RVS AX$20Instruction$20Manual

RVS AX$20Instruction$20Manual
RVS-AX
Analogue Soft Starter
8-170A, 220-600V
Instruction Manual
Ver. 4.2.02
1
Table of Contents
Page
3
4
5
6
7
8
9
10
Subject
Starter Selection
Installation Notes
Wiring
Starter Settings
Motor Protection
Start-up Procedure
Technical Specification
Dimensions
Safety
• Read this manual carefully before operating the equipment and follow its instructions.
• Installation, operation and maintenance should be in strict accordance with this manual,
national codes and good practice. Installation or operation not performed in strict
accordance with these instructions will void manufacturer's warranty.
• Disconnect all power inputs before servicing the soft-starter and/or the motor.
• After installation, check and verify that no parts (bolts, washers, etc) have fallen into the
starter.
Attention
1.
2.
3.
4.
This product was designed and tested for compliance with IEC947-4-2 for class A equipment.
Use of the product in domestic environments may cause radio interference, in which case the user may
be required to employ additional mitigation methods.
Utilization category is AC-53a or AC53b. Form1.
For further information, see Technical Specification.
Warnings
• Internal components and P.C.B's are at Mains potential when the RVS-AX is connected to
mains. This voltage is extremely dangerous and may cause death or severe injury if
contacted.
• When RVS-AX is connected to Mains, even if start signal has not been issued, full voltage
may appear on motor's terminals. Therefore, for isolation purposes it is required to connect
an isolating device (C/B, switch, line contactor, etc) upstream to the RVS-AX.
• Starter must be properly grounded to ensure correct operation and safety.
• Check that Power Factor capacitors are not connected to the output side of the soft starter
The company reserves the right to make any improvements or modifications to its products without prior notice.
2
Starter Selection
The starter should be selected in accordance with the
following criteria:
The RVS-AX electronic soft starter incorporates six
thyristors to start a three-phase squirrel cage induction
motor. By supplying a slowly increasing voltage, it
provides soft start and smooth stepless acceleration,
while drawing the minimum current necessary to start
the motor.
1. Motor Current & Starting Conditions
Select the starter according to motor's Full Load
Ampere (FLA) - as indicated on its nameplate (even if
the motor will not be fully loaded).
The RVS-AX is designed to operate under the
following maximum conditions:
A Soft Stop feature can be enabled when the RampDown potentiometer is adjusted. When used, upon stop
signal (open contact terminals 1 and 2), motor's voltage
is slowly reduced to zero.
Soft-Start Characteristics
U%
I%
M%
Ambient
Temp.
I start
Acc. Time
40° C
300% In
350% In
400% In
30 Sec
20 Sec
5 Sec
100
Max. Starts per Hour: four (4) starts per hour at
maximum ratings and up to 10
starts per hour at light load
applications (consult factory).
Note: For very frequent starts (inching applications)
the inching current should be considered as the
Full Load Current (FLC) – consult factory.
400
50
100
100
10
Voltage
Current
Torque
Soft-Stop Characteristics
2. Mains Voltage
U%
The Soft-Stop characteristic
may be used for controlled
deceleration of pumps and high
friction loads.
100
50
10
Each starter is factory set for one of the following
levels according to the Ordering Information.
Voltage
380 - 415 V
440 V
460 - 500 V *
575 - 600 V
Voltage
Starter Type
FLC (Amp.)
RVS-AX 8
RVS-AX 17
RVS-AX 31
RVS-AX 44
RVS-AX 58
RVS-AX 72
RVS-AX 105
RVS-AX 145
RVS-AX 170
+10
+10
+10
+10
-15 %
-15 %
-15 %
-15 %
Frequency: 50 / 60 Hz.
RVS-AX ratings and Frame sizes
Max. Motor
FLA (Amp)
8
17
31
44
58
72
105
145
170
Tolerance
* Starter’s rated 460-500VAC can be field modified for
system voltage of 220-240V, by placing the internal
Jumper J3 as shown below.
Frame Size
(Aluminum)
A1
U
V
W
A2
A3
J3
1 2 3
Dimensions (mm) & Weights (Kg)
Size
Width
Height
Depth
Weights (Kg)
A1
A2
A3
120
129
172
232
380
380
102
181.5
191.5
2.6
8.2
11.8
220 to 240V
1
3
2
3
460 to 500V
1
2
3
Installation Notes
Short Circuit Protection
The RVS-AX should be protected against a short
circuit by Thyristor Protection fuses.
The recommended I2 t values are:
Prior to Installation
Check that Motor's Full Load Ampere (FLA) is lower
than or equal to starters Full Load Current (FLC) and
that Mains voltage is as indicated on the front panel.
Mounting
• The starter must be mounted vertically. Allow
sufficient space above and below the starter for
suitable airflow.
• It is recommended to mount the starter directly on
the rear metal plate of the switchgear for better
heat dissipation.
• Do not mount the starter near heat sources.
• Protect the starter from dust and corrosive
atmospheres.
RVS-AX type
RVS-AX 8
RVS-AX 17
RVS-AX 31
RVS-AX 44
RVS-AX 58
RVS-AX 72
RVS-AX 105
RVS-AX 145
RVS-AX 170
Temperature Range and Heat Dissipation
The starter is rated to operate over a temperature range
of –10ºC (14ºF) to +40ºC (104ºF).
Relative non-condensed humidity inside the enclosure
should not exceed 93%.
The heat dissipation during continuous operation is
Approx. 0.4 x In (in watts).
Example: When motor's current is 100 Amp, heat
dissipation will be approx. 40 watts.
Internal enclosure heating can be reduced using
additional ventilation.
Caution
Power factor correction capacitors must not be
installed on starter's Load side. When required,
Install capacitors on the Line side.
Warning
When Mains voltage is connected to the starter,
even if start signal has not been initiated, full
voltage may appear on the starter’s load
terminals. Therefore, for isolation purposes it is
required to connect an isolating device (C/B,
switch, line contactor, etc) upstream to the RVSAX (on the Line Side).
Additional Ventilation
RVS-AX
RVS-AX
I²t
400
2000
3000
6000
12000
18000
60000
100000
140000
General purpose enclosure
with filter on the air inlet and
Fan on air outlet.
Built-in Bypass
The RVS-AX incorporates
internal bypass relays
C/T
allowing current flow
C/T
through the thyristors only
during starting process. At
the end of the starting
X3
process, the built-in relays
bypass the thyristors and
carry the current to the
RVS-AX
Motor.
M
Upon stop signal, or in case
of fault, all three bypass
relays will open and stop the motor.
When Ramp-Down potentiometer is set to allow softStop process, upon stop command, the bypass relays
will open immediately and the current will flow
through the thyristors. The voltage
will then be
reduced slowly and smoothly to zero.
Fan, creating air circulation
Voltage Spike Protection
Voltage spikes can cause malfunction of the starter and
damage the SCRs. When expected, use suitable
protection such as Metal Oxide Varistors (consult
factory for further details).
4
Wiring
Stop / Start......................................... Terminals 1 - 2
By voltage free contact (Dry contact)
Close: Start command.
Open: Stop command.
Block and Connection Diagram
L1
L2 L3
RVS -AX
Warning
Do not apply voltage to terminals 1 - 2.
Reduced T2/Voltage
Starter
Neutral ...................................................... Terminal 3
Neutral wire (when used) is required only for operation
of the Phase Loss Protection (Phase Loss can not be
detected when Neutral is not connected to Terminal 3).
See detailed description in “Phase Loss” explanation.
Motor FLC
On
50%
100%
10%
50%
Ram p-Up/Down
Initial Voltage
Run
O verload
Current Lim it
Phase Loss
100%
Open terminal – not connected ................ Terminal 4
400%
O ver Tem p.
Ram p-Up
2
End of Acceleration (E.O.A) .......... Terminals 5 - 6
Voltage free, N.O., 8A / 250VAC, 2000VA max.
The contact closes after the time adjusted on the
"Ramp-Up" potentiometer. The contact returns to its
original position on stop signal, on fault condition,
upon voltage outage and at the beginning of Soft Stop.
30 Sec .
Res et
Ram p-Dow n
0.2
30 Sec .
T1/U T2/V T3/W
Start
Stop
N
1
3
2
En d of
Acce leratio n
5
4
6
Fa ult
7
Use of E.O.A. Contact
This contact can be used for:
• Activating a valve after a compressor has reached
full speed
• Loading a conveyor after the motor has reached
full speed.
8
NOTE: The RVS-AX incorporates an internal control
voltage transformer connected to phases L1&L3, in
case of phase loss of L1 or L3 the starter will stop the
motor. In case of phase loss for L2 the phase loss fault
will trip the starter only if Terminal 3 – Neutral, is
used).
Fault contact .................................... Terminals 7 - 8
Voltage free, N.O., 8A / 250VAC, 2000VA max.
The contact closes upon operation of any fault. The
contact returns to its original position (after the fault
has been removed) upon reset, or upon disconnection
the Mains voltage.
Connection Diagram
L1
L2
L3
Warning
Do not use the Fault contact to trip an upstream
contactor. When the Fault contact trips the
upstream contactor, Mains voltage will be
disconnected, thus resetting the starter and the
motor will restart instantaneously upon voltage
restoration (see Fault Resetting).
Neutral
2
V1
4
Warning
Start/Stop with a maintained contact!
When the line contactor is operated by a
maintained contact, in case of Mains failure, the
motor will be automatically restarted upon
voltage restoration.
When resetting after a fault with the Reset
button, the motor will restart upon fault reset.
It is therefore recommended not to connect the
fault relay to the line contactor.
Ground
6
R2C
R2A
R1C
R1A
5
Fault
U1
3
RV S -AX
T3/W
T2/V
S1
1
x3
T1/U
Neutral
Start / Stop
5/L3
3/L2
1/L1
I> I> I>
Not Used
Q1
7
8
End Of
Acceleration
W1
M
5
Starter Settings
Current Limit
Determines
motor's
highest
I%
current during starting.
600%
Range is 100-400% of FLC (as
400%
set on starter's FLC adjustment).
Too high of a setting will allow
100%
higher currents to be drawn from
Mains, resulting in faster
acceleration.
Too low of a setting may prevent the motor from
completing the acceleration process and reaching full
speed.
Generally, this setting should be set to the highest
acceptable value in order to prevent stalling.
Front Panel Layout
°
°
50%
°
°
10%
°
°
°
°
100%
FLC %
°
°
50%
Initial Voltage
°
°
°
° °
100% 400%
2
°
°
°
°
0.2
°
°
Current Limit
°
Ramp-Up
°
30 Sec.
Caution
Starting Current should not exceed the allowable
conditions as shown in page 3.
°
Ramp-Down
°
30 Sec.
FLC - Full Load Current (Motor FLC)
The adjustment allows easy setting of the RVS-AX
current level, automatically adjusting current based
functions (Overload, Current Limit, etc).
Set FLC potentiometer according to the following
equation:
Motor FLA
FLC =
× 100
FLC
Where:
Motor FLA is the motor's Full Load Current rating as
shown on its nameplate.
FLC is the starter Full Load Current as shown on its
label.
Example:
When starting a 27A motor using RVS-AX 31:
27
FLC% =
× 100 = 87%
87 %
°
°
°
31
FLC %
° °
Therefore set the FLC% to a 50%
100%
reading of 87% (see Ex.)
Ramp-up Time
Determines motor's voltage rampup time from initial to full
voltage.
Range: 2-30 sec.
It is recommended to set RampUp Time to the minimum
acceptable value (approx. 5 Sec).
U%
100%
2
30
Sec.
Notes:
1. Setting Current Limit low will extend Ramp-Up
Time.
2. When motor reaches full speed before voltage
reaches nominal, Ramp-Up Time adjustment is
overridden, causing voltage to quickly ramp up to
nominal.
Initial Voltage
Determines the initial voltage
U%
to the motor (torque is directly
100%
proportional to the square of
the voltage).
50%
Range: 10-50% of nominal
voltage.
10%
This
adjustment
also
2
30
Sec.
determines the inrush current
and mechanical shock.
Too high of a setting may cause high initial mechanical
shock and high inrush current (even if Current Limit is
set low, as the Initial Voltage setting over-rides the
Current Limit setting).
Too low of a setting may result in prolonged time until
motor starts revolving. The motor should start
revolving immediately after Start signal.
Ramp-Down time (Soft-stop)
Used to control deceleration of
U%
high friction loads. When Ramp100%
Down potentiometer is set, upon
stop signal the starter output
voltage is gradually ramped
down.
0.2
30 sec
Range: 0.2-30 sec. When "Rampdown Time" is set to minimum, the motor will stop
immediately.
6
Motor Protection
Heatsink Over temperature Protection
A thermal sensor mounted on the heatsink trips the
starter when its heatsink temperature rises above 85ºC.
Se co nds
Electronic Overload
The built-in inverse 1000
time
electronic
overload becomes
operational
after 100
end of acceleration
process.
Trip
current is factory set
10
to 115% of Motor
Full Load Current
(from the setting on
1
Motor
FLC
1
3
5
0
2
4
6
potentiometer),
I(Load)/In
E.g. In order to
increase the O/L trip point; increase FLC setting above
the calculated level. Trip time varies from 60 sec. at
150% of nominal current to 2 sec. at 600% of nominal
current.
Warning
The Over-temperature Protection is designed to
operate under normal conditions and will operate
incase abnormal conditions occur:
• Incorrect starter selection
• Too frequent starting at max. conditions
• Repeated starting under fault conditions
• Extended low overload
• Insufficient ventilation
• Other abnormal conditions
Note- In case of frequent starting the internal
thyristors may overheat before the heatsink reaches
its over-temperature protection of 85ºC, thus
causing component malfunction.
Phase Loss
The protection becomes operational when the starter is
energized; it protects the motor from single phasing. It
will trip the starter when one or two phases are missing
for more than 1 sec.
Caution
When starter is operated by a maintained contact,
resetting the fault will start the motor immediately.
When phase loss occurs during starting or when motor
is not loaded, it may happen that motor will stop
without accurate indication of the Phase Loss LED.
Note: Phase loss protection operates only when
Terminal 3 is connected to Neutral.
Warning
Do not use the Fault contact to trip an upstream
contactor. When the Fault Contact closes on fault
and trips the upstream contactor, Mains voltage
will be disconnected, thus resetting the RVS-AX
and the motor will restart instantaneously (see
Fault Resetting).
Fault Logic, Alarm and Reset Circuits
Upon operation of
any protection, the
On
starter locks in a
fault
mode,
Ramp Up / Down
disabling thyristors
firing. The proper
Run
fault
indication
LED lights and the
Overload
Fault contact closes.
To reset the starter,
Phase Loss
after the fault has
been removed, press
Over Temp.
Reset button on
starter's front panel
or disconnect Mains
Reset
voltage.
7
Startup Procedure
1. Set FLC (Motor Full Load Current) - according to
Examples of Starting Curves
Light Loads - Pumps, Etc.
Current limit - set to 300%
Initial Voltage - set to 30%
Ramp-up time - set to 5 sec.
2. Calculation: FLC = Motor FLA × 100
Starter FLC
3. Set other potentiometers according to system
requirements (see next column for examples)
U%
I%
600%
400%
300%
100%
4. Connect Mains voltage to starter Line terminals.
50%
30%
5. Start the motor, if it begins revolving shortly after
start signal proceed to Para. 5. If not, increase
Initial Voltage setting until motor starts to turn
shortly after start signal.
When initial inrush current and mechanical shock
are too high, decrease Initial Voltage setting and
proceed to Para 6.
100%
10%
t
t
5
Upon start, the voltage quickly increases to the Initial
Voltage value (30% Un) and then gradually ramps-up
to nominal.
The current will simultaneously increase to peak
current value, which can be the Current Limit setting or
less, before smoothly decreasing to the operating
current. The motor will accelerate to full speed quickly
and smoothly.
6. Motor begins to turn. If speed smoothly
accelerates to nominal proceed to Para 6. If
current during acceleration is too high, slightly
decrease Current Limit setting. If motor speed
does not increase to nominal, increase Current
Limit setting.
High inertia loads – Crushers, Centrifuges, Mixers Etc.
Current Limit - set to 350%
Initial Voltage - set to 50%
Ramp-Up time - set to 5 sec.
7. Disconnect the start command (open Terminals 1
and 2) and wait until the motor stops.
8. Slightly increase Initial Voltage and Current Limit
adjustments to allow for load variations.
U%
100%
9. Start the motor again and verify that acceleration
process to full speed is as required.
I%
600%
350%
50%
10. If acceleration time is too short, increase Ramp-Up
time setting.
10%
100%
20
When Soft stop is required, set Ramp-Down
Potentiometer to the required time (minimum
deceleration time is recommended).
Check that soft stopping process is as required.
t
20
t
Upon Start the voltage and current increase until
current reaches Current Limit value. The voltage
remains at this value until motor reaches nominal
speed, where current starts to decrease, voltage
continues to ramp-up to nominal. At this time, the
motor should have smoothly accelerated to full speed.
Note:
If Ramp Down potentiometer is not in the minimum
setting. Emergency stop may be performed by
disconnecting the mains voltage.
8
Technical Specification
Environment
Supply voltage
Three phase, line to line,
380 – 415 Vac +10% -15%
460 – 500 Vac +10% -15% *
575 – 600 Vac +10% -15%
Frequency
50 / 60 Hz
Load
Three-Phase, Three-Wire, Squirrel Cage
Induction Motor
Degree of protection
IP 20
Altitude
1000 m above sea level
* 460 – 500 Vac is applicable for 220 – 240 Vac
by changing the position of the internal jumper –
J3. As shown in page 3.
Consult factory for derating
Adjustments
FLC (Full Load Current)
50% - 100%
Starting Torque (Initial Voltage)
10-50 % of full voltage
Current limit
100 % - 400% of nominal current
Ramp Up Time (soft start)
2 - 30 sec.
Ramp Down Time (Soft Stop)
0.2 - 30 sec.
Protection
Electronic Overload
Inverse time (I2t), factory preset at 115% of FLC, active only during Run.
Phase Loss
Trips when one phase is missing (When Neutral is connected)
Heatsink Over temperature
Trips when the heatsink temperature exceeds 85ºC.
Reset buttons
To reset the starter, after the fault has been removed.
Indications
Indication lights (LEDs)
ON - Green
Lights when three phases are connected to the
RVS-AX.
Ramp Up / Ramp Down – Yellow
Lights upon start signal or during soft stopping.
RUN – Green
Lights upon end of starting. When the internal
bypass relays close.
Overload – Red
Inverse time electronic overload becomes
operational after the End Of Acceleration process
(see page 7).
Phase loss – Red
Lights when one or two phases are missing for
more than 1 sec.
Over temperature – Red
Lights on and trips the starter when the heatsink
temperature rises above 85ºC.
Temperatures
Operating
-10° to 40°C
Storage
-20° to 70°C
Relative humidity
93 % - non condensed
EMC
Immunity to radio electric interference
EN 1000-4-3 level 3
Conforming to EN 60947-4-2
Electrostatic discharge
EN 1000-4-2 level 3
Conforming to EN 60947-4-2
Immunity to electrical transients
EN 1000-4-4 level 4
Conforming to EN 60947-4-2
Shock waves of voltage / current
EN 1000-4-5 level 3
Conforming to EN 60947-4-2
Radiated and conducted emissions
EN 1000-4-6 level 3
Radio frequency emissions
According to EN 55011 class A
Conforming to EN 60947-4-2
Shock resistance
8 gn
Conforming to EN 60947-4-2
Vibration resistance
2 gn
Conforming to EN 60947-4-2
Mechanical
Output relay
End of Acceleration Contact
N.O.
Rated operating current
5 A, 250 V - Size A1
8 A, 250 V – Size A2
9
Dimensions
S=2.5m m 2
S=2.5mm2
S=16m m 2
A2
172
93
A1
7
8.5
L1 L2 L3
16
4
92
7
RVS - AX
40
40
220
232
R educed Voltage Starter
RVS - AX
U V W
360
380
Reduced Voltage Starter
102
90
120
A3
92
108
129
4
182
181.5
172
8.5
7
113
4
Power & Control Connections
RVS-AX
332
354
380
Reduced Voltage Starter
52
52
113
150
N:\eli\Eli's 95_bup\Solcon-CD for Distributors 16-12-2001\Instruction Manuals\RVS-AX Instruction Manual.doc
4
Starter Type
In Ampere
RVS-AX 8
RVS-AX 17
RVS-AX 31
RVS-AX 44
RVS-AX 58
RVS-AX 72
RVS-AX 105
RVS-AX 145
RVS-AX 170
Size Power
Connections
A1
Control
Connections
Terminals
16 mm2
Terminals
1.5 mm2
A2
A3
Bus Bars
4mm x 20mm
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