ABB Training - 2007

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ABB SSMt Training - 2007

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ABB SSM Product Training

Startup, Operation & Service Session

INTRODUCTION & OBJECTIVES OF SESSIONA

SSM DESCRIPTIONB

SSM FUNCTIONS - PROGRAMMINGC

COMMISSIONINGD

TROUBLESHOOTING & MAINTENANCEE

PROGRAMMING EXERCISEF

CONCLUSIONG

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Objectives List - A


SSM DESCRIPTIONB


COMMISSIONINGD



CONCLUSIONG



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INTRODUCTION

Who Am I?

What do I do for ABB?

What Service Area Do You Typically Cover?

Have You Already Worked With An SSM?

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 SSM Medium Voltage Soft Starter

Identify Key Components Of The Soft StarterDefine Customer Inputs And Default Settings

Successfully Commission An SSM Soft Starter

Troubleshoot And Repair An SSM Soft StarterFind Needed Information In The Support Documentation

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In Order To Have A Better Experience For All Of Us

Dont Hesitate To Ask Questions

Hands-On Practice Is Favored

Everyone Needs To Operate The Programming Consoles

Or The Software On Your Laptop

Cell Phones And Email Only During Breaks

We All Take Breaks At The Same Time

We All Work Together During The Training Session

(Nobody Left Behind)

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Objectives List - B

INTRODUCTION & OBJECTIVES OF THIS SESSIONA

SSM DESCRIPTIONB


COMMISSIONINGD



CONCLUSIONG



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Abbreviations Used In This Presentation

CPU Central Processing Unit

DCU Digital Control UnitFLA Full Load Amperes

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

OL Over Load

RTD Resistance-TemperatureDevice

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

Isolation Switch (Disconnector)

Provides Isolation Of Soft StarterFrom Power Supply

Vacuum Isolation Contactor

Provides Start Sequence To

SCR Stack Assembly

SCR Stack With I2t Overload

Provides Voltage Ramp And

Advanced Protection Features

Vacuum Bypass Contactor

Bypasses SCRS When MotorReaches Full Speed

Isolated Low Voltage Control

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PowerN

etwork

The ABB SSM - Defined

The ABB SSM 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 SSM 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!

Soft StarterProtection LoadMotor

By pass Contactor

Main Contactor

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What Sets the Soft Starter Apart From

Standard Across-The-Line Starters?

Integral MPR

SSM With Full Motor Protection Relay Features

Options For Ground Fault And RTD Modules

Extreme Flexibility

Many Styles Of Ramp Profiles

Lowers The Starting Current Of The Motor Reduces Electrical Stresses On The Power System And

The Motor

Reduces Peak Starting Torque Stresses On The Motor

And Load Mechanical Components

Promotes Longer Service Life And Less Downtime

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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 And Record

Communicate

Goals Beyond On & Off Starting

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ABB SSM 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 / 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

Metering Functions

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Pump

Blower

Compressor

Chiller Fans

Chipper

Other Applications

Ball Mill

Rod Mill

Conveyor

Power ConversionHVAC

Shredder

ABB SSM Medium Voltage

Soft Starter Applications

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Diodes have no gate input to control them. They simplyallow current to flow in one direction and block current

flowing from the opposite direction. The net output with an

AC input is a 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

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 crossingpoint 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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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 needs to be electrically isolated since theyare 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 DevicesSCR 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 alternation of the sine wave crosses the

zero point, the SCR will turn off. In order for the SCR toconduct for the next alternation, the SCR must have a

gate signal applied again before the next zero crossing

point.

The Output of the SCRs is typically

coupled to a DV/DT (RC) network to help

reduce voltage switching transients. DV/DTnetworks are important because they help

eliminate false triggering of SCRs.

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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

R d G t Fi i Ci it

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Rugged Gate Firing Circuit

Auto-Synchronizing To Line

Independent Phase Tracking

Best Circuit For Generator Power

Measure

Fire

Measure

Fire

Measure

Fire

Measure

Fire

Measure

Fire

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Rugged Gate Firing CircuitContd

Competition Uses A Cheaper System

Measure Once (Bet You Can Guess The Rest!)

Susceptible To Frequency Drift, Noise

Measure

Once

Fire Fire FirePhase Locked Loop Firing:6 Pulses From One Signal

H k P k St l SCR

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Anode

Cathode

Gate

Hockey Puck Style SCR

Informational Purposes ONLY

SCRs Will Not Be Examined At This Level In The Field

T i l SSM SCR St k A bl

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Typical SSM SCR Stack Assembly

This SCR stack assembly is the lowest level that should be replaced at

customer site.

Field service representatives will not be required to replace SCRs withinthis 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

Soft Starter Medium Voltage Compartment

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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 interfacewithin 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 BoardGate Drive Boards

SSM El t i l I l ti Di

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Sensing

Systems

= MV

MTR

Magnetic

Isolation

Optical

Isolation

= Fiber Optic= 28V

= 120V

GateDrive

SSM Electrical Isolation Diagram

LV

Controls

Fiber Optics Description

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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 ReflectionWhen 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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Construction


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Cladding - A Semi-Reflective Material

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ABB SSM - 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

SSM Digital Controller - Additional Features

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SSM Digital 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

SSM Digital Controller - Communications

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SSM Digital Controller Communications

RS485 Modbus RTU Built-In

RS232 Windows Based Programming / Monitor Program


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g



SSM DESCRIPTIONB


COMMISSIONINGD



CONCLUSIONG

SSM S t i t P 1

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SSM 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)

SSM Setpoint Page 1

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g

Basic Overload Protection - Start Up (& Run) NEMA / UL Pre-Programmed O/L Trip Curves

Class 5 Through Class 30

10

100

600

100% 600%

%FLA

Seconds

400%

Class 30

Class 20

Class 10

SSM Setpoint Page 2

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SSM Setpoint Page 2

Motor Starting, Deceleration And Ramp Type Settings

Most Starting Situations Require Only VOLTAGE RAMP With CURRENT LIMITStarting 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 SSM 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 SSM IsOperating In CURRENT LIMIT. If The Starter Trips On Acceleration Time Trip,

Increase CURRENT LIMIT To Reduce The Starting Time

Typical Starting Profile

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Typical Starting Profile

Voltage Ramp With Current Limit

TIME

VOLTS /

AMPS

INITIAL VOLTAGE

RAMP TIME

CURRENT LIMIT

AT

SPEED

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SSM 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

SSM Setpoint Page 2

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SSM Setpoint Page 2

Dual Ramps

Contact Closure Selects Between Ramps

Ramp 1 - Voltage Ramp w /

Current Lim it

Ramp Time

Current Limit

Setting

Current Limit over rides

Ramp Time

Current level held to

Limit setting

Full SpeedRampStart

Ramp 2 - Loaded Restart,

Across-the-Line

Full Voltage Start, No Ramp Time

High Current Full Torque Starting

SSM Setpoint Page 2

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SSM 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)

SSM Setpoint Page 2

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SSMSetpoint 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 VOLTSCURRENT Trip

Start

Init ial Torqu e

Sett ing

1/4 Second

SSM Setpoint Page 2Flexible Deceleration Pump Control

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Flexible Deceleration - Pump Control Allows Full Adjustment

Independent of Acceleration Ramp

Automatic Stop Level - Prevents excessiveheating in the motor

Voltage

RunStart Ramp StopBegin Decel

Torque (Coast)

Valve clos es here

Pump Control - Hydraulic System Problems

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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 FLOW

PUMP ON

VALVE CLOSED


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Pump Control Hydraulic System Problems


WATER HAMMER

Check valves keep head pressure from pushing fluids

backwards into the pump.

HEAD PRESSURE

PUMP ON

VALVE OPENS

PUMP FLOW PUMP PRESSURE / FLOW


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p y y


WATER HAMMER

When pump suddenly stops, flow reverses until check valve

closes.

PUMP OFF

VALVE CLOSES

PUMP FLOW HEAD PRESSURE


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p y y

The energy of the back-flowing water is trapped, creating a

SHOCK WAVE traveling at the speed of sound

Liquids dont compress, so energy is forced onto piping, fittings

and seals

PUMP OFF

VALVE CLOSES

Pump Control - Controlled Deceleration Benefits

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p

Controlled Deceleration can reduce Water Hammer

Reduced pump pressure closes valves more slowly,

in near neutral pressure Kinetic energy is slowly dissipated

Shock wave is not created

VALVE OPEN

PUMP ON

VALVE CLOSING

SOFT STOPPUMP OFF

VALVE CLOSED

SSM Setpoint Page 3

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p g

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

SSM Setpoint Page 3

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g

Electrical Protection Features

Over VoltageUnder Voltage

Frequency Window

Phase Current Loss

Phase Current Imbalance

Shorted Load Protection

Zero Sequence Ground Fault Option

SSM Setpoint Page 3

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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

SSM Setpoint Page 4

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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 IndicationWhen current is above 7% of programmed FLA Aux 4 = Bypass Contactor

SSM Setpoint Page 5

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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 58 can be assigned to Trip / Alarm functions and wired

as needed.

SSM Setpoint Page 6

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User Input / Output Configuration.

4-20 mA Tachometer Input.

4-20 mA Analog Outputs 1 & 2.

4 Programmable External Input Trip Channels

SSM Setpoint Page 6

Programmable Input / Output Features

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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, StatorTemperature, or RPM

SSM Setpoint Page 7

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Custom Acceleration Curve.

3 Separate CurvesA, B & C.

8 Programmable StepsVoltage and Duration for each

step.

Maximum Current Threshold Set point.

SSM Setpoint Page 7

Custom Ramp Profiles

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Custom Ramp Profiles

3 Programmable Custom Curves

8 Data Points in Each Enter Voltage, Current, Time

Match ramp profile to practically any application

SSM Setpoint Page 8

3 Overload Protection Choices During Start-up

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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

SSM Setpoint Page 8Measured Start Capacity For Start Up

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Class 20 I2t curve

Area Under Curve protect ion

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

SSM Setpoint Page 8

Overload Protection Benefits

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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.

SSM Setpoint Page 8

2 Overload Protection Choices During Run

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g

Basic Overload Protection

Run Overload is programmed the same as for Starting

Custom (Modified) Curve

Overload Protection - During RunCustom (Modified) Curve Protection

B i ith Cl 5 th h Cl 30

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Modified Curve

Example:

New LRA = 400%

Time = 25 sec. 10

100

600

100% 600% %FLA

Secon

ds

400%

Class 20 Curve:

LRA= 600%

Time = 20 sec.

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

SSM Setpoint Page 8Learned Curve Protection For Start-Up

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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

Ti

me

% of Nameplate FLA

SSM Setpoint Page 8

Duty Cycle Protection

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y y

Coast Down Lockout Timer Back spin lockout

Starts-per-Hour Lockout

Time-Between-Starts Lockout

SSM Setpoint Page 8

Coast Down Lockout Timer

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Backspin Lockout

Keeps motor from restarting while spinning

On

OffStartStart

Coast Down Time

Stop

Begin

Timing

Run Time

Start

SSM Setpoint Page 8

Duty Cycle Protection

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Start

y y

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

SSM Setpoint Page 9

Up To 12 Flexible RTD Inputs Configurable for any RTD type

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Up To 12 Flexible RTD InputsConfigurable 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

SSM Setpoint Page 10

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Security / Passwords

Factory Level 2 Password = 100One with two zeros.

Factory Level 3 Password = 1000One 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 Reset will regain control (refer to

instructions to perform it).


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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

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System Set points

Setup Default Screen Display during Run.

Thermal Register Setup.

RTD Failure Alarm Settings.

Thermal Register Alarm Settings.

Clear Thermal Register.

SSM Setpoint Page 12The BEST Motor Overload Protection

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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

SSM Setpoint Page 12Motor Thermal Modeling

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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

SSM Setpoint Page 12Retentive Thermal Memory

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CPU

Tracks the motors 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

Example:

SSM Setpoint Page 12Motor Thermal Modeling

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Thermal

Register in

Non VolatileMemory

0%

(Over Load)

25%

50%

75%

100%(Cold)

Example:

Thermal

Capacity used

in Starting

Cooling Rate

while Running

Remaining

Thermal

Capacity

E l

SSM Setpoint Page 12Retentive Thermal Memory With Real Time Clock

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Thermal

Register in

Non VolatileMemory

0%

(Over Load)

25%

50%

75%

100%(Cold)

Example:

Thermal

Capacity used

in Starting

Power Fail !

Cooling Rate

while Off

Recalculated

Remaining

Thermal

Capacity

Power Restored

SSM Setpoint Page 12Benefits

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Makes Full Use of Motor Data

Takes advantage of quicker cooling

Eliminates Guess Work or Compromises

Helps prevent premature restarting and failed starts

SSM Setpoint Page 12Dynamic Reset Capacity

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CPU Learns the Motor and Load

Records Thermal Capacity Needed

Averages previous successful starts

Inhibits Reset

Until enough thermal capacity is recovered

SSM Setpoint Page 12Dynamic Reset Capacity

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Thermal

Register in

Non VolatileMemory

0%

(Over Load)

25%

50%

75%

100%(Cold)

Thermal

Capacity usedin Successful

Start

Example:

Running

Overload

10% Remaining

Cooling

RateWhileOff

FromOver Load

Trip

No Reset until 90%

remaining based on

capacity used in

previous successfu

start.

RESETRESETRESET

SSM Setpoint Page 12True TimeCool-Down Rates

Non-linear rate of cooling

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Motor

Temp

Cooling RateLow

High

g

Based on Thermal Model values

Accounts for extra convection Hot motors cool more quickly at first

Cooling rate slows as it cools

True Time

Variable Cool Rate

Typical OL Relay

Cool Down Rate

SSM Setpoint Page 12Benefits Dynamic Reset Capacity

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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

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Password for Setpoint Page 13 = 48562 (Not Documented).

Unit Maximum CurrentUse SF X FLA calculation to enable

correct settings in Setpoint Page 1.

Phase CT Primary RatioValue of CTs located inside of red

box in SSM enclosure. Set from the factory.

Ground CT Primary Ratio Setting.

PT / VT Primary Ratio Setting.

SSM Setpoint Page 13 - Continued

Sync Bypass CloseSets triggering of bypass contactor - Firing

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Angle and/or Current Drop Off.

Bypass Drop Out DelayProgrammable delay for the opening ofbypass contactor after stopping.

Bypass DiscrepancyNot used, Future Option.

Shunt TripNot Used, Future Option.

Starter SettingsOffset adjustment factors to correct current &

voltage limit output during starting. Not normally accessed.

Tachometer Input OffsetAdjustment factors for compensation.

SSM Setpoint Page 13 - Continued

Analog O tp ts 1 &2 Offset Programmable o tp t control

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Analog Outputs 1 &2 OffsetProgrammable output control.

RTD CalibrationRefer to procedure

Short Circuit Limit Adjustment and Delay.

Reset all relaysNo longer needed.

Factory ResetRefer to Factory Reset Procedure.


ABB SSM Product TrainingStartup, Operation & Service Session

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SSM DESCRIPTIONB


COMMISSIONINGD



CONCLUSIONG

SSM - Service Manual Documents

Tab 1Theory of OperationHow The SSM Works

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Tab 2SSM ManualSoft Starter Document

Tab 3Electrical DrawingsSoft Starter Kit Drawings

Tab 4Application InformationCommon Issues Seen In The Field

Tab 5CommunicationsMODBUS RTU Using RS-485

Tab 6Service ProceduresAlignments And Adjustments

Tab 7RTD Data SheetsTemp / Resistance Maps

SSM CommissioningFinal Inspection Before Start Up

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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

Due to a lack of understanding, the SSM is the first thing to be blamed

when something doesnt seem to work right during commissioning

The Misunderstood SSM

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MOTOR LOAD

?TRANSFORMER

Many times, the end-user has to be educated in order to become

comfortable with the SSM. Primarily, the end-user needs to realize that theSSM 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

Motor Torque produced is proportional to both

SSM - 3 Dimensional Box Theory

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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 theAmount of Output must create sufficient Motor

Torque

TIME

AMPS

VOLTSMOTOR

TORQUE



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SSM DESCRIPTIONB


COMMISSIONINGD



CONCLUSIONG

SSM - Troubleshooting Outline

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Most troubleshooting is done primarily with the supplied SSM

Service Manual and the Soft Starter drawings

Hands-on troubleshooting with an actual SSM will be performed

tomorrow

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

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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

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

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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 markon the Main Board.

Minimum bend radius of the optical fiber

Fiber Optic TroubleshootingBend Radius

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Minimum bend radius of the optical fiberused in the Limitamp SSM is 2 [51mm].

If a bend radius is too small, the fiber corewill have tiny cracks on the outer portion ofradius.

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

The clear fiber optic core has a lowermelting point than the jacket

Fiber Optic TroubleshootingHeat Damage

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g p j

Heat damage can cause a minor distortionor slight swelling that is barely visible on thesurface of the jacket

The damage can be felt with the fingers,simply by pinching fiber lightly betweenindex finger & thumb, then drag fingers

North/South, East/West down length of fiber

Use caution when routing fibers throughstarter and around circuit boards

Melted / Swelled Fiber Optic Cables

From Heat Shrinking Wire Markers

Near Fiber Optic Harness



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SSM DESCRIPTIONB


COMMISSIONINGD



CONCLUSIONG

SSM Setpoint Programming Exercise

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Refer To Programming Exercise Presentation



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SSM DESCRIPTIONB


COMMISSIONINGD



CONCLUSIONG

Mini-Quiz1. What setpoint page requires you to input the motor data information?

2. If you needed to extend the time delay for the Acceleration Time Trip beyond

30 d t h t t i t ld k thi h ?

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30 seconds, at what setpoint page would you make this change?

3. Name at two ways it is possible to damage a fiber-optic cable.4. What are the 2 field-installable options for the SSM?

5. What are the three connection points of an SCR?

6. Does the SSM use a PLL circuit to control SCR firing?

7. What is the maximum amount of RTDs that can be programmed into the

Digital Control Unit (DCU)?

8. Name the 2 communication busses used for data transfer on the CPU Board

and Communications Board.

9. What are the 3 setpoints programmed into Setpoint Page 2 to start a motor

using Voltage Ramping with Current Limit?

10.What diameter are the firing LEDs on the Main Board?