ABB Training - 2007

ABB SSMt Training - 2007

ABB SSM Product Training
Startup, Operation & Service Session
INTRODUCTION & OBJECTIVES OF SESSION A
SSM DESCRIPTION B
SSM FUNCTIONS - PROGRAMMING C
COMMISSIONING D
TROUBLESHOOTING & MAINTENANCE E
PROGRAMMING EXERCISE F
CONCLUSION G
Objectives List - A
SSM DESCRIPTION B
COMMISSIONING D
CONCLUSION G
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?

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 Starter

Define Customer Inputs And Default Settings

Successfully Commission An SSM Soft Starter

Troubleshoot And Repair An SSM Soft Starter

Find Needed Information In The Support Documentation
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)
Objectives List - B
INTRODUCTION & OBJECTIVES OF THIS SESSION A
SSM DESCRIPTION B
COMMISSIONING D
CONCLUSION G
Abbreviations Used In This Presentation
CPU Central Processing Unit
DCU Digital Control Unit
FLA 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-Temperature
Device
RVAT Reduced Voltage
Autotransformer
SCR Silicon Controlled
Rectifier (Thyristor)
SF Service Factor
RVSS Reduced Voltage Soft
Starter
TCB Terminal & Control Board
Soft Starter - Basic Features
Isolation Switch (Disconnector)
Provides Isolation Of Soft Starter
From Power Supply
Vacuum Isolation Contactor
Provides Start Sequence To
SCR Stack Assembly
SCR Stack With I
2
t Overload
Provides Voltage Ramp And
Advanced Protection Features
Vacuum Bypass Contactor
Bypasses SCRS When Motor
Reaches Full Speed
Isolated Low Voltage Control

P
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k

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 Starter Protection
Load Motor
By pass Contactor
Main Contactor
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

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
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
Human / Machine Interface
Full Digital Control
LCD Operator
Interface
Non-Volatile Memory
Digital Sequencer
Ensures Proper
Contactor Sequence
Fiber-Optic Isolation
Metering Functions

Pump
Blower
Compressor
Chiller
Fans
Chipper
Other Applications
Ball Mill
Rod Mill
Conveyor
Power Conversion
HVAC
Shredder

ABB SSM Medium Voltage
Soft Starter Applications
Diodes have no gate input to control them. They simply
allow current to flow in one direction and block current
flowing from the opposite direction. The net output with an
AC input is a 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 crossing
point of the half alternation of the sine wave. These devices
work similar to the control valves of a fluid pumping system
(On/Off). Like diodes and SCRs, they also only work in one
direction.
To create an electrical device that can function on both
halves of the sine wave, two devices are needed, one for
each direction.
Each gate needs to be electrically isolated since they
are at completely different potentials in relation to the
cathodes of the SCRs.
input
Output
gate
gate
c
R
Output
Input
SCR Switching
Dampened By DV/DT
(RC) Network
Solid State Devices SCR Function
input
Output
Waveform Direction
We can turn an SCR on at some point before the
current zero crossing point of the sine wave. When the
current of the alternation of the sine wave crosses the
zero point, the SCR will turn off. In order for the SCR to
conduct 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/DT
networks are important because they help
eliminate false triggering of SCRs.
SCR Control Assembly
Looking at a whole system as a unit, each phase of the medium voltage power
supply connects to its own SCR Stack Assembly. The Digital Control Unit (DCU)
controls the gate drive outputs in order to turn the SCRs on based on detecting the
point where the current sine wave crosses the zero horizon.

This is a very basic block diagram an SCR control system, but is a good
representation of its fundamental operation.
Phase C [L3]
Input
Phase C [T3]
Output
Gate Drive
DV/DT
Current / Temp /
Voltage Feedback
Computerized
Controller
Phase B [L2]
Input
Phase B [T2]
Output
Phase A [L1]
Input
Phase A [T1]
Output
DV/DT DV/DT
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
Rugged Gate Firing Circuit Contd
Competition Uses A Cheaper System
Measure Once (Bet You Can Guess The Rest!)
Susceptible To Frequency Drift, Noise
Measure
Once
Fire Fire
Fire
Phase Locked Loop Firing:
6 Pulses From One Signal

Anode
Cathode
Gate
Hockey Puck Style SCR
Informational Purposes ONLY
SCRs Will Not Be Examined At This Level In The Field
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 within
this assembly in the field due to SCR matching requirements, specialty
tooling and the specific compressive forces needed to properly clamp
the SCRs into an assembly.
SCR
DV/DT Boards
The DV/DT Boards are used to reduce voltage transients across the stack assemblies

MOV (Metal Oxide Varistor) 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
Soft Starter Medium Voltage Compartment
DV/DT Boards
MOV Boards
Temp/CT Board
Gate Drive Boards

Sensing
Systems

= MV
MTR
Magnetic
Isolation
Optical
Isolation
= Fiber Optic
= 28V
= 120V

Gate
Drive

SSM Electrical Isolation Diagram

LV
Controls

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.
Construction
Cladding - A Semi-Reflective Material
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
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
RS485 Modbus RTU Built-In
RS232 Windows Based Programming / Monitor Program
SSM DESCRIPTION B
COMMISSIONING D
CONCLUSION G
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
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
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 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 Is
Operating In CURRENT LIMIT. If The Starter Trips On Acceleration Time Trip,
Increase CURRENT LIMIT To Reduce The Starting Time
Typical Starting Profile
Voltage Ramp With Current Limit
TIME
VOLTS /
AMPS
INITIAL VOLTAGE
RAMP TIME
CURRENT LIMIT
AT
SPEED
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
Dual Ramps
Contact Closure Selects Between Ramps
Ramp 1 - Voltage Ramp w/
Current Limit
Ramp Time
Current Limit
Setting
Current Limit over rides
Ramp Time
Current level held to
Limit setting
Full Speed
Ramp
Start
Ramp 2 - Loaded Restart,
Across-the-Line
Full Voltage Start, No Ramp Time
High Current Full Torque Starting
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
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 VOLTS
CURRENT
Trip
Start
Initial Torque
Setting
1/4 Second
SSM Setpoint Page 2
Flexible Deceleration - Pump Control
Allows Full Adjustment
Independent of Acceleration Ramp
Automatic Stop Level - Prevents excessive
heating in the motor
Voltage
Run
Start Ramp
Stop
Begin Decel
Torque
(Coast)
Valve closes here
PUMP OFF
Pump Control - Hydraulic System Problems
Trapping the kinetic energy of moving water causes
WATER HAMMER
Check valves keep head pressure from pushing fluids
backwards into the pump
HEAD PRESSURE PUMP FLOW
PUMP ON
VALVE CLOSED
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
WATER HAMMER
When pump suddenly stops, flow reverses until check valve
closes.

PUMP OFF
VALVE CLOSES
PUMP FLOW HEAD PRESSURE
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
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 STOP
PUMP OFF
VALVE CLOSED
SSM 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
SSM 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
SSM 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
SSM 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

SSM 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.
SSM Setpoint Page 6
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
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
SSM 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.
SSM 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
SSM Setpoint Page 8
3 Overload Protection Choices During Start-up
Basic Overload Protection for Start (& Run)
Programmable overload Class 5 - 30
Measured Start Capacity
I
2
t thermal capacity from data
Learned Curve Protection
Starter learns from recorded data
Class 20 I
2
t curve
Area Under Curve protection
SSM Setpoint Page 8
Measured Start Capacity For Start Up
Uses basic overload curve as programmed
User enters maximum I
2
t value from motor
manufacturer or commissioning data
Basic curve is altered
Matches motor more closely
Measured I
2
t
capacity
SSM 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.
SSM Setpoint Page 8
2 Overload Protection Choices During Run
Basic Overload Protection
Run Overload is programmed the same as for Starting
Custom (Modified) Curve
Modified Curve
Example:
New LRA = 400%
Time = 25 sec.
10
100
600
100% 600% %FLA
S
e
c
o
n
d
s

400%
Class 20 Curve:
LRA= 600%
Time = 20 sec.
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
SSM 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.
0
100
200
300
400
500

T
i
m
e

% of Nameplate FLA
SSM Setpoint Page 8
Duty Cycle Protection
Coast Down Lockout Timer
Back spin lockout

Starts-per-Hour Lockout

Time-Between-Starts Lockout
SSM Setpoint Page 8
Coast Down Lockout Timer
Backspin Lockout
Keeps motor from restarting while spinning
On
Off
Start Start
Coast Down Time
Stop
Begin
Timing
Run Time
Start
Start
SSM 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)
Start Start
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.

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 Reservoir

Spare

CPU
SSM 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 Reset will regain control (refer to
instructions to perform it).
Communications Settings

Modbus Baud Rate and Addressing.

RS232 Baud Rate.

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

Setup Default Screen Display during Run.

Thermal Register Setup.

RTD Failure Alarm Settings.

Thermal Register Alarm Settings.

Clear Thermal Register.
The BEST 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
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
Retentive Thermal Memory
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
Thermal
Register in
Non Volatile
Memory
0%
(Over Load)

25%

50%

75%

100%
(Cold)
Example:
Thermal
Capacity used
in Starting
Cooling Rate
while Running
Remaining
Thermal
Capacity
Thermal
Register in
Non Volatile
Memory
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
Retentive Thermal Memory With Real Time Clock
Benefits
Makes Full Use of Motor Data
Takes advantage of quicker cooling
Eliminates Guess Work or Compromises
Helps prevent premature restarting and failed starts
CPU Learns the Motor and Load
Records Thermal Capacity Needed
Averages previous successful starts
Inhibits Reset
Until enough thermal capacity is recovered
Thermal
Register in
Non Volatile
Memory
0%
(Over Load)

25%

50%

75%

100%
(Cold)
Thermal
Capacity used
in Successful
Start
Example:
Running
Overload
10% Remaining
Cooling
Rate
While
Off
From
Over Load
Trip
No Reset until 90%
remaining based on
capacity used in
previous successful
start.
RESET RESET RESET
Motor
Temp
Cooling Rate
Low
High
True Time
Cool-Down Rates
Non-linear rate of cooling
Based on Thermal Model values
Accounts for extra convection
Hot motors cool more quickly at first
Cooling rate slows as it cools
True Time

Variable Cool Rate
Typical OL Relay
Cool Down Rate
Benefits Dynamic Reset Capacity
Avoids Exhausting Starts/Hour Rating
Prevents having to wait longer for reset
Takes the guesswork away from the operator
Saves Operating Costs
Helps prevent motor damage
Decreases downtime
Unit Factory Settings

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

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

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

Ground CT Primary Ratio Setting.

PT / VT Primary Ratio Setting.
SSM 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.
SSM 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.
SSM DESCRIPTION B
COMMISSIONING D
CONCLUSION G
SSM - Service Manual Documents
Tab 1 Theory of Operation How The SSM Works

Tab 2 SSM 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
SSM 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

MOTOR

LOAD

?

TRANSFORMER
Due to a lack of understanding, the SSM is the first thing to be blamed
when something doesnt seem to work right during commissioning

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 the
SSM does not make power. It works similar to a fluid control valve, slowly
building up voltage and current to the motor

If the system power is weak and the voltage drops so low as to reduce the
Motor Torque below the Load Torque, the system will not come up to
rated speed
The Misunderstood SSM
Motor Torque produced is proportional to both
the Field and Rotor Voltages. This means that
Motor Torque is proportional to the square of the
Motor Terminal Voltage

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

The box beside can be manipulated, but the
Amount of Output must create sufficient Motor
Torque
SSM - 3 Dimensional Box Theory
TIME
AMPS
VOLTS
MOTOR
TORQUE
SSM DESCRIPTION B
COMMISSIONING D
CONCLUSION G
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
SSM - Troubleshooting Outline
Test To Perform Ohm Meter Reading Test Result
From Position A to Position B Greater than 10K Ohm
Pass
Less than 10K Ohm
Fail
From Position B to Position C Greater than 10K Ohm
Pass
Less than 10K Ohm
Fail
Gate (G) to Cathode (K) for each SCR 8 to 100 Ohms Pass (Typical 8 to 20 Ohms)
Less than 8 or greater than 100 Ohms
Fail
Troubleshooting & Maintenance - SCR Test Procedure
When the condition of the SCRs is suspected, a resistance check can be
performed on the SCR heat sink assemblies in the right-hand cabinet to confirm if
they have been damaged. This test is to be performed on each individual
assembly per phase (there are 3 SCR heat sink assemblies per phase).

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

Refer to the image to the right for test connection references.
Fiber Optic Troubleshooting - Connectors
Be sure to check all connections and block
orientations as shown.

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

Ensure indexing dot in the fiber-optic block
is placed over the white silk-screened mark
on the Main Board.
Minimum bend radius of the optical fiber
used in the Limitamp SSM is 2 [51mm].

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

Straightening a fiber after too tight of a bend
has been made will not fix it.
Fiber Optic Troubleshooting Bend Radius
The clear fiber optic core has a lower
melting point than the jacket

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

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

Use caution when routing fibers through
starter and around circuit boards
Melted / Swelled Fiber Optic Cables
From Heat Shrinking Wire Markers
Near Fiber Optic Harness
Fiber Optic Troubleshooting Heat Damage
SSM DESCRIPTION B
COMMISSIONING D
CONCLUSION G
SSM Setpoint Programming Exercise
Refer To Programming Exercise Presentation
SSM DESCRIPTION B
COMMISSIONING D
CONCLUSION G
Mini-Quiz
1. 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 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?

ABB Training - 2007

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ABB SSMt Training - 2007

ABB SSMt Training - 2007

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