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
Table of contents
Conductix-Wampfler Automation GmbH / 04/2023
ST-87x /ST-88x
3
STB_0005, 7, en_GB

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
Table of contents
Conductix-Wampfler Automation GmbH / 04/2023
ST-87x /ST-88x
4
STB_0005, 7, en_GB

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
Table of contents
Conductix-Wampfler Automation GmbH / 04/2023
ST-87x /ST-88x
5
STB_0005, 7, en_GB

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
Table of contents
Conductix-Wampfler Automation GmbH / 04/2023
ST-87x /ST-88x
6
STB_0005, 7, en_GB

15 Customer service and addresses......................................................... 147
16 Index........................................................................................................ 149
Table of contents
Conductix-Wampfler Automation GmbH / 04/2023
ST-87x /ST-88x
7
STB_0005, 7, en_GB

Table of contents
Conductix-Wampfler Automation GmbH / 04/2023
ST-87x /ST-88x
8
STB_0005, 7, en_GB

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
1
Conductix-Wampfler Automation GmbH / 04/2023
ST-87x /ST-88x
9
STB_0005, 7, en_GB

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
1
Conductix-Wampfler Automation GmbH / 04/2023
ST-87x /ST-88x
10
STB_0005, 7, en_GB