Eaton AMPGARD RVSS Operating and maintenance manual

Instruction Booklet IB020004EN Effective October 2020
Contents
Description Page
1. Introduction ............................2
1.1 Basic description of a single unit .........2
1.2 Upper cell ...........................2
1.3 Lower cell ...........................3
1.4 RVSS truck ..........................4
2. Installation .............................4
2.1 RVSS truck removal ...................4
2.2 RVSS truck transport ..................7
2.3 RVSS truck reinstallation ...............7
2.4 RVSS structure transport/lifting ..........8
3. General notes and maintenance ............9
3.1 Additional reference documents .........9
3.2 Standard drawings and dimensions......10
3.3 Emergency bypass mode .............13
3.4 Maintenance .......................13
3.5 Support services ....................14
Read and understand these instructions before
attempting any installation 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.
Instructions for installation and maintenance
of the AMPGARD Reduced Voltage Soft Starter

2
Instruction Booklet IB020004EN
Effective October 2020
Instructions for installation and maintenance
of the AMPGARD Reduced Voltage Soft Starter
EATON www.eaton.com
m DANGER
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, 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
To ensure the safe and successful installation and maintenance of
the AMPGARD Reduced Voltage Soft Starter (RVSS). This equip-
ment may be installed as an individual structure or may be part of a
lineup of AMPGARD products.
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 Figure 1).
Figure 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 Main contactor, and current transformers (see Figure 2). A low
voltage control compartment is located on the front of the controller
medium voltage door. Refer to IB48041 (Instructions for AMPGARD
400 ampere medium voltage starter) for operating and maintenance
instructions on the upper cell.
Figure 2. Upper cell.
Main fuses
Main contactor Isolation switch
handle mechanism
Current transformer
Upper cell
Lower cell

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Instruction Booklet IB020004EN
Effective October 2020
Instructions for installation and maintenance
of the AMPGARD Reduced Voltage Soft Starter
EATON www.eaton.com
The following standard components are located on the front of the
low voltage door of the upper cell (see Figure 3).
• Run-Off indicating lights - Denote the Main contactor status.
• 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 bypass contactor closes.
• RVSS fault indicating light – In the event of a soft starter fault, the
RVSS fault indicating light will illuminate.
• E-Stop - Removes control power from the Main contactor coil
circuit and signals the controller of an emergency stop condition.
• Motor Protection Relay - Optional relay used to provide motor
protection while running on Bypass.
Figure 3. Low voltage components.
1.3 Lower cell
The lower cell consists of a welded frame with an upper tray for
the Bypass contactor and rails on the floor for the AMPGARD RVSS
truck assembly. The bottom door comes with an interlock tab that
prevents access to the lower cell until the isolation switch and
upper door have been opened before gaining access to the medium
voltage cell. The RVSS truck assembly and Bypass contactor are
shown racked into place in Figure 4.
Figure 4. Lower cell.
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
(see Figure 5). Refer to IB020003EN (AMPGARD RVSS Medium
Voltage Solid-State Soft Starter User Manual) for details on operating
the keypad.
Figure 5. Keypad, MUI Monitoring User Interface.
Bypass contactor
Door interlock tab
Low voltage
compartment
Medium
voltage door
RVSS truck
assembly

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Instruction Booklet IB020004EN
Effective October 2020
Instructions for installation and maintenance
of the AMPGARD Reduced Voltage Soft Starter
EATON www.eaton.com
The control system for the RVSS is located in this low voltage
compartment. Components include the DSP control board, IOB
input-output interface board, C445 BCM Base Control Module and
MUI Monitoring User Interface (see Figure 5 and Figure 6).
Figure 6. Control system boards.
1.4 RVSS truck
The RVSS power poles are mounted on an easy to remove, roll out
truck assembly. Additionally, each pole is individually removable and
replaceable without extracting the rest of the truck assembly. (see
Figure 7).
Figure 7. RVSS truck.
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 in
Section 2.1. Truck removal provides easy access to the cable area in
the lower cell for bottom entry starters and is required if dielectric
testing of the starter assembly 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.
m CAUTION
TO PREVENT DAMAGE TO THE RVSS, REMOVE THE RVSS TRUCK
INCLUDING ANY INPUT OR OUTPUT MV CONNECTIONS BEFORE
PERFORMING MEGGER/HIPOT TESTING.
2.1 RVSS truck removal
m DANGER
HIGH VOLTAGE FROM RC SNUBBER STORED ENERGY MAY BE PRESENT
AFTER DISCONNECTING POWER TO THE UNIT. WAIT AT LEAST 15 MIN-
UTES BEFORE MAKING CONTACT WITH RVSS POWER POLES TO ALLOW
FOR PROPER VOLTAGE DISCHARGE.
1. Ensure the starter is de-energized by opening the isolation
switch and LOTO the feeder. Open the medium voltage doors
on the upper and lower cells (see Figure 8). (See IB48041 for
more information.)
Figure 8.
RVSS power poles
Bypass contactor
Pull bar
Pole hold-down plate

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Instruction Booklet IB020004EN
Effective October 2020
Instructions for installation and maintenance
of the AMPGARD Reduced Voltage Soft Starter
EATON www.eaton.com
2. In the lower RVSS truck cell locate and disconnect the fiber optic
and 48V power supply cables plugged in the PCB cards. (see
Figure 9).
Figure 9.
ote:N Remove the three fiber optic connections at the top of the fanout PCB
and the 48VDC power plug before removing the phase leg assembly. Leave
the five front facing fiber optic connectors in place.
3. Undo the hook and loop straps fastening the fibers and power
wires to the truck pull bars and tie back the fibers and 48V power
wires to the left side of the cell. Ensure they are clear of the
truck and roll-out rails during extraction to prevent them from
damage (see Figure 10).
Figure 10.
4. Unbolt the hold-down brackets from both the truck & the cell
frame, and remove them (see Figure 11).
Figure 11.
Velcro
straps
Pole hold-down plate Truck hold-down brackets

6
Instruction Booklet IB020004EN
Effective October 2020
Instructions for installation and maintenance
of the AMPGARD Reduced Voltage Soft Starter
EATON www.eaton.com
5. Place the ramp in front of the starter so that the outside flanges
align with the truck rails inside the cell. Insert the front flange of
the ramp over the edge and into the U-channel 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 (see
Figure 12).
Figure 12.
m CAUTION
• VERIFY THAT THE FIBER OPTIC HARNESS AND 48V CONTROL POWER
HARNESS ARE BOTH SECURED AWAY FROM THE TRUCK EXIT PATH TO
PREVENT HARNESS DAMAGE.
• PROVIDE AT LEAST 60 INCHES OF CLEARANCE IN FRONT OF THE START-
ER TO ACCOMMODATE THE RAMP AND TRUCK.
• TRUCK APPROXIMATE WEIGHT IS 260 LBS.
• ONCE THE TRUCK DESCENT DOWN THE RAMP BEGINS, THE TRUCK
SPEED INCREASES RAPIDLY.
6. The truck is now ready to be removed. Grasping the upper
glass-polyester pull bars, being careful not to damage the PCB
cards, draw the truck out onto the ramp. Keep both hands on the
truck and brace against it as it travels down the ramp to control
speed (see Figure 13).
Figure 13.
7. Alternately, a single pole may be removed without extract-
ing the rest of the truck for rapid replacement. Unbolt the
required pole hold-down plate (see Figure 11). Remove the
pertinent fibers and power wires, grasp the top and bottom
of the pole and draw out (see Figure 14).
ote:N Bypass contactor is independent from the solid-state truck assem-
bly thus, if preferred, the unit may be run in bypass mode with the truck
removed for service. See section 3.3 for details on this procedure.
Truck rail
Ramp

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Instruction Booklet IB020004EN
Effective October 2020
Instructions for installation and maintenance
of the AMPGARD Reduced Voltage Soft Starter
EATON www.eaton.com
Figure 14.
2.2 RVSS truck transport
Once the truck has been removed, it may be easily rolled away. It is
recommended that if space permits, to extract the truck onto a pallet
for ease of transportation (see Figure 15). Be careful not to push
or pull on the PCB cards while maneuvering the truck as this may
damage them.
Figure 15.
m CAUTION
• SECURE THE RVSS TRUCK TO THE PALLET BEFORE TRANSPORT.
• DO NOT LOCATE ANY OBJECTS ON THE TRUCK DURING
LIFTING/MOVING.
• STAND CLEAR OF THE TRUCK DURING LIFTING AND TRANSPORT.
2.3 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 side sheets at the front of the truck,
push the truck up the ramp and into the cell.
2. Slide the truck two-thirds into the cell and then using the pull
bars push firmly to insert the truck stabs into the rear finger
cluster assembly (see Figure 16).
Figure 16.
3. Reassemble the retaining brackets in front of the truck frame
with two bolts to the cell frame and one bolt to the truck on each
pole.
ote:N The truck hold-down brackets can only be reattached to both the
truck and cell frame if the truck stabs are fully inserted into the fingers.
If they do not line up, recheck stab engagement and attempt to push
the truck farther into the cell. (Refer back to Figure 11 for example of
correctly installed brackets.)
Bevel edge
Contact point

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Instruction Booklet IB020004EN
Effective October 2020
Instructions for installation and maintenance
of the AMPGARD Reduced Voltage Soft Starter
EATON www.eaton.com
4. Reconnect truck control/power harness (see Figure 9).
• Plug the nine fiber optic cables labeled A+, A-, B+, B-, C+, C-, TA,
TB & TC in the correctly marked ports on the truck fanout boards.
(Standing in front of the structure, left-to-right is phase-A, phase-
B, phase-C respectively.)
• Reconnect the 48V power supply wires to the fanout board power
sockets on each pole.
• Strap fiber and 48V power supply wire harness back down to the
truck using the hook & loop straps.
2.4 RVSS structure transport/lifting
For moving the AMPGARD RVSS structure, units are shipped on
fork truck pallets (see Figure 17). These allow easy transport to the
installation area where they may then be lifted off the pallets and
into place by use of overhead lifting angles.
Figure 17. Moving pallet with a forklift.
• To remove from shipping pallet, locate and remove the lag bolts
holding all structures down to the shipping pallet (see Figure 17
below and note A in Figure 21.)
Figure 18.

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Instruction Booklet IB020004EN
Effective October 2020
Instructions for installation and maintenance
of the AMPGARD Reduced Voltage Soft Starter
EATON www.eaton.com
• Attach overhead crane hooks to the provided lifting angles (see
Figure 19 and Figure 20 below).
Figure 19.
Figure 20.
m CAUTION
OBSERVE ALL SAFETY REGULATIONS WHILE LIFTING & MOVING
STRUCTURE INTO PLACE.
3. General notes and maintenance
m DANGER
HIGH VOLTAGE FROM RC SNUBBER STORED ENERGY MAY BE PRESENT
AFTER DISCONNECTING POWER TO THE UNIT. WAIT AT LEAST 15 MIN-
UTES BEFORE MAKING CONTACT WITH RVSS POWER POLES TO ALLOW
FOR PROPER VOLTAGE DISCHARGE.
3.1 Additional reference documents
For additional reference and information, see the following list:
• IB020003EN AMPGARD RVSS user manual
• IB48041 NG 400A starter
• IB48018N SL Contactor 160-400A

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Instruction Booklet IB020004EN
Effective October 2020
Instructions for installation and maintenance
of the AMPGARD Reduced Voltage Soft Starter
EATON www.eaton.com
3.2 Standard drawings and dimensions
Figure 21. Typical dimensions.

11
Instruction Booklet IB020004EN
Effective October 2020
Instructions for installation and maintenance
of the AMPGARD Reduced Voltage Soft Starter
EATON www.eaton.com
Figure 22. AMPGARD RVSS typical schematic 1.

12
Instruction Booklet IB020004EN
Effective October 2020
Instructions for installation and maintenance
of the AMPGARD Reduced Voltage Soft Starter
EATON www.eaton.com
Figure 23. AMPGARD RVSS typical schematic 2.

13
Instruction Booklet IB020004EN
Effective October 2020
Instructions for installation and maintenance
of the AMPGARD Reduced Voltage Soft Starter
EATON www.eaton.com
3.3 Emergency bypass mode
In case of emergency, the starter can be used as a full voltage
starter. Turn the SS2 SOFTSTART BYPASS switch located in the low
voltage compartment of the upper section to bypass. If power is
applied, you should hear the Bypass contactor close immediately on
operation of the SS2 switch. The solid-state truck is now bypassed
and the unit will start directly across the line as soon as the Main
contactor is closed from a start command (see Figure 24 below.)
Figure 24.
Since the Bypass contactor is separate from the solid-state truck
assembly on this model, no medium voltage cabling needs to be
moved to allow running with the truck removed for service or repair.
m DANGER
HIGH VOLTAGE FROM RC SNUBBER STORED ENERGY MAY BE PRESENT
AFTER DISCONNECTING POWER TO THE UNIT. WAIT AT LEAST 15 MIN-
UTES BEFORE MAKING CONTACT WITH RVSS POWER POLES TO ALLOW
FOR PROPER VOLTAGE DISCHARGE.
To run with the truck removed: Isolate all power sources and allow
15 minutes for everything to discharge. Follow instructions in Section
2.1 for truck removal. Ensure that the 48V control power wires and
fibers are secured safely back out of the way while the truck is
out. Close all enclosure doors and restore power. After power is
restored, change the SS2 SOFTSTART BYPASS switch to “BYPASS”.
3.4 Maintenance
Please refer to section 3.1 for additional information regarding main-
tenance of AMPGARD and SL contactor. This section will address
some of the more specific features of the RVSS product.
In general, fastener torque will follow standard AMPGARD specifica-
tions shown in Table 1. More specific requirements for the SL
contactor can be found in IB48018N. Due to the highly precise
nature required in the SCR pole construction, the internal compo-
nents of the solid-state truck assembly are not intended to be
field-serviceable. Should the RVSS truck have a component fail, it is
recommended that the corresponding full phase pole be replaced.
(See Section 2.1 for removal and replacement procedure.)
Table 1.
Bolt size
dia-thread Steel grade 2 18 - 8 St. St. Brass Silicone bronze 316 St. St. Steel grade 5
Inch-lbs.
2 - 56 1 - 2 1 - 2 0.75 - 1 1 - 2 1 - 2 -
3 - 48 2-3 2-3 1.50 - 3 2-3 2-3 -
4 - 40 3-4 3-4 2-3 2-4 3-5 -
5 - 40 5-7 4-7 3-4 4-6 5-7 -
6 - 32 6-8 6-9 4-5 5-8 6-9 -
8 - 32 11 - 15 12 - 16 7-9 10 -14 12 - 16 -
10 - 24 16 - 22 14 - 18 9 - 13 12 - 16 15 - 19 -
10 - 32 18 - 25 17 - 25 11 - 15 16 - 23 18 - 26 -
1/4 - 20 37 - 53 36 - 60 22 - 32 36 - 60 48 - 72 57 - 81
1/4 - 28 42 - 60 -25 - 36 - - 65 - 93
Foot-lbs.
5/16 - 18 7-9 7-9 4-5 9 - 13 8 - 11 10 - 14
3/8 - 16 12 - 16 12 - 16 7 - 10 14 - 19 12 - 17 18 - 28
7/16 - 14 19 - 26 17 - 25 11 - 15 25 - 35 18 - 25 28 - 40
1/ 2 - 13 28 - 39 30 - 45 16 - 23 40 - 50 30 - 45 42 - 60
9/16 - 12 40 - 56 50 - 60 24 - 34 55 - 70 50 - 70 61 - 87
5/8 - 11 55 - 78 50 - 75 33 - 47 75 - 95 55 - 80 84 - 120
3/4 - 10 97 - 138 70 - 100 58 - 83 14 0 -170 75 - 105 150 - 213
3/4 - 16 108 - 154 -64 - 92 - - 167 - 238
7/8 - 9 94 - 133 105 - 155 93 - 133 240 - 270 110 - 160 240 - 343
1 - 8 140 - 200 160 - 230 140 - 200 310 - 395 165 - 235 360 - 515
1 - 14 157 - 224 -157 - 224 - - 405 - 578

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Instruction Booklet IB020004EN
Effective October 2020
Instructions for installation and maintenance
of the AMPGARD Reduced Voltage Soft Starter
EATON www.eaton.com
3.5 Support services
The goal of Eaton is to ensure your greatest possible satisfaction
with the operation of our products. We are dedicated to providing
fast, friendly and accurate assistance. That is why we offer you so
many ways to get the support you need. Whether it’s by phone, fax,
or email, you can access Eaton’s support information 24 hours a day,
seven days a week. Our wide range of services is listed below.
You should contact your local distributor for product pricing, availabil-
ity, ordering, expediting, and repairs.
Website
Use the Eaton website to find product information. You can also find
information on local distributors or Eaton’s sales offices.
Website address
www.eaton.com/electrical
Eaton contact information
For the location of your nearest Eaton sales office or distributor,
call toll-free 1-800-525-2000 or log on to www.eaton.com. Eaton’s
Electrical Services and Systems (EESS) can be reached at 1-800-498-
2678. Eaton’s Ampgard Customer Solution Center can be contacted
at 1-877-ETN-CARE (386-2273) Option 2, Option 7, Option 3. The
direct number is 1-800-523-3775. For email communications, use
ESMVD/MV[email protected].
Please locate this label on your structure and have the general order,
G.O., number available when calling for assistance.

15
Instruction Booklet IB020004EN
Effective October 2020
Instructions for installation and maintenance
of the AMPGARD Reduced Voltage Soft Starter
EATON www.eaton.com
Notes:

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Publication No. IB020004EN / TBG 001498
October 2020
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of their respective owners.
Instructions for installation and maintenance
of the AMPGARD Reduced Voltage Soft Starter
Instruction Booklet IB020004EN
Effective October 2020
DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITY
The information, recommendations, descriptions and safety nota-
tions in this document are based on Eaton Corporation’s (“Eaton”)
experience and judgment and may not cover all contingencies.
If further information is required, an Eaton sales office should be
consulted. Sale of the product shown in this literature is subject
to the terms and conditions outlined in appropriate Eaton selling
policies or other contractual agreement between Eaton and the
purchaser.
THERE ARE NO UNDERSTANDINGS, AGREEMENTS, WARRANTIES,
EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF
FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY,
OTHER THAN THOSE SPECIFICALLY SET OUT IN ANY EXISTING
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STATES THE ENTIRE OBLIGATION OF EATON. THE CONTENTS OF
THIS DOCUMENT SHALL NOT BECOME PART OF OR MODIFY
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In no event will Eaton be responsible to the purchaser or user in
contract, in tort (including negligence), strict liability or other-wise
for any special, indirect, incidental or consequential damage or loss
whatsoever, including but not limited to damage or loss of use of
equipment, plant or power system, cost of capital, loss of power,
additional expenses in the use of existing power facilities, or claims
against the purchaser or user by its customers resulting from the
use of the information, recommendations and descriptions contained
herein. The information contained in this manual is subject to change
without notice.