Magnetek 188-10130 Instruction Manual
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Magnetek 188-10130 Instruction Manual

Magnetek 188-10130 Instruction Manual

Digital soft starter
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RVS-DX Digital Soft Starter
Instruction Manual
Power Control Systems
April 1, 2004
Part Number: 188-10130
© Copyright 2004 Magnetek

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Summary of Contents for Magnetek 188-10130

  • Page 1 RVS-DX Digital Soft Starter Instruction Manual Power Control Systems April 1, 2004 Part Number: 188-10130 © Copyright 2004 Magnetek...

  • Page 2: Table Of Contents

    Contents: Disclaimer of Warranty Chapter1: Introduction Overview ..............1-3 Starter Selection .
  • Page 3 Chapter 7: Start-Up Procedure Start-Up Procedure ............7-3 Start-Up Procedure with Pump Control Chapter 8: Troubleshooting Troubleshooting...
  • Page 4 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 5: Disclaimer Of Warranty

    Disclaimer of Warranty Magnetek, hereafter referred to as Company, assumes no responsibility for improper programming of a soft starter by untrained personnel. A soft starter should only be programmed by a trained technician who has read and understands the contents of this manual. Improper programming of a soft starter can lead to unexpected, undesirable, or unsafe operation or performance.
  • Page 6 ATTENTION 1. This product was designed for compliance with IEC 947-4-2 for class A equipment. 2. RVS-DX are listed under UL508C. RVS-DX, Digital Soft Starter Instruction Manual—4/01/04...

  • Page 7: Chapter1: Introduction

    c h a p t e r Introduction...
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  • Page 9: Overview

    Overview The RVS-DX is a digital electronic soft starter, incorporating six SCR’s to start a three phase squirrel cage induction motor by supplying a slowly increasing voltage, providing soft start and smooth stepless acceleration, while drawing the minimum current necessary to start the motor. The RVS-DX is equipped with internal bypass relays initiated by its microprocessor control (on units 31-310 amps).
  • Page 10 Max. FLA Frame Size *Dual rated soft starters come pre-set for 460 volts. To set for 230 volts, simply change the rated line volt parameter in the main parameters (See Chapter 6-Parameters). No control voltage required) Frame Size Width (in.) RVS-DX, Digital Soft Starter Instruction Manual—04/01/04 Model Number 230/460 Volts*...

  • Page 11: Chapter 2: Installation

    c h a p t e r Installation...
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  • Page 13: Physical Installation

    Physical Installation Location of the RVS-DX is important to achieve proper performance and normal operating life. The unit should be installed in an area where it will be protected from: • Direct sunlight, rain or moisture • Corrosive gases or liquids •...

  • Page 14: Built-In Bypass After Acceleration

    Built in Bypass After Acceleration The bypass after acceleration allows the RVS-DX to control the motor during starting and stopping for smooth, step-less acceleration and deceleration. However, once up to full voltage the RVS-DX is bypassed to reduce the watt loss. The RVS-DX incorporates internal bypass relays allowing current flow through the SCR’s only during the soft start process.
  • Page 15 c h a p t e r RVS-DX Terminals and Wiring...
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  • Page 17: Control Terminals

    Control Terminals Terminal Function Control Supply (Note 1) Start/Stop Aux. Input Auxiliary Output Contact (Note 3) Fault Contact (Note 4) 1. The control power should be connected to A2, and control neutral to A1. 2. The auxiliary input can be programmed to operate as a reset, dual adjustment, generator starting, slow speed, slow speed reverse, or external fault (see chapter 6 on parameters to set the auxiliary input).

  • Page 18: Typical Wiring Diagram

    Typical Wiring Diagram RVS-DX, Digital Soft Starter Instruction Manual—04/01/04...
  • Page 19 Operating “Inside the Delta” Using the RVS-DX soft starter “inside the delta” reduces the required soft starter rating by 1.73 ( √3) factor. For example, for a 150 amp, 460 volt motor, the RVS-DX-170-D is selected to operate in standard “line” mode. However, for “inside the delta” mode (150 amp÷1.73=87 amps), the RVS- DX-105-D can be selected, thereby, reducing cost and physical space in the application.

  • Page 20: Inside The Delta Operation

    Typical Wiring for Inside the Delta Operation: RVS-DX, Digital Soft Starter Instruction Manual—04/01/04...

  • Page 21: Chapter 4: Control Layout

    c h a p t e r Control Layout...
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  • Page 23: Digital Operator Layout

    Digital Operator Layout LED Arrangement: Ramp Fault Description Lights when control power is connected to RVS-DX Lights during starting or soft stopping process (motor supply voltage is ramping up or down) Lights after completion of starting process (motor is receiving full voltage Flashes during slow speed operation) Lights when any of the built-in protections cause a fault Flashes when Insulation Alarm relay is activated...

  • Page 24: Keypad Arrangement

    Keypad Arrangement Keypad Mode Select Up Arrow Down Arrow Store Reset RVS-DX, Digital Soft Starter Instruction Manual—04/01/04 Description This button scrolls through the following modes: Display Only Main Parameters Start Parameters Stop Parameters Dual Adjustment Parameters Special Feature Parameters Fault Parameters I/O Programming Parameters Serial Communication Parameters Statistical Data...

  • Page 25: Lcd Display

    LCD Display The LCD display consists of two lines of alphanumeric characters, displaying: system parameters starter settings, motor current, fault indication and statistical data. The LCD can be displayed in four different languages: English, French, German and Spanish. The first line displays the function and the second line displays the setting (or measure value).

  • Page 26: Extended Parameter Settings

    Extended Parameter Setting The RVS-DX incorporates a parameter, “WIDER SETTINGS”, in the special Features Parameters. If the RVS-DX is significantly larger than your motor, you can enable the “wider settings” to extend parameter settings of the following: Extended Parameter Settings Parameter Initial Voltage Current Limit...

  • Page 27: Chapter 5 : Features

    c h a p t e r Features...
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  • Page 29: Start/Stop Features

    Start/Stop Features The RVS-DX incorporates many features that assist in starting and/or stopping various applications. These features are described within this section. Pump Control (Start Curves) Induction motors produce peak torque up to three times the rated torque. This peak torque can occur towards the end of the starting process.
  • Page 30 Initial Voltage The initial voltage determines the motor’s initial torque setting (the torque is directly proportional to the square of the voltage). The initial voltage can be set from 10 to 50%. The initial voltage also affects the inrush current and mechanical shock. An initial voltage setting that is too high may cause mechanical shock and a high inrush current.
  • Page 31 Stop Curves For many applications, the load torque decreases in a square relation to the speed. In these applications, reducing the voltage will reduce the torque and the motor will smoothly decelerate to a stop. With these applications the standard stop curve (0) will be adequate. The stop curve (0) reduces the voltage linearly from nominal to zero.
  • Page 32 Dual Adjustment The dual adjustment feature allows the RVS-DX 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-DX to operate a two speed motor with adequate motor protection.

  • Page 33: Motor Protection Features

    Motor Protection Features The RVS-DX 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 34 Undervoltage The under voltage function becomes available only after the start signal. The starter will trip when the main voltage drops below the preset level for a time period longer than the under voltage delay. The under voltage trip setting ranges from 50-90%. The under voltage delay can be adjusted from 1 to 10 seconds.

  • Page 35: Heatsink Over Temperature

    Heatsink Over Temperature The starter has thermal sensors mounted on the heatsink, tripping the starter when the heatsink temperature rises above 85°C. The over temperature protection is designed to operate under normal conditions. The SCRs could overheat and fail before the heatsink reaches 85°C in the following situations: if the starter is run at extended low overload, with insufficient ventilation, sized improperly, started too frequently, or started frequently beyond maximum conditions.

  • Page 36: Short Circuit Protection

    Additional Protection Available: Short Circuit Protection Protects the starter against a short circuit by SCR protection fuses. A chart can be found in Appendix C, page C-3. Transient Protection Line transient voltages can cause a malfunction of the starter and damage to the SCR’s. All RVS-DX soft starters have MOV’s to protect from normal line voltage spikes.

  • Page 37: Parameters

    c h a p t e r Parameters...
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  • Page 39 Mode Mode Upon Initiation Parameter Display Page 1 Main Parameters % Of Motor FLA Select Select To Review All Press Parameters Option Card Not Starter FLC Installed 105 Amp BACK TO TOP Motor FLA 105 Amp Connection Type Line Rated Line Volt. 460 Volt Undercurr.

  • Page 40: Mode+Store

    Mode Mode Page 5 Special Features Fault Parameters Parameters Select Press Slow Speed Torq. Phase SEQ Y/N Insulation Alarm Max. Slow Sp Time 30 Sec. Wider Settings Insultation Trip Disabled Store Enable Auto Reset En. Save & SL. Spd. Thermistor Type BACK TO TOP Thermistor Trip Under Cur.

  • Page 41: Service Mode

    Parameter % of MOTOR FLA The operating current as a % of the motor FLA MOTOR INSULATION* Displays the insulation level of the motor’s windings THERMISTOR RES.* Displays the motor thermistor resistance ANALOG OUTPUT Normal=analog output increases with increasing current Inverted=analog output decreases with increasing current * Requires an option card for these parameters to be displayed.

  • Page 42: Main Parameters

    The User access level is always available. The maximized access is available when Dispaly Mode parameter is set to maximized (changing available parameters from minimized to maximized level), but these parameters can only be changed when the RVS-DX is stopped. Parameter Description/Function LANGUAGE...
  • Page 43 Parameter Description/Function SOFT STOP CURVE Determines the soft stop curve STOP TACHO GAIN Allows tach. curves after scrolling through soft stop curves Deceleration time setting DEC. TIME Final Torque setting FINAL TORQUE Press 'Store' to save changes made to any of STORE ENABLE the Stop Parameters STOP PARAMETERS...
  • Page 44 FAULT PARAMETERS (display mode set to maximized to access) Parameter Description/Function PHASE SEQ. Y/N Phase sequence trip setting INSULATION ALARM Insulation alarm setting INSULATION TRIP Insulation trip setting AUTO RESET Auto reset 'on/off' setting THERMISTOR TYPE Thermistor type setting THERMISTOR TRIP Thermistor trip setting UNDER CUR.

  • Page 45: Statistical Data

    Parameter Description/Function LAST STRT PERIOD Displays the last starting time in seconds LAST START MAX-I Displays the maximum current during last start TOTAL RUN TIME Displays the motor’s hour counter since commencement or “Statistical Data” was reset. TOTAL # OF START Displays total number of starts since commissioning or Statistical Data was reset LAST TRIP...

  • Page 46: Start-Up Procedure

    c h a p t e r Start-Up Procedure...
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  • Page 48: Examples Of Starting Curves

    Start-Up Procedure NOTE: If the motor is NOT connected to the load terminals, the “WRONG CONNECTION” fault indication will appear on LCD display. Start-Up Procedure: 1. Connect an N.O. maintained push button from terminals B1 to A2. 2. Connect control power to terminals A1 and A2. (ON LED should illuminate.) 3.
  • Page 49 High Inertia Loads-Fans, Centrifuges, etc. Initial Voltage (IV)-set 50% Current limit (CL)-set 400% Acceleration time (AT)-set 20 sec. Voltage and current increase until current reaches “ Current Limit”. The volatage is held at this value until motor is close to nominal speed, then current will begin to decrease.

  • Page 50: Start-Up Procedure With Pump Control

    Start Up Procedure With Pump Control Starting Curve 1. Adjust main parameters as necessary (FLA, FLC, etc). 2. Set Starting Curve, Acceleration Time, Current Limit, and Initial Voltage to their default values (curve 0, 10 sec., 400% and 30% respectively). 3.
  • Page 51 Final torque during soft-stopping a pump motor 1. While decelerating, the check valve may close before Deceleration Time has elapsed, thus, allowing current to flow through stator winding causing unnecessary heat. Select Final Torque sensitivity to 1, and stop the pump, confirm that current stopped flowing through the motor shortly after the check valve closed.

  • Page 52: Troubleshooting

    C h a p t e r Troubleshooting...
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  • Page 54: Troubleshooting

    Troubleshooting Upon fault the motor stops, “Fault” LED illuminates and fault relay operates. The LCD will display “Trip: fault description”. Check “Statistical Data” for additional fault-related information. Fault ALARM: INSULATION TRIP: INSULATION TRIP: THERMISTOR TOO MANY STARTS LONG START TIME O/C–SHEAR PIN OVERLOAD UNDERCURRENT...
  • Page 55 Fault WRONG PARAMETERS NOTE: When operating in generator mode, shorted SCR and wrong connection faults are not active. RVS-DX, Digital Soft Starter Instruction Manual—4/01/04 Description Parameters were not transferred from RAM to EEPROM. This may happen after replacing the EEPROM with a new version program. Press “Reset” key, then “Mode” and down arrow keys simultaneously and save new default parameters by pressing “Store”...

  • Page 56: Technical Data/Specifications

    a p p e n d i x Technical Data/Specifications...
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  • Page 58 RVS-DX Technical Data/Specifications General Information: Supply Voltage Frequency Control Supply Control Inputs & Outputs Load Stop Parameters: Start FLC Motor FLA Pump Control Curves Pulse Start Duration Initial Voltage Current Limit Acceleration Time Deceleration Time Dual Adjustments Slow Speed Torque Motor Protection: Too Many Starts Start Inhibit...
  • Page 59 Control: Displays Keypad Aux. Contact–immediate or end of accel Fault Contact Temperatures: Operating Temperature Storage Temperature Standards: Dielectric Test Degree of Protection Pollution Degree Emissions Immunity Safety UL508c listed Normal Service Conditions Altitude Humidity Starter Consumption Ratings: Size A1 & A2 Size A3-A5 RVS-DX, Digital Soft Starter Instruction Manual—4/01/04 LCD in 4 (field selectable) languages and 4 LEDs...

  • Page 60: Appendix B: Dimensional Drawings

    a p p e n d i x Dimensional Drawings...
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  • Page 62: Dimensional Drawings

    Dimensional Drawings Protected Chassis RVS-DX 8-44A RVS-DX 58-72 RVS-DX, Digital Soft Starter Instruction Manual—4/01/04...
  • Page 63 Protected Chassis RVS-DX 85-105A RVS-DX 145-170A RVS-DX, Digital Soft Starter Instruction Manual—4/01/04...
  • Page 64 Protected Chassis RVS-DX 210-310A RVS-DX, Digital Soft Starter Instruction Manual—4/01/04...

  • Page 65: Fuse Selection Table

    a p p e n d i x Fuse Selection Table...
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  • Page 67: Fuse Selection Table

    Fuse Selection Table 230 Volt Fuse Max. SCR 250V Fuse Kit* RVS-DX T Allowed Rating Part Number 161-20045 17-D 5,00 161-20046 31-D 10,000 161-20046 44-D 12,000 161-20047 58-D 15,000 161-20048 72-D 18,000 161-20048 85-D 40,000 161-20048 105-D 60,000 161-20048 145-D 100,000 161-20049 170-D...

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