Eaton AMPGARD Series Parts list manual

For more information visit: www.cutler-hammer.eaton.com
IB48068
Read and understand these instructions
before attempting any installation,
operation, or maintenance of the
AMPGARD Reduced Voltage Soft Starter.
This e uipment shall be installed and
serviced only by ualified electrical
personnel.
Retain this document for future use.
Cutler-Hammer
Instructions for Installation, Operation, and Maintenance
of the AMPGARD Reduced Voltage Soft Starter
Instruction Bulletin

Instruction Leaflet Instructions for Installation,
Page 2 Effective: March 2010 Operation, and Maintenance of the
AMPGARD Reduced Voltage Soft Starter
For more information visit: www.cutler-hammer.eaton.com
IB48068
Cutler-Hammer
Table of Contents
Description Page
Purpose………………………………………………………………..2
1 Introduction..…………………………………………………. 3
1.1. Basic Description of a Single Unit………………. 3
1.2. Upper Cell………………………………………………. 3
1.3. Lower Cell………………………………………………. 4
1.4. RVSS Truck……………….……………………………. 5
2 Installation…………………………………………………….. 5
2.1 RVSS Truck Removal………..……………………… 6
2.2 RVSS Truck Transport……………………………… 9
2.3 Cable Shield Removal……………………………... 9
2.4 RVSS Truck Reinstallation………………………. 10
3 Operation…………………………………………………..... 11
3.1 Reduced Voltage Operation…………………… .11
3.2 Full Voltage Operation…………………………….13
HAZARDOU VOLTAGE
ALL POWER OURCE MU T BE
I OLATED AND LOCKED OUT
BEFORE ERVICING THE
EQUIPMENT.
READ AND UNDER TAND THE E
IN TRUCTION IN THEIR ENTIRETY
BEFORE IN TALLING, OPERATING,
OR MAINTAINING THI
EQUIPMENT. ONLY QUALIFIED
PER ON HOULD IN TALL,
MAINTAIN, ADJU T, OR REPAIR
THE E UNIT . A QUALIFIED
PER ON I ONE WHO I FAMILIAR
WITH THE CON TRUCTION AND
OPERATION OF THE EQUIPMENT
AND THE HAZARD A OCIATED
WITH IT.
Purpose
This instruction book is to ensure the safe and
successful installation, operation, and
maintenance of the AMPGARD Reduced Voltage
Soft Starter (RVSS). This e uipment may be
installed as an individual structure or may be part
of a lineup of AMPGARD products.

Instruction Leaflet Instructions for Installation,
Page 3 Effective: March 2010 Operation, and Maintenance of the
AMPGARD Reduced Voltage Soft Starter
For more information visit: www.cutler-hammer.eaton.com
IB48068
Cutler-Hammer
ection 1 – Introduction
1.1 Basic Description of a ingle Unit
The AMPGARD RVSS is designed to start medium
voltage motors at reduced voltages with specific
ramp times and amperages. An individual unit
consists of a standard structure that is 36 inches
wide by 30 inches deep by 92 inches tall, including
the main bus. The top half is referred to as the
upper cell and the bottom half as the lower cell.
(See Fig. 1.)
Fig. 1 AMPGARD RV
1.2 Upper Cell
The upper cell consists of a full voltage starter with a
non-load break isolation switch, medium voltage
current limiting fuses, an SL contactor, and current
transformers. A low voltage control compartment is
located on the front of the controller medium voltage
door. (See Fig. 2.) Refer to IB48041 (Instructions
for AMPGARD 400 Ampere Medium Voltage Starter)
for operating and maintenance instructions on the
upper cell.
Fig. 2 Upper Cell
Upper Cell
Lower Cell
Low Voltage
Compartment
Main Contactor
Main Fuses
Isolation witch
Handle Mechanism

Instruction Leaflet Instructions for Installation,
Page 4 Effective: March 2010 Operation, and Maintenance of the
AMPGARD Reduced Voltage Soft Starter
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IB48068
Cutler-Hammer
The following components are located on the front of
the low voltage door of the upper cell. (See Fig. 3.)
•Bypass Mode Indicating Light – After the motor
is started and reaches speed, the bypass
contactor closes to bypass the SCRs in the soft
starter. The Bypass Mode Indicating Light will
illuminate when the SCRs are bypassed.
•RVSS Fault Indicating Light – In the event of a
soft starter failure, the RVSS Fault Indicating
Light will illuminate.
•RVSS Fault Reset Pushbutton – In the event of
a soft starter failure, the RVSS Fault Reset
pushbutton must be depressed to clear the
fault.
•Optional start-stop pushbuttons and run-
stopped indicating lights are supplied when
specified.
Fig. 3 Low Voltage Components
1.3 Lower Cell
The lower cell consists of a welded frame with rails
for the AMPGARD RVSS truck assembly. There is a
medium voltage door with a flange that prevents
access to the lower cell until the isolation switch and
upper door have been opened to ensure that line
voltage is not present. The RVSS truck assembly is
shown racked into place in Fig. 4.
Fig. 4 Lower Cell
Door Interlock Tab
Low Voltage
Compartment
RV Truck
Assembly
Medium
Voltage Door

Instruction Leaflet Instructions for Installation,
Page 5 Effective: March 2010 Operation, and Maintenance of the
AMPGARD Reduced Voltage Soft Starter
For more information visit: www.cutler-hammer.eaton.com
IB48068
Cutler-Hammer
A second low voltage compartment is located on the
lower cell medium voltage door. The keypad
operator interface is located on the front of the low
voltage door and is used to configure the RVSS.
Refer to DEH41021 (Medium Voltage Solid State
OEM Soft Starter Manual) for details on operating the
keypad. (See Fig. 5.)
Fig. 5 Keypad Operator Interface
The control system for the RVSS is located in this low
voltage compartment. Components include the CPU
board, MCB mother board, terminal and control
board, and CT board. (See Fig. 6.)
Fig. 6 Control ystem Boards
1.4 RV Truck
The RVSS power poles are mounted on an easy to
remove, roll out truck assembly. An SL contactor is
mounted on top of the truck which is used to bypass
the SCRs in the soft starter when the motor reaches
full speed. A pull bar located in front is used during
truck removal and reinstallation. (See Fig. 7.)
Fig. 7 RV Truck
ection 2 – Installation
Refer to IB48041 (Instructions for AMPGARD 400
Ampere Medium Voltage Starter) for installation
instructions. During installation, the RVSS truck may
be removed by following the instructions on the next
page. Truck removal provides easy access to the
cable area in the lower cell for bottom entry starters
and is re uired if dielectric testing is to be
performed. To remove the RVSS truck utilizing the
provided ramp, a minimum clearance of 60 inches is
re uired in front of the starter.
RV
Power
Poles
Bypass Contactor
Pull Bar
CAUTION:
•To prevent damage to the RVSS, remove the
RVSS truck prior to dielectric testing.

Instruction Leaflet Instructions for Installation,
Page 6 Effective: March 2010 Operation, and Maintenance of the
AMPGARD Reduced Voltage Soft Starter
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IB48068
Cutler-Hammer
2.1 RV Truck Removal
1Ensure that the starter is off. Open the isolation
switch. Open the medium voltage doors on the
upper and lower cells. (See IB48041 for more
information.)
3 Locate the fiber optic harness connections on the
left side of the MCB mother board.
2 Open the lower cell low voltage door. Remove
the black plastic cover shielding the MCB mother
board which is located in the upper, left corner
of the low voltage compartment.
4 Disconnect the three fiber optic cables labeled
THA, THB, and THC.
Fiber Optic Cables
THA, THB, THC
Fiber Optic
Connector Bloc
k
MCB Mother
Board
Board Cover

Instruction Leaflet Instructions for Installation,
Page 7 Effective: March 2010 Operation, and Maintenance of the
AMPGARD Reduced Voltage Soft Starter
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IB48068
Cutler-Hammer
5 Remove the fiber optic connector block which is
fastened with two screws.
7 Disconnect the control harness from the bypass
contactor on top of the truck. Secure the free
end of the harness on the left side of the lower
cell, ensuring that the harness is not in the exit
path of the truck.
6 Pull the fiber optic harness through the
rectangular cutout in the bottom of the low
voltage compartment into the lower cell. Secure
the loose end of the harness on top of the truck.
8 Locate the retaining brackets on the lower front
of the truck. Remove the brackets by taking out
two bolts in each bracket.
Control
Harness
Retaining
Brackets

Instruction Leaflet Instructions for Installation,
Page 8 Effective: March 2010 Operation, and Maintenance of the
AMPGARD Reduced Voltage Soft Starter
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IB48068
Cutler-Hammer
9 Place the ramp in front of the starter so that the
outside flanges align with the truck rails inside
the cell. Insert the front flanges of the ramp
over the edge at the bottom of the lower cell.
Check that the ramp will not slide left to right or
front to back to ensure that it is properly
positioned.
10 The truck is now ready to remove. With both
hands on the pull bar at the front of the truck,
pull the truck forward. Keep both hands on the
pull bar as the truck travels down the ramp and
brace against the truck to control the speed.
CAUTION:
•The truck is heavy, approximately 360 lbs.
•Once the truck descent down the ramp begins,
the truck speed increases rapidly.
•Provide at least 60 inches of clearance in front
of the starter to accommodate the ramp and
truck.
•Verify that the fiber optic harness and bypass
contactor control harness are both secured
away from the truck exit path to prevent
harness damage.
•Do not pull on the bypass contactor to remove
the truck, as the contactor may be damaged.
Truck
Rail
Ramp

Instruction Leaflet Instructions for Installation,
Page 9 Effective: March 2010 Operation, and Maintenance of the
AMPGARD Reduced Voltage Soft Starter
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IB48068
Cutler-Hammer
2.2 RV Truck Transport
Once the truck has been removed, it may be easily
rolled away. To aid in truck transport, insert a one
inch diameter pipe into the bracket on the left side of
the truck and use the pipe to push the truck. (See
Fig. 8.) Do not pull or push on the bypass contactor
to move the truck, as damage to the contactor could
occur.
Fig. 8 Truck Transport
An overhead lift is recommended for lifting the truck.
Holes are provided on each corner of the truck top
for lifting. (See Fig. 9.) If an overhead lift is not
available, roll the truck onto a pallet with the ramp
and utilize a forklift.
Fig. 9 Truck Lifting
2.3 Cable hield Removal
For additional access to the cable area in bottom
entry starters, the cable shield shown in Fig. 10 may
be removed.
Fig. 10 Cable hield
CAUTION:
•To prevent damage to cables, the cable shield
must be reinstalled before reinserting the truck
into the cell.
Cable
hield
Cable Entry
Area
Lifting
Holes
Bracket

Instruction Leaflet Instructions for Installation,
Page 10 Effective: March 2010 Operation, and Maintenance of the
AMPGARD Reduced Voltage Soft Starter
For more information visit: www.cutler-hammer.eaton.com
IB48068
Cutler-Hammer
2.4 RV Truck Reinstallation
1Place the ramp in front of the starter. Place the
truck in front of the ramp, aligning the wheels
inside the ramp’s outside flanges. With both
hands on the pull bar at the front of the truck,
push the truck up the ramp and into the cell.
3 Close the medium voltage lower door to ensure
that the hardware on the lower, right hand face
of the truck does not interfere with the door. If
the door does not close properly, the truck is not
located correctly. Push the truck further into the
cell and recheck the finger to stab engagement.
4 Reassemble the retaining brackets in front of the
truck wheels with two bolts on each bracket.
6 Reconnect the fiber optic harness to the MCB
mother board in the lower cell low voltage
compartment.
•Reconnect the three fiber optic cables
labeled THA, THB, and THC to the marked
locations on the board.
•Orient the connector block so that the small
hole in the corner of the block will align with
the stud on the board. Assemble the
connector block with two screws.
•Reassemble the black plastic cover over the
board, using four screws.
2 Slide the truck as far into the cell as possible.
Use a mirror to check that the fingers on the
bypass contactor are engaged around the stabs
in the rear of the cell.
5 Reconnect the control harness to the bypass
contactor on top of the truck.
Note: If truck is positioned correctly,
there will be no interference between the
closed door and this truck hardware.
Note: Orient small hole in corner of
connector block with stud on board.

Instruction Leaflet Instructions for Installation,
Page 11 Effective: March 2010 Operation, and Maintenance of the
AMPGARD Reduced Voltage Soft Starter
For more information visit: www.cutler-hammer.eaton.com
IB48068
Cutler-Hammer
ection 3 – Operation
3.1 Reduced Voltage Operation
Refer to the schematic in Fig. 12 for the following
description of operation. The AMPGARD RVSS
includes a main isolation contactor M that closes just
before soft start ramping begins and opens after a
stop is completed. During a fault condition, the
RVSS control system will shut down the soft start
and then the main contactor will open. During a
short circuit or ground fault detected by a separate
motor relay, the relay will immediately open the main
contactor to limit potential damage to the system.
See the notes on the schematic for programming the
relay.
When the start contact is closed and no trip condition
is present, control relay CR closes, main contactor M
closes, and the RVSS begins ramping. Bypass
contactor B closes when the motor reaches full speed
as determined by both time and current settings.
The RVSS is set at the factory with typical starting
characteristics that perform well in most applications.
After the power and control connections have been
made, use the initial RVSS settings to operate the
motor. If you wish to review the settings or make
adjustments to fit your application, see section 5.1.2
of DEH41021 (Medium Voltage Solid State OEM Soft
Starter Manual). Note that if using the internal
overload protective function in addition to the
primary motor protective relay and the minimum FLA
setting is larger than the motor FLA, set the Overload
Trip FLA to the minimum available.
AFTER TURNING OFF POWER, WAIT AT LEA T
15 MINUTE BEFORE MAKING CONTACT WITH
THE RV POWER POLE BECAU E HIGH
VOLTAGE MAY BE PRE ENT.
Fig. 11 AMPGARD RV Outline

Instruction Leaflet Instructions for Installation,
Page 12 Effective: March 2010 Operation, and Maintenance of the
AMPGARD Reduced Voltage Soft Starter
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IB48068
Cutler-Hammer
Fig. 12 AMPGARD RV Typical chematic

Instruction Leaflet Instructions for Installation,
Page 13 Effective: March 2010 Operation, and Maintenance of the
AMPGARD Reduced Voltage Soft Starter
For more information visit: www.cutler-hammer.eaton.com
IB48068
Cutler-Hammer
3.2 Full Voltage Operation
In case of emergency, the starter can be used as a
full voltage starter. Turn the Normal-Bypass switch
located in the low voltage compartment of the upper
section to Bypass. (See Fig 13.)
Fig. 13 Bypass witch
If the RVSS truck must be removed for repair, the
load side cables in the lower cell can be uickly
moved to the line side for full voltage starting. (See
Figs. 14 and 15.)
AFTER TURNING OFF POWER, WAIT AT LEA T
15 MINUTE BEFORE MAKING CONTACT WITH
THE RV POWER POLE BECAU E HIGH
VOLTAGE MAY BE PRE ENT.
Remove the RVSS truck per Section 2.1. Remove the
phase barriers from the lower stab assembly in the
lower cell, disconnect the load side cables, and
reassemble them to the upper stab assembly. Turn
the Normal-Bypass switch to Bypass.
Fig. 14 Lower Cell with Truck Removed
Fig. 15 Cables Moved to Line ide