Cutler-Hammer. Instructions for Installation, Operation, and Maintenance of the AMPGARD Reduced Voltage Soft Starter

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1 Operation, and Maintenance of the Instruction Bulletin Read and understand these instructions before attempting any installation, operation, or maintenance of the. This equipment shall be installed and serviced only by qualified electrical personnel. Retain this document for future use.

2 Page 2 Effective: March 2010 Operation, and Maintenance of the Table of Contents Description Page Purpose..2 1 Introduction Basic Description of a Single Unit Upper Cell Lower Cell RVSS Truck Installation RVSS Truck Removal RVSS Truck Transport Cable Shield Removal RVSS Truck Reinstallation Operation Reduced Voltage Operation Full Voltage Operation.13 HAZARDOUS VOLTAGE ALL POWER SOURCES MUST BE ISOLATED AND LOCKED OUT BEFORE SERVICING THE EQUIPMENT. READ AND UNDERSTAND THESE INSTRUCTIONS IN THEIR ENTIRETY BEFORE INSTALLING, OPERATING, OR MAINTAINING THIS EQUIPMENT. ONLY QUALIFIED PERSONS SHOULD INSTALL, MAINTAIN, ADJUST, OR REPAIR THESE UNITS. A QUALIFIED PERSON IS ONE WHO IS FAMILIAR WITH THE CONSTRUCTION AND OPERATION OF THE EQUIPMENT AND THE HAZARDS ASSOCIATED WITH IT. Purpose This instruction book is to ensure the safe and successful installation, operation, and maintenance of the AMPGARD Reduced Voltage Soft Starter (RVSS). This equipment may be installed as an individual structure or may be part of a lineup of AMPGARD products.

3 Page 3 Effective: March 2010 Operation, and Maintenance of the Section 1 Introduction 1.1 Basic Description of a Single Unit The AMPGARD RVSS is designed to start medium voltage motors at reduced voltages with specific ramp times and amperages. An individual unit consists of a standard structure that is 36 inches wide by 30 inches deep by 92 inches tall, including the main bus. The top half is referred to as the upper cell and the bottom half as the lower cell. (See Fig. 1.) 1.2 Upper Cell The upper cell consists of a full voltage starter with a non-load break isolation switch, medium voltage current limiting fuses, an SL contactor, and current transformers. A low voltage control compartment is located on the front of the controller medium voltage door. (See Fig. 2.) Refer to IB48041 (Instructions for AMPGARD 400 Ampere Medium Voltage Starter) for operating and maintenance instructions on the upper cell. Upper Cell Low Voltage Compartment Main Fuses Fig. 2 Upper Cell Main Contactor Isolation Switch Handle Mechanism Lower Cell Fig. 1 AMPGARD RVSS

4 Page 4 Effective: March 2010 Operation, and Maintenance of the The following components are located on the front of the low voltage door of the upper cell. (See Fig. 3.) Bypass Mode Indicating Light After the motor is started and reaches speed, the bypass contactor closes to bypass the SCRs in the soft starter. The Bypass Mode Indicating Light will illuminate when the SCRs are bypassed. RVSS Fault Indicating Light In the event of a soft starter failure, the RVSS Fault Indicating Light will illuminate. RVSS Fault Reset Pushbutton In the event of a soft starter failure, the RVSS Fault Reset pushbutton must be depressed to clear the fault. Optional start-stop pushbuttons and runstopped indicating lights are supplied when specified. 1.3 Lower Cell The lower cell consists of a welded frame with rails for the AMPGARD RVSS truck assembly. There is a medium voltage door with a flange that prevents access to the lower cell until the isolation switch and upper door have been opened to ensure that line voltage is not present. The RVSS truck assembly is shown racked into place in Fig. 4. Door Interlock Tab Low Voltage Compartment Fig. 4 Lower Cell Medium Voltage Door RVSS Truck Assembly Fig. 3 Low Voltage Components

5 Page 5 Effective: March 2010 Operation, and Maintenance of the A second low voltage compartment is located on the lower cell medium voltage door. The keypad operator interface is located on the front of the low voltage door and is used to configure the RVSS. Refer to DEH41021 (Medium Voltage Solid State OEM Soft Starter Manual) for details on operating the keypad. (See Fig. 5.) 1.4 RVSS Truck The RVSS power poles are mounted on an easy to remove, roll out truck assembly. An SL contactor is mounted on top of the truck which is used to bypass the SCRs in the soft starter when the motor reaches full speed. A pull bar located in front is used during truck removal and reinstallation. (See Fig. 7.) Bypass Contactor Pull Bar RVSS Power Poles Fig. 5 Keypad Operator Interface Fig. 7 RVSS Truck The control system for the RVSS is located in this low voltage compartment. Components include the CPU board, MCB mother board, terminal and control board, and CT board. (See Fig. 6.) Section 2 Installation Refer to IB48041 (Instructions for AMPGARD 400 Ampere Medium Voltage Starter) for installation instructions. During installation, the RVSS truck may be removed by following the instructions on the next page. Truck removal provides easy access to the cable area in the lower cell for bottom entry starters and is required if dielectric testing is to be performed. To remove the RVSS truck utilizing the provided ramp, a minimum clearance of 60 inches is required in front of the starter. Fig. 6 Control System Boards CAUTION: To prevent damage to the RVSS, remove the RVSS truck prior to dielectric testing.

6 Page 6 Effective: March 2010 Operation, and Maintenance of the 2.1 RVSS Truck Removal Board Cover 1 Ensure that the starter is off. Open the isolation switch. Open the medium voltage doors on the upper and lower cells. (See IB48041 for more information.) 2 Open the lower cell low voltage door. Remove the black plastic cover shielding the MCB mother board which is located in the upper, left corner of the low voltage compartment. Fiber Optic Cables THA, THB, THC Fiber Optic Connector Block MCB Mother Board 3 Locate the fiber optic harness connections on the left side of the MCB mother board. 4 Disconnect the three fiber optic cables labeled THA, THB, and THC.

7 Page 7 Effective: March 2010 Operation, and Maintenance of the 5 Remove the fiber optic connector block which is fastened with two screws. 6 Pull the fiber optic harness through the rectangular cutout in the bottom of the low voltage compartment into the lower cell. Secure the loose end of the harness on top of the truck. Control Harness Retaining Brackets 7 Disconnect the control harness from the bypass contactor on top of the truck. Secure the free end of the harness on the left side of the lower cell, ensuring that the harness is not in the exit path of the truck. 8 Locate the retaining brackets on the lower front of the truck. Remove the brackets by taking out two bolts in each bracket.

8 Page 8 Effective: March 2010 Operation, and Maintenance of the CAUTION: The truck is heavy, approximately 360 lbs. Once the truck descent down the ramp begins, the truck speed increases rapidly. Provide at least 60 inches of clearance in front of the starter to accommodate the ramp and truck. Verify that the fiber optic harness and bypass contactor control harness are both secured away from the truck exit path to prevent harness damage. Do not pull on the bypass contactor to remove the truck, as the contactor may be damaged. Truck Rail Ramp 9 Place the ramp in front of the starter so that the outside flanges align with the truck rails inside the cell. Insert the front flanges of the ramp over the edge at the bottom of the lower cell. Check that the ramp will not slide left to right or front to back to ensure that it is properly positioned. 10 The truck is now ready to remove. With both hands on the pull bar at the front of the truck, pull the truck forward. Keep both hands on the pull bar as the truck travels down the ramp and brace against the truck to control the speed.

9 Page 9 Effective: March 2010 Operation, and Maintenance of the 2.2 RVSS Truck Transport Once the truck has been removed, it may be easily rolled away. To aid in truck transport, insert a one inch diameter pipe into the bracket on the left side of the truck and use the pipe to push the truck. (See Fig. 8.) Do not pull or push on the bypass contactor to move the truck, as damage to the contactor could occur. Bracket 2.3 Cable Shield Removal For additional access to the cable area in bottom entry starters, the cable shield shown in Fig. 10 may be removed. Cable Shield Cable Entry Area Fig. 8 Truck Transport An overhead lift is recommended for lifting the truck. Holes are provided on each corner of the truck top for lifting. (See Fig. 9.) If an overhead lift is not available, roll the truck onto a pallet with the ramp and utilize a forklift. Fig. 10 Cable Shield CAUTION: To prevent damage to cables, the cable shield must be reinstalled before reinserting the truck into the cell. Lifting Holes Fig. 9 Truck Lifting

10 Page 10 Effective: March 2010 Operation, and Maintenance of the 2.4 RVSS Truck Reinstallation 1 Place the ramp in front of the starter. Place the truck in front of the ramp, aligning the wheels inside the ramp s outside flanges. With both hands on the pull bar at the front of the truck, push the truck up the ramp and into the cell. 2 Slide the truck as far into the cell as possible. Use a mirror to check that the fingers on the bypass contactor are engaged around the stabs in the rear of the cell. 3 Close the medium voltage lower door to ensure that the hardware on the lower, right hand face of the truck does not interfere with the door. If the door does not close properly, the truck is not located correctly. Push the truck further into the cell and recheck the finger to stab engagement. Note: If truck is positioned correctly, there will be no interference between the closed door and this truck hardware. 4 Reassemble the retaining brackets in front of the truck wheels with two bolts on each bracket. 5 Reconnect the control harness to the bypass contactor on top of the truck. 6 Reconnect the fiber optic harness to the MCB mother board in the lower cell low voltage compartment. Reconnect the three fiber optic cables labeled THA, THB, and THC to the marked locations on the board. Orient the connector block so that the small hole in the corner of the block will align with the stud on the board. Assemble the connector block with two screws. Reassemble the black plastic cover over the board, using four screws. Note: Orient small hole in corner of connector block with stud on board.

11 Page 11 Effective: March 2010 Operation, and Maintenance of the Section 3 Operation 3.1 Reduced Voltage Operation Refer to the schematic in Fig. 12 for the following description of operation. The AMPGARD RVSS includes a main isolation contactor M that closes just before soft start ramping begins and opens after a stop is completed. During a fault condition, the RVSS control system will shut down the soft start and then the main contactor will open. During a short circuit or ground fault detected by a separate motor relay, the relay will immediately open the main contactor to limit potential damage to the system. See the notes on the schematic for programming the relay. AFTER TURNING OFF POWER, WAIT AT LEAST 15 MINUTES BEFORE MAKING CONTACT WITH THE RVSS POWER POLES BECAUSE HIGH VOLTAGE MAY BE PRESENT. When the start contact is closed and no trip condition is present, control relay CR closes, main contactor M closes, and the RVSS begins ramping. Bypass contactor B closes when the motor reaches full speed as determined by both time and current settings. The RVSS is set at the factory with typical starting characteristics that perform well in most applications. After the power and control connections have been made, use the initial RVSS settings to operate the motor. If you wish to review the settings or make adjustments to fit your application, see section of DEH41021 (Medium Voltage Solid State OEM Soft Starter Manual). Note that if using the internal overload protective function in addition to the primary motor protective relay and the minimum FLA setting is larger than the motor FLA, set the Overload Trip FLA to the minimum available. Fig. 11 AMPGARD RVSS Outline

12 Page 12 Effective: March 2010 Operation, and Maintenance of the Fig. 12 AMPGARD RVSS Typical Schematic

13 Page 13 Effective: March 2010 Operation, and Maintenance of the 3.2 Full Voltage Operation In case of emergency, the starter can be used as a full voltage starter. Turn the Normal-Bypass switch located in the low voltage compartment of the upper section to Bypass. (See Fig 13.) Remove the RVSS truck per Section 2.1. Remove the phase barriers from the lower stab assembly in the lower cell, disconnect the load side cables, and reassemble them to the upper stab assembly. Turn the Normal-Bypass switch to Bypass. Fig. 14 Lower Cell with Truck Removed Fig. 13 Bypass Switch If the RVSS truck must be removed for repair, the load side cables in the lower cell can be quickly moved to the line side for full voltage starting. (See Figs. 14 and 15.) Fig. 15 Cables Moved to Line Side AFTER TURNING OFF POWER, WAIT AT LEAST 15 MINUTES BEFORE MAKING CONTACT WITH THE RVSS POWER POLES BECAUSE HIGH VOLTAGE MAY BE PRESENT.

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