Korakot PHOTJANASUNTORN 1/95 Korakot PHOTJANASUNTORN 2/95 Motortronics MVC Plus Product Training...

Korakot PHOTJANASUNTORN 1/951/95


Motortronics MVC Plus Product TrainingStartup, Operation & Service Session

INTRODUCTION & OBJECTIVES OF SESSIONA

MVC PLUS DESCRIPTIONB

MVC PLUS FUNCTIONS - PROGRAMMINGC

COMMISSIONINGD

TROUBLESHOOTING & MAINTENANCEE

PROGRAMMING EXERCISE F

CONCLUSION G


Objectives List - A



COMMISSIONINGD



CONCLUSION G




INTRODUCTION

Who Am I, & Who Are You?

What Do I Do ?

What Services Do You Typically Provide For Your Company (Sales, Field Service, Maintenance)?

Have You Already Worked With A Motortronics MVC Plus Soft Starter?

What Do You Expect To Gain From This Session?


OBJECTIVES FOR THIS COURSE WORK

After Completion Of This Training Session,

Attendees Should Be Able To:

Describe The Functions And Typical Field Applications Of An MVC Plus Medium Voltage Soft Starter

Identify Key Components Of The Soft Starter

Define Input Connections & Default Settings

Successfully Commission An MVC Plus Soft Starter

Troubleshoot An MVC Plus Soft Starter

Find Needed Information In The Support Documentation


Objectives List - B

INTRODUCTION & OBJECTIVES OF THIS SESSIONA



COMMISSIONINGD



CONCLUSION G



Abbreviations Used In This Presentation

CPU Central Processing Unit

DCU Digital Control Unit

FLA Full Load Amperes

FLC Full Load Current

GTO Gate Turn Off

HMI Human Machine Interface

HP Horse Power

IGBT Insulated Gate Bipolar Transistor

LRA Locked Ramp Amperes

MOV Metal Oxide Varistor

MVSS Medium Voltage Soft Starter

MVSS Medium Voltage Soft Starter

OL Over Load

RTD Resistance-Temperature Device

RVAT Reduced Voltage

Autotransformer

SCR Silicon Controlled Rectifier (Thyristor)

SF Service Factor

RVSS Reduced Voltage Soft Starter

TCB Terminal & Control Board


Soft Starter - Basic Features

Isolation Switch (Disconnector)Isolation Switch (Disconnector)

Provides Isolation Of Soft Starter From Power Supply

Vacuum Isolation ContactorVacuum Isolation Contactor

Provides Start Sequence To SCR Stack Assembly

SCR Stack With ISCR Stack With I22t Overloadt Overload

Provides Voltage Ramp And Advanced Protection Features

Vacuum Bypass ContactorVacuum Bypass Contactor

Bypasses SCRS When Motor Reaches Full Speed

Isolated Low Voltage ControlIsolated Low Voltage Control

CPT & PTCPT & PT

TransformersTransformers

Supply Control Power And SCR Firing Detection

Main FusesMain Fuses

Medium Voltage

R-Style Motor Protection Fuses


The MVC PLUS - Defined The MVC Plus Incorporates A Complete Reduced Voltage Soft Starter System

Within a NEMA 12R Drip-Proof Enclosure.

Reduced Voltage Solid-State Devices (SCRs) Vary The Amount Of The AC Sine Wave Sent To The Motor.

The MVC Plus Accelerates And Decelerates A Motor By Limiting The Current Through Voltage Phase Angle Control.

Once The Motor Is At Full Voltage, The Soft Starting System Is Bypassed With A Contactor.

Medium Voltage Soft Starters Are NOT Variable Speed Drives And Do Not Have The Functionality Of A Drive. They Are NOT Cheap Drives!

Main ContactorMain Contactor

LoadLoadProtectionProtection Soft StarterSoft Starter MotorMotor

Bypass ContactorBypass ContactorPo

wer

Net

wo

rk


Protect The Motor And Load

Reduce Mechanical Stress

Limit Starting Current

Reduce Stress On The Electrical Grid

Reduce Electrical System Disturbance

Provide Soft Stopping

Meter & Record

Communicate

Goals Beyond Simple On & Off Starting


MVC PLUS Metering Features

10 Current Based Metering Functions

6 Status Screens

Recorder for 60 Events with Time / Date Stamp

29 RTD Option Screens

Voltage Monitoring Functions– Including Line Voltage, Frequency, PF, kW, kW Demand,

kVAR, kVAR Demand, kWH, kVA, kVA Demand.

Statistical Data Capture With Demand Reset


Human / Machine Interface

Full Digital Control

– LCD Operator Interface

– Non-Volatile Memory

Digital Sequencer

– Ensures Proper Contactor Sequence

Fiber-Optic Isolation (Operator Protection)

Metering Functions

RS-422 Comunication Buss Between COM Board And CPU Board


Pump

Blower

Compressor

Chiller

Fans

Chipper

Ball Mill

Rod Mill

Conveyor

Power Conversion

HVAC

Shredder

MVC PLUS Medium Voltage Soft Starter Applications

Other Applications


Diodes have no gate input to control them. They simply allow current to flow in one direction and block current flowing from the opposite direction. The net output with an AC input is a ½ sine wave.

Several types of electrical devices can be used to manipulate power These devices are based on semi-conductor principles When used in industry, they are normally referred to as “Power

Electronics”

Input

Output

Gate

Diode Output

SCR Output

GTO Output

Description Of Solid State Devices

SCRs (Silicon Controlled Rectifier) have a gate input used to turn them on but then act like a diode. They cannot turn off until the AC current reverses direction in the next ½ alternation of the sine wave. Like a diode, they only work in one direction. Motor soft starters use SCRs almost exclusively.

GTO (Gate Turn Off) SCRs, IGBTs (Insulated Gate Bipolar Transistors) and similar devices can be turned on and off to create output waveforms independent of the zero crossing point of the half alternation of the sine wave. These devices work similar to the control valves of a fluid pumping system (On/Off). Like diodes and SCRs, they also only work in one direction.


To create an electrical device that can function on both halves of the sine wave, two devices are needed, one for each direction. Each gate drive needs to be electrically isolated since they are at completely different potentials in relation to the cathodes of the SCRs.

input

Output

gate

gate

c

R

Output

Input

SCR Switching Dampened By DV/DT (RC) Network

Solid State Devices – SCR Function

input Output

Waveform Direction

We can turn an SCR on at some point before the current zero crossing point of the sine wave. When the current of the ½ alternation of the sine wave crosses the zero point, the SCR will turn off. In order for the SCR to conduct for the next ½ alternation, the SCR must have a gate signal applied again before the next zero crossing point.

The SCR output is typically coupled to a DV/DT (RC) network to help reduce voltage switching transients. DV/DT networks are important because they help eliminate false triggering of SCRs.


SCR Control Assembly

Looking at a whole system as a unit, each phase of the medium voltage power supply connects to its own SCR ‘Stack Assembly’. The Digital Control Unit (DCU) controls the gate drive outputs in order to turn the SCRs on based on detecting the point where the current sine wave crosses the zero horizon.

This is a very basic block diagram an SCR control system, but is a good representation of its fundamental operation.

Phase C [L3] Input

Phase C [T3] Output

Gate Drive

DV/DT

Current / Temp / Voltage Feedback

Computerized Controller

Phase B [L2] Input

Phase B [T2] Output

Phase A [L1] Input

Phase A [T1] Output

DV/DTDV/DT


Rugged Gate Firing Circuit

Auto-Synchronizing To Line

Independent Phase Tracking

Best Sensing Circuit For Generator Power

Measure

Fire

Measure

Fire

Measure

Fire

Measure

Fire

Measure

Fire

Measure

Fire


Rugged Gate Firing Circuit

Competition Uses A Cheaper System

Measure Once (Bet You Can Guess The Rest!)

Susceptible To Frequency Drift, Noise

“Phase Locked Loop” Firing: 6 Pulses From One Signal

Measure Once

Fire Fire Fire


Anode

Cathode

Gate

Hockey Puck Style SCR

Informational Purposes ONLY SCRs Will Not Be Examined At This Level In The Field


Typical MVC PLUS SCR Stack Assembly

This SCR stack assembly is the lowest level that may be replaced at customer site.

Field service representatives will not be required to replace SCRs within this assembly in the field due to SCR matching requirements, specialty tooling and the specific compressive forces needed to properly clamp the SCRs into an assembly.

SCR


DV/DT Boards The DV/DT Boards are used to reduce voltage transients across the stack assemblies

MOV (Metal Oxide Varistor) BoardsThe primary function of the MOV Boards are to protect the Gate-to-Cathode interface within each individual SCR.

Temp/CT Boards Provides SCR temperature and 3-phase current data to the DCU

Gate Drive Boards Sends firing control signals to the SCRs

Soft Starter Medium Voltage Compartment

DV/DT Boards

MOV Boards

Temp/CT Board

Gate Drive Boards


Sensing Systems

= MV

MTRMTR

OpticalIsolation

= Fiber Optic

= 28V= 120V

Gate Drive

MVC PLUS Electrical Isolation Diagram

LVControls

Magnetic Isolation


Fiber Optics - Description

Internal Reflection

When a ray of light (at the correct wavelength) is introduced into the fiber-optic cable, it bounces down its length, striking the core-to-cladding surface at an angle that will reflect it back into the core. If the angle of reflection is correct, the reflected light continues to be reflected down the length of the fiber with minimal loss.

Introducing the Light Source

In a fiber optic cable, as light is introduced into the end of the fiber at an angle that is directly in line with its axis, the light is guided through the core to the opposite end. Due to its design, the fiber acts as an optical waveguide, bouncing the 660 nanometer (optical red) light at equal distances off of its walls.


Fiber Optics - DescriptionConstruction


Fiber Optics - DescriptionCladding - A Semi-Reflective Material


MVC PLUS - Fiber Optics Facts

1000 micron (1 millimeter) diameter core

Plastic Optical Fiber (POF)

Cladding is a semi-reflective coating on the core

660 nanometer wavelength, optical red light

Not a laser, will not damage eyesight

1 megabit maximum transmission rate, actual signal is 250 kHz max

Maximum 1 kilometer transmission length, less than 4 meters (per fiber length) in RVSS

SCR firing transmitters are 10mm water-clear LEDs (Light Emitting Diodes) mounted on the Main Board


MVC PLUS Controller - Additional Features

3 Level Non-Volatile Memory System– High speed RAM for system operation– EPROM for Factory Settings and Defaults– EEPROM for User Settings– No battery backup required for user settings

Real Time Clock– Used in protection and metering – 10+ year battery backup


MVC PLUS Controller - Communications

RS485 Modbus RTU Built-In

RS232 Windows Based Programming / Monitor Program






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MVC PLUS Setpoint Page 1 Where To Input Motor Nameplate Data

These Settings Include Data Used By The CPU For Motor Thermal Capacity Modeling

Motor FLA And Service Factor Are Governed By (SF x FLA) Calculation For Unit Maximum Current In Setpoint Page 13 (More Information Later)


MVC PLUS Setpoint Page 1Basic Overload Protection - Start Up (& Run)

NEMA / UL Pre-Programmed O/L Trip Curves Class 5 Through Class 30

10

100

600

100% 600%

%FLA%FLA

SecondSecondss

400%

Class 30Class 30

Class 20Class 20

Class 10Class 10


MVC PLUS Setpoint Page 2

Motor Starting, Deceleration And Ramp Type Settings

Most Starting Situations Require Only VOLTAGE RAMP With CURRENT LIMIT Starting Profile

The INITIAL VOLTAGE Setting Is Used To Move The Rotor From A Standstill And Nothing More

The RAMP TIME Setting Is An Approach Vector Between INITIAL VOLTAGE Setting And CURRENT LIMIT Setting. A Long RAMP TIME Setting Delays The Time For The MVC Plus To Settle Into CURRENT LIMIT Mode

The CURRENT LIMIT Setting Is Where The “Real Work” Begins. The Maximum Power (Setpoint Limited) That Is Applied To The Motor When The MVC Plus Is Operating In CURRENT LIMIT. If The Starter Trips On Acceleration Time Trip, Increase CURRENT LIMIT To Reduce The Starting Time


Typical Starting ProfileVoltage Ramp With Current Limit

TIME

VOLTS / AMPS

AT SPEEDINITIAL VOLTAGE

Initial Voltage - Setpoint 2.3.V1Initial Voltage - Setpoint 2.3.V1

RAMP TIME

Ramp Time - Setpoint 2.3.V2Ramp Time - Setpoint 2.3.V2

CURRENT LIMIT

Current Limit - Setpoint 2.3.V3Current Limit - Setpoint 2.3.V3


MVC PLUS Setpoint Page 2Advanced Ramp Features

Ramp Features– Voltage Ramp w/ Current Limit– Current Limit / Current Step– Closed Loop Current / Torque Ramp– Tach. Feedback Speed Ramp

Custom Ramp Profiling Dual Ramps Pump Control / Deceleration


MVC PLUS Setpoint Page 2Dual Ramp - Soft Start

Start Ramp 1 Selected

Ramp 1 - Voltage Ramp w/ Current Limit

Ramp

Time

Current Limit Setting

Current Limit overrides Ramp Time

Current Level Held to Limit Setting

Full Speed

RampStart


MVC PLUS Setpoint Page 2Dual Ramp - Near ATL

Start Ramp 2 Selected

Ramp 2 - Loaded Restart,“Near Across-the-Line”

Almost Full-Voltage Start, No Ramp Time

High Current Near Full-Torque Starting


MVC PLUS Setpoint Page 2Uses For Dual Ramp Profiles

Loaded Restart After a Power outage– Conveyors, Crushers

Higher Torque for Occasional Starting Requirements

– Specialized Machinery – Design C Motors– Two-Speed Motors (To Start At Either Speed)


MVC PLUS Setpoint Page 2Shorted Load Protection During Start

“Toe-in-the-Water” Circuit

– First 1/4 second of ramp time

– Checks rate of current rise

– Prevents collateral damage

MOTOR VOLTSCURRENT Trip

Start

Initial TorqueSetting

1/4 Second


MVC PLUS Setpoint Page 2Flexible Deceleration - Pump Control

Allows Full Adjustment

Independent of Acceleration Ramp

Automatic Stop Level - Prevents excessive heating in the motor

Voltage

RunStart Ramp StopBegin Decel

Torque (Coast)

Valve Closes Here


PUMP OFF

Pump Control - Hydraulic System Problems

Trapping the kinetic energy of moving water causes “WATER HAMMER”

– Check valves keep head pressure from pushing fluids backwards into the pump

HEAD PRESSUREPUMP FLOWPUMP FLOW

PUMP ONPUMP ONVALVE CLOSED




– Check valves keep head pressure from pushing fluids backwards into the pump.

HEAD PRESSURE

PUMP ONPUMP ONVALVE OPENS

PUMP FLOWPUMP FLOW PUMP PRESSURE / FLOWPUMP PRESSURE / FLOW



PUMPPUMP OFFOFFVALVE CLOSES

PUMP FLOW`PUMP FLOW` HEAD PRESSURE



The energy of the back-flowing water is trapped, creating a SHOCK WAVE traveling at the speed of sound

Liquids don’t compress, so energy is forced onto piping, fittings and seals

PUMP OFFPUMP OFFVALVE CLOSES


– When the pump suddenly stops, flow reverses until check valve closes.


Controlled Deceleration can reduce Water Hammer Reduced pump pressure closes valves more

slowly, at near-neutral pressure– Kinetic energy is slowly dissipated– Shock wave is not created

VALVE OPENPUMP ONPUMP ON

VALVE CLOSINGSOFT STOPSOFT STOPPUMP OFFPUMP OFF

VALVE CLOSED




Phase and Ground Detection Settings

All Trip and Alarm Settings can be enabled / disabled and Values for Trip / Alarm are programmed here *

* With the exception of Acceleration Time Trip Setting located in Setpoint Page 8 and RTD / Thermal Capacity Alarm Settings in Setpoint Page 12


MVC PLUS Setpoint Page 3Electrical Protection Features

Over Voltage

Under Voltage

Frequency Window

Phase Current Loss

Phase Current Imbalance

Shorted Load Protection

Zero Sequence Ground Fault Option


MVC PLUS Setpoint Page 3Load Protection

Over Current – Jam relay, electronic shear pin

Under Current – Load loss, broken belt, loss of prime

Phase Sequence– ABC, ACB, or Disabled

Anti-Oscillation Control– Prevents surging in pump systems



Output Relay Assignments.

Up to 3 Relays can be assigned per Trip / Alarm function.

Dedicated Relays

– Aux 1 = Trip

– Aux 2 = Alarm

– Aux 3 = Run Indication – When current is above 7% of programmed FLA

– Aux 4 = Bypass Contactor


MVC PLUS Setpoint Page 5 Output Relay Configuration.

Output Relays can be assigned for failsafe and whether Latched or Not.

Aux 1 (Trip) must be Latched.

First 4 Relays are pre-assigned from the factory.

Relays 5 – 8 can be assigned to Trip / Alarm functions and wired as needed.



User Input / Output Configuration.

4-20 mA Tachometer Input.

4-20 mA Analog Outputs 1 & 2.

4 Programmable External Input Trip Channels


MVC PLUS Setpoint Page 6Programmable Input / Output Features

120V Inputs– 2 wire or 3 wire control, external trip.

1 Analog Tachometer Input– 4-20mA signal. The pickup for the signal generator to the starter must be at

least 4 pulses/rotation from the motor shaft.

4 Programmable External Input Trip Channels– 1, 3 & 4 are for Factory Use Only. This is a +5VDC loop. Use dry contacts

only, do not apply AC power to this loop.

8 Digital Outputs – Each can be assigned to alarms and/or trips– Not used in Start/Stop circuit

2ea 4-20ma Analog Outputs– Programmable for RMS Current, % Motor Load, Bearing Temperature, Stator

Temperature, or RPM



Custom Acceleration Curve.

3 Separate Curves - A, B & C.

8 Programmable Steps – Voltage and Duration for each step.

Maximum Current Threshold Set point.


MVC PLUS Setpoint Page 7 Custom Ramp Profiles

3 Programmable Custom Curves

8 Data Points in Each Enter Voltage, Current, Time

– Match ramp profile to practically any application


MVC PLUS Setpoint Page 83 Overload Protection Choices During Start-up

Basic Overload Protection for Start (& Run)– Programmable overload Class 5 – 30

–

Measured Start Capacity– I2t thermal capacity from data

Learned Curve Protection– Starter learns from recorded data


Class 20 I2t curve

Area Under Curve protectionArea Under Curve protection

MVC PLUS Setpoint Page 8Measured Start Capacity For Start Up Uses basic overload curve as programmed

User enters maximum I2t value from motor manufacturer or commissioning data

Basic curve is altered

Matches motor more closely

Measured I2t capacity


MVC PLUS Setpoint Page 8Overload Protection Benefits

Provides “Trip Free” Overload (No over-ride)– Cannot be defeated by cycling power

– Not all solid state overloads do this!

Prevents Motor Damage– Protection from careless operators.


MVC PLUS Setpoint Page 82 Overload Protection Choices During Run

Basic Overload Protection– Run Overload is programmed the same as for Starting

Custom (Modified) Curve


Modified CurveModified Curve

Example:Example:

New LRA = New LRA = 400%400%

Time = 25 sec.Time = 25 sec.

10

100

600

100% 600% %FLA%FLA

Secon

dS

econ

dss

400%

Class 20 Class 20 Curve:Curve:

LRA= 600%LRA= 600%

Time = 20 Time = 20 sec. sec.

Overload Protection - During RunCustom (Modified) Curve Protection

Begin with Class 5 through Class 30 Program 2 data points

– Locked rotor amps (LRA) and trip time

Creates a Custom Curve by modifying the Basic curve


MVC PLUS Setpoint Page 8Learned Curve Protection For Start-Up

Starter placed in “Learn Mode”

CPU samples I/t data points – Time slice programmable from 1-300 sec.– Learned curve is stored and compared at each start.

0

100

200

300

400

500

% of Nameplate FLA


MVC PLUS Setpoint Page 8Duty Cycle Protection

Coast Down Lockout Timer– Back spin lockout

Starts-per-Hour Lockout

Time-Between-Starts Lockout


MVC PLUS Setpoint Page 8Coast Down Lockout Timer

Backspin Lockout– Keeps motor from restarting while spinning

On

OffStartStart

Coast Down Time

Stop

Begin Timing

Run Time

Start


Start

MVC PLUS Setpoint Page 8Duty Cycle Protection

Starts-per-Hour Lockout Timer– Prevents “Short Cycle” motor damage

Time Between Starts Lockout– Minimum time before start attempts

(used with Starts / Hour lockout)

StartStart

Time Between Starts

Start

Time Between Starts

Start

Time Between Starts

Start

Starts / Hour Lockout

(if set at 3)

Start



Up To 12 Flexible RTD Inputs – Configurable for any RTD type.

RTD Biasing of Thermal Register.

RTD Voting.

Max Temp Recording

Field Installable - See Instructions

for RTD calibration

RTD Option Card

Front Bearing (Cu)

Stator A1 (Pt)Stator B1 (Pt)Stator C1 (Pt)Back Bearing (Cu)Ambient (Ni)

Stator B2 (Pt)Stator C2 (Pt)

Bearing Box (Cu)Stator A1 (Pt)

Oil ReservoirSpare

CPU



Security / Passwords

Factory Level 2 Password = 100 - One with two zeros.

Factory Level 3 Password = 1000 - One with three zeros.

Password for Setpoint Page 13 (Factory Setting) is not documented.

Level 2 & 3 Passwords can be changed. If customer forgets his password, only Factory Password will regain control.



Communications Settings

Modbus Baud Rate and Addressing.

RS232 Baud Rate.

RS485 (Modbus) Channel is pipelined over RS422 (Display) Channel. Polling too much or too fast can cause “Wait To Communicate” to be displayed.



System Set points

Setup Default Screen Display during Run.

Thermal Register Setup.

RTD Failure Alarm Settings.

Thermal Register Alarm Settings.

Clear Thermal Register.


MVC PLUS Setpoint Page 12 Custom Motor Overload Protection

Motor Thermal Modeling – With retentive memory

Dynamic Reset Capacity – With “True Time” cooling rates

Dual Protection Modes– Separate settings for Start & Run

– Example: Class 30 for starting and Class 10 for running

– Great for long haul conveyor applications


MVC PLUS Setpoint Page 12 Motor Thermal Modeling

Thermal Register – In processor memory

– Mathematical representation of the motor

Created from Nameplate Data– Adjusts to starting / running conditions

Dual Use– Warning and/or tripping


MVC PLUS Setpoint Page 12 Retentive Thermal Memory

CPU – Tracks the motor’s thermal state

Records thermal state when power fails

Automatically stored in non-volatile memory– EEPROM, no batteries needed

Returns to normal on power-up

Re-calibrates for elapsed off-time


Thermal Register in

Non Volatile Memory

0%0%(Over Load)(Over Load)

25%25%

50%50%

75%75%

100%100%(Cold)(Cold)

Example:

Thermal Capacity used in Starting

Cooling Rate Cooling Rate while while

RunningRunning

Remaining Thermal Capacity

MVC PLUS Setpoint Page 12 Motor Thermal Modeling


Thermal Register in

Non Volatile Memory


25%25%

50%50%

75%75%


Example:

Thermal Capacity used in Starting

Power Fail!Power Fail!

Cooling Rate Cooling Rate while Offwhile Off

Recalculated

Remaining Thermal Capacity

Power RestoredPower Restored

MVC PLUS Setpoint Page 12Retentive Thermal Memory With Real Time Clock


MVC PLUS Setpoint Page 12 Benefits

Makes Full Use of Motor Data– Takes advantage of quicker cooling

Eliminates Guess Work or Compromises – Helps prevent premature restarting and failed starts


MVC PLUS Setpoint Page 12 Dynamic Reset Capacity

CPU “Learns” the Motor and Load

Records Thermal Capacity Needed – Averages previous successful starts

Inhibits Reset – Until enough thermal capacity is recovered


Thermal Register in

Non Volatile Memory


25%25%

50%50%

75%75%


Thermal Capacity used in

Successful Start

Example:Example:

Running Overload

10% 10% RemainingRemaining

CoolingRateWhile

OffFrom

Over LoadTrip

No Reset until No Reset until 90% remaining 90% remaining based on based on capacity used in capacity used in previous previous successfulsuccessful start. start.

RESETRESETRESET

MVC PLUS Setpoint Page 12 Dynamic Reset Capacity


MotoMotor r

TempTemp

Cooling RateCooling Rate LowLow

HighHigh

MVC PLUS Setpoint Page 12 True Time® Cool-Down Rates

Non-linear rate of cooling– Based on Thermal Model values

Accounts for extra convection– Hot motors cool more quickly at first– Cooling rate slows as it cools

True TimeTrue Time® Variable Cool Variable Cool

RateRate

Typical OL Typical OL Relay Relay

Cool Down Cool Down RateRate


MVC PLUS Setpoint Page 12 Benefits Dynamic Reset Capacity

Avoids Exhausting Starts/Hour Rating– Prevents having to wait longer for reset

– Takes the “guesswork” away from the operator

Saves Operating Costs– Helps prevent motor damage

– Decreases downtime



Unit Factory Settings

Password for Setpoint Page 13 = 48562

(Not Documented).

Unit Maximum Current – Use SF X FLA calculation to enable correct settings in Setpoint Page 1.

Phase CT Primary Ratio – Value of CTs located inside of red box in MVC Plus enclosure. Set from the factory.

Ground CT Primary Ratio Setting.

PT / VT Primary Ratio Setting.


MVC PLUS Setpoint Page 13 - Continued

Sync Bypass Close – Sets triggering of bypass contactor - Firing Angle and/or Current Drop Off.

Bypass Drop Out Delay – Programmable delay for the opening of bypass contactor after stopping.

Bypass Discrepancy – Not used, Future Option.

Shunt Trip – Not Used, Future Option.

Starter Settings – Offset adjustment factors to correct current & voltage limit output during starting. Not normally accessed.

Tachometer Input Offset – Adjustment factors for compensation.


MVC PLUS Setpoint Page 13 - Continued

Analog Outputs 1 &2 Offset – Programmable output control.

RTD Calibration – Refer to procedure

Short Circuit Limit Adjustment and Delay.

Reset all relays – No longer needed.

Factory Reset – Refer to Factory Reset Procedure.





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MVC PLUS - Service Manual Documents

Tab 1 – Theory of Operation – How The MVC Plus Works

Tab 2 – MVC Plus Manual – Soft Starter Document

Tab 3 – Electrical Drawings – Soft Starter Kit Drawings

Tab 4 – Application Information – Common Issues Seen In The Field

Tab 5 – Communications – MODBUS RTU Using RS-485

Tab 6 – Service Procedures – Alignments And Adjustments

Tab 7 – RTD Data Sheets – Temp / Resistance Maps


MVC PLUS CommissioningFinal Inspection Before Start Up

Collect Data for Set Point Programming– Collect Nameplate Data from: Motor, Transformer, Load, Gearbox

Medium voltage cable Hi-Pot tests performed and successful

Check all control wiring

Verify all connections, fuses, current transformer circuit

Verify that all protective & timing relays have been set

With disconnect switch closed, verify MV door cannot be opened

Verify LV compartment plugs are connected

Verify that all insulating barriers are clean & dry

Inspect the equipment for loose parts, litter, tools …

Review any key interlocking schemes

Verify that all barriers and doors are secured


MOTOR

LOAD?

TRANSFORMER

Due to a lack of understanding, the MVC Plus is the first thing to be blamed when something doesn’t seem to work right during commissioning

Many times, the end-user has to be educated in order to become comfortable with the MVC PLUS. Primarily, the end-user needs to realize that the MVC PLUS does not make power. It works similar to a fluid control valve, slowly building up voltage and current to the motor

If the system power is weak and the voltage drops so low as to reduce the

Motor Torque below the Load Torque, the system will not come up to rated speed

The Misunderstood MVC PLUS


Motor Torque produced is proportional to both the Field and Rotor Voltages. This means that Motor Torque is proportional to the square of the Motor Terminal Voltage

The system will never make it to rated speed if not enough torque is available from the motor to overcome the Load Torque

The box beside can be manipulated, but the Amount of Output must create sufficient Motor Torque

MVC PLUS - 3 Dimensional Box Theory

TIME

AMPS

VOLTS MOTOR TORQUE






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Most troubleshooting is done primarily with the supplied MVC Plus Service Manual and the Soft Starter drawings

Hands-on troubleshooting with an actual MVC Plus chassis unit will be performed later

MVC PLUS - Troubleshooting Outline


Test To Perform Ohm Meter Reading Test Result

From Position A to Position B Greater than 10K Ohm Pass

Less than 10K Ohm Fail

From Position B to Position C Greater than 10K Ohm Pass

Less than 10K Ohm Fail

Gate (G) to Cathode (K) for each SCR 8 to 100 Ohms Pass (Typical 8 to 20 Ohms)

Less than 8 or greater than 100 Ohms Fail

Troubleshooting & Maintenance - SCR Test Procedure When the condition of the SCRs is suspected, a resistance check can be

performed on the SCR heat sink assemblies in the right-hand cabinet to confirm if they have been damaged. This test is to be performed on each individual assembly per phase (there are 3 SCR heat sink assemblies per phase).

Note: Allow 15 minutes after shutdown for the stack assembly DV/DT networks to discharge any stored DC voltages.

Refer to the image to the right for test connection references.


Fiber Optic Troubleshooting - Connectors

Be sure to check all connections and block orientations as shown.

Ensure all fiber-optic connectors are fully seated in their proper assemblies on the circuit boards (SCR Stack Assembly).

Ensure indexing dot in the fiber-optic block is placed over the white silk-screened mark on the Main Board.


Minimum bend radius of the optical fiber used in the Limitamp MVC Plus is 2” [51mm].

If a bend radius is too small, the fiber core will have tiny cracks on the outer portion of radius.

Straightening a fiber after too tight of a bend has been made will not fix it.

Fiber Optic Troubleshooting – Bend Radius


The clear fiber optic core has a lower melting point than the jacket

Heat damage can cause a minor distortion or slight swelling that is barely visible on the surface of the jacket

The damage can be felt with the fingers, simply by pinching fiber lightly between index finger & thumb, then drag fingers North/South, East/West down length of fiber

Use caution when routing fibers through starter and around circuit boards

Melted / Swelled Fiber Optic Cables From Heat Shrinking Wire Markers Near Fiber Optic Harness

Fiber Optic Troubleshooting – Heat Damage






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MVC PLUS Setpoint Programming Exercise

Refer To Programming Exercise Presentation






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