Eaton AMPGARD MV4S Instructions For Installation, Use And Maintenance Manual

For more information visit: www.cutler-hammer.eaton.com

IB48068

Read and understand these instructions

before attempting any installation,

operation, or maintenance of the

AMPGARD Reduced Voltage Soft Starter.

This equipment shall be installed and

serviced only by qualified electrical

personnel.

Retain this document for future use.

Cutler-Hammer

Instructions for Installation, Operation, and Maintenance

of the AMPGARD Reduced Voltage Soft Starter

Instruction Bulletin

Instruction Leaflet Instructions for Installation,

Page 2 Effective: March 2010 Operation, and Maintenance of the

AMPGARD Reduced Voltage Soft Starter

For more information visit: www.cutler-hammer.eaton.com

IB48068

Cutler-Hammer

Table of Contents

Description Page

Purpose………………………………………………………………..2

1 Introduction..…………………………………………………. 3

1.1. Basic Description of a Single Unit………………. 3

1.2. Upper Cell………………………………………………. 3

1.3. Lower Cell………………………………………………. 4

1.4. RVSS Truck……………….……………………………. 5

2 Installation…………………………………………………….. 5

2.1 RVSS Truck Removal………..……………………… 6

2.2 RVSS Truck Transport……………………………… 9

2.3 Cable Shield Removal……………………………... 9

2.4 RVSS Truck Reinstallation………………………. 10

3 Operation…………………………………………………..... 11

3.1 Reduced Voltage Operation…………………… .11

3.2 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.

Instruction Leaflet Instructions for Installation,

Page 3 Effective: March 2010 Operation, and Maintenance of the

AMPGARD Reduced Voltage Soft Starter

For more information visit: www.cutler-hammer.eaton.com

IB48068

Cutler-Hammer

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.)

Fig. 1 AMPGARD RVSS

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.

Fig. 2 Upper Cell

Upper Cell

Lower Cell

Low Voltage

Compartment

Main Contactor

Main Fuses

Isolation Switch

Handle Mechanism

Instruction Leaflet Instructions for Installation,

Page 4 Effective: March 2010 Operation, and Maintenance of the

AMPGARD Reduced Voltage Soft Starter

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IB48068

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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 run-

stopped indicating lights are supplied when

specified.

Fig. 3 Low Voltage Components

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.

Fig. 4 Lower Cell

Door Interlock Tab

Low Voltage

Compartment

RVSS Truck

Assembly

Medium

Voltage Door

Instruction Leaflet Instructions for Installation,

Page 5 Effective: March 2010 Operation, and Maintenance of the

AMPGARD Reduced Voltage Soft Starter

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IB48068

Cutler-Hammer

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.)

Fig. 5 Keypad Operator Interface

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.)

Fig. 6 Control System Boards

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.)

Fig. 7 RVSS Truck

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.

RVSS

Power

Poles

Bypass Contactor

Pull Bar

CAUTION:

• To prevent damage to the RVSS, remove the

RVSS truck prior to dielectric testing.

Instruction Leaflet Instructions for Installation,

Page 6 Effective: March 2010 Operation, and Maintenance of the

AMPGARD Reduced Voltage Soft Starter

For more information visit: www.cutler-hammer.eaton.com

IB48068

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2.1 RVSS Truck Removal

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.)

3 Locate the fiber optic harness connections on the

left side of the MCB mother board.

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.

4 Disconnect the three fiber optic cables labeled

THA, THB, and THC.

Fiber Optic Cables

THA, THB, THC

Fiber Optic

Connector Bloc

k

MCB Mother

Board

Board Cover

Instruction Leaflet Instructions for Installation,

Page 7 Effective: March 2010 Operation, and Maintenance of the

AMPGARD Reduced Voltage Soft Starter

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IB48068

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5 Remove the fiber optic connector block which is

fastened with two screws.

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.

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.

8 Locate the retaining brackets on the lower front

of the truck. Remove the brackets by taking out

two bolts in each bracket.

Control

Harness

Retaining

Brackets

Instruction Leaflet Instructions for Installation,

Page 8 Effective: March 2010 Operation, and Maintenance of the

AMPGARD Reduced Voltage Soft Starter

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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.

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

Instruction Leaflet Instructions for Installation,

Page 9 Effective: March 2010 Operation, and Maintenance of the

AMPGARD Reduced Voltage Soft Starter

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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.

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. 9 Truck Lifting

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.

Fig. 10 Cable Shield

CAUTION:

• To prevent damage to cables, the cable shield

must be reinstalled before reinserting the truck

into the cell.

Cable

Shield

Cable Entry

Area

Lifting

Holes

Bracket

Instruction Leaflet Instructions for Installation,

Page 10 Effective: March 2010 Operation, and Maintenance of the

AMPGARD Reduced Voltage Soft Starter

For more information visit: www.cutler-hammer.eaton.com

IB48068

Cutler-Hammer

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.

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.

4 Reassemble the retaining brackets in front of the

truck wheels with two bolts on each bracket.

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.

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.

5 Reconnect the control harness to the bypass

contactor on top of the truck.

Note: If truck is positioned correctly,

there will be no interference between the

closed door and this truck hardware.

Note: Orient small hole in corner of

connector block with stud on board.

Instruction Leaflet Instructions for Installation,

Page 11 Effective: March 2010 Operation, and Maintenance of the

AMPGARD Reduced Voltage Soft Starter

For more information visit: www.cutler-hammer.eaton.com

IB48068

Cutler-Hammer

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.

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 5.1.2

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.

AFTER TURNING OFF POWER, WAIT AT LEAST

15 MINUTES BEFORE MAKING CONTACT WITH

THE RVSS POWER POLES BECAUSE HIGH

VOLTAGE MAY BE PRESENT.

Fig. 11 AMPGARD RVSS Outline

Instruction Leaflet Instructions for Installation,

Page 12 Effective: March 2010 Operation, and Maintenance of the

AMPGARD Reduced Voltage Soft Starter

For more information visit: www.cutler-hammer.eaton.com

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Fig. 12 AMPGARD RVSS Typical Schematic

Instruction Leaflet Instructions for Installation,

Page 13 Effective: March 2010 Operation, and Maintenance of the

AMPGARD Reduced Voltage Soft Starter

For more information visit: www.cutler-hammer.eaton.com

IB48068

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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.)

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.)

AFTER TURNING OFF POWER, WAIT AT LEAST

15 MINUTES BEFORE MAKING CONTACT WITH

THE RVSS POWER POLES BECAUSE HIGH

VOLTAGE MAY BE PRESENT.

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. 15 Cables Moved to Line Side

Eaton AMPGARD MV4S Instructions For Installation, Use And Maintenance Manual

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