RVS-DX Digital Soft Starter Instruction Manual Power Control Systems April 1, 2004 Part Number: 188-10130 © Copyright 2004 Magnetek Contents: Disclaimer of Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii-iii Chapter1: Introduction Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Starter Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Chapter 2: Installation Physical Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Built-in Bypass After Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Chapter 3:Terminals & Wiring Control Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Typical Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Inside the Delta Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Chapter 4: Control Layout Digital Operator Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Extended Parameter Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Chapter 5 : Features Start/Stop Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Motor Protection Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Chapter 6: Parameters Parameter Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 RVS-DX, Digital Soft Starter Instruction Manual— 04/01/04 Chapter 7: Start-Up Procedure Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Start-Up Procedure with Pump Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Chapter 8: Troubleshooting Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Appendix A: Technical Data/Specifications Technical Data/Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 Appendix B: Dimensional Drawings Dimensional Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3 Appendix C: Fuse Selection Fuse Selection Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3 RVS-DX, Digital Soft Starter Instruction Manual— 04/01/04 ©2004 MAGNETEK All rights reserved. This notice applies to all copyrighted materials included with this product, including, but not limited to, this manual and software embodied within the product. This manual is intended for the sole use of the persons to whom it was provided, and any unauthorized distribution of the manual or dispersal of its contents is strictly forbidden. This manual may not be reproduced in whole or in part by any means whatsoever without the expressed written permission of Magnetek. DANGER, WARNING, CAUTION and NOTE Statements DANGER, WARNING, CAUTION, and Note statements are used throughout this manual to emphasize important and critical information. You must read these statements to help ensure safety and to prevent product damage. The statements are defined below. DANGER DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations. WA R N I N G WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION CAUTION indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. It may also be used to alert against unsafe practices. NOTE: A NOTE statement is used to notify people of installation, operation, programming, or maintenance information that is important, but not hazard-related. RVS-DX, Digital Soft Starter Instruction Manual—4/01/04 i Disclaimer of Warranty Magnetek, hereafter referred to as Company, assumes no responsibility for improper programming of a soft starter by untrained personnel. A soft starter should only be programmed by a trained technician who has read and understands the contents of this manual. Improper programming of a soft starter can lead to unexpected, undesirable, or unsafe operation or performance. This may result in damage to equipment or personal injury. Company shall not be liable for economic loss, property damage, or other consequential damages or physical injury sustained by the purchaser or by any third party as a result of such programming. Company neither assumes nor authorizes any other person to assume for Company any other liability in connection with the sale or use of this product. WA R N I N G Improper programming of a soft starter can lead to unexpected, undesirable, or unsafe operation or performance. IMPORTANT 1. Read this manual carefully and follow its instructions before operating equipment. 2. 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. 3. Disconnect all power inputs before wiring or servicing the equipment. 4. After installation, verify that no hardware (bolts, washers, etc.) have fallen into the power section. WARNING 1. Internal components and printed circuit boards are at main potential when the RVS-DX is connected to main power. This voltage is extremely dangerous, and may cause death or severe injury if contacted. 2. The control PCB employs CMOS ICs that are easily damaged by static electricity. Use proper electrostatic discharge (ESD) procedures when handling the control PCB. 3. When the RVS-DX is connected to main power, even if control power is not connected and the motor is stopped, full voltage may appear on the RVS-DX’s output terminals. 4. RVS-DX must be grounded to ensure correct operation, safety, and to prevent damage. 5. Power factor capacitors must NOT be connected to the output side of the RVS-DX. RVS-DX, Digital Soft Starter Instruction Manual—4/01/04 ii ATTENTION 1. This product was designed for compliance with IEC 947-4-2 for class A equipment. 2. RVS-DX are listed under UL508C. RVS-DX, Digital Soft Starter Instruction Manual—4/01/04 iii c h a p t e r 1 Introduction This page intentionally left blank. Overview The RVS-DX is a digital electronic soft starter, incorporating six SCR’s to start a three phase squirrel cage induction motor by supplying a slowly increasing voltage, providing soft start and smooth stepless acceleration, while drawing the minimum current necessary to start the motor. The RVS-DX is equipped with internal bypass relays initiated by its microprocessor control (on units 31-310 amps). Using the soft stop, the RVS-DX slowly reduces the motor voltage, thus softly stopping a high friction load. In applications where the inertia of a load would cause the motor to “free wheel”; the soft stop will not stop the motor any faster than the coast to stop. Starter Selection Select the RVS-DX soft starter according to the motor’s Full Load Amps. Also consider the following information: Ambient Temp. I start 300% In 40°C 30 Sec. 350% In 20 Sec. 400% In 5 Sec. Maximum starts per hour: NOTE: Acc Time 4 starts per hour at maximum ratings up to 10 starts/hour for lightly loaded applications. For very frequent starts (inching applications) the inching current should be considered the FLA. Supply Voltage (Line to Line): +10%–15% Standard Supply Voltage: 220–240 volts 460–500 volts 575–600 volts Special Order Voltage: 380–440 volts NOTE: All RVS-DX units are suitable for 50/60 Hz. Control Voltage: 110-120 volts (+10% -15%); 50/60 Hz (standard) 220-240 volts (+10% -15%); 50/60 Hz RVS-DX, Digital Soft Starter Instruction Manual—04/01/04 1-3 Model Number Max. FLA Frame Size 8 17 A1 31 44 58 A2 72 85 A3 105 145 A4 170 210 A5 310 390 tbd 230/460 Volts* 575 Volt RVS-DX-8-D RVS-DX-8-E RVS-DX-17-D RVS-DX-17-E RVS-DX-31-D RVS-DX-31-E RVS-DX-44-D RVS-DX-44-E RVS-DX-58-D RVS-DX-58-E RVS-DX-72-D RVS-DX-72-E RVS-DX-85-D RVS-DX-85-E RVS-DX-105-D RVS-DX-105-E RVS-DX-145-D RVS-DX-145-E RVS-DX-170-D RVS-DX-170-E RVS-DX-210-D RVS-DX-210-E RVS-DX-310-D RVS-DX-310-E RVS-DX-390-D RVS-DX-390-E *Dual rated soft starters come pre-set for 460 volts. To set for 230 volts, simply change the rated line volt parameter in the main parameters (See Chapter 6-Parameters). No control voltage required) Approximate Dimensions and Weights Frame Size Width (in.) Height (in.) Depth (in.) Weight (lbs.) A1 4.72 9.13 4.8 6.6 A2 5.08 10.83 7.15 11.5 A3 5.08 14.96 7.15 18.7 A4 6.77 14.96 7.54 27.5 A5 14.96 17.91 11.61 92.4 RVS-DX, Digital Soft Starter Instruction Manual—04/01/04 1-4 c h a p t e r 2 Installation This page intentionally left blank. Physical Installation Location of the RVS-DX is important to achieve proper performance and normal operating life. The unit should be installed in an area where it will be protected from: • Direct sunlight, rain or moisture • Corrosive gases or liquids • Vibration, airborne dust or metallic particles When preparing to mount the RVS-DX, lift it by its base, never by the front cover. For effective cooling as well as proper maintenance, the RVS-DX must be installed on a flat, non-flammable vertical surface (wall or panel) using four mounting screws. There must be a minimum of 4.7 inches of clearance above and below the RVS-DX for sufficient airflow. A minimum of 1.2 inches of clearance is required on each side of the RVS-DX. The protected chassis is rated to operate over a temperature range of -14°F (-10°C) to +122°F (40°C). Relative non-condensing humidity should not exceed 93%. Enclosures If the RVS-DX is to be mounted in a customer supplied enclosure, the heat dissipation should be considered when sizing an enclosure. Maximum surrounding air temperature should not exceed 40°C. Since the RVS-DX does have built in bypass after acceleration, the watts loss is minimized. The RVS-DX watts loss is approximately 0.4 x the FLA in watts. (example: for a motor of 100A, expect watts loss of the starter to be 40 watts.) Internal enclosure heating can be reduced by using additional ventilation. RVS-DX, Digital Soft Starter Instruction Manual—04/01/04 2-3 Built in Bypass After Acceleration The bypass after acceleration allows the RVS-DX to control the motor during starting and stopping for smooth, step-less acceleration and deceleration. However, once up to full voltage the RVS-DX is bypassed to reduce the watt loss. The RVS-DX incorporates internal bypass relays allowing current flow through the SCR’s only during the soft start process. At the end of the soft start, the built-in relays bypass the SCR’s and carry current to the motor. Upon stop signal, or in case of fault, all three bypass relays will open and stop the motor. When the decel time is set to allow soft stopping, upon stop command, the bypass relays will open immediately and the current will flow through the SCR’s. The voltage will then be reduced slowly and smoothly to zero. RVS-DX units rated 31-310 amps have built-in bypass. C/T C/T x3 M RVS-DX, Digital Soft Starter Instruction Manual—04/01/04 2-4 c h a p t e r 3 RVS-DX Terminals and Wiring This page intentionally left blank. Control Terminals Terminal Function Description A1 A2 Control Supply (Note 1) B1 Start/Stop Input from a N.O. maintained contact. Connect terminals A2 & B1 to start, and open to stop. C1 Aux. Input Input from a N.O. maintained contact. Connect terminals A2 & C1 to operate the function. (Note 2) 13 14 Auxiliary Output Contact (Note 3) N.O. output contact can be set to Immediate or End of Acceleration. (Note 3). 23 24 Fault Contact (Note 4) N.O. contact closes upon any fault and returns to open position (after the fault has been removed) upon reset, or disconnection of main supply voltage. 120V control power must be connected at terminals A1 & A2. 1. The control power should be connected to A2, and control neutral to A1. 2. The auxiliary input can be programmed to operate as a reset, dual adjustment, generator starting, slow speed, slow speed reverse, or external fault (see chapter 6 on parameters to set the auxiliary input). 3.If the auxiliary output is set to Immediate, the contact closes at the start signal, and opens at the stop signal, end of soft stop fault, or at loss of voltage. If the auxiliary output is set to End of Acceleration, the contact closes after acceleration and opens at stop or soft stop signals, fault, or loss of voltage. 4. If the fault contact is set to fail-safe, the contact closes immediately when control power is connected, and opens upon fault. WA R N I N G Do not use the fault contact to trip an upstream contactor. When the fault contact trips the upstream contactor, main voltage will be disconnected thus resetting the soft starter and the motor will restart immediately upon power being restored. WA R N I N G Start/stop with maintained contact. When the line contractor is operated by a maintained contact, if main supply voltage is lost, the motor will automatically restart upon voltage restoration. When resetting after a fault, the motor will restart upon the fault being reset. RVS-DX, Digital Soft Starter Instruction Manual—04/01/04 3-3 Typical Wiring Diagram RVS-DX, Digital Soft Starter Instruction Manual—04/01/04 3-4 Operating “Inside the Delta” Using the RVS-DX soft starter “inside the delta” reduces the required soft starter rating by 1.73 ( √3) factor. For example, for a 150 amp, 460 volt motor, the RVS-DX-170-D is selected to operate in standard “line” mode. However, for “inside the delta” mode (150 amp÷1.73=87 amps), the RVSDX-105-D can be selected, thereby, reducing cost and physical space in the application. The following programming parameters are disabled, once the ‘inside the delta’ is selected: • Pulse Start • Pump Curve selection (only standard curve available) • Slow Speed and Slow Speed Reverse • Phase Sequence The motor rating for standard “Line” and “Inside the Delta” connections are show here: RVS-DX FLA HP at 460V for “Line” HP at 460V for “Inside Delta” RVS-DX-8-D 8 5 7.5 RVS-DX-17-D 17 10 15 RVS-DX-31-D 31 20 32 RVS-DX-44-D 44 30 50 RVS-DX-58-D 58 40 68 RVS-DX-72-D 72 50 85 RVS-DX-85-D 85 60 100 RVS-DX-105-D 105 75 125 RVS-DX-145-D 145 100 170 RVS-DX-170-D 170 125 215 RVS-DX-210-D 210 150 250 RVS-DX-310-D 310 200 340 RVS-DX-390-D 390 300 515 Model Number HP Ratings are approximate. The RVS-DX should always be sized by the motor full load amps for “line” starting and the motor FLA/1.73=soft starter FLA for “inside delta”. RVS-DX, Digital Soft Starter Instruction Manual—04/01/04 3-5 Typical Wiring for Inside the Delta Operation: RVS-DX, Digital Soft Starter Instruction Manual—04/01/04 3-6 c h a p t e r 4 Control Layout This page intentionally left blank. Digital Operator Layout LED Arrangement: Description On Lights when control power is connected to RVS-DX Ramp Lights during starting or soft stopping process (motor supply voltage is ramping up or down) S LED Run Lights after completion of starting process (motor is receiving full voltage Flashes during slow speed operation) Fault Lights when any of the built-in protections cause a fault Flashes when Insulation Alarm relay is activated RVS-DX, Digital Soft Starter Instruction Manual—04/01/04 4-3 Keypad Arrangement Description Mode This button scrolls through the following modes: Display Only Main Parameters Start Parameters Stop Parameters Dual Adjustment Parameters Special Feature Parameters Fault Parameters I/O Programming Parameters Serial Communication Parameters Statistical Data S Keypad Select This button scrolls through the various parameters Up Arrow Increases a parameter setting Down Arrow Decreases a parameter setting Store Saves the modified parameters. The “STORE” button will only save the modified parameter when pressed after the LCD display reads “STORE ENABLE”. The “STORE ENABLE” will follow the last parameter within each mode. Reset Cancels a displayed fault and allows restarting. The “Reset” button is only operable if the start command has been removed and the fault condition is cleared. RVS-DX, Digital Soft Starter Instruction Manual—04/01/04 4-4 LCD Display The LCD display consists of two lines of alphanumeric characters, displaying: system parameters starter settings, motor current, fault indication and statistical data. The LCD can be displayed in four different languages: English, French, German and Spanish. The first line displays the function and the second line displays the setting (or measure value). Upon initiation of the starter the LCD will display the operating current as a percentage of motor FLA. % Of Motor FLA By pressing the “Mode Key” you can scan through all of the modes. Main Parameters Start Parameters Stop Parameters Dual Adjustment Parameters Special Features Parameters Fault Parameters These modes are “skipped” when Display Mode Parameter is set to “minimized”. I/O Programming Parameters Comm. Parameters Statistical Data **** Stop at the required mode and press the “Select” button to review each parameter (function of the mode.) When you have reached the required parameter, modify its value with up arrow and down arrow buttons. To store the new parameters press the “Select” button until the “STORE ENABLE” message is displayed on the LCD, and then press the “Store” button. When new parameter data has been successfully saved, the LCD will read “DATA SAVED OK”. RVS-DX, Digital Soft Starter Instruction Manual—04/01/04 4-5 Extended Parameter Setting The RVS-DX incorporates a parameter, “WIDER SETTINGS”, in the special Features Parameters. If the RVS-DX is significantly larger than your motor, you can enable the “wider settings” to extend parameter settings of the following: Extended Parameter Settings Parameter Original Setting Range Extended Setting Range Initial Voltage 10-50% 10-80% Current Limit 100-400% 100-500% Acceleration Time 1-30 seconds 1-90 seconds Deceleration Time 0-30 seconds 0-90 seconds Max. Start Time 1-30 seconds 1-250 seconds RVS-DX, Digital Soft Starter Instruction Manual—04/01/04 4-6 c h a p t e r 5 Features This page intentionally left blank. Start/Stop Features The RVS-DX incorporates many features that assist in starting and/or stopping various applications. These features are described within this section. Pump Control (Start Curves) Induction motors produce peak torque up to three times the rated torque. This peak torque can occur towards the end of the starting process. In pump applications, this peak torque may cause high pressure in the pipes. The RVS-DX incorporates four different starting curves. The start curve (curve 0) is the standard curve and the default. It is the most stable and suitable curve for the motor, preventing prolonged starting and motor overheating. Pump start curves (1, 2, and 3) automatically control the voltage ramp-up to reduce peak torque. The multiple starting curves are shown below: Voltage Torque Speed DOL 0 1 2 3 Time NOTE: Always start with Start curve 0. If towards end of acceleration, peak torque is too high, proceed to curve 1, then 2 and 3 if necessary. Tach Feedback (0-10 VDC) The tach feedback provides linear acceleration and deceleration curves according to RPM feedback. Twelve tachometer gain levels can be selected for closed loop control for starting and stopping. NOTE: Always begin with minimum gain (0) and proceed with higher gain levels if required. Pulse Start The pulse start feature is used to break away high friction loads. High friction loads may require close to across the line starting torque for a very short duration of time. The pulse start feature accomplishes this with an 80% voltage boost (without current limit) for a period of 0.1 to 1 second. After this pulse, the voltage is ramped down to the initial voltage setting where it begins ramping up again to full voltage. RVS-DX, Digital Soft Starter Instruction Manual—4/01/04 5-3 Initial Voltage The initial voltage determines the motor’s initial torque setting (the torque is directly proportional to the square of the voltage). The initial voltage can be set from 10 to 50%. The initial voltage also affects the inrush current and mechanical shock. An initial voltage setting that is too high may cause mechanical shock and a high inrush current. An initial voltage setting that is too low may result in a prolonged period of time before the motor begins to turn. Generally, this setting should cause the motor to begin turning immediately after the start signal, while minimizing mechanical shock and inrush current. Current Limit The current limit feature sets the highest current level that will reach the motor during the starting process. The current limit may be set from 100 to 400%. Once the present current limit value is reached the voltage will level off and only continue ramping up once the current is below the limit again. If the current limit is set too high, there will be a greater current draw from the main power and a faster acceleration. If the current limit is set too low, the motor may be unable to reach full speed (the starter may trip on maximum start time). Generally the setting should be high enough to start the motor without stalling. Acceleration Time The acceleration time determines the motor’s voltage ramp up time from initial to full voltage. The acceleration time can be set from 1 to 30 seconds. The time it takes the motor to reach full speed may not necessarily be the same as the acceleration time. The following situations may override the acceleration time setting. 1. Since current limit overrides acceleration time, setting the current limit low will extend the acceleration time (but never to exceed maximum start time). 2. When the motor reaches full speed prior to reaching nominal voltage, acceleration time is overridden and voltage quickly ramps up to nominal. (This situation is common with lightly loaded motors.) 3. Using curves (1, 2, or 3) will prevent a quick acceleration time. Generally this setting should be the minimum acceptable time. Maximum Start Time The maximum start time is the maximum allowable time from start signal to end of acceleration. If the voltage does not reach nominal during this time period, the RVS-DX will trip, and the LCD display will read “LONG START TIME”. The maximum start time is settable from 1 to 30 seconds. RVS-DX, Digital Soft Starter Instruction Manual—4/01/04 5-4 Stop Curves For many applications, the load torque decreases in a square relation to the speed. In these applications, reducing the voltage will reduce the torque and the motor will smoothly decelerate to a stop. With these applications the standard stop curve (0) will be adequate. The stop curve (0) reduces the voltage linearly from nominal to zero. In some other applications (namely pumps), a considerable amount of the torque is constant and does not decrease with speed. In these applications the motor torque could fall below load torque during stopping, causing the motor to stall. By using stop curves (1, 2 or 3) the motor will smoothly decrease to zero speed and prevent the stall condition. The stop curves are shown in the graph below: Voltage Deceleration 0 1 2 3 NOTE: Always begin with Stop Curve 0. If your motor stalls quickly, instead of slowly decreasing its speed then try selecting stop curve 1, then 2 and then 3 if necessary. Deceleration Time (Soft Stop) The deceleration time is used for controlled deceleration of high friction loads. When the soft stop is initiated the RVS-DX’s output voltage is gradually ramped down. The deceleration time is programmable from 0 to 30 seconds. Final Torque The final torque setting determines the torque towards the end of the soft stop. If the motor stalls while current is still flowing and the speed has softly been reduced to zero, increase the final torque setting to prevent unnecessary motor heating. The final torque can be set from 0 to 10 (maximum). RVS-DX, Digital Soft Starter Instruction Manual—4/01/04 5-5 Dual Adjustment The dual adjustment feature allows the RVS-DX to have two sets of starting characteristics. This feature is very beneficial in applications where the motor may be starting loaded or unloaded. There is also a dual setting for motor FLA, which allows the RVS-DX to operate a two speed motor with adequate motor protection. The RVS-DX is transferred to the dual adjustment settings by connection of control power to terminal C1, when it is programmed to Dual Adjust. The dual adjustment parameters are: IV Initial voltage 10-50% CL Current limit 100-400% AT Acceleration time 1-30 seconds DT Deceleration time 0-30 seconds FLA Motor FLA 8-390 Amps depending upon RVS-DX’s FLC. Slow Speed Torque The slow speed torque determines the torque while the motor is operating at 1/6 of the nominal speed. The slow speed torque can be set from 1 to 10. Maximum Slow Speed Time The maximum slow speed time sets the allowable operation time that the RVS-DX can run at slow speed. The setting range is from 1 to 30 seconds. WA R N I N G Operating current while motor is running at 1/6 speed is much higher than nominal current and motor ventilation is much weaker. Special precaution should be taken to prevent overheating while running at slow speed for long periods of time. RVS-DX, Digital Soft Starter Instruction Manual—4/01/04 5-6 Motor Protection Features The RVS-DX incorporates advanced microprocessor-based digital circuitry, which allows for sophisticated motor protection with digital accuracy. The motor protection features are covered in detail below. Too Many Starts The “too many starts” feature allows programming of the maximum allowable starts during the “starting period”. The maximum amount of starts may be set from 1 to 10 starts within a 1 to 60 minute starting period. Start Inhibit The start inhibit sets the time period which starting is disabled after a “TOO MANY STARTS” trip. The setting range is from 1 to 60 minutes. NOTE: When trying to start the motor before the “Start Inhibit” time has elapsed, the LCD will display “WAIT BEFORE ⇒ RESTART: xx MIN.”. Maximum Start Time (Stall Protection) The maximum start time will trip the starter if the motor does not reach full speed during the “Maximum Start Time”. The maximum start time is settable from 1 to 30 seconds. Electronic Fuse (Shear-pin) The electronic fuse is used to protect the starter and motor from high current. The electronic fuse has two operating modes: one for during start, and one for during operation. During starting: the starter trips when the current exceeds 850% of the motor FLA setting in 1 cycle or less. During operation: (After acceleration period; “Run” LED will be on.) The starter trips when current exceeds the set current level of 200 to 850% in the programmed delay time. NOTE: The electronic fuse is not intended to replace fast acting fuses to protect SCR’s. Electronic Overload The electronic overload becomes operational when the “RUN” LED is lit. The starter incorporates a thermal memory register which calculates heating minus dissipation of the motor. When the thermal memory fills up, the starter trips. The thermal register resets itself 15 minutes after the motor stops. The electronic overload is settable from 75 to 150% of motor’s FLA. (Factory setting is 115%). The tripping time at 5xFLA is adjustable from 1 to 10 seconds, thus allowing a trip curve selection. Undercurrent The undercurrent is operational when the motor is running. The starter trips when motor current drops below the set undercurrent trip level for a time period longer than the undercurrent delay time. The undercurrent setting ranges from (0=off) 20 to 90% of FLA, and the undercurrent delay ranges from 1 to 40 seconds. RVS-DX, Digital Soft Starter Instruction Manual—4/01/04 5-7 Undervoltage The under voltage function becomes available only after the start signal. The starter will trip when the main voltage drops below the preset level for a time period longer than the under voltage delay. The under voltage trip setting ranges from 50-90%. The under voltage delay can be adjusted from 1 to 10 seconds. The under voltage fault can be auto reset. The auto reset must be enabled (see “Fault Parameters” in Chapter 6). The starter will re-check for the under voltage fault after 60 seconds and will auto reset as long as the run signal has been removed and the fault condition has cleared. Overvoltage The overvoltage function becomes operational only after the start signal. The starter will trip when the main voltage rises above the preset level for a time period longer than the overvoltage delay. The overvoltage trip setting ranges from 110-150%. The overvoltage delay can be adjusted from 1 to 10 seconds. Phase Loss (and under/over frequency) This protection feature is operational when the starter is energized. It is designed to protect the motor from single phasing. The starter will trip when 1 or 2 phases are missing for more than one second. The starter will also trip when frequency is less than 45 Hz or greater than 65 Hz. The phase loss fault can be auto reset. The auto reset must be enabled (see Fault Parameters). The starter will recheck for the phase loss fault after 60 seconds, and will auto reset as long as the run signal has been removed and the fault condition has cleared. Phase Sequence The phase sequence function becomes operational as soon as the starter is energized. The phase sequence protection must be enabled (see “Fault Parameters” in Chapter 6). The starter will trip when the phase sequencing is wrong. Low Slow Speed Time This function will trip the starter if the motor operates at slow speed (forward or reverse direction) longer than the Maximum Slow Speed Time (settable from 1 to 30 seconds). When the motor operates at slow speed it draws higher than nominal current (depending upon the slow speed torque setting), thus the motor and starter may overheat. NOTE: Always operate the motor at slow speed for the minimum possible time to prevent overheating. Wrong Connection The wrong connection protection indicates when the motor is not connected to the load terminals, or there is an internal disconnection in the motor winding. Shorted SCR Protection The shorted SCR protection trips the starter when one or more SCRs have been shorted. NOTE: The soft starter will also trip on the “SHORTED SCR” if the main voltage is applied to the load terminals. RVS-DX, Digital Soft Starter Instruction Manual—4/01/04 5-8 Heatsink Over Temperature The starter has thermal sensors mounted on the heatsink, tripping the starter when the heatsink temperature rises above 85°C. WA R N I N G The over temperature protection is designed to operate under normal conditions. The SCRs could overheat and fail before the heatsink reaches 85°C in the following situations: if the starter is run at extended low overload, with insufficient ventilation, sized improperly, started too frequently, or started frequently beyond maximum conditions. Wrong Parameters This protection indicates when incorrect parameters have been entered into the EEPROM. This can also occur when parameters have been incorrectly transferred from RAM to EEPROM. External Fault The external fault becomes operational when the starter is energized. The starter will trip when the external (N.O.) contact on terminal C1 closes for more than 2 seconds. (Aux. input C1 must be programmed to External Fault). Fault and Reset When any of the above protections cause the starter to trip, it locks in a fault condition and disables the SCR firing. The “Fault” LED illuminates, the LCD displays the fault message, and the fault contact (at terminals 23 & 24) closes. The fault may be reset: –via the “Reset” key on the keypad. –via input at terminal C1. NOTE: The fault may only be reset once the fault condition has cleared and the run signal is removed. NOTE: If fault occurs due to voltage outage, fault condition is latched and reappears upon voltage restoration. Fault and Auto Reset The phase loss and under voltage trips can be auto reset. The auto reset must be enabled. This is accomplished in the “Fault Parameters” mode. When auto reset is enabled, the faults due to phase loss and under voltage will receive a reset signal after a delay of 60 seconds. If the fault condition has cleared and the start signal has been removed, then the fault will be reset. RVS-DX, Digital Soft Starter Instruction Manual—4/01/04 5-9 Additional Protection Available: Short Circuit Protection Protects the starter against a short circuit by SCR protection fuses. A chart can be found in Appendix C, page C-3. Transient Protection Line transient voltages can cause a malfunction of the starter and damage to the SCR’s. All RVS-DX soft starters have MOV’s to protect from normal line voltage spikes. RVS-DX, Digital Soft Starter Instruction Manual—4/01/04 5-10 c h a p t e r 6 Parameters This page intentionally left blank. Mode Mode Mode Mode Mode Upon Initiation Parameter Display Page 1 Page 2 % Of Motor FLA Main Parameters Start Parameters Stop Parameters Select Select Select Select To Review All Parameters Press Page 3 BACK TO TOP Soft Start Curve 0 (Standard) Soft Stop Curve 0 (Standard) Start Tacho Gain 0 (Min. Gain) Stop Tacho Gain 0 (Min. Gain) Connection Type Line Pulse Time 0 Sec. Dec. Time 0 Sec. Rated Line Volt. 460 Volt Initial Voltage 30% Final Torque 0 (Min) Undercurr. Trip 0% Of FLA Initial Current 100% Store Enable Stop Parameters Under Curr. Delay 10 Sec. Current Limit 400% of FLA BACK TO TOP O/C Shear Pin 850% Of FLA ACC. Time 10 Sec. O/C Delay 0.5 Sec. Max. Start Time 30 Sec. Overload Trip 115% of FLA Number of Starts 10 Overload Delay 4 Sec.–at 5 FLA Starts Period 30 Min. Undervolt. Trip 75% Start Inhibit 15 Min. Starter FLC 105 Amp Motor FLA 105 Amp Undervolt. Delay 5 Sec. Overvolt. Trip 120% Dual Adj. Parameters Select Keys To Change Parameter Value When DIP SW#1.2 is set ON Option Card Not Installed Page 4 When Prog. Input C! is set to Generator Start/Stop DA: (Generator) Parameters DA: Int. Volt 30% DA: Int. Current 100% DA: Cur. Limit 400% of FLA DA: Acc. Time 100 Sec. DA: Dec. Time 0 Sec. DA: Motor FLA 105 Amp Store Enable D. Adj. Parameters BACK TO TOP Note: Available after initial voltage setting is above maximum level. Store Enable Start Parameters BACK TO TOP Overvolt. Delay 2 Sec. Display Mode Minimized Parameters Lock Not Locked Store Enable Main Parameters BACK TO TOP RVS-DX, Digital Soft Starter Instruction Manual—4/01/04 6-3 Mode Mode Page 5 Special Features Parameters Select Mode Mode Page 6 Page 7 Page 8 Fault Parameters I/O Programming Parameters Comm. Parameters Select Select Select Press Mode Page 9 Statistical Data - **** Select Keys To Change Parameter Value Slow Speed Torq. 8 Phase SEQ Y/N No Prog. Input #C1 Remote Reset Comm. Protocol Modbus Last Strt Period No Data Max. Slow Sp Time 30 Sec. Insulation Alarm Off Fault Relay Type Fault Drive Number 0 Last Start MaxI No Data Wider Settings Disabled Insultation Trip Off Prog. Aux. Relay Immediate Baud Rate 9600 Total Run Time 0 Hourse Store Enable En. Save & SL. Spd. Auto Reset No Relay On Delay 0 Sec. Parity Check Even Thermistor Type PTC Relay Off Delay 0 Sec. Serial Link No. 248 (Off) Thermistor Trip Off Analog Output Normal Under Cur. Reset Off Store Enable I/O Prog. Param. BACK TO TOP Store Enable Fault Parameters Store Enable Comm. Parameters BACK TO TOP Store Enable Default Param. SELECT Last Trip No Data Trip Current 0% Of FLA Total # of Trips 0 Previous Trip 1...9 No Data BACK TO TOP BACK TO TOP MODE Total # Of Start 0 BACK TO TOP Reset Statistics SELECT Program Version STRT.DN-110701 + MODE+STORE RESET+STORE Save Default Parameters & Back to Parameters Display Page Clear Statistical Data & Back to Page 9 % Of Motor FLA To Exit Default Parameters Mode Press MODE + RVS-DX, Digital Soft Starter Instruction Manual—4/01/04 6-4 SELECT Voltage Adjust. X Volts Current Adjust. X% Of FLC Statistical Data - **** Back To: Store Enable Default Paramet. DISPLAY MODE Parameter Description Default Value Range Access % of MOTOR FLA MOTOR INSULATION* THERMISTOR RES.* The operating current as a % of the motor FLA Displays the insulation level of the motor’s windings Displays the motor thermistor resistance n/a Option card-not installed Option card-not installed 0-100% ? ? Display only Option card Option card ANALOG OUTPUT Normal=analog output increases with increasing current Inverted=analog output decreases with increasing current Option card-not installed* Normal or Inverted Option card * Requires an option card for these parameters to be displayed. If there are no option cards, the display will read,“Option Card—Not Installed”. SERVICE MODE Parameter Description Default Access: To Enter or Exit the Service Mode press “Mode” &T simultaneously. STORE ENABLE DEFAULT PARAMET. RESET STATISTICS PROGRAM VERSION VOLTAGE ADJUST. CURRENT ADJUST. Reset ALL parameters to default settings Press “Mode” & Store simultaneously to save default parameters. Reset statistical data. Press “Reset” & “Store” simultaneously to reset statistic parameters. STRT.DN-xxxxxx xxx VOLT xxx% of FLC View the software version. Factory calibration of phase to phase voltage. Factory calibration of current. RVS-DX, Digital Soft Starter Instruction Manual—4/01/04 6-5 The User access level is always available. The maximized access is available when Dispaly Mode parameter is set to maximized (changing available parameters from minimized to maximized level), but these parameters can only be changed when the RVS-DX is stopped. MAIN PARAMETERS Parameter LANGUAGE Description/Function RATED LINE VOLT. UNDERCURR. TRIP UNDERCURR. DELAY O/C—SHEAR PIN O/C DELAY OVERLOAD TRIP OVERLAD DELAY UNDERVOLT. TRIP UNDERVOLT. DELAY OVERVOLT. TRIP OVERVOLT. DELAY DISPLAY MODE Full load current of the RVS-DX starter Full load amps of the motor Determines how the soft starter will be connected Rated input line voltage Under current trip setting Under current delay setting Over current (shear pin) trip setting Over current (shear pin) delay setting Overload trip setting Overload delay setting at 500% of mtr FLA Under voltage trip setting Under voltage delay setting Over voltage trip setting Over voltage delay setting Determines the parameters available to view. PARAMETER LOCK STORE ENABLE MAIN PARAMETERS Locks all parameters from being changed. Press 'Store' to save changes made to any of the Main Parameters STARTER FLC MOTOR FLA CONNECTION TYPE Default Value Range Access English (1) (1) LINE English, French, German & Spanish 8-390 amps 50-100% of FLC setting Line or Inside Delta user user user user 460 0% 10 850 .5 115 4 75% 5 120% 2 MINIMIZED NOT LOCKED 220-600 V 0; 20-90% FLA 1-40 seconds 100-850% FLA 0-5 seconds 75-150% FLA 1-10 seconds 50-90% 1-10 seconds 110-125% 1-10 seconds Minimized or Maximized user user user user user user user user user user user user user Language the Parameters are viewed in Locked or not locked START PARAMETERS Parameter Description/Function CURRENT LIMIT ACC. TIME MAX. START TIME NUMBER OF STARTS STARTS PERIOD STARTS INHIBIT Determines the soft start curve Allows tach. curves after scrolling through soft start curves Pulse (of 80% voltage) start time setting Initial voltage setting Allows initial current setting after scrolling through Initial Voltage settings Current limit setting Acceleration time setting Maximum starting time setting Maximum number of starts setting Period of time for max. number of starts Time Delay after max. number of starts were made STORE ENABLE START PARAMETERS Press 'Store' to save changes made to any of the Start Parameters SOFT START CURVE START TACHO GAIN PULSE TIME INITIAL VOLTAGE INITIAL CURRENT RVS-DX, Digital Soft Starter Instruction Manual—4/01/04 6-6 Default Value Range Access 0(standard) 0-4 0-5 0-1 second 10-50% (80%)(3) 100-400% user user(2) user user user 100-400% (500%) 1-30 sec. (90 sec.)(3) 1-30 sec. (250 sec.)(3) off; 1-10 1-60 minutes 1-60 minutes user user user user user user 0 30 400 10 30 10 30 15 STOP PARAMETERS Parameter SOFT STOP CURVE STOP TACHO GAIN DEC. TIME FINAL TORQUE STORE ENABLE STOP PARAMETERS Description/Function Determines the soft stop curve Allows tach. curves after scrolling through soft stop curves Deceleration time setting Final Torque setting Press 'Store' to save changes made to any of the Stop Parameters Default Value Range Access 0 (standard) 0-4 0-5 user user (2) 0 0 0-30 sec. (90 sec.) (3) 0-10 user user DUAL ADJUSTMENT PARAMETERS(display mode set to maximized to access) Parameter D. ADJ: GENERATOR PARAMETERS DA: INIT. VOLT. DA: INIT CURRENT DA: CURR. LIMIT DA: ACC. TIME DA: DEC. TIME DA: MOTOR FLA STORE ENABLE D.ADJ PARAMETERS Description/Function Default Value Used for dual adjustment setting or generator settings. Initial voltage setting for dual adjust Allows Initial current setting after scrolling through Initial Voltage settings. Current limit setting for dual adjust Acceleration time setting for dual adjust Deceleration time setting for dual adjust Motor FLA setting for dual adjust Press 'Store' to save changes made to any of the Dual Adjustment Parameters Range Access maximized 30 10-50% (80%.) (3) 100-400% maximized maximized 400 10 0 STARTER FLC value 100-400% (500%) (3) 1-30 sec. (90 sec.) (3) 1-30 sec. (90 sec.) (3) 50-100% of FLC setting maximized maximized maximized maximized SPECIAL FEATURES PARAMETERS (display mode set to maximized to access) Parameter Description/Function Default Value Range Access SLOW SPEED TORQ. MAX. SLOW SP TIME WIDER SETTINGS STORE ENABLE SPECIAL FEATURES Slow speed torque level setting Maximum slow speed operation time Enables extended parameter settings (p.4-6) Press “Store” to save changes made to any of the Special Features Parameters 8 30 DISABLED 1-10 1-30 sec. (250 sec.) (3) Enabled or Disabled maximized maximized maximized RVS-DX, Digital Soft Starter Instruction Manual—4/01/04 6-7 FAULT PARAMETERS (display mode set to maximized to access) Parameter PHASE SEQ. Y/N INSULATION ALARM INSULATION TRIP AUTO RESET THERMISTOR TYPE THERMISTOR TRIP UNDER CUR. RESET STORE ENABLE FAULT PARAMETERS Description/Function Phase sequence trip setting Insulation alarm setting Insulation trip setting Auto reset 'on/off' setting Thermistor type setting Thermistor trip setting Under current auto reset time setting Press 'Store' to save changes made to any of the Fault Parameters Default Value Range Access NO OFF OFF NO PTC OFF OFF Yes=on; No=off off; 0.2-5 Mohm off; 0.2-5 Mohm Yes=on; No=off PTC, NTC off; 0.1-10.0 Kohm 10-120 min.; off maximized maximized maximized maximized maximized maximized I/O PROGRAMMING PARAMETERS (display mode set to maximized to access) Parameter Description/Function Default Value PROG.INPUT C1 Sets terminal C1 to: Dual adjust, generator mode, slow speed/reverse, external fault, remote reset. Remote Reset FAULT RELAY TYPE Fault Fault-fail safe PROG. AUX. RELAY Immediate or End of Accel RELAY ON DELAY RELAY OFF DELAY Time Delay before relays turns on Time Delay before relay turns off ANALOG OUTPUT Normal=output increases with increasing current Inverted=output increases with decreasing current STORE ENABLE I/O PROG. PARAM Range Access Dual Adjustment, Generator mode, slow speed/rev., external fault, reset maximized Fault Fault, Fault-Fail Safe maximized Immediate Immediate, End of Accel. maximized 0 0 0-60 seconds 0-60 seconds maximized maximized Normal Normal, Inverted maximized Press 'Store' to save changes made to any of the I/ O Programming Parameters COMMUNICATION PARAMETERS (display mode set to maximized to access) Parameter COMM. PROTOCOL DRIVE NUMBER BAUD RATE PARITY CHECK SERIAL LINK NO. STORE ENABLE COMM.PARAMETERS Description/Function Serial Communicaitons protocol selection Drive number setting Baud rate setting Parity Check setting Serial link number Press 'Store' to save changes made to any of the Communication Parameters RVS-DX, Digital Soft Starter Instruction Manual—4/01/04 6-8 Default Value Range Access Modbus 0 9600 Even 248 (off) Modbus, Profibus 0-999 1200, 2400, 4800, 9600 Even, Odd, NO 1-248 maximized maximized maximized maximized maximized STATISTICAL DATA Parameter Description/Function LAST STRT PERIOD LAST START MAX-I TOTAL RUN TIME TOTAL # OF START LAST TRIP TRIP CURRENT TOTAL # OF TRIPS PREVIOUS TRIP -1 PREVIOUS TRIP -2 PREVIOUS TRIP -3 PREVIOUS TRIP -4 PREVIOUS TRIP -5 PREVIOUS TRIP -6 PREVIOUS TRIP -7 PREVIOUS TRIP -8 PREVIOUS TRIP -9 Default Value Displays the last starting time in seconds Displays the maximum current during last start Displays the motor’s hour counter since commencement or “Statistical Data” was reset. Displays total number of starts since commissioning or Statistical Data was reset Describes the last fault Displays the current at the last fault Displays the total number trips since commencement or “Statistical Data” was reset. Describes the second last fault Describes the third last fault Describes the fourth last fault Describes the fifth last faul Descries the sixth last fault Describes the seventh last fault Describes the eight last fault Describes the ninth last fault Describes the tenth last fault Range Access NO DATA NO DATA 0 HOURS user user user 0 user NO DATA 0% of FLA 0 user user user NO DATA NO DATA NO DATA NO DATA NO DATA NO DATA NO DATA NO DATA NO DATA user user user user user user user user user (1) The FLC of the RVS-DX is pre-determined by the size of the power section. This setting can be adjusted lower, but not higher than the unit’s rating. The Motor FLA setting is shown in amps. The default value will be matched to the FLC of the RVS-DX value, and can be modified from 50-100% of the FLC value. (2) Access to these parameters is available when dip switch 1.2 is ON. (3) The setting in parenthesis is the maximum setting of that parameter when the WIDER PARAMETERS is set to enable. RVS-DX, Digital Soft Starter Instruction Manual—4/01/04 6-9 c h a p t e r 7 Start-Up Procedure This page intentionally left blank. Start-Up Procedure NOTE: If the motor is NOT connected to the load terminals, the “WRONG CONNECTION” fault indication will appear on LCD display. Start-Up Procedure: 1. Connect an N.O. maintained push button from terminals B1 to A2. 2. Connect control power to terminals A1 and A2. (ON LED should illuminate.) 3. Reveiw all parameters with “Mode” and “Select” keys and set parameters as required. 4. If necessary, return to Default Parameters (see page 6-5, “Service” Mode). 5. Connect main voltage to starter’s line terminals (L1, L2, and L3), and motor to load terminals (U, V, and W). 6. Set LCD to show “% OF MOTOR FLA”. 7. Press the “Start” button. If motor starts to turn shortly after the start signal proceed to Step 8. If the motor does not begin turning, increase the “Initial Voltage” and press “Start” again. When starting if initial inrush and mechanical shock are too high, decrease “Initial Voltage” setting, and proceed to Step 8. 8. Motor has begun to turn. If speed accelerates to nominal proceed to Step 9. If the motor speed does not accelerate to nominal, increase the “Current Limit” setting. If the current during acceleration process is too high, decrease the “Current Limit” setting, and proceed to Step 9. 9. Press the “Soft Stop” button and wait for the motor to stop. 10. Slightly increase the “Initial Voltage” and “Current Limit” settings to allow for load changes. 11. Press “Start” button and see that the motor “Acceleration Time” to full speed is as required. 12. If acceleration time is too short, increase “Acceleration Time” setting as required. 13. Check the total starting time and set “Max. Start Time” to approximately 5 seconds longer than the maximum time required to start the motor. 14. Repeat the same for the soft stop process. NOTE: When power factor correction capacitors are used, they must be installed on the soft starter line side. Examples of starting curves Light Loads-Pumps, Fans, etc. Initial Voltage (IV)-set to 30% (Factory Default) Current Limit (CL)-set 300% Acceleration Time (AT)-set 5 sec. Voltage quickly increases to the Initial Voltage value and then gradually rampsup to nominal. Current simultaneously and smoothly increases to reach Current Limit setting or less, before smoothly decreasing to the operating current. Motor speed will accelerate to full speed quickly and smoothly. RVS-DX, Digital Soft Starter Instruction Manual—04/01/04 7-3 High Inertia Loads-Fans, Centrifuges, etc. Initial Voltage (IV)-set 50% Current limit (CL)-set 400% Acceleration time (AT)-set 20 sec. Voltage and current increase until current reaches “ Current Limit”. The volatage is held at this value until motor is close to nominal speed, then current will begin to decrease. The HRVS-DX continues to ramp-up the voltage until reaching nominal. Motor speed smoothly accelerates to full speed. Special starting-Using Dual Adjustment Using two starting characteristics, the starter will accelerate to the Dual Adjustment-IV reaching 100% current limit. After the Immediate Relay delay time, voltage to terminal C1 is switched off, using the standard characteristic to complete acceleration. This method of starting is useful to prevent initial high acceleration. (Application: Submersible pumps, Drum fans with resonating frequency, etc.) Dual Adj. Par. Standard Par. 10% 25% t1=2-30 sec t2=2-30 sec Current Limit 200% 300-400% Imm. Rel. ON delay Tx=1-60 sec — Initial Voltage Acceleration Time RVS-DX, Digital Soft Starter Instruction Manual—04/01/04 7-4 Start Up Procedure With Pump Control Starting Curve 1. Adjust main parameters as necessary (FLA, FLC, etc). 2. Set Starting Curve, Acceleration Time, Current Limit, and Initial Voltage to their default values (curve 0, 10 sec., 400% and 30% respectively). 3. Start the pump while watching the pressure gauge as the pump starts and look for overshooting (“Pressure Surge”) of the gauge needle above the target pressure. In case of over pressure, choose a peak torque reduction Pump control during curve (Pump Control curve 1!). Voltage 4. Set Start Curve 1!, increase Acceleration Time to 15 sec. and reduce Current Limit to 350%. Start the pump and watch the pressure gauge while the pump starts. 5. In most cases, overshooting is reduced, if the overshoot persists, increase Acceleration time to 25 sec. (confirm with motor manufacturer) and try again. 6. If the overpressure persists, increase Starting Curve setting to 2!, or 3!, if necessary. Each increase in Starting Curve setting will reduce the Peak Torque, thus, reducing the overpressure and preventing the “Pressure Surge” during start. 7. To increase starting time above these maximums, employ “Extended Parameters Settings” (page 5-7). Stopping Curve 1. Adjust main parameters as necessary (FLA, FLC, etc.) 2. Set Stop Curve and Deceleration Time, to their default values (curve 0, 10 sec., respectively). 3. Stop the pump, watching the pressure gauge and check valve as the pump stops. Look for overshooting (“Water Hammer”) of the gauge (abruptly stops the pump and the motor). 4. Select Stop Curve 1, increase Deceleration time to 15 seconds. Stop the pump and watch the pressure gauge and the rate of closing of the check valve as the pump stops. Abrupt stopping of the pump and motor will cause a loud audible noise emitted from the check valve. 5. In most cases, “Water Hammer” is reduced. If the “Water Hammer” persists, increase the time to 25 seconds (confirm with motor manufacturer) and try again. 6. If the “Water Hammer” persists, increase Stop Curve setting to 2!, or 3!. Each increase in stop curve will reduce the abrupt stop of the pump, thus, preventing the “Water Hammer” phenomenon. RVS-DX, Digital Soft Starter Instruction Manual—04/01/04 7-5 Final torque during soft-stopping a pump motor 1. While decelerating, the check valve may close before Deceleration Time has elapsed, thus, allowing current to flow through stator winding causing unnecessary heat. Select Final Torque sensitivity to 1, and stop the pump, confirm that current stopped flowing through the motor shortly after the check valve closed. 2. If current still flows more than 3-5 seconds after check valve closure, increase Final Torque up to 10 if necessary, to stop current flow earlier. RVS-DX, Digital Soft Starter Instruction Manual—04/01/04 7-6 C h a p t e r 8 Troubleshooting This page intentionally left blank. Troubleshooting Upon fault the motor stops, “Fault” LED illuminates and fault relay operates. The LCD will display “Trip: fault description”. Check “Statistical Data” for additional fault-related information. Fault Description ALARM: INSULATION (Optional) Initiates a signal when motor insulation level decreases below set level. TRIP: INSULATION (Optional) Trips the starter when motor insulation level decreases below trip value. Check motor and cable insulation level. TRIP: THERMISTOR (Optional) Trips the starter when motor’s thermistor resistance decreases below trip value. Check thermistor and cable’s resistance; check motor temperature near thermistor location. TOO MANY STARTS Trips the starter if the number of starts during “Start Period” exceeds the preset number. Wait until motor and starter cool down–according to “Start Inhibit” setting. LONG START TIME Trips the starter if output voltage does not reach nominal at the preset time. Check “FLA”, “FLC” and “Max. Start Time” settings. Increase “Initial Voltage”, “Current Limit” and “Max. Start Time” settings or decrease “Acceleration Time” as necessary. O/C–SHEAR PIN The electronic fuse trips the starter instantaneously when current exceeds 8.5 X FLA during starting or 200-850% during running. Check “FLA”, “FLC” settings, motor and cable connections. Check that the motor is not stalled. OVERLOAD Trips the starter when current exceeds the Overload Trip level and thermal register has filled up. Check “FLA”, “FLC” and “Overload” settings, and check the motor current. Wait 15 minutes to let the motor and stater cool down before starting. UNDERCURRENT Trips the starter when line current drops below the preset level for the preset time. Check “Undercurrent Trip” and “Undercurrent Delay” settings. Check line current through L1, L2, and L3. UNDERVOLTAGE Trips the starter when line voltage drops below the preset level for the preset time. Check “Undervoltage Trip” and “Undervoltage Delay” settings. Check line voltage through L1, L2 and L3. OVERVOLTAGE Trips the starter when line voltage rises above the preset level for the preset time. Check “Overload Trip” and “Overvoltage Delay” settings. Check line voltage through L1, L2 and L3. PHASE LOSS Trips the starter if 1 or 2 phases are missing. Check line voltages through L1, L2 and L3. Check that the frequency variations are between 45 to 65 Hz. PHASE SEQUENCE Trips the starter if input phase sequence is wrong. Check line phase sequence and if wrong, swap two wires on the line side. If the motor rotates in the wrong direction, swap two wires on the load side. MAX. SLOW SP TIME Trips the starter when operating at slow speed for extended period of time. Check that operation time at Slow Speed is shorter than the “Max. Slow Speed Time” setting. NOTE: Motor and starter may overheat when operating at slow speed for an extended period of time. WRONG CONNECTION Trips the starter when motor is not properly connected to load terminals. SHORTER SCR Trips the starter and prevents starting if one or more SCRs are short circuited or when motor windings are shorted. Check with an ohmmeter between L1-U, L2-V and L3-W, resistance > 20 KΩ. SCRs may fail due to: • High short current not protected by proper fuses. • High voltage spikes not protected by proper external varistors. • Frequent starting at max. conditions or fault conditions. OVERTEMPERATURE Heatsink overtemperature. Trips the starter when the heatsink temperature rises above 85°C. Improve cooling. Check the motor staring is not too frequent. EXTERNAL FAULT Trips the starter when a N.O. contact between terminal A2 and C1 closes for over two seconds. Check contact position and cause of closure. RVS-DX, Digital Soft Starter Instruction Manual—4/01/04 8-3 Fault Description WRONG PARAMETERS Parameters were not transferred from RAM to EEPROM. This may happen after replacing the EEPROM with a new version program. Press “Reset” key, then “Mode” and down arrow keys simultaneously and save new default parameters by pressing “Store” and “Mode” keys simultaneously. (If “Fault” LED is illuminated, press “Reset” key after storing parameters.) NOTE: When operating in generator mode, shorted SCR and wrong connection faults are not active. RVS-DX, Digital Soft Starter Instruction Manual—4/01/04 8-4 a p p e n d i x A Technical Data/Specifications This page intentionally left blank. RVS-DX Technical Data/Specifications General Information: Supply Voltage Line to Line 220-600V (to be specified) +10%, -15% Frequency 45-65Hz (fixed or variable source) Control Supply 110-120V +10%, -15% Control Inputs & Outputs 110-120V Load Three phase, three wire, squirrel cage induction motors Stop Parameters: Start FLC Starter’s full load current Motor FLA Motor’s full load amps, 50-100% of starter FLC Pump Control Curves 6 field selectable curves to prevent over-pressure and water hammer Pulse Start Duration A pulse of 80% voltage for an adjustable time of 0.1-1 second, for starting high friction loads Initial Voltage 10-50% voltage (can be extended to 10-80%) Current Limit 100-400% of motor FLA (can be extended to 100-500%) Acceleration Time 1-30 seconds (can be extended to 1-90 seconds) Deceleration Time 0-30 seconds (can be extended to 0-90 seconds) Dual Adjustments Secondary settings for: Motor FLA, Initial Voltage, Current Limit, Acceleration Time and Deceleration Time Slow Speed Torque Torque while the motor is operating at 1/6 speed Motor Protection: Too Many Starts Maximum allowable number of starts, range: off, 1-10; during time period of 1-60 minutes Start Inhibit Time period of 1-60 minutes during which starting is prevented after the “TOO MANY STARTS” fault Long Start Time (Stall Protection) Maximum allowable starting time 1-30 seconds (can be extended to 1-250 seconds) Overcurrent (Shear Pin) Two operating functions: during starting trips and starter at 850% and during running at 200-850% current, both within 1 cycle. Electronic Overload (I2T) Adjustable 75-150% of motor FLA, adjustable trip time at 500% current of 1-10 seconds Undercurrent Trips when current drops below 20-90% current for time delay of 1-10 seconds Undervoltage Trips when main voltage drops below 50-90% for a time delay of 1-10 seconds Overvoltage Tips when main voltage increases above 110-125% for a time delay of 1-10 seconds Phase Loss (Under/Over Frequency) Trips when one or two phases are missing and when frequency is not between 40 and 65 Hz Phase Sequence Trips when phase sequence is wrong Long Slow Speed Time Trips if operating at slow speed for more than 1-30 seconds Wrong Connection Prevents starting; Trips if motor is not connected or incorrectly connected to the starter Shorted SCR Trips is case one or more SCR’s have been shorted Heatsink Overtemperature Trips when heatsink temperature rises above 85°C External Fault Trips when an External Control closes for 2 seconds RVS-DX, Digital Soft Starter Instruction Manual—4/01/04 A-3 Control: Displays LCD in 4 (field selectable) languages and 4 LEDs Keypad 6 keys for easy setting Aux. Contact–immediate or end of 1 N.O., 8A, 250 VAC, 2000 VA accel Fault Contact 1 N.O., 8A, 250 VAC, 2000 VA Temperatures: Operating Temperature -10°C to +40°C Storage Temperature -20°C to +70°C Standards: Dielectric Test 2500 VAC Degree of Protection IP20 for frame size A1 IP00 for frame size A2-A5 Pollution Degree 3 EMC Emissions Immunity EN 55011 EN 55082-2 Safety EN 600947-1 UL508C UL508c listed CISPR 11 Class A ESD 8KV air, IEC 801-2 Fast transients 2KV, IEC 801-4 Related to safety requirements. on units 8-170 Amps Normal Service Conditions Altitude Up to 1000m. For equipment to be used at high altitudes consult Factory. Humidity 95% at 50°C or 98% at 45°C. Starter Consumption Ratings: Size A1 & A2 Total starter consumption: 185VA Size A3-A5 Total starter consumption: 215VA RVS-DX, Digital Soft Starter Instruction Manual—4/01/04 A-4 a p p e n d i x B Dimensional Drawings This page intentionally left blank. Dimensional Drawings Protected Chassis RVS-DX 8-44A RVS-DX 58-72 RVS-DX, Digital Soft Starter Instruction Manual—4/01/04 B-3 Protected Chassis RVS-DX 85-105A RVS-DX 145-170A RVS-DX, Digital Soft Starter Instruction Manual—4/01/04 B-4 Protected Chassis RVS-DX 210-310A RVS-DX, Digital Soft Starter Instruction Manual—4/01/04 B-5 a p p e n d i x C Fuse Selection Table This page intentionally left blank. Fuse Selection Table 230 Volt 460 Volt 575 Volt RVS-DX Max. SCR I2T Allowed Fuse Amp Rating 250V Fuse Kit* Part Number RVS-DX Max. SCR I2T Allowed Fuse Amp Rating 500V Fuse Kit* Part Number RVS-DX Fuse Max. SCR Amp I2T Allowed Rating 700V Fuse Kit* Part Number 8-D 400 40 161-20045 8-D 400 40 161-20055 8-E 400 30 161-20038 17-D 5,00 60 161-20046 17-D 5,00 60 161-20056 17-E 5,000 50 161-20039 31-D 10,000 60 161-20046 31-D 10,000 60 161-20056 31-E 10,00 90 161-20040 44-D 12,000 100 161-20047 44-D 12,000 100 161-20057 44-E 12,000 125 161-20041 58-D 15,000 200 161-20048 58-D 15,000 200 161-20058 58-E 15,000 150 161-20042 72-D 18,000 200 161-20048 72-D 18,000 200 161-20058 72-E 18,000 175 161-20043 85-D 40,000 200 161-20048 85-D 40,000 200 161-20058 85-E 40,000 200 161-20044 RVS-DX, Digital Soft Starter Instruction Manual—4/01/04 C-3 105-D 60,000 200 161-20048 105-D 60,000 200 161-20058 105-E 60,000 250 161-20065 145-D 100,000 350 161-20049 145-D 100,000 300 161-20059 145-E 100,000 300 161-20066 170-D 140,000 350 161-20049 170-D 140,000 400 161-20060 170-E 140,000 400 161-20067 210-D 200,000 500 161-20050 210-D 200,000 400 161-20060 210-E 200,000 500 161-20068 310-D 600,000 600 161-20051 310-D 600,000 600 161-20061 310-E 600,000 800 161-20069 390-D 700,00 800 161-20052 390-D 700,000 800 161-20062 390-E 700,000 900 Consult factory *Fuse Kit consists of fuses and fuse blocks.
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