VS1000 series high voltage solid soft starters

1. The world's leading background monitoring system is the perfect integration of intelligent manufacturing and artificial intelligence

2. Adopting the most advanced special chip for motor control, with high calculation accuracy, fast response and high reliability

3. Using solid-state high-voltage and high-power components, small size, low heat generation, fast response time, good starting consistency, and low maintenance

4. The soft stop function is adopted to make the load slow down smoothly and eliminate the water hammer effect of pump loads

5. Adopting full digital control, smoother, more stable start and stop, high reliability, suitable for heavy load occasions in the industrial field

6. Specially designed power-down memory electronic overload protection function, not affected by power-down

7. Use standard high voltage cabinet with five defense functions

8. Using digital or LCD touch panel to operate and display, the interface is rich, intuitive to use and easy to operate

 

1. Product overview
The VSG1000 series of high-voltage solid-state soft starter developed by Visker Electric (China) Co., Ltd. It combines high-performance computer control, digital signal processing, high-voltage high-power thyristor (thyristor) control, high-frequency switching power supply, optical fiber isolation control, and man-machine Interface, digital network communication, comprehensive motor protection and many other technologies are applied to the start-stop control of high-voltage motors, using current limiting or voltage ramp up and down working methods. Control the input voltage of the motor, thereby limiting and reducing the motor current, not only Make the motor start and stop smoothly and stably, protect the safe and reliable operation of the motor, and realize remote monitoring and operation.

This device uses solid-state, high-voltage and high-power components as current regulation and control components, without mechanical transmission mechanisms, liquid materials, and electromagnetic conversion devices. Compared with other traditional starting devices, this device has small size, low heat generation, fast response time, high degree of intelligence, convenient display operation, high reliability, multiple protection functions, good starting consistency, and almost zero maintenance.

The voltage range of this device covers 2.3kV~15kV. The current range covers 40A~1000A. The power range covers 130kW~20000kW. It can meet the requirements of most medium and high voltage asynchronous motors.

1.1 Why use soft starter
A three-phase asynchronous motor will generate a large starting current when it is started directly. Depending on the load and motor configuration. The starting current can generally reach 5-9 times the rated operating current. Such a large starting current causes a great impact on the power grid, causing a voltage drop on the power supply bus and affecting the normal operation of other electrical equipment on the same bus. In order to solve the peak power supply, additional investment in transmission and distribution has been caused. In addition, the higher peak torque produced by the large starting current will not only impact the motor but also affect the dragged load, increasing mechanical wear and affecting the service life of the equipment. Using the soft starter to start and stop the motor can control and reduce the motor current when starting and stopping, avoiding the above adverse effects.

1.2 Disadvantages of the traditional liquid resistance (water resistance) soft start scheme
●The positive value of water resistance is affected by many factors, such as ambient temperature, plate condition, electrolyte concentration, power supply condition, etc. Therefore, the starting current control accuracy is very poor. The error range is large and the maintenance workload is large

●The heat generated when the water resistance starts to heat up the water, and it needs to wait for the water to cool down when restarting. Therefore.. The liquid soft start scheme has a limit to the number of continuous starts. The larger the motor capacity, the less the number of continuous starts.

●When the water resistance is started. Sometimes the vaporization resistance is too large. The starting current will not cross the threshold and cause the starting failure (especially the thermal resistance type). This is also the starting current setting value of the water resistance type. Minor reason

●Water resistance starting current setting value is generally more than three times the rated current value, it will still produce a large torque impact, and cause greater damage to the motor and mechanical equipment.

●Water resistance can only freely stop when parking. No soft stop

●Water resistance cannot provide perfect motor protection function

1.3 Advantages of Wisker high-pressure solid-state soft starter
●Advanced and perfect start-stop function

▶Controllable starting current (1.5~5.0le). Reduce the peak current of the power supply and reduce the cost of power distribution equipment

▶Controllable starting torque to achieve linear and smooth starting of the motor. Reduce mechanical wear. Improve the service life of transmission equipment

▶Stable load acceleration can reduce mechanical shock and prevent production accidents or product damage

▶Provide the pulse kick start function to deal with heavy load occasions with large static friction

▶Using the soft stop function, the load can be smoothly decelerated. Eliminate the water effect of pump loads

▶Using full digital control. Start-stop is smoother and more stable. High reliability. Competent for heavy-duty occasions in the industrial field

●High reliability

▶Using solid-state high-voltage and high-power components. Small size, low heat generation, fast response, good starting consistency, and low maintenance

▶Provide BOD self-trigger protection function. Reliable protection of solid-state high-voltage high-power components

▶Provide a variety of protection functions for overcurrent, overload, undervoltage, and lack of equivalence. Comprehensive protection of the start, stop and operation of the motor

▶Specially designed power-down memory electronic overload protection function. Not affected by power-down. It can replace the protection function of thermal relay

▶High security

▶All electrical isolation between high and low voltage uses optical fiber isolation and magnetic isolation

▶With low voltage (380V) motor pre-commissioning function

▶Using a standard high voltage cabinet with five prevention functions

●Ease of use

▶A soft starter can control and drag multiple motors to start and stop

▶Using digital panel operation display, rich interface, intuitive use and easy operation

▶With standard digital communication interface, it can remotely monitor and operate soft starter and motor

▶The daily maintenance workload is small

1.4 Applications of high-voltage solid-state soft starter
Visker high-voltage solid-state soft starter devices can be widely used in various industries that use medium and high-voltage three-phase asynchronous motors. Typical loads are as follows:

●Pump load

●Centrifuge

●Compression molding machine

●Oil Pumping Unit

●Conveyor belt

●Blender

●Crusher

●Ball Mill

●Air compressor, refrigeration compressor

●Lifts, cranes, tractors

●Fan load such as blower and induced draft fan

1.5 Product composition and working principle
The high-voltage solid-state soft-start device is mainly composed of high-voltage thyristor (thyristor) components, high-voltage vacuum contactors, signal acquisition circuits, trigger circuits, and power supply drive circuits. Main control board, digital operation panel, optical fiber isolation signal line, magnetic coupling isolation power line, secondary relay control loop, high voltage cabinet and other parts.

 

Schematic diagram of the composition of high-voltage solid-state soft starter

 

The basic working principle of the high-voltage solid-state soft starter is to accurately monitor the zero-crossing point of the AC voltage in real time, and then delay the trigger to turn on the thyristor according to the zero-crossing time.

By precisely controlling the change of the conduction angle of the AC voltage: to achieve precise adjustment of the voltage change.

 

The main circuit of this product uses multiple thyristors, which can meet the requirements of a wide range of voltage and current levels. This device is in the starting control, when the motor speed reaches the limit
When the speed is constant or the output voltage reaches 100%, it will switch to the bypass contactor to supply power to the motor. After switching to bypass power supply, the SCR components will stop working. such
Will greatly reduce the heat of equipment components. Reduce energy consumption. Extend service life. Improve product reliability.

2. Product selection
2.1 Ordering information

 

2.2 Selection table

 

 

 

10kV selection table

 

2.3 Selection Guide
●Before consulting the manufacturer, please prepare the following information:

Motor rated power, motor rated current, motor rated voltage, motor rated speed, load type (pump, fan, etc.). Average number of starts per hour or minimum start interval, ambient temperature, altitude, etc.

●The influence of altitude on selection

When the altitude exceeds 1000 meters, the derating is 1% for every 100 meters.

Relationship between current derating factor and altitude

 

●The influence of temperature on selection

When the operating environment temperature exceeds +45C, it will be derated by 2% for every 1°C exceeding.

The relationship between current derating factor and temperature

 

Example: The installation altitude is 1500m. The operating environment temperature is +50°C. The current derating factor due to height rise is 0.95. The current derating factor due to temperature rise is 090. If a 10kV. 250A high-voltage solid-state soft starter device is allowed to work at this time, the motor rated current is: I = 250x095x0.90 = 213.75A.

 

3. Product specifications
3.1 Applicable standards
●GB/T110221999 "Common technical requirements for high-voltage switchgear and control equipment standards"

●GB39062006 "3.6KV~40.5kV AC Metal-enclosed Switchgear and Control Equipment"

●GB311.11997 "Insulation coordination of high-voltage power transmission and transformation equipment"

●GB/T13422 1992 "Electrical Test Method of Semiconductor Power Converter"

●GB/T3859.1 1993 "Regulations on Basic Requirements for Semiconductor Converters"

●GB/T3859.2 1993 "Semiconductor Converter Application Guidelines"

●GB/T148082001 "AC high voltage contactor and contactor-based motor starter"

GB 14048.6-2008 "Low-voltage switchgear and control equipment Part 4-2: Contactors and motor starters, AC semiconductor motor controllers and starters (including soft starters)"

●GBT 16927.1-1997 "High Voltage Test Technology Part 1:-General Test Requirements"

●GBT 16927.2-1997 "High Voltage Test Technology Part 2: Measurement System"

●GBT 17626.1-2006 "Electromagnetic Compatibility Test and Measurement Technology Immunity Test Summary"

●GBT17626.2-2006 "Electromagnetic Compatibility Test and Measurement Technology Electrostatic Discharge Immunity Test"

●GBT17626.3-2006 "Electromagnetic Compatibility Test and Measurement Technology Radio Frequency Electromagnetic Field Radiation Immunity Test"

●GBT17626.4-2008 "Electromagnetic Compatibility Test and Measurement Technology Electrical Fast Transient Pulse Group Immunity Test"

●GBT 17626.5-2008 "Electromagnetic compatibility test and measurement technology surge (impact) immunity test"

●GBT17626.6-2008 "Electromagnetic Compatibility Test and Measurement Technology Radio Frequency Field Induced Conducted Disturbance Immunity"

3.2 Technical parameters

 

3.3 Form factor

Front view of soft starter                    Rear view of soft starter

Side view of soft starter

3.4 Installation dimensions

Installation drawing of the bottom of the soft starter

 

4. Instructions for use
4.1 Working process
The working process of soft starter is generally divided into standby state, starting process, running state and stopping process. As shown in the figure below, the starting process is between t0 and t1. The operating state between t1 and t2 is the stopping process between t2 and t3. .Before starting (t0) or after stopping (t3) is the standby state.

 

Schematic diagram of the working process of the soft starter

 

●Standby

After the soft starter is powered on, it first enters the standby state. During this state, the soft starter waits for a start command. At the same time, it receives parameter data from the operation panel.

●Starting process

The soft starter provides the following starting methods;

➊Voltage ramp start

Adopt voltage ramp start mode. The user can set the initial start: voltage and start time through the operation panel. The soft-start output voltage will start from the initial starting voltage set by the user, and continue to boost according to the rising slope determined by the starting time until full voltage output. Then put in the bypass contactor to turn off the thyristor. The starting process ends and enters the running state.

❷Current limit start

The current limit start mode is adopted, and the user can set the current limit multiple through the operation panel. The soft starter will automatically track the detection current and adjust the output voltage to ensure that the current value of the motor is maintained near the current limit multiple set by the user until it is judged that the motor reaches the speed, release the full voltage output, and then put in the bypass contactor, close Turn off the thyristor. The start-up process ends and enters the running state.

The current-limiting feature enables large inertia loads to be started and accelerated with the minimum current. It is also suitable for the starting of many constant torque loads to ensure the use of limited grid capacity.

 

❸Voltage ramp plus current limit start

The soft starter starts in the voltage ramp mode first. At the same time, it tracks and detects the motor current: when the detected current value reaches the set current limit multiple. Switch to the current limit mode, the soft starter adjusts the output voltage to ensure that the motor current value is maintained near the current limit multiple set by the user until it is judged that the motor has reached speed. Release the full voltage output, and then put the bypass contactor into The thyristor is turned off, the start-up process ends and enters the running state.

This method has the advantages of low current in the early stage of starting and controllable maximum current, and is suitable for starting pumps, fans and other loads under limited grid capacity.

 

❹Pulse kick start (optional)

In order to overcome the relatively large static friction torque, this device can choose to add the pulse kick function in the above starting mode. The thyristor first outputs full pressure to overcome the static friction torque, and then returns to the aforementioned starting mode. The output voltage gradually increases from small to large. Until the specified time or speed is reached, then the full voltage output is released and the bypass contactor is turned off. Thyristor, the starting process ends and enters the running state.

 

●Operation status

After the start-up process is over. The soft starter enters the running state. At this time, the soft starter continues to run, but the SCR is closed. The motor feeds and runs through the bypass contactor. The soft starter still monitors the running status of the motor. During this period, if an overcurrent, overload, or equal failure occurs, the soft starter will generate a fault alarm signal, interrupt the operation at the same time, and enter the free stop process.

●Parking process

The soft start device provides users with two parking methods: free stop and soft stop (voltage ramp stop).

➊Free parking

After receiving the stop signal, the soft starter disconnects the bypass contactor, and the motor freely stops without power. The soft starter enters the standby state after stopping.

❷Soft stop (voltage ramp stop)

It adopts soft parking (voltage slope parking) mode. The user can set the parking time. After receiving the stop signal, the soft starter first triggers the thyristor to conduct, and then disconnects the bypass contactor. Then according to the soft stop time set by the user, the control output voltage is gradually reduced until the thyristor is completely turned off. After parking, the soft starter enters the standby state.

The voltage ramp soft stop feature can effectively reduce the impact of the reverse torque when stopping, and is often used to alleviate the water hammer effect in pump loads.

4.2 Protection instructions
●Lack phase protection

When the soft starter detects a lack of phase in the power supply, it will issue a phase lack alarm and stop the motor from starting or running.

●Undervoltage protection

When the soft starter detects that the grid voltage is very low, it will issue an undervoltage alarm and stop the motor from starting or running.

●Undercurrent and phase loss protection

In the running state, when the soft starter detects that the motor current is zero, it will issue an undercurrent and phase loss alarm and stop the motor from starting or running.

●Timeout protection

In the current limit mode, when the starting process exceeds the predetermined time and the motor has not reached speed, an overtime alarm will be issued and the starting process will be stopped.

●Overcurrent protection

When the soft starter detects that the current is higher than the over-current limit, an over-current alarm is issued and the motor is stopped from starting or running.

●Overload protection

The soft start device is based on the monitored current, duration, and temperature based on the protection characteristics of the thermal relay. Accurately calculate and judge whether the soft starter and the motor are overloaded. If an overload occurs, an overload alarm will be issued and the motor will stop starting or running. The overload protection is divided into four trip levels. The overload protection curve diagram and overload level characteristic table of the soft starter and the motor are as follows:

Overload protection curve

 

The overload protection of the VSG series soft starter has a power-down memory function. It will not be affected by power outages or shutdowns. It has high setting accuracy, good stability, long life, simple operation, and can play a protective role for thermal relays.

4.3 Common applications

●Standard one for one application

Standard one for one application diagram

 

The general standard use of high-voltage solid-state soft starter is--one application, a soft starter is only fixedly connected to drive one motor, which can realize soft start, soft stop and comprehensive protection functions for this motor. The high-voltage switchgear in the picture is provided by the user and is responsible for powering the soft starter.

●One for multiple applications

One-to-multiple application refers to the use of one high-voltage solid-state soft starter to start multiple motors in sequence. The performance parameters of the motors to be dragged should be basically the same. The one-to-multiple soft-start application scheme with very different performance parameters is not recommended (consult the manufacturer when selecting the model). In this scheme, since one soft start device cannot protect multiple motors, it is necessary to equip another motor protection device.
 

One for three application diagram

4.4 Network communication
This device is equipped with a standard RS-485 communication interface, which can be connected to the factory's automation system. For example, it can be connected to PLC (programmable control) and DCS (distributed control system). It can realize the integrated automatic control of factory equipment. It can also be connected to a remote monitoring computer to realize remote intelligent monitoring.

The RS-485 communication connection of this device adopts MODBUS communication protocol.

Schematic diagram of soft starter network communication

 

4.5 Operation panel
The standard operation panel of this device adopts interactive digital design, consisting of 4 LED indicators, 4 LED digital tubes and 6 buttons. All parameter settings, modification and display can be completed on the operation panel.

This device can add an LCD touch screen panel according to user requirements.

The 4 LED indicators from left to right are:

Red one power indicator

Green a thyristor (SCR) status light

Green-Bypass status light

Red-fault indicator

4-digit LED digital tube display parameters:

The first digit on the left shows the function code

The three digits on the right display the corresponding parameter value

6 operating buttons are used to display modified parameters and start-stop devices

Operation panel

 

The following table is a reference for some typical load applications. Please adjust according to the actual situation.