Magnetek RVS-DN Instruction Manual
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Magnetek RVS-DN Instruction Manual

Digital soft starter
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RVS-DN Digital Soft Starter
Instruction Manual
Power Control Systems
April 1, 2004
Part Number: 188-10036
© Copyright 2004 Magnetek

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  • Page 1 RVS-DN Digital Soft Starter Instruction Manual Power Control Systems April 1, 2004 Part Number: 188-10036 © Copyright 2004 Magnetek...

  • Page 2: Table Of Contents

    ............5-9 RVS-DN, Digital Soft Starter Instruction Manual— 04/01/04...
  • Page 3 ............C-3 RVS-DN, Digital Soft Starter Instruction Manual— 04/01/04...
  • Page 4 ..........F-3 RVS-DN, Digital Soft Starter Instruction Manual— 04/01/04...
  • Page 5 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.

  • Page 6: Disclaimer Of Warranty

    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-DN is connected to main power, even if control power is not connected and the motor is stopped, full voltage may appear on the RVS-DN’s output terminals.
  • Page 7 1. This product was designed for compliance with IEC 947-4-2 for class A equipment. 2. RVS-DN units rated 8 to 1800 amps are listed under UL508C. 3. RVS-DN units rated 8 to 1400 amps are LR approved. RVS-DN units rated 1800 amps and larger are designed to meet LR requirements.
  • Page 8 RVS-DN, Digital Soft Starter Instruction Manual—4/01/04...

  • Page 9: Chapter1: Introduction

    c h a p t e r Introduction...
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  • Page 11: Overview

    Motor Current and Starting Conditions: Select the RVS-DN according to the motor FLA as indicated on its nameplate (even if the motor will not be fully loaded). The chart on the following page indicates ratings, frame sizes and protected chassis part number for each input voltage range. The RVS-DN is designed to operate at 400% of motor FLA for 30 seconds at 50°C allowing (4) four starts per hour at these...
  • Page 12 Approximate Dimensions and Weights: Frame Size Width (in.) Height (in.) Depth (in.) Weight (lbs.) 6.02 12.20 8.54 10.82 15.16 9.37 14.96 17.91 11.50 24.53 26.00 11.42 28.50 43.30 14.56 29.53 51.18 15.43 35.43 51.18 16.14 RVS-DN, Digital Soft Starter Instruction Manual–4/01/04...

  • Page 13: Starter Selection When Operating "Inside The Delta

    Using the RVS-DN soft starter “inside the delta” reduces the required soft starter rating by 1.73(√3) factor. As an example, for a 150 amp, 460 volt motor, the RVS-DN-170-D is selected to operate in standard ‘line’ mode. However, for ‘inside the delta’ mode (150 amp ÷1.73 = 87 amps), the RVS- DN-105-D can be selected.

  • Page 14: Maximum Starts Per Hour

    T = actual starting time EXAMPLE: The motor is rated at 65 amps. The RVS-DN starter is rated at 72 amps with a “Current Limit” setting of 350%. The actual measured starting time is 5 seconds. 72 x 400 x 30...

  • Page 15: Chapter 2: Installation

    c h a p t e r Installation...
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  • Page 17: Physical Installation

    (50°C). Enclosures If the RVS-DN is to be mounted in an enclosure, the size of the enclosure should be determined by the heat dissipation. The RVS-DN’s watts loss is approximately 3 x the FLA in watts. (Example-for a motor of 100A, expect the watts loss of the starter to be 300 watts.) NEMA 1 enclosure–The NEMA 1 must be properly ventilated or additional fans may be needed.

  • Page 18: 230/460 Volt Setup

    3 additional bus bars, labeled L1b, L2b, and L3b. These bus bars are wired in after the CT’s, allowing current to be monitored even while in bypass. Consult Magnetek’s soft starter price book for part numbers and pricing of the preparation for bypass option.

  • Page 19: Terminals

    c h a p t e r Terminals...
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  • Page 21 Automatic fan mode–fan operates for 5 minutes after start commands and stop commands are given when internal jumper at right lug of JI terminal (C). This mode should only be used if a bypass contactor is directly controlled by the RVS-DN “End- of-Acceleration” contact. Control Voltage Neutral Neutral side of 120V control power.
  • Page 22 The tach feedback is an option that has to be special ordered. Do not use Tach with a rectified AC output. Terminal 21 should be connected to ground or neutral if the system has one. RVS-DN’s power section incorporates an internal artificial neutral that should only be used when the system is not grounded and a neutral connection is not available.

  • Page 23: Chapter 4: Wiring

    c h a p t e r Wiring...
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  • Page 25: Control Terminals

    Control Terminals The RVS-DN control terminals are show below. Typical wiring diagrams are shown on pages 4-5 and 4-6. 1 120V Control Supply 2 Fan Control 3 Neutral of Control Supply 4 Stop 5 Soft Stop 6 Start 7 Energy Save/Slow Speed/Reset...
  • Page 26 3P + GR Connect terminal 21 to Ground 3P + N Connect terminal 21 to Neutral 3P + N + GR Connect terminal 21 to Neutral 3 P Leave terminal 21 unconnected 3P +GR Leave Terminal 21 unconnected RVS-DN, Digital Soft Starter Instruction Manual–4/01/04...

  • Page 27: Typical Control Wiring

    Stop Start 120V 3. N.O. contact used for start/soft stop, with single source for supply and control inputs. When “C” closes the motor soft starts, and when “C” opens the motor will soft stop. RVS-DN, Digital Soft Starter Instruction Manual–4/01/04...
  • Page 28 * Add jumper at terminal 7 for slow speed reversing. 7. External Fault contact. The starter will trip 2 120V seconds after “C” closes. NOTE: Must not be used when terminal 21 is NOT connected to neutral/ground. RVS-DN, Digital Soft Starter Instruction Manual–4/01/04...
  • Page 29 Typical Wiring for “Inside the Delta” Operation Typical Wiring Diagram RVS-DN, Digital Soft Starter Instruction Manual–4/01/04...

  • Page 30: Fan Control

    5-10 minutes after the current stops. WA R N I N G The RVS-DN is supplied with the internal jumper connected to terminal A for continuous operation. If this jumper is changed, it is the customer’s responsibility to operate fan(s).

  • Page 31: Chapter 5 : Internal Control Layout

    c h a p t e r Internal Control Layout...
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  • Page 33: Control Module Layout

    Control Module Layout The RVS-DN has a consistent control module for all units rated 85 amps and larger. The Control Module layout is illustrated below. On units rated 8-72 amps, the control board is visible when the front cover is removed, and additional boards are consolidated within the firing board (located below the control board).

  • Page 34: Digital Operator Layout

    Digital Operator LED Arrangement: Description Lights when control power is connected to RVS-DN Start Lights during starting process (motor supply voltage is ramping up) Lights after completion of starting process (motor is receiving full voltage Flashes during slow speed operation) S.
  • Page 35 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-DN, Digital Soft Starter Instruction Manual–4/01/04...
  • Page 36 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. RVS-DN, Digital Soft Starter Instruction Manual–4/01/04...

  • Page 37: Dip Switch Settings

    Dip Switch Settings The RVS-DN incorporates a dip switch, containing eight separate switches. The dip switch is located on the main printed circuit board in the digital control module (see control module layout on p. 5-3). When necessary, open the front panel and set the switches as required.
  • Page 38 1-30 seconds 1-250 seconds Switch No. 8–Software Lock This software lock prevents parameter modification. When pressing the “Store” key or the up and down arrow key, the LCD display will read “UNAUTHORIZED ⇒ ACCESS”. RVS-DN, Digital Soft Starter Instruction Manual–4/01/04...

  • Page 39: Memory System

    Memory System The RVS-DN incorporates 3 memory systems: EPROM, EEPROM and RAM EPROM– This is a read-only, non-volatile memory containing factory set parameters (default) that can be changed. EEPROM– This is a read/write, non-volatile memory in which the field adjustable parameters, statistical and fault data are saved and stored.
  • Page 40 RVS-DN, Digital Soft Starter Instruction Manual–4/01/04 5-10...

  • Page 41: Chapter 6: Features

    c h a p t e r Features...
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  • Page 43: Start/Stop Features

    In pump applications, this peak torque may cause high pressure in the pipes. The RVS-DN 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.
  • Page 44 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-DN will trip, and the LCD display will read “LONG START TIME”. The maximum start time is settable from 1 to 30 seconds.
  • Page 45 1 to 30 seconds. NOTE: When the RVS-DN is using the Bypass after Acceleration option, the soft stop signal opens the end of acceleration contact (which then opens the bypass contactor). The load will then be transferred back to the soft starter and the voltage will ramp down.
  • Page 46 The dual adjustment feature allows the RVS-DN 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-DN to operate a two speed motor with adequate motor protection.

  • Page 47: Optional Features

    The Modbus RS-485 Serial Communications Option consists of an optional board within the control section. This option allows the user to program and read parameters, view fault indications and statistical data, operate (inputs and outputs), and reset the RVS-DN soft starter via a PLC using Modbus RS-485 communication.
  • Page 48 NOTE: 1. For correct operation it is important that the RVS-DN is properly grounded and that the control module is properly fastened to the power section. 2. This option cannot be used in conjunction with the Motor Insulation Option card.

  • Page 49: Motor Protection Features

    Motor Protection Features The RVS-DN 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”.
  • Page 50 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-DN, Digital Soft Starter Instruction Manual–4/01/04 6-10...
  • Page 51 Additional Protection Available: Short Circuit Protection Protects the starter against a short circuit by fast-acting fuses. A chart can be found in Appendix E, page E-3. RVS-DN, Digital Soft Starter Instruction Manual–4/01/04 6-11...
  • Page 52 Line transient voltages can cause a malfunction of the starter and damage to the SCR’s. Starters 85 amps and above have MOV’s to protect from normal line voltage spikes. For 8-72 amp starters or when higher transients are expected, additional external protection should be used. RVS-DN, Digital Soft Starter Instruction Manual–4/01/04 6-12...

  • Page 53: Parameters

    c h a p t e r Parameters...
  • Page 54 480 Volt is above maximum level. Start Inhibit Overvolt. Delay 2 Sec. 15 Min. Run Contact Del. Store Enable 5 Sec. Main Parameters Store Enable BACK TO TOP Start Parameters BACK TO TOP RVS-DN, Digital Soft Starter Instruction Manual–4/01/04...
  • Page 55 X Volts Back to Page 9 Current Adjust. Parameters X% Of FLC Display Page Statistical Data Back To: % Of Motor FLA **** Store Enable Default Paramet. To Exit Default Parameters Mode Press MODE + RVS-DN, Digital Soft Starter Instruction Manual–4/01/04...
  • Page 56 Normal or Inverted Option card Inverted=analog output decreases with increasing current * Requires an option card for these parameters to be displayed. If there are no option cards, the display will read,“Option Card-No Installed”. RVS-DN, Digital Soft Starter Instruction Manual–4/01/04...
  • Page 57 RVS-DN is stopped. MAIN PARAMETERS Parameter Description/Function Default Value Range Access STARTER FLC Full load current of the RVS-DN starter 8-3500 amps user MOTOR FLA Full load amps of the motor STARTER FLC value 50-100% of FLC setting user UNDERCURR.
  • Page 58 Maximum slow speed operation time 1-30 sec. (250 sec.) (3) maximized STORE ENABLE Press 'Store' to save changes made to any of the Energy Save & Slow Speed Parameters EN. SAVE & SL. SPD maximized RVS-DN, Digital Soft Starter Instruction Manual–4/01/04...
  • Page 59 Parity Check setting Even Even, Odd, NO maximized SERIAL LINK NO. Serial link number 248 (off) 1-248 maximized STORE ENABLE Press 'Store' to save changes made to any of the Communication Parameters COMM.PARAMETERS maximized RVS-DN, Digital Soft Starter Instruction Manual–4/01/04...
  • Page 60 Factory calibration of current. Notes: (1) The FLC of the RVS-DN is pre-determined by the size of the power section. This setting can be adjusted lower, but not higher than the unit’s rating. (2) Access to these parameters is available when dip switch 2 is ON.

  • Page 61: Start-Up Procedure

    c h a p t e r Start-Up Procedure...
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  • Page 63 15. 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. RVS-DN, Digital Soft Starter Instruction Manual–04/01/04...
  • Page 64 “ Current Limit”. The volatage is held at this value until motor is close to nominal speed, then current will begin to decrease. The RVS-DN continues to ramp-up the voltage until reaching nominal. Motor speed smoothly accelerates to full speed.

  • Page 65: Start-Up Procedure With Pump Control

    (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-DN, Digital Soft Starter Instruction Manual–04/01/04...
  • Page 66 2. If current still flows more than 3-5 seconds after check valve closure, incrase Final Torque up to 10 if necessary, to stop current flow earlier. RVS-DN, Digital Soft Starter Instruction Manual–04/01/04...

  • Page 67: Troubleshooting

    C h a p t e r Troubleshooting...
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  • Page 69 • Frequent starting at max. conditions or fault conditions. OVERTEMPERATURE Heatsink overtemperature. Trips the starter when the heatsink temperature rises above 85°C. Improve cooling or use Bypass After acceleration option. Check the motor staring is not too frequent. RVS-DN, Digital Soft Starter Instruction Manual–4/01/04...
  • Page 70 “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-DN, Digital Soft Starter Instruction Manual–4/01/04...

  • Page 71: Technical Data/Specifications

    a p p e n d i x Technical Data/Specifications...
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  • Page 73 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 RVS-DN, Digital Soft Starter Instruction Manual–4/01/04...
  • Page 74 Total starter consumption: 185VA Size B Fan 60 VA Total starter consumption: 215VA Size C Fans 105VA (35VAx3) Total starter consumption: 255VA Size D, E, F, G Fans 150VA (50VAx3) Total starter consumption: 300VA RVS-DN, Digital Soft Starter Instruction Manual–4/01/04...

  • Page 75: Appendix B: Application Drawings

    a p p e n d i x Application Drawings...
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  • Page 77: Typical Configuration

    Typical Configuration The schematic drawing below is an RVS-DN configurable, consisting of an RVS-DN soft starter with circuit breaker, control transformer, LED kit, run/stop/remote switch all mounted in a NEMA 1 enclosure. The schematic drawing illustrates the wiring of the RVS-DN. For more information on the configurable part number and components, refer to the price book.

  • Page 78: Bypass After Acceleration

    Bypass After Acceleration The schematic drawing below is an RVS-DN with the bypass after acceleration, as well as a circuit breaker, control transformer and start/stop push buttons. If the RVS-DN starter is rated from 44 to 820 amps and ordered in a NEMA 12 enclosure, the bypass after acceleration is standard. The bypass after acceleration eliminates the enclosure heating.

  • Page 79: Reversing With Contactors

    Reversing with 2 Series Contactors The schematic drawing below is an RVS-DN with contactor reversing. The RVS-DN does offer a reversing feature as standard, however this is a slow speed reversing that can not be used continuously. To obtain a full speed reverse that can operate for long time periods, contactor reversing must be used.

  • Page 80: Operation From A Generator

    Operation from a Generator The schematic drawing on the following page illustrates the use of a generator to power the RVS- DN. The schematic also illustrates the use of bypass after acceleration (as if the RVS-DN were mounted in a Nema 12 enclosure).
  • Page 81 Operation from a Generator RVS-DN, Digital Soft Starter Instruction Manual–4/01/04...

  • Page 82: Brake Motor

    Brake Motor The schematic drawing below is an RVS-DN soft starter wired to be used in conjunction with a brake motor. Upon starting the “immediate contact” is energized, thus releasing the brake and allowing the voltage to ramp-up (be sure that the ON and OFF delays for the immediate contact are set to 0, in I/O Programming Parameters).

  • Page 83: Insulation Test

    1. The input (series) contactor must be opened. 2. “ON” and “STOP” LED’s must be illuminated. (Thus the control transformer must be wired before the input contactor, so the RVS-DN has control power when the input contactor is open). 3. Motor and RVS-DN must be grouned properly.
  • Page 84 RVS-DN, Digital Soft Starter Instruction Manual–4/01/04 B-10...

  • Page 85: Appendix C: Dimensional Drawings

    a p p e n d i x Dimensional Drawings...
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  • Page 87: Dimensional Drawings

    Dimensional Drawings Protected Chassis 6.0" 5.1" .25" 5.9" RVS-DN 8-31 Amp 6.0" 5.1" .25" 5.9" RVS-DN 44-72 Amp RVS-DX, Digital Soft Starter Instruction Manual—4/01/04...
  • Page 88 Protected Chassis RVS-DN 85-170 Amp RVS-DN210-390 Amp RVS-DX, Digital Soft Starter Instruction Manual—4/01/04...
  • Page 89 Protected Chassis 5.90" 7.67" 7.67" 2.87" 7.67" 7.67" 0.35" 9.17" 7.67" 11.42" 7.67" 24.52" RVS-DN 460-950 Amp RVS-DX, Digital Soft Starter Instruction Manual—4/01/04...
  • Page 90 Protected Chassis 5.17" 9.0" 9.0" .35" 9.0" 9.0" 9.0" .65" 7.5" 9.0" 9.0" .35" .35" .78" 9.0" 9.0" 14.56" 5.17" 28.46" RVS-DN 1100-1800 Amp RVS-DX, Digital Soft Starter Instruction Manual—4/01/04...

  • Page 91: Ul/Cul Installation Instructions

    a p p e n d i x UL/cUL Installation Instructions...
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  • Page 93 System design needs to take into account the power supply source and motor drive together with the electronic soft starter. Particular features to be considered are torque production, harmonic production and their consquential effects and EMC. These points are relevant for marine, off-shore or industrial use. RVS-DN, Digital Soft Starter Instruction Manual–4/01/04...
  • Page 94 RVS-DN, Digital Soft Starter Instruction Manual–4/01/04...

  • Page 95: Fuse Selection Table

    a p p e n d i x Fuse Selection Table...
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  • Page 97 460 Volt 575 Volt Fuse Fuse Fuse Max. SCR Max. SCR Max. SCR 250V Fuse Kit* 500V Fuse Kit* 700V Fuse Kit* RVS-DN T Allowed Rating Part Number RVS-DN T Allowed Rating Part Number RVS-DN T Allowed Rating Part Number...
  • Page 98 RVS-DN, Digital Soft Starter Instruction Manual–4/11/03...

  • Page 99: Overload Trip Time Calculation

    a p p e n d i x Overload Trip Time Calculation...
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  • Page 101 If settings are as in default then O/L Trip Time =1,375,000 x 4 = 4 sec. -115 Example 3: Motor FLA=80A, actual current=200A, Overload Delay (OLD)=10 I%=200 x 100/80=250% O/L Trip Time =1,375,000 x 10 = 47 sec. -115 RVS-DN, Digital Soft Starter Instruction Manual–4/01/04...
  • Page 102 RVS-DN, Digital Soft Starter Instruction Manual–4/01/04...

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