100, for example, is used for speed feedback and rotor monitoring, with protection class IP20 and an operating temperature rating of +70°C, and is connected to the motor rotor and control system module via specific interfaces.

Communication-related specifications

Communication interface: Control system module with integrated RS232 channel, partial support for RS485 multi-drop systems, communication speed settable via jumpers up to 115200bps.

Communication protocols: A variety of communication protocols are supported, such as MMS (SattLink), COMLI, 3964R, etc., to meet different communication needs.

Load Related Functions

Load Measurement and Optimisation: Accurate measurement of load and a variety of load-based functions are achieved by connecting load sensors. Such as load cell linearisation for accurate measurement and calibration of different weights; torque-based load estimation function to estimate the load in specific situations; mass inertia compensation function to compensate for inertial mass effects in load measurement based on factors such as acceleration and gravity .

Overload and Speed Regulation: Complete overload protection logic, when the load exceeds the warning or stop limit, it will trigger the corresponding instructions and actions to protect the safety of the equipment. There is also a high-speed descending function (Cycle Time Reducer), which can increase the descending speed of the empty hook and shorten the working cycle under certain load conditions. At the same time, for different load conditions, it can achieve reasonable adjustment of the speed, such as limiting the lifting speed during light load to prevent the rope from shaking.

Brake-related functions

Brake control and monitoring: precise control and comprehensive monitoring of the braking process. According to the speed and direction signals, the braking can be applied at the right time, such as braking in time when the speed is close to zero or when the direction signal changes. It also has a brake delay function, which can delay the brake release in specific situations to reduce oscillation in motion. In addition, the on and off state of the brake is strictly monitored, and if the brake does not respond within the specified time, a fault will be triggered and appropriate measures will be taken .

Special brake compensation: For different types of brakes, a variety of compensation functions are provided. For example, for slow closing brakes, the load is kept stable electrically during the braking process; for slow opening brakes, the speed reference can be kept at zero before it opens, avoiding conflicts between the motor and the brake and current/torque spikes.

Speed Control Related Functions

Multiple speed control modes: Provides two modes of speed control and acceleration control. In speed control mode, the speed is precisely controlled by PID regulator, and the control parameters can be adjusted according to different working conditions. Acceleration control mode is more suitable for driver-controlled travelling movement, where the driver's operation can directly affect the acceleration, and can be smoothly switched to speed control mode when encountering limit switches.

Speed reference and optimisation: The speed reference system supports a variety of inputs, including potentiometers or stepper main switches. The analogue reference can be shaped and acceleration and deceleration ramp times can be set to suit different conditions. In addition, a variety of speed-related optimisation functions are available, such as reducing speed when approaching limit switches, limiting the maximum speed to maintain the effectiveness of the speed controller, and automatically adjusting ramp times for weak power conditions.

Other special functions

Master-slave control function: In the master-slave control system, it is possible to achieve co-operation between different ASTATs. However, it is necessary to pay attention to the super-synchronous mode and the limitation conditions of shared movement, and at the same time, there are specific requirements for the setting of speed and limit switches, so as to ensure the synchronisation and safety of master and slave equipment in the process of movement.

Standby and Emergency Functions: There is a bypass function that enables standby mode in case of partial equipment failure, such as using one motor for rescue operations. There is also a quick-stop function, which allows electrical braking independently of the master switch in case of emergency, guaranteeing the safety of equipment and personnel .