Conductix-Wampfler ST-87 Series User manual

STB_0005_ST-87x_ST-88x
www.conductix.com
Controller description
ST-87x / ST-88x
Vehicle controller

STB_0005, 7, en_GB
Translation of the original
© 2023 Conductix-Wampfler Automation GmbH
Conductix-Wampfler Automation GmbH
Handelshof 16 A
14478 Potsdam
Germany
Telephone: [phone]
Fax: [phone]
Email: [email protected]
Internet: www.conductix.com

Table of contents
1 Information on the description.................................................................. 9
1.1 Revision history............................................................................. 9
1.2 How to use and store the description............................................ 9
1.3 Applicable documents................................................................. 10
1.4 Copyright protection.................................................................... 10
1.5 Illustrations.................................................................................. 10
1.6 Brands......................................................................................... 10
2 Warranty and liability................................................................................ 11
2.1 Warranty...................................................................................... 11
2.2 Limitation of liability...................................................................... 11
3 Safety instructions................................................................................... 13
3.1 Warning concept.......................................................................... 13
3.1.1 Arrangement of warnings............................................................ 13
3.1.2 Structure of warnings................................................................... 13
3.1.3 Signal words................................................................................ 14
3.1.4 Hazard symbols........................................................................... 14
3.1.5 Suggestions and recommendations............................................ 15
3.2 Intended use................................................................................ 16
3.3 Foreseeable incorrect use........................................................... 16
3.4 Modifications and alterations....................................................... 16
3.5 Responsibility of the operator...................................................... 17
3.6 Personnel and qualifications........................................................ 18
3.7 Special hazards........................................................................... 20
3.8 Safety instructions for the system operator and manufacturer.... 21
3.9 Safety devices............................................................................. 22
3.10 Safe isolation............................................................................... 23
4 Product description.................................................................................. 25
4.1 Series 8....................................................................................... 25
4.2 87x / 88x series model name....................................................... 25
4.3 87x / 88x series power classes.................................................... 25
4.4 87x / 88x series scope of functions.............................................. 25
4.5 Type label.................................................................................... 26
4.6 ST-87x / 88x designs................................................................... 27
4.7 Basic device................................................................................ 28
5 Transport and storage.............................................................................. 29
5.1 Transport..................................................................................... 29
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5.2 Transport inspection.................................................................... 29
5.3 Storage........................................................................................ 30
6 Mechanical installation............................................................................ 31
6.1 Open spaces and cooling............................................................ 34
6.2 Installation position...................................................................... 36
6.3 Installation................................................................................... 37
6.3.1 Installation with direct screw connection..................................... 39
6.3.2 Installation with attachment bracket............................................ 40
7 Electrical installation................................................................................ 43
7.1 Notes about electrical installation................................................ 46
7.1.1 Residual current circuit breaker and mains fusing....................... 46
7.1.2 Electromagnetic compatibility...................................................... 46
7.1.3 EMC installation notes................................................................. 48
7.1.4 Cable routing............................................................................... 52
7.1.5 Control system motor output....................................................... 52
7.1.6 Protective measures.................................................................... 53
7.2 Connecting the electrical parts of the control system.................. 54
7.3 Electrical connections.................................................................. 56
7.3.1 Connection overview................................................................... 56
7.3.2 X1 - Supply.................................................................................. 57
7.3.3 X2 - Motor.................................................................................... 58
7.3.4 X10 - BLDC motor encoder......................................................... 59
7.3.5 X10 - Brake resistance................................................................ 60
7.3.6 X13 - Sensors.............................................................................. 60
7.3.7 X14 - Sensors.............................................................................. 61
7.3.8 X15 - Sensors.............................................................................. 62
7.3.9 X16 - Sensors.............................................................................. 62
7.3.10 X17 - Sensors.............................................................................. 63
7.3.11 X30 - USB.................................................................................... 64
7.4 Earthing the control system......................................................... 65
8 Commissioning......................................................................................... 67
8.1 Notes about commissioning........................................................ 70
8.2 Requirements.............................................................................. 71
8.3 Commissioning procedure........................................................... 72
8.4 Switch on control system............................................................. 73
8.5 Assign control system parameters.............................................. 75
8.5.1 Vehicle parameters and configuration switches.......................... 76
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8.5.1.1 Creating and saving parameters and configuration
switches.................................................................................. 77
8.5.1.2 Transferring parameters and configuration switches.............. 78
8.5.2 Vehicle tables – PCM system (ST-87x/ST-88x)........................... 80
8.5.2.1 Creating and saving vehicle tables......................................... 81
8.5.2.2 Transferring vehicle tables..................................................... 81
8.5.3 Vehicle tables – rail bus SB (ST-87x-SB/ST-88x-SB).................. 83
8.5.3.1 Creating and saving vehicle tables......................................... 84
8.5.3.2 Transferring vehicle tables..................................................... 85
8.6 Configuring the bus communication (ST-87x-SB/ST-88x-SB)..... 87
8.7 Test control system...................................................................... 88
8.7.1 Test – motor functions.................................................................. 88
8.7.2 Test – Sensors and peripherals.................................................... 90
8.7.3 Test – Communication.................................................................. 91
8.8 Optimise settings......................................................................... 93
9 Operation................................................................................................... 95
9.1 Operating modes......................................................................... 97
9.2 Switching the control system on and off...................................... 98
9.2.1 Switch on control system............................................................. 98
9.2.2 Switches the control system off................................................... 99
9.3 Displays..................................................................................... 100
9.3.1 Status LEDs............................................................................... 100
9.3.2 Display....................................................................................... 102
9.3.3 Display modes........................................................................... 104
9.3.3.1 Creating/modifying display modes....................................... 104
9.3.3.2 Calculating and evaluating hexadecimal values................... 105
9.4 Vehicle remote control............................................................... 107
9.4.1 Changing operating mode......................................................... 108
9.4.2 Moving the vehicle manually..................................................... 109
10 Faults........................................................................................................ 111
10.1 Displaying faults and errors........................................................ 111
10.2 Error messages......................................................................... 112
10.3 Error codes................................................................................ 112
10.4 Fault types................................................................................. 113
10.5 Fault reset.................................................................................. 114
11 Service and maintenance....................................................................... 117
11.1 Maintenance and cleaning......................................................... 117
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11.1.1 Maintenance.............................................................................. 117
11.1.2 Cleaning..................................................................................... 118
11.2 Removing / replacing the control system................................... 118
11.2.1 Control system removal............................................................. 119
11.2.2 Control system installation......................................................... 120
11.3 Repairing the control system..................................................... 120
12 Disposal................................................................................................... 121
12.1 Information on disposal and environmental regulations............ 121
13 Technical specifications......................................................................... 123
13.1 Device........................................................................................ 123
13.2 Input data................................................................................... 125
13.3 Output data................................................................................ 126
13.4 Interfaces................................................................................... 128
13.5 Cable lengths and specifications............................................... 128
13.6 Approvals and standards........................................................... 129
14 Information and parameter assignment............................................... 131
14.1 Three-phase current asynchronous motor................................ 131
14.1.1 Layout and function................................................................... 131
14.1.2 How it works.............................................................................. 132
14.2 Permanent magnet synchronous motor.................................... 135
14.2.1 Layout and function................................................................... 135
14.2.2 How it works.............................................................................. 136
14.2.3 Parameters for the settings of the controlled operation............. 138
14.2.4 Parameters for the settings of controlled operation (vector con-
trol)............................................................................................ 139
14.3 Brushless DC motors................................................................. 140
14.3.1 Layout and function................................................................... 140
14.4 Frequency converters................................................................ 140
14.4.1 Layout and function................................................................... 141
14.4.2 Rectifier..................................................................................... 141
14.4.3 Intermediate circuit.................................................................... 141
14.4.4 Inverter...................................................................................... 142
14.4.5 Control circuit............................................................................. 143
14.4.6 ST-87x/88x Current Monitor...................................................... 143
14.4.6.1 Hardware short circuit shutdown.......................................... 143
14.4.6.2 I2t-monitor (maximum load integral)..................................... 143
14.4.6.3 Software-based shutdown in the event of excess current.... 145
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15 Customer service and addresses......................................................... 147
16 Index........................................................................................................ 149
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1 Information on the description
1.1 Revision history
We reserve the right to make changes to the information present in this
document, which result from our constant effort to improve our products.
Version Date Comment/reason for change
1 03.2018 Basic version
2 04.2018 Text corrections
3 04.2018 Text corrections
3.1 06.2021 Corrections pin configuration X1, X13, X14
4 08.2021 New chapter structure
5 05.2022 Conductix-Wampfler Automation GmbH
6 03.2023 New start display
7 04.2023 Certification updated
1.2 How to use and store the description
This documentation forms part of the product. It contains important informa-
tion and notes on using the product. It affects:
nMechanical and electrical installation
nCommissioning
nOperation
nMaintenance and service
To work safely with the product, it is necessary to observe the safety notes
and action instructions. All persons working with the product must have
understood the user information in this description and apply it conscien-
tiously. The operator must fulfil his duty of care and ensure that all persons
working with the product have read and understood the user information
and are implementing it.
This description forms part of the product and must be accessible to all per-
sons working with the product at all times.
Information on the description
How to use and store the description
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1.3 Applicable documents
The documents contained in the project documentation also apply if the
device / system is part of a project-specific system plan.
The following documents are considered part of this description. They are
located at the end of this description or they are included as an extra
description in the scope of delivery.
nConnection diagram ANS
nDevice drawing GER
nSoftware description BV
Connected devices and components are covered by their own documenta-
tion.
Applies additionally when the vehicle control system is used in the bus
master system:
nProject-specific interface description BV
1.4 Copyright protection
The contents, texts, drawings, pictures and other illustrations of this
description are protected by copyright and subject to intellectual property
rights. Any misuse is punishable by law.
Reproduction in whole or in part of this description is only permitted within
the limits of the legal provisions of the copyright law. Any modification or
shortening of the text is prohibited without the explicit written consent of
Conductix-Wampfler Automation GmbH.
1.5 Illustrations
The illustrations that accompany this description have been purposely
selected. They are provided for basic understanding and may differ from
the actual design. No claims shall be accepted for possible discrepancies.
1.6 Brands
The popular names, trade names, production descriptions, etc. used in this
description may constitute trademarks even without special designations
and as such may be subject to legal requirements.
Information on the description
Brands
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2 Warranty and liability
2.1 Warranty
The warranty only covers production defects and faulty components.
The manufacturer assumes no responsibility for damages caused during
transport or unpacking. In no case and under no circumstances will the
manufacturer be liable for defects or damages caused by misuse, incorrect
installation or inadequate environmental conditions or from dust or corro-
sive substances.
Consequential damages are excluded from the warranty.
Should you have further questions regarding the warranty, please contact
the supplier.
2.2 Limitation of liability
All information and notes in this description have been compiled taking into
account the applicable standards and regulations, the state of the art and
our many years of knowledge and experience.
Conductix-Wampfler Automation GmbH assumes no liability for damage
and malfunctions during operation due to:
nFailure to comply with the description
nNon-intended use
nUse by untrained personnel
nUnauthorised alteration or modification
nUse of the product, despite negative transport inspection
Furthermore, Conductix-Wampfler Automation GmbH's warranty obligation
will cease to exist in case of a failure to comply with the description.
Warranty and liability
Limitation of liability
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Warranty and liability
Limitation of liability
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3 Safety instructions
This section contains information on all safety aspects for optimum protec-
tion of personnel and for safe operation without malfunctions.
To prevent dangers, these notes must be read and followed by personnel.
Only then can safe operation be guaranteed.
Of course, all legally applicable general safety and accident prevention reg-
ulations must be complied with.
Conductix-Wampfler Automation GmbH assumes no liability for damage or
accidents that were caused by non-observance of these safety notes.
3.1 Warning concept
This description contains notes that must be observed for your own per-
sonal safety and to avoid property damage. Notes regarding your personal
safety are highlighted by a warning triangle; notes regarding property
damage do not have a warning triangle.
When several hazard levels occur, the warning always refers to the highest
level. If a warning of injury to persons is indicated with a warning triangle,
the same warning might include an additional warning of property damage.
3.1.1 Arrangement of warnings
If warnings refer to an entire section, they are placed at the beginning of the
section (e.g. chapter start).
If warnings refer to a specific action instruction, they are placed in front of
the respective action instruction.
3.1.2 Structure of warnings
nSIGNAL WORD
n↳ Type of danger and its source
n↳ Possible consequences, if not observed
n↳ Danger avoidance measures
n↳ Preventive measures
Safety instructions
Warning concept > Structure of warnings
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3.1.3 Signal words
Warnings are indicated using signal words based on hazard levels.
Signal word Meaning
LWARNING! This combination of symbol and
signal word indicates a possible
dangerous situation that can result
in death or serious injury if it is not
avoided.
LCAUTION! This combination of symbol and
signal word indicates a possible
dangerous situation that can result
in minor injury if it is not avoided.
NOTICE! This combination of symbol and
signal word indicates a possible
dangerous situation that can result
in material damage if it is not
avoided.
3.1.4 Hazard symbols
Warnings of the groups 'danger' and 'warning' are content-based. They are
presented with clear danger symbols.
Warnings of the 'caution' group do not have a specific danger symbol.
Warning signs Type of danger
Warning – automatic start-up.
Warning - danger of crushing.
Warning – high-voltage.
Warning – danger of falling.
Warning – falling objects.
Warning – hot surface.
Safety instructions
Warning concept > Hazard symbols
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Warning signs Type of danger
Warning – danger zone.
3.1.5 Suggestions and recommendations
This symbol indicates important information to help you handle the
product.
Safety instructions
Warning concept > Suggestions and recommendations
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3.2 Intended use
The controller has been designed and constructed exclusively for the
intended use described below.
Conductix/LJU vehicle control systems are equipped with frequency con-
verters. These controllers are intended for use in industrial and commercial
systems for the operation of motors, which can be used with frequency con-
verters.
Electrical systems or machines must comply with the EU Directive
2006/42/EC (Machinery Directive) or the DIN EN 60204-1 standard if they
are to be fitted with Conductix/LJU vehicle control systems. Intended opera-
tion is only permitted in compliance with the EMC Directive (2014/30/EU
EMC).
3.3 Foreseeable incorrect use
Any use that goes beyond this description is forbidden.
L WARNING!
Hazard from improper use!
Any use of the controller other than and/or beyond the one intended can
cause hazardous situations.
nOnly use the controller as intended.
nOnly connect motors that are suitable for use with frequency con-
verters.
nDo not connect any other loads.
nIt is paramount to comply with all the specifications and permitted
conditions at the place of use.
nDo not use the controller in potentially explosive atmospheres.
nDo not operate the controller in environments with harmful oils,
gases, vapours, dusts, radiation, etc.
nDo not use the controller for the transportation of people or animals.
3.4 Modifications and alterations
For the purpose of avoiding hazards and for ensuring optimum perform-
ance, any modifications, additions, or alterations to the controller require
Conductix-Wampfler Automation GmbH's express consent.
Safety instructions
Modifications and alterations
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L WARNING!
Injury hazard from structural modifications!
Unauthorised technical modifications can cause substantial bodily harm
or material damage.
nReplace faulty control systems.
nA faulty control system should only be replaced by an identical control
system.
3.5 Responsibility of the operator
The control system is used in an industrial environment. The operator of the
control system is therefore subject to statutory obligations regarding work
safety.
In addition to the work safety instructions in this description, the safety,
accident prevention and environmental regulations applicable to the area
where the control system is used must be complied with.
The following applies in particular:
nThe operator must become familiar with the applicable work safety reg-
ulations and must also determine the dangers that are posed by the
particular work conditions at the location where the control system is to
be used by means of a risk assessment. This must be realised in the
form of operating instructions for operating the control system.
nThis description must be kept within easy reach of the control system be
accessible to those persons charged with working both on and with the
control system at al times.
nThe specifications of the description must be adhered to fully and
unconditionally.
nThe control system may only be operated when in a perfect and opera-
tionally safe condition. The control system must be checked for detect-
able defects prior to each time it is put into service.
nThe system operator must ensure that the responsibilities for activities
on the system are unambiguously defined and only adequately qualified
personnel familiar with the operating and safety regulations are working
on and with the control system.
Safety instructions
Responsibility of the operator
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3.6 Personnel and qualifications
The product / system belonging to this description may only be handled by
personnel qualified for the respective task. This is done taking into account
the descriptions associated with the particular task, especially the safety
and warning information contained therein.
Due to their training and experience, qualified personnel are able to recog-
nize risks and avoid possible hazards when dealing with this product /
system.
L WARNING!
Injury hazard from insufficient qualification!
Improper handling can cause substantial bodily harm or material
damage.
L WARNING!
Danger posed by faulty installation and initial commissioning.
The installation and initial commissioning of the control system require
trained specialist personnel with sufficient experience. Faults with the
installation may lead to potentially fatal situations or considerable mate-
rial damage.
nHave installation and initial commissioning performed exclusively by
employees of the manufacturer or by trained personnel authorised by
it.
nWorks on electric components may only be carried out by qualified
electricians or persons instructed and supervised by a qualified elec-
trician in accordance with the electro-technical regulations.
nBefore carrying out any kind of work on the controller, make sure it is
de-energised and secured against accidental reconnection.
nPrior to commissioning, ensure that all safety equipment is installed
and functioning properly.
nPrior to commissioning, ensure that parameter assignment on the
control system has been performed correctly in accordance with the
electrical and mechanical conditions of the system.
Installation and
commissioning
Safety instructions
Personnel and qualifications
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L WARNING!
Electrical hazard!
Contact with live parts poses an immediate danger to life.
The touching of open terminals and wires may lead to death or serious
injury.
nOnly qualified electricians are allowed to work on electrical system
components, devices or equipment.
nDe-energise system parts to work on them.
nCheck the de-energised state of system parts disconnected from the
mains voltage before starting to work on them.
nDo not open covers during operation.
nCall on the assistance of a second person who can actuate the
EMERGENCY-STOP mechanism or the main switch in an emer-
gency, when working on live parts.
nSome components in the system may still be live even after the
system has been switched off. They are specially designated. Ensure
to follow the notes on their designation when working on these com-
ponents!
nUse only insulated tools to work on the electric system!
The operation and maintenance of the control system must only be per-
formed by trained and qualified personnel. Staff undergoing instruction and
training are allowed to perform activities on and with the control system
under the constant supervision of a trained and qualified individual.
Electrical work
Operation and
maintenance
Safety instructions
Personnel and qualifications
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3.7 Special hazards
L WARNING!
Live parts
Contact with live parts poses an immediate danger to life. Damage to the
insulation or individual components can be life-threatening.
nIn case of damage to the insulation, turn off power supply immedi-
ately.
nCheck devices and connected components regularly. Any loose con-
nections, damaged cables and insulations as well as all damages that
could pose a risk to safety must be rectified immediately. Any faulty
protection against accidental contact must be repaired immediately.
nWorks on electric components may only be carried out by qualified
electricians or persons instructed and supervised by a qualified elec-
trician in accordance with the electro-technical regulations.
nBefore carrying out any kind of work on the control system, make
sure it is de-energised and secured against accidental reconnection.
nAlways use insulated tools.
L WARNING!
Electrical voltage after shutdown
Some components of the vehicle controllers, especially the intermediate
circuit of the frequency inverters, may still retain voltage after switching
off. Work on these components may only be carried out after the inter-
mediate circuit has discharged!
Disconnect the power supply safely:
nDisconnect system from power.
nDisconnect collectors from busbars.
Waiting time after voltage isolation: At least 10 minutes
L WARNING!
Start/stop switch
The start/stop switch does not disconnect the controller from the power
supply. Dangerous voltage is present.
nThe control system must be disconnected from the power supply
when performing work on it.
Safety instructions
Special hazards
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