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

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

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

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

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

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

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

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.

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

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.

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