Many industrial facilities are replacing Reduced Voltage Autotransformer (RVAT) starters with modern soft starters because they are often easier to maintain, more readily available, and offer improved motor protection and system monitoring. As legacy motor control equipment reaches the end of its service life, upgrading to a modern soft starter has become an increasingly practical solution for many applications.
So, why are more facilities not making the switch?
What is an RVAT Starter?
An RVAT (Reduced Voltage Autotransformer) starter is designed to reduce the amount of electrical current a motor draws when it starts. Instead of applying full voltage immediately, it temporarily lowers the voltage to the motor before switching it to full line voltage once it reaches speed.
RVAT starters became popular because they:
- Reduced high starting current
- Helped prevent voltage dips on the electrical system
- Reduced mechanical shock during startup
- Met utility and facility requirements for starting large motors
They have been widely used in applications such as pumps, compressors, conveyors, fans, and other heavy industrial equipment.
Why are Facilities Replacing RVAT Starters with Soft Starters?
As RVAT systems age, many facilities are finding that replacing them with another RVAT starter is not always the best long-term solution.
Higher Replacement Costs
An RVAT starter consists of large autotransformers, contactors, timers and other mechanical components. When these systems fail, repairing them can become expensive.
Instead of investing in older technology, many facilities are choosing to modernize with soft starters that offer additional functionality in a more compact design.
Longer Lead Times
As RVAT technology becomes less common, replacement components can be more difficult to source. Longer lead times can delay maintenance projects and increase the risk of costly downtime if a starter fails unexpectedly.
Modern soft starters are often more readily available, helping facilities get equipment back up and running faster.
Simpler Design
Compared to traditional RVAT systems, soft starters have fewer major components and a simpler overall design.
This can mean:
- Easier installation
- Less maintenance
- Fewer components that can wear out or fail
- A smaller footprint inside the control panel
For maintenance teams, a simpler system often means less time spent troubleshooting and servicing equipment.
More Than Just a Replacement
One of the biggest advantages of upgrading to a soft starter is that facilities gain more than a new way to start a motor.
Modern soft starters offer several additional benefits that weren't available when many RVAT systems were originally installed.
Smoother Motor Starts
Rather than switching between fixed voltage levels, a soft starter gradually increases the voltage supplied to the motor. This creates a smoother startup that can help:
- Reduce mechanical stress on equipment
- Minimize water hammer in pumping systems
- Reduce wear on belts, couplings, and gearboxes
- Extend the life of motors and driven equipment
Better Motor Protection
Modern soft starters continuously monitor motor performance and can detect problems before they become costly failures.
Many include built-in protection features such as:
- Thermal overload protection
- Phase loss detection
- Stall and jam protection
- Underload protection
- Fault history for faster troubleshooting
These features help improve reliability while reducing unplanned downtime.
Smart Connectivity
Today's industrial facilities rely on connected equipment to improve maintenance and operations.
Modern soft starters can easily connect to existing plant control systems, making it easier to monitor equipment and identify issues before they become costly failures.
A Practical Retrofit Option
One of the biggest advantages of replacing an RVAT starter with a soft starter is that the existing motor often does not need to be replaced.
By retrofitting the motor control system instead of replacing the entire application, facilities can modernize their equipment while minimizing costs and downtime.
For organizations looking to improve reliability without completely redesigning their systems, a retrofit can be a practical solution.
Supporting Your Next Upgrade
While RVAT starters have served multiple industries well for decades, many facilities are taking the opportunity to modernize as aging systems reach the end of their service life.
Benshaw's family of soft starters is designed to support these retrofit projects by providing smooth motor starting, advanced motor protection, and integration with today's industrial automation systems.
Whether you're replacing an aging RVAT starter or planning a new installation, upgrading to a modern soft starter can help simplify maintenance, improve reliability, and prepare your facility for the future.