Transcript Document

Korakot PHOTJANASUNTORN
1/95
Motortronics MVC Plus Product Training
Startup, Operation & Service Session
A
INTRODUCTION & OBJECTIVES OF SESSION
B
MVC PLUS DESCRIPTION
C
MVC PLUS FUNCTIONS - PROGRAMMING
D
COMMISSIONING
E
TROUBLESHOOTING & MAINTENANCE
F
PROGRAMMING EXERCISE
G
Korakot PHOTJANASUNTORN
CONCLUSION
2/95
ObjectivesMVC
List -Plus
A Product Training
Motortronics
Startup, Operation & Service Session
A
INTRODUCTION & OBJECTIVES OF SESSION
B
MVC PLUS DESCRIPTION
C
MVC PLUS FUNCTIONS - PROGRAMMING
D
COMMISSIONING
E
TROUBLESHOOTING & MAINTENANCE
F
PROGRAMMING EXERCISE
G
Korakot PHOTJANASUNTORN
CONCLUSION
3/95
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?
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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
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ObjectivesMVC
List -Plus
B Product Training
Motortronics
Startup, Operation & Service Session
A
INTRODUCTION & OBJECTIVES OF THIS SESSION
B
MVC PLUS DESCRIPTION
C
MVC PLUS FUNCTIONS - PROGRAMMING
D
COMMISSIONING
E
TROUBLESHOOTING & MAINTENANCE
F
PROGRAMMING EXERCISE
G
Korakot PHOTJANASUNTORN
CONCLUSION
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Abbreviations Used In This Presentation
CPU
DCU
FLA
FLC
GTO
HMI
HP
IGBT
Central Processing Unit
Digital Control Unit
Full Load Amperes
Full Load Current
Gate Turn Off
Human Machine Interface
Horse Power
Insulated Gate Bipolar
Transistor
LRA
Locked Ramp Amperes
MOV Metal Oxide Varistor
MVSS Medium Voltage Soft
Starter
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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
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Soft Starter - Basic Features
Main Fuses
Medium Voltage
R-Style Motor
Protection Fuses
Isolation Switch (Disconnector)
Provides Isolation Of Soft Starter
From Power Supply
Vacuum Isolation Contactor
Provides Start Sequence To
SCR Stack Assembly
Isolated Low Voltage Control
CPT & PT
Transformers
Supply Control
Power And SCR
Firing Detection
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SCR Stack With I2t Overload
Provides Voltage Ramp And
Advanced Protection Features
Vacuum Bypass Contactor
Bypasses SCRS When Motor
Reaches Full Speed
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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.
Power Network
 Medium Voltage Soft Starters Are NOT Variable Speed Drives And Do Not
Have The Functionality Of A Drive. They Are NOT Cheap Drives!
Main Contactor
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Protection
Soft Starter
Motor
Load
Bypass Contactor
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Goals Beyond Simple On & Off Starting
 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
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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
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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
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MVC PLUS Medium Voltage Soft
Starter Applications
 Pump
 Ball Mill
 Blower
 Rod Mill
 Compressor
 Conveyor
 Chiller
 Power Conversion
 Fans
 HVAC
 Chipper
 Shredder
 Other Applications
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Description Of Solid State Devices
Input
Gate
Output
 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”
 Diodes have no gate input to control them. They simply
Diode Output
SCR Output
GTO Output
Korakot PHOTJANASUNTORN
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.
 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.
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Solid State Devices – SCR Function
input
gate
gate
Output
input
Output
Waveform 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.
 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.
SCR Switching
Dampened By DV/DT
(RC) Network
Input
R
c
 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.
Output
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SCR Control Assembly
Phase A [L1]
Input
Phase B [L2]
Input
Phase C [L3]
Input
Gate Drive
Computerized
Controller
DV/DT
DV/DT
DV/DT
Current / Temp /
Voltage Feedback
Phase A [T1]
Output
Phase B [T2]
Output
Phase C [T3]
Output
 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.
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Rugged Gate Firing Circuit
 Auto-Synchronizing To Line
 Independent Phase Tracking
 Best Sensing Circuit For Generator Power
Measure Measure Measure Measure Measure Measure
Fire
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Fire
Fire
Fire
Fire
Fire
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Rugged Gate Firing Circuit
 Competition Uses A Cheaper System
 Measure Once (Bet You Can Guess The Rest!)
 Susceptible To Frequency Drift, Noise
Measure Once
“Phase Locked Loop” Firing:
Fire
Fire
Fire
6 Pulses From One Signal
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Hockey Puck Style SCR
 Informational Purposes ONLY
 SCRs Will Not Be Examined At This Level In The Field
Anode
Cathode
Gate
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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
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Soft Starter Medium Voltage Compartment
 DV/DT Boards
The DV/DT Boards are used to reduce voltage transients across the stack assemblies
 MOV (Metal Oxide Varistor) Boards
The 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
DV/DT Boards
MOV Boards
Temp/CT Board
Gate Drive Boards
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MVC PLUS Electrical Isolation Diagram
Magnetic
Isolation
Gate
Drive
MTR
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= MV
= 120V
= 28V
= Fiber Optic
Sensing
Systems
Optical
Isolation
LV
Controls
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Fiber Optics - Description
 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.
 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.
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Fiber Optics - Description
Construction
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Fiber Optics - Description
Cladding - A Semi-Reflective Material
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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
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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
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MVC PLUS Controller - Communications
 RS485 Modbus RTU Built-In
 RS232 Windows Based Programming / Monitor Program
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Motortronics MVC Plus Product Training
Startup, Operation & Service Session
A
INTRODUCTION & OBJECTIVES OF SESSION
B
MVC PLUS DESCRIPTION
C
MVC PLUS FUNCTIONS - PROGRAMMING
D
COMMISSIONING
E
TROUBLESHOOTING & MAINTENANCE
F
PROGRAMMING EXERCISE
G
Korakot PHOTJANASUNTORN
CONCLUSION
29/95
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)
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MVC PLUS Setpoint Page 1
Basic Overload Protection - Start Up (& Run)
 NEMA / UL Pre-Programmed O/L Trip Curves
 Class 5 Through Class 30
600
100
Seconds
Class 30
Class 20
10
100%
400%
600%
Class 10
%FLA
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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
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Typical Starting Profile
Voltage Ramp With Current Limit
Initial Voltage - Setpoint 2.3.V1
Ramp Time - Setpoint 2.3.V2
Current Limit - Setpoint 2.3.V3
CURRENT LIMIT
VOLTS /
AMPS
RAMP TIME
AT
SPEED
INITIAL VOLTAGE
TIME
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MVC PLUS Setpoint Page 2
Advanced 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
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MVC PLUS Setpoint Page 2
Dual Ramp - Soft Start
 Start Ramp 1 Selected
Ramp 1 - Voltage Ramp w/
Current Limit
Ramp
Start
Current Limit Setting
Full Speed
Current Level Held to
Ramp
Current Limit overrides
Limit Setting
Time
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Ramp Time
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MVC PLUS Setpoint Page 2
Dual 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
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MVC PLUS Setpoint Page 2
Uses 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)
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MVC PLUS Setpoint Page 2
Shorted 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
CURRENT
Start
VOLTS
Trip
Initial Torque
Setting
1/4 Second
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MVC PLUS Setpoint Page 2
Flexible Deceleration - Pump Control
 Allows Full Adjustment
 Independent of Acceleration Ramp
 Automatic Stop Level - Prevents excessive
heating in the motor
Start Ramp
Run
Begin Decel
Stop
Valve Closes Here
Voltage
Torque
Korakot PHOTJANASUNTORN
(Coast)
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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
PUMPOFF
ON
PUMP
PUMP FLOW
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VALVE CLOSED
HEAD PRESSURE
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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.
PUMP ON
PUMP FLOW
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VALVE OPENS
HEAD PRESSURE
PUMP PRESSURE / FLOW
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Pump Control - Hydraulic System Problems
VALVE CLOSES
PUMP OFF
PUMP FLOW`
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HEAD PRESSURE
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Pump Control - Hydraulic System Problems
 Trapping the kinetic energy of moving water causes “WATER
HAMMER”
– When the pump suddenly stops, flow reverses until check valve closes.
 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
VALVE CLOSES
PUMP OFF
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Pump Control - Hydraulic System Problems
 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
VALVEOPEN
CLOSING
CLOSED
VALVE
PUMP
OFF
PUMPSTOP
ON
SOFT
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MVC PLUS Setpoint Page 3
 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
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MVC PLUS Setpoint Page 3
Electrical Protection Features
 Over Voltage
 Under Voltage
 Frequency Window
 Phase Current Loss
 Phase Current Imbalance
 Shorted Load Protection
 Zero Sequence Ground Fault Option
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MVC PLUS Setpoint Page 3
Load 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
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MVC PLUS Setpoint Page 4
 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
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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.
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MVC PLUS Setpoint Page 6
 User Input / Output Configuration.
 4-20 mA Tachometer Input.
 4-20 mA Analog Outputs 1 & 2.
 4 Programmable External Input Trip
Korakot PHOTJANASUNTORN
Channels
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MVC PLUS Setpoint Page 6
Programmable 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
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MVC PLUS Setpoint Page 7
 Custom Acceleration Curve.
 3 Separate Curves - A, B & C.
 8 Programmable Steps – Voltage and
Duration for each step.
 Maximum Current Threshold Set point.
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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
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MVC PLUS Setpoint Page 8
3 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
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MVC PLUS Setpoint Page 8
Measured 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
Area Under Curve protection
Class 20 I2t curve
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MVC PLUS Setpoint Page 8
Overload 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.
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MVC PLUS Setpoint Page 8
2 Overload Protection Choices During Run
 Basic Overload Protection
– Run Overload is programmed the same as for Starting
 Custom (Modified) Curve
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Overload Protection - During Run
Custom (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
600
Class 20 Curve:
LRA= 600%
100
Seconds
Time = 20 sec.
Modified Curve
Example:
New LRA = 400%
10
Time = 25 sec.
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100%
400%
600%
%FLA
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MVC PLUS Setpoint Page 8
Learned 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.
500
400
300
200
% of Nameplate FLA
100
Ti
m
e
0
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MVC PLUS Setpoint Page 8
Duty Cycle Protection
 Coast Down Lockout Timer
– Back spin lockout
 Starts-per-Hour Lockout
 Time-Between-Starts Lockout
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MVC PLUS Setpoint Page 8
Coast Down Lockout Timer
 Backspin Lockout
– Keeps motor from restarting while spinning
Coast Down Time
Run Time
On
Off
Start
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Begin
Timing
Stop
Start
Start
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MVC PLUS Setpoint Page 8
Duty 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)
Time Between
Starts
Time Between
Starts
Start
Start
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Start
Start
Time Between
Starts
Start
Start
Starts / Hour
Lockout
(if set at 3)
Start
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MVC PLUS Setpoint Page 9
 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
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RTD Option Card
Front Bearing (Cu)
Stator A1 (Pt)
Stator B1 (Pt)
Stator C1 (Pt)
Back Bearing (Cu)
Ambient (Ni)
Stator C2 (Pt)
Stator B2 (Pt)
Stator A1 (Pt)
Bearing Box (Cu)
Oil Reservoir
Spare
CPU
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MVC PLUS Setpoint Page 10
 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.
Korakot PHOTJANASUNTORN
64/95
MVC PLUS Setpoint Page 11
 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.
Korakot PHOTJANASUNTORN
65/95
MVC PLUS Setpoint Page 12
 System Set points
 Setup Default Screen Display during Run.
 Thermal Register Setup.
 RTD Failure Alarm Settings.
 Thermal Register Alarm Settings.
 Clear Thermal Register.
Korakot PHOTJANASUNTORN
66/95
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
Korakot PHOTJANASUNTORN
67/95
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
Korakot PHOTJANASUNTORN
68/95
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
Korakot PHOTJANASUNTORN
69/95
MVC PLUS Setpoint Page 12
Motor Thermal Modeling
Example:
0%
(Over Load)
Cooling Rate
while Running
25%
50%
75%
Thermal
Register
Thermalin
Non
Volatile
Capacity
used
Remaining
Memory
inThermal
Starting
Capacity
100%
(Cold)
Korakot PHOTJANASUNTORN
70/95
MVC PLUS Setpoint Page 12
Retentive Thermal Memory With Real Time Clock
Example:
0%
(Over Load)
Power Fail!
25%
50%
75%
Thermal
Register
Thermalin
Non Volatile
Capacity
used
Recalculated
Memory
in
Starting
Remaining
Cooling Rate
while Off
Power Restored
Thermal
Capacity
100%
(Cold)
Korakot PHOTJANASUNTORN
71/95
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
Korakot PHOTJANASUNTORN
72/95
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
Korakot PHOTJANASUNTORN
73/95
MVC PLUS Setpoint Page 12
Dynamic Reset Capacity
Example:
0%
(Over Load)
25%
50%
75%
100%
(Cold)
Korakot PHOTJANASUNTORN
Cooling
Rate
While
Off
From
Over Load
Trip
Thermal
Thermalin
Register
Running
Capacity
used
Non
Overload
Volatile
in Successful
Memory
Start
10% Remaining
RESET
No Reset until 90%
remaining based on
capacity used in
previous successful
start.
74/95
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
Typical OL Relay
Cool Down Rate
High
Motor
Temp
True Time®
Variable Cool Rate
Korakot PHOTJANASUNTORN
Cooling Rate
Low
75/95
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
Korakot PHOTJANASUNTORN
76/95
MVC PLUS Setpoint Page 13
 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.
Korakot PHOTJANASUNTORN
77/95
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.
Korakot PHOTJANASUNTORN
78/95
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.
Korakot PHOTJANASUNTORN
79/95
Motortronics MVC Plus Product Training
Startup, Operation & Service Session
A
INTRODUCTION & OBJECTIVES OF SESSION
B
MVC PLUS DESCRIPTION
C
MVC PLUS FUNCTIONS - PROGRAMMING
D
COMMISSIONING
E
TROUBLESHOOTING & MAINTENANCE
F
PROGRAMMING EXERCISE
G
Korakot PHOTJANASUNTORN
CONCLUSION
80/95
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
Korakot PHOTJANASUNTORN
81/95
MVC PLUS Commissioning
Final 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
Korakot PHOTJANASUNTORN
82/95
The Misunderstood MVC PLUS
 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
TRANSFORMER
Korakot PHOTJANASUNTORN
?
MOTOR
LOAD
83/95
MVC PLUS - 3 Dimensional Box Theory
 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
VOLTS
 The box beside can be manipulated, but the
Amount of Output must create sufficient Motor
Torque
MOTOR
TORQUE
AMPS
TIME
Korakot PHOTJANASUNTORN
84/95
Motortronics MVC Plus Product Training
Startup, Operation & Service Session
A
INTRODUCTION & OBJECTIVES OF SESSION
B
MVC PLUS DESCRIPTION
C
MVC PLUS FUNCTIONS - PROGRAMMING
D
COMMISSIONING
E
TROUBLESHOOTING & MAINTENANCE
F
PROGRAMMING EXERCISE
G
Korakot PHOTJANASUNTORN
CONCLUSION
85/95
MVC PLUS - Troubleshooting Outline
 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
Korakot PHOTJANASUNTORN
86/95
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.
Test To Perform
From Position A to Position B
From Position B to Position C
Gate (G) to Cathode (K) for each SCR
Korakot PHOTJANASUNTORN
Ohm Meter Reading
Test Result
Greater than 10K Ohm
Pass
Less than 10K Ohm
Fail
Greater than 10K Ohm
Pass
Less than 10K Ohm
Fail
8 to 100 Ohms
Pass (Typical 8 to 20 Ohms)
Less than 8 or greater than 100 Ohms
Fail
87/95
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.
Korakot PHOTJANASUNTORN
88/95
Fiber Optic Troubleshooting – Bend Radius
 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.
Korakot PHOTJANASUNTORN
89/95
Fiber Optic Troubleshooting – Heat Damage
 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
Melted / Swelled
Fiber Optic Cables
From Heat Shrinking
Wire Markers Near
Fiber Optic Harness
 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
Korakot PHOTJANASUNTORN
90/95
Motortronics MVC Plus Product Training
Startup, Operation & Service Session
A
INTRODUCTION & OBJECTIVES OF SESSION
B
MVC PLUS DESCRIPTION
C
MVC PLUS FUNCTIONS - PROGRAMMING
D
COMMISSIONING
E
TROUBLESHOOTING & MAINTENANCE
F
PROGRAMMING EXERCISE
G
Korakot PHOTJANASUNTORN
CONCLUSION
91/95
MVC PLUS Setpoint Programming Exercise
Refer To Programming Exercise Presentation
Korakot PHOTJANASUNTORN
92/95
Motortronics MVC Plus Product Training
Startup, Operation & Service Session
A
INTRODUCTION & OBJECTIVES OF SESSION
B
MVC PLUS DESCRIPTION
C
MVC PLUS FUNCTIONS - PROGRAMMING
D
COMMISSIONING
E
TROUBLESHOOTING & MAINTENANCE
F
PROGRAMMING EXERCISE
G
Korakot PHOTJANASUNTORN
CONCLUSION
93/95
uestions &
Answers
Korakot PHOTJANASUNTORN
94/95
Thanks
For your attention
Korakot PHOTJANASUNTORN
95/95