Emerson AMPGARD RVSS User manual

Instruction Booklet IB020003EN Effective January 2021
AMPGARD RVSS
Reduced Voltage Soft-Starter
User manual

2EATON www.eaton.com
Instruction Booklet IB020003EN
Effective January 2021
AMPGARD RVSS
Reduced Voltage Soft-Starter
User Manual

3EATON www.eaton.com
Instruction Booklet IB020003EN
Effective January 2021
AMPGARD RVSS
Reduced Voltage Soft-Starter
User Manual
LIMITATION OF LIABILITY
This instruction booklet is published solely for information purposes
and should not be considered all-inclusive. If further information
is required, you should consult an authorized Eaton sales
representative.
The 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 the parties. This literature
is not intended to and does not enlarge or add to any such contract.
The sole source governing the rights and remedies of any purchaser
of this equipment is the contract between the purchaser and Eaton.
NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING
WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE
OR MERCHANTABILITY, OR WARRANTIES ARISING FROM
THE COURSE OF DEALING OR USAGE OF TRADE, ARE MADE
REGARDING THE INFORMATION, RECOMMENDATIONS, AND
DESCRIPTIONS CONTAINED HEREIN.
In no event will Eaton be responsible to the purchaser or user in
contract, in tort (including negligence), strict liability or otherwise
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 description contained
herein.
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The goal of Eaton is to ensure your greatest possible satisfaction
with the operation of our products. We are dedicated to providing
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You should contact your local distributor for product pricing,
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Use the Eaton website to find product information. You can also find
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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].
®
AMPGARD® Medium Voltage Control
StarterType
Interrupting
Rated Voltage
Rated Supply
Rated Load
Control Volts
Controller Class
General Order
Drawing Ref.
25A4075H09 Made in Arden NC, USA
Phases
Enclosure
S.F.
BIL
Conductors:
Unit
Mfg Date
Please locate this label on your structure and have the general order,
G.O., number available when calling for assistance.

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Instruction Booklet IB020003EN
Effective January 2021
AMPGARD RVSS
Reduced Voltage Soft-Starter
User Manual
Contents
Section 1: Product Overview........................................................... 11
1.1 Manual objectives ............................................................ 11
1.2 Documentation .............................................................. 11
1.3 Starter features .............................................................. 11
1.4 Theory of operation ........................................................... 13
1.5 Starting modes .............................................................. 15
1.6 Stopping Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.7 RVSS power and control one-line diagram ......................................... 17
1.8 Representative schematic diagrams .............................................. 17
Section 2: Protection and diagnostics.................................................... 21
2.1 Signals .....................................................................21
2.3 Optional motor protective relay ..................................................23
2.4 Monitoring ..................................................................23
2.5 Communication to other devices................................................. 24
2.6 Trending .................................................................... 24
2.7 Fault log .................................................................... 24
2.8 Event (Snapshot) ............................................................. 24
Section 3: Metering.................................................................. 25
3.1 Current .....................................................................25
3.2 Voltage ..................................................................... 25
3.3 Power .....................................................................25
3.4 Temperature................................................................. 25
3.5 Operating (system) ...........................................................25
Section 4: Inputs / outputs ............................................................ 26
Section 5: Communication ............................................................27
5.1 Communication between BCM, I/O Board and MUI.................................. 27
5.2 Communication using Modbus Serial ............................................. 27
5.3 Communication using Modbus TCP/Ethernet IP .....................................27
5.4 Programming ................................................................28
Section 6: Hardware description ......................................................29
6.1 RVSS Enclosure and components arrangement .....................................29
6.2 Power module ...............................................................32
6.3 Bypass contactor ............................................................. 36
6.4 Power supplies............................................................... 36
6.5 Optional motor protective relay ..................................................36
6.6 Auxiliary interlocks ............................................................37
6.7 System control elements....................................................... 37
Section 7: Functional description...................................................... 43
7.1 Jog .....................................................................43
7.2 Normal start ................................................................. 43
7.3 Coast stop .................................................................. 43
7.4 Soft stop ................................................................... 43
7.5 Bypass mode ................................................................43
Section 8: Commissioning procedure .................................................. 44
8.1 Preliminary setup .............................................................44
8.2 System characteristics documentation ............................................44
8.3 Programming ................................................................44
8.4 Hi-pot and megger tests ....................................................... 44
8.5 Removing the RVSS SCR truck ..................................................44
Section 9: Programming ............................................................ 46
9.1 Overview ...................................................................46
9.2 MUI operations ..............................................................46

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Instruction Booklet IB020003EN
Effective January 2021
AMPGARD RVSS
Reduced Voltage Soft-Starter
User Manual
9.3 inControl installation ..........................................................52
9.5 Example starter configuration process ............................................77
Section 10: Troubleshooting ..........................................................82
10.1 Pre-start (power-on) faults ...................................................... 82
10.2 Start initiation checks.......................................................... 83
10.2 Running Faults ...............................................................84
Appendices .......................................................................85
Appendix A - Modbus register map and bit assignments ..................................86
Appendix B - Startup documents.....................................................98
Appendix C - Links to supporting information .......................................... 109
Appendix D - Setup parameter information .............................................110
Appendix E - inControl parameter screenshots......................................... 122
Appendix F - Motor Controller Status codes explanation ................................. 157
Appendix G - inControl motor control screen .......................................... 159
Appendix H - Monitoring parameter information........................................ 160
Appendix I - Motor protective settings ............................................... 161
Appendix J - Arc features information ................................................ 162
Appendix K - Retrofits information................................................... 163
Appendix L - Spare parts .......................................................... 164
Appendix M - Accessories ......................................................... 165
Notes: ................................................................... 166
Notes: ................................................................... 167

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Instruction Booklet IB020003EN
Effective January 2021
AMPGARD RVSS
Reduced Voltage Soft-Starter
User Manual
List of Tables
Table 1. Appendices and subjects ................................................. 11
Table 2. AMPGARD RVSS Ratings and Specifications ................................. 12
Table 4. RVSS protection ........................................................ 21
Table 5. I/O board signals........................................................ 26
Table 6. Ethernet card module status (MS) indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Table 7. Ethernet card network status (NS) indicator .................................. 38
Table 8. I/O Board connectors J12 and J13 signals ....................................42
Table 9. I/O board status LED functions ............................................ 42
Table 11. Monitoring menu data ................................................... 48
Table 10. Setup wizard MUI parameters ............................................. 48
Table 12. MUI PRG menu groups................................................... 49
Table 13. Running/Stopped/Auto LED color settings....................................51
Table 14. Serial connection settings ................................................56
Table 15. Ethernet card module status indicator states .................................72
Table 16. Ethernet card network status indicator states .................................73
Table 17. Login window fields and buttons ...........................................73
Table 18. Start page functions ..................................................... 74
Table 19. Main application window areas............................................. 75
Table 20. Quick access toolbar functions. ............................................ 76
Table 21. Modbus register map.................................................... 86
Table 22. Active fault/trip - register 312 .............................................. 93
Table 23. Active warning / alarm - register 313 ........................................93
Table 24. Tripped status bits - register 314 ........................................... 94
Table 25. Warning status bits - register 316 ..........................................94
Table 26. Motor controller status bits - register 319 .................................... 95
Table 27. Pre-Start fault code - register 332 .......................................... 95
Table 28. System status bits - register 300 ...........................................96
Table 29. Start type - register 1018 (profile1), 1033 (profile 2).............................96
Table 30. Decel type - register 1019 (profile1), 1034 (profile 2) ............................ 96
Table 31. MUI control bits - register 1004 ............................................96
Table 32. Trigger source event logger - register 819 ....................................96
Table 33. Trigger Configuration - register 822 .........................................96
Table 34. Trigger command word - register 802 ....................................... 97
Table 35. Datalogger module status - register 435 .....................................97
Table 36. Fault disable bitwise - register 1096......................................... 97
Table 37. RVSS motor characteristic parameters...................................... 107
Table 38. RVSS voltage ramp plus current limit mode of operation ....................... 107
Table 39. Approximate RVSS settings for voltage ramp with current limit .................. 107
Table 40. NEMA locked rotor codes ............................................... 108
Table 41. Reference documents .................................................. 109
Table 42. Software links......................................................... 109
Table 43. AMPGARD RVSS Setup Parameters or Status (see inControl) ....................111
Table 44. Eight bit binary to hexadecimal converter ................................... 158
Table 45. Current values ........................................................ 160
Table 46. Voltage values......................................................... 160
Table 47. Power values ......................................................... 160

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Instruction Booklet IB020003EN
Effective January 2021
AMPGARD RVSS
Reduced Voltage Soft-Starter
User Manual
List of Figures
Figure 1. NEMA B motor typical speed - torque diagram. ............................... 13
Figure 2. Silicon controlled rectifier symbol. .......................................... 14
Figure 3. SCRs connected for soft start operation...................................... 14
Figure 4. SCRs wired for three-phase soft start operation................................ 15
Figure 5. Voltage ramp with current limit mode........................................ 15
Figure 6. Kickstart control mode.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 7. Coast stop control mode.................................................. 16
Figure 8. Linear deceleration voltage soft stop. ....................................... 16
Figure 9. Power and Control Block Diagram........................................... 18
Figure 10. Schematic diagram first page. ............................................. 19
Figure 11. Schematic diagram second page. .......................................... 20
Figure 12. Pre-start checks sequence ................................................22
Figure 13. Example MUI Setup Wizard screen .........................................25
Figure 14. BCM Modbus serial port. ................................................. 27
Figure 15. BCM DIP switches for IP address assignment. ................................ 27
Figure 16. RVSS front panel view with doors closed..................................... 29
Figure 17. RVSS front panel view with doors open. ..................................... 30
Figure 18. Starter cell low voltage door. ..............................................31
Figure 19. RVSS starter low voltage compartment components............................31
Figure 20. RVSS cell low voltage door with MUI. ....................................... 31
Figure 21. RVSS control devices in LV compartment..................................... 31
Figure 22. RVSS low voltage compartment components. ................................ 32
Figure 23. RVSS SCR truck assembly - front. ..........................................32
Figure 24. RVSS SCR truck assembly - rear. ...........................................33
Figure 25. SCR truck mounted in RVSS cell............................................33
Figure 26. RVSS heat sinks and SCRs. ............................................... 33
Figure 27. RVSS phase leg assembly. ................................................33
Figure 28. Fan-out board...........................................................34
Figure 29. Gate driver board........................................................35
Figure 30. Snubber board. .........................................................35
Figure 31. Shelf-mounted bypass contactor............................................36
Figure 32. 24 VDC power supply. ...................................................36
Figure 33. 48 VDC power supply. ...................................................36
Figure 34. Base control module (BCM). .............................................. 37
Figure 35. BCM LED status indications. ..............................................38
Figure 36. Monitoring user interface (MUI). ...........................................39
Figure 37. MUI control functions. ...................................................39
Figure 38. I/O Board with Digital Signal Processor (DSP).. ................................40
Figure 39. I/O Board with DSP removed. ............................................. 41
Figure 40. Bypass selector switch SS2. .............................................. 43
Figure 41. SCR truck retaining brackets. .............................................. 45
Figure 42. Insert truck ramp flanges over the cell bottom. ................................45
Figure 43. Use Power Pole handles to pull out truck. ....................................45
Figure 44. RVSS SCR truck removed. ................................................45
Figure 45. Monitoring user interface (MUI) on power-up. ................................. 46
Figure 46. MUI at the PRG | 1. Control subtopic. .......................................47
Figure 47. Setup wizard Active Op Mode setting.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Figure 48. MUI setup wizard selection on power-up. ....................................47
Figure 49. Navigating the MUI top menus. ............................................ 48
Figure 50. MUI Program menu...................................................... 49
Figure 51. MUI diagnostics. ....................................................... 50
Figure 52. MUI faults and events. ................................................... 50
Figure 53. MUI inhibits. ...........................................................50

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Instruction Booklet IB020003EN
Effective January 2021
AMPGARD RVSS
Reduced Voltage Soft-Starter
User Manual
Figure 54. MUI control button disabled notification screen. ............................... 51
Figure 55. Information flow diagram and FDT/DTM layout. ...............................52
Figure 56. inControl One Installer welcome screen......................................52
Figure 57. inControl license agreement screen. ........................................52
Figure 58. inControl setup type selection screen........................................ 53
Figure 59. inControl performing complete installation. ..................................53
Figure 60. inControl custom installation. .............................................. 53
Figure 61. inControl installation completed. ........................................... 53
Figure 62. Ampgard RVSS Device executable icon. ..................................... 54
Figure 63. DTM install first screen. ..................................................54
Figure 64. DTM install second screen. ............................................... 54
Figure 65. DTM install third screen. .................................................. 54
Figure 66. DTM install fourth screen. ................................................ 54
Figure 67. DTM install fifth screen. .................................................. 54
Figure 68. DTM install final screen................................................... 55
Figure 69. Files to be uninstalled. ...................................................55
Figure 70. BCM Modbus serial connection port. ....................................... 55
Figure 71. BCM RS-485 connections. ................................................ 56
Figure 72. MUI micro USB port..................................................... 56
Figure 73. inControl desktop icon.................................................... 56
Figure 74. inControl initial screen. ...................................................57
Figure 75. Select empty project. .................................................... 57
Figure 76. Focus on DEVICE tab. ...................................................57
Figure 77. Click File Save. .........................................................58
Figure 78. Browse for file destination. ............................................... 58
Figure 79. Save as destination. .....................................................59
Figure 80. New project file name appears in Network Summary. ..........................59
Figure 81. Update Catalogue button. ................................................60
Figure 82. Drag the Modbus Serial device from the Catalogue to the Network. ............... 60
Figure 83. Modbus Serial - Modal Configuration popup................................... 61
Figure 84. Windows COM port properties............................................. 61
Figure 85. Modbus Serial - Configuration tab...........................................62
Figure 86. Successful connection from BCM to PC inControl. ............................. 62
Figure 87. Connect Ampgard RVSS device to Modbus Serial. ............................. 63
Figure 88. Modbus Serial - Set Address window (Modbus Slave Address)....................63
Figure 89. Unsuccessful communications attempt. .....................................64
Figure 90. Successful communications setup. .........................................64
Figure 91. First time password setting option. .........................................64
Figure 92. Security screen with set password and login procedures. ....................... 65
Figure 94. Setup wizard first screen..................................................66
Figure 95. Active control mode selections. ............................................ 66
Figure 96. Local control source selections............................................. 66
Figure 97. Remote control source selection. ..........................................67
Figure 98. Phase order selection. ................................................... 67
Figure 99. Setup wizard second screen. ..............................................68
Figure 100. InControl AMPGARD RVSS application initial screen. ...........................68
Figure 101. RVSS application initial screen quick toolbar buttons. ........................... 69
Figure 102. Admin PW entry field. ...................................................69
Figure 103. 12. Security | 2. Admin PW MUI screen. .....................................69
Figure 104. BCM DIP switches for IP address with Ethernet Card. .......................... 70
Figure 105. Connect Modbus TCP to Network. ......................................... 71
Figure 106. Modbus TCP - Set Address window. ........................................ 71
Figure 107. Modbus TCP connected to network. ........................................72
Figure 108. Drag the Ampgard RVSS DTM to the Modbus TCP node.........................72

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Instruction Booklet IB020003EN
Effective January 2021
AMPGARD RVSS
Reduced Voltage Soft-Starter
User Manual
Figure 109. Network and module status LEDs. .........................................73
Figure 110. Login window. .........................................................73
Figure 111. Start page. ............................................................ 74
Figure 112. inControl main application window. ......................................... 75
Figure 113. Save layout. ........................................................... 76
Figure 114. Reset layout............................................................ 76
Figure 115. Quick access toolbar .................................................... 76
Figure 116. MUI bottom row , and OK softkeys and MODE/BACK button. ..................77
Figure 117. 24 VDC power supply....................................................82
Figure 118. 48 VDC power supply....................................................82
Figure 119. SCR truck rear power pole test points ....................................... 83
Figure 120. Example motor nameplate ............................................... 107
Figure 121. Example motor thermal limit curve ........................................ 108
Figure 122. Motor controller status display field. ....................................... 157
Figure 123. Motor controller status fault messages...................................... 157
Figure 124. Hex to binary mapping of motor controller status.............................. 157
Figure 125. inControl motor control screen. ........................................... 159

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Instruction Booklet IB020003EN
Effective January 2021
AMPGARD RVSS
Reduced Voltage Soft-Starter
User Manual
HAZARDOUS VOLTAGE
ALL POWER SOURCES MUST BE ISOLATED AND LOCKED OUT BEFORE
SERVICING THE EQUIPMENT
.
DE-ENERGIZE AND LOCK OUT ALL INCOMING POWER CONNECTIONS
AT THEIR SOURCE BEFORE SERVICING ANY PART OF THE EQUIPMENT
DIRECTLY CONNECTED TO THE INCOMING POWER, INCLUDING MAIN
HORIZONTAL BUS, VERTICAL BUS, BUS POTENTIAL TRANSFORMERS,
OR CONTROL POWER TRANSFORMERS.
READ AND UNDERSTAND THESE INSTRUCTIONS IN THEIR ENTIRETY
BEFORE INSTALLING, OPERATING, OR MAINTAINING THIS EQUIPMENT.
ONLY QUALIFIED PERSONS SHOULD INSTALL, MAINTAIN, ADJUST, OR
REPAIR THESE UNITS. A QUALIFIED PERSON IS ONE WHO IS FAMILIAR
WITH THE CONSTRUCTION AND OPERATION OF THE EQUIPMENT AND
THE HAZARDS ASSOCIATED WITH IT.
IMPORTANT USER INFORMATION
Read and understand these instructions before attempting any
installation, operation, or maintenance of the AMPGARD RVSS
Reduced Voltage Soft Starter.
This equipment shall be installed and serviced only by qualified
electrical personnel.
Retain this document for future use.
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