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EX MV MX3 User Manual [May16].vp

1. 23 TABLE OF CONTENTS 3 6 Power Wiring S p edes S p m e a eS 24 3 61 Recommended Wire Gauges u q s 40006800 D bbe Yo 24 3 6 2 Power Wire Connections 24 3 6 3 Motor Lead Length gt so bee e w g a ker RRS EE Re K Rn 24 3 0 4 Compression tes e L pen k susah h hu GR ee ad 24 3 6 5 Torque Requirements for Power Wiring 25 3 7 Current Tr nsfOrihefS gt orae pan Bee ye RUE Fc Oed 26 3 11 CI Mo nt ng aos oom dmm a g kukun aa B e p 26 9 7 2 CIPolafity exc poe ek os qox ek Ex Ry OS y EROR S S 26 3 7 3 Zero Sequence Ground Fault Current 26 3 8 Control Card Layout een 28 3 9 EXMVRNDOGI OCardLayout eee 29 3 10 Terminal Block 30 9 11 Control Wiring ok ae eek eae RR x ERU TRUE PE EG RU Ren 31 3 11 1 Control 31 311 2 Output Relays cu te beds Ret Se Sre sP Sede EN 31 3 11 3 Digital Input 2 666 says Se pue RE RRR E m Rom RR G RR A 32 3 114 Analog Input 2225 yy u ee be be o eeepc G 33 3 115 AnalogOutpul 592249
2. Figure 10 EXMVRMY Control Card Layout 120 VAC Stack In A Benshaw Only Unfused 120 VAC ee Stack Control TE Control Power B 120 el Ta 6 Auxiliary Relays P52 54 7 I O 5 7 D T Digital eF Inputs 48 50 yo1 3 EE Modbus Communications Port P68 71 FUN 10 13 J2 Keypad Port F P65 1 0 18 Analog Input P55 59 8 12 Analog Output P60 62 13 15 H Analog Voltage Current k Selector Switch SW1 3 H Part Serial Pars Dom Up Ente Software Part 2 3 4 5 6 27 3 INSTALLATION Card Layout 3 9 I O Card Layout Figure 11 EXMVRMX2 I O Card Layout J Remote RTC Modules RJ45 Soc et IE STAT J3 B Relay Outpuls R4 to RG SCR 1A to 1F Phase 1 Fiber Opte J6 C Digital Inputs to DIS J MOT PTC Motor D Thermistor Line SCR 2A to ZF Voltage Divider Phase 2 Ced Fiber Opte Line PTs s J12 to Additional F O Xmi er Card Phase SCR to 3F Phase 3 Fiver Optic 413 Load Voltage Drader H Cerd G 414 Load PTS 3415 Zero Sequence Ground Fault CT H 28 3 INSTALLATION EXMVRMX Terminal Block Layout 3 10 Terminal Block Layout Figure 12 EXMVRMX Terminal Block Layout J1 J4 Remote Auxili
3. Display Cutout Figure 21 Large Display Keypad Mounting Dimensions Part KPMX3LLCD 127 00 5 00 63 50 63 50 2 50 2 50 8 8x 85 8 8x Installing Display The remote display is installed as follows Install the gasket onto the display Insert the display through the door cutout Insert the mounting clips into the holes in each side of the display Tighten the mounting clips until they hold the display securely in place Torque requirements are 0 7 NM or 6 195 in lbs Plug the cable into the display connector on the MX card See Figure 10 Control Card Layout on page 27 for the connector location Route the cable through the enclosure to the display Observe the wiring considerations as listed in Section 3 4 3 on page 21 Plug the other end of the cable into the LCD display 35 3 INSTALLATION RTD Module Installation 3 13 3 13 1 3 13 2 3 13 3 3 13 4 RTD Module Installation Location The mounting location for the Remote RTD Module should be chosen to give easy access to the RTD wiring control terminals and indicator LEDs as well as providing a location to mount the power supply The Remote RTD Module is specifically designed to be mounted close to the equipment it is monitoring This eliminates long RTD wire lengths which save time and money on installation and wiring The Benshaw Remote RTD Module is designed to mount on industry standard 35mm wide by 7 5mm deep DIN rail F
4. 116 71 RID Overload Bi Sing em RR d 118 7 1 8 Overload Auto Lockout 222 deeem ey EO ew UR exe voe ROS N 119 7 1 9 Separate Starting and Running Motor Overload Settings 119 7 1 10 Motor Cooling While 120 71 11 Motor Cooling While Running 121 7 1 12 Emergency Motor Overload Reset was wO ee 121 7 2 Motor Service Factor ee cr ke RING ee NX S ee 122 73 Acceleration Control 123 7 3 1 Current Ramp Settings Ramps Times 123 7 3 2 Programming A Kick Current 2 124 7 3 3 TruTorque Acceleration Control Settings and 124 7 3 4 Power Control Acceleration Settings and Times 126 7 3 5 Open Loop Voltage Ramps 127 7 3 6 Dual Acceleration Ramp 128 7 3 7 Tachometer Ramp 128 7 4 Deceleration Control css w Re tti W hm 131 7 41 Voltage Control 131 7 4 2 TruTorqueDeceleration k aq k ERE RR REE EE 132 TABLE OF CONTENTS 7 5 Braking Controls u uu weet oa e
5. 41 44 Alphanumeric Display 4 42 441 Power Up Screen 2 02 Xx a aym ECR S S D ae eS 42 44 2 Operate Serge z su l us ee eae E hamus d 42 44 3 P apameter GrOup SSTeenSru eG pe ese 45 44 4 Meter Pages e sse S S w sue Sun decer me bo S 44 445 Fault Log Screen cios xe s Ow S ROO E S WU ee eS 45 446 Fault Sereen 5o koe 3 99 c ke mox SQ e x a RUE RU 45 4 4 7 45 448 Locko tScr et 5 PURO owe Saee a ok E TR E RO RUE cs 46 449 Alarm Screen 525255528 a Sle fos bed Roe X E LE oum ode DRE X e 47 45 Procedure for Setting 47 TABLE OF CONTENTS 46 Jump Code EG bees doe p PER 44 ones tes 48 4 7 Restoring Factory Parameter 48 48 Resetting a Fault s sct acot odor oo k up hg ee Soe os d 48 49 Emergency Overload Reset 2 48 410 LED Display u c mes PE Re BE Yoko m b e 48 5 PARAMETER GROUPS za sa SU w Kae EOM a 50 5 1 Introduction s ess OK KOS SQ DOS 50 5 2 LCD Display Pa
6. Class 35 _ Class 30 Class 25 10 Mmo L Class 20 Class 15 eL Class 10 4 Class 5 14 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 Current FLA The motor overload will NOT trip when the current is less than motor Full Load Amps FLA Service Factor SF The motor overload pick up point current is at motor Full Load Amps FLA Service Factor SF The motor overload trip time will be reduced when there is a current imbalance present 36 NOTE Refer to Theory of Operation Chapter 7 in section 7 1 for more motor overload details and a larger graph Refer to http www benshaw com olcurves html for an automated overload calculator 11 2 TECHNICAL SPECIFICATIONS 2 2 5 CT Ratios Table 3 CT Ratios Minimum FLA Maximum FLA GT RAG E3 2 2 6 Optional RTD Module Specifications The starter has the option of operating with up to two Benshaw SPR 100P remote RTD modules Table 4 Remote RTD Module Specifications RTD Type DIN 43760 Maximum Lead Resistance Recommended Lead Resistance Shorted Lead Detection Open Lead Detection RTD Sensing Current RTD Sensing Voltage Range 0 to 200 C 32 to 392 F Resolution 1 C 1 8 F Accuracy 1 0 full scale 2 C or 3 6 F Sampling Rate 1 RTD per second Number of RTDs Input Voltage 24 Volts DC 20 2 5W Communication Type Modbus RTU RS 485 19 2Kbps Modbus Addresses 16 to 23
7. Review acceleration ramp settings QST07 set too low p 55 Motor loading too high and or current not dropping below 175 FLA indicating Reduce load on motor during starting that the motor has not come up to speed Display shows Aceelor Run Motor FLA QST01 or CT ratio Verify that Motor FLA and CT ratio FUN03 parameter set incorrectly parameters are set correctly Abnormally low line voltage Fix cause of low line voltage A mechanical or supplemental brake is Verify that any external brakes are still engaged disengaged Motor Hums before turning Motor FLA QST01 is incorrect Review Motor FLA set point CT ratio FUN03 15 incorrect Review CT ratio set point 8 4 4 Starter not accelerating as desired Kick start current CFN11 too high Decrease or turn off Kick current Motor accelerates too quickly 22 Motor FLA 05701 or CT ratio Verify that Motor FLA and CT ratio FUNO3 parameter set incorrectly parameters are set correctly Starter Type parameter FUNOT set Verify that Starter Type parameter is set incorrectly correctly OSTOT Review acceleration ramp settings set too low FUN03 parameter set incorrectly parameters are set correctly 152 8 TROUBLESHOOTING amp MAINTENANCE 8 4 5 Starter not decelerating as desired Decel Time CFN18 set too short Increase Decel Time Motor stops too quickly Decel Begin and End Levels CFN16 and Increase Decel Begin and or Decel CF
8. 4o SUM S S QS Rr 33 3 11 6 ae a ASE HOES HR xu Eu 33 MOLOE TET 225 sesh Ath ua Z ho aa en ae vanes gh ta RI ck SSE amir h d Sean aio owe 4 34 3 11 8 RTD Module 34 3 12 Remote LCD Keypad Display 35 3432 1 Remote Display iuc ere d cibos n 5 os Sr ku a act ace eon A 35 3 122 Display Cutout s ek ek oe R SOS RE NOE ELSE RO E ene 36 3 12 3 Installing Display o e e e g e ROS a 9 S E E E RR p Rx P a s 36 3 13 RTD Module Installation 37 3 12 1 Locati n 64 4 24 40s RR 8246954605 HE xx RUE XO EX W BREE HEELS 37 3 13 2 Modbus Address iio ox REOR ee RS cec kupu ges 37 3 13 3 Power Connection e deis eR Re eee we oR 37 3 13 4 RS485 Comim nicaton i oos ose XA REG Ge Y GP ATA SRS 37 3 13 5 RED 8 ed ee eroe bd de teak a desi gene Ses hp as RET ae 38 3 13 6 RTD Temperature vs Resistance 38 4 KEYPAD OPERATION 2555524 severe sniker W s 40 1 x REUS A e ee SEULS Q S e eed rd 40 4 2 Description of the LEDs on the 40 4 3 Description of the Keys on the Remote LCD
9. 5 185 APPENDIX E EU DECLARATION OF CONFORMITY 186 APPENDIX F MODBUS REGISTER 187 APPENDIX G APPLICATION 55 201 APPENDIX 3 YEAR WARRANTY 204 APPENDIX I PARAMETER 5 206 vi Introduction 1 INTRODUCTION Using This Manual Layout Symbols This manual is divided into 9 sections Each section contains topics related to the section The sections are as follows Introduction Technical Information Installation Keypad Operation Parameters Parameter Descriptions Theory of Operation Troubleshooting amp Maintenance Appendices There 2 symbols used in this manual to highlight important information The symbols appear as the following Electrical Hazard warns of situations in which a high voltage can cause physical injury death and or damage equipment Caution warns of situations in which physical injury and damage to equipment may occur by means other than electrical Highlight mark an important point in the documentation HAZARD OF ELECTRIC SHOCK EXPLOSION OR ARC FLASH Only qualified personnel familiar with medium voltage equipment are to perform work described in this set of instructions Apply appropriate personal protective equipment PPE and follow safe electrical work practices
10. Off 16 23 Off RTD02 RTD Mod2 Addr RTD Module 2 Address 5 207 APPENDIX I PARAMETER TABLES RTD 24 Other Trip Other Trip Level RTD 25 RTD Voting RTD Voting RTD 26 RTD Biasing RTD Motor OL Biasing Off On pm RTD27 RTD Bias Min RTD Bias Minimum Level 0 198 lt 0 RTD28 RTD Bias Mid RTD Bias Mid Point Level 1 199 101 ERI RTD29 RTD Bias Max RTD Bias Maximum Level 105 200 C 155 Function Group Ave Current L1 Current L2 Current L3 Current Curr Imbal Ground Fault FUN 01 P71 Meter 1 Meter 1 Ave Volts Ave 11 12 Volts Current L2 L3 Volts L3 L1 Volts Overload Power Factor Watts VA 101 0 Disabled 00 00 00 00 00 00 Off 40 10 100 10 vars kW hours MW hours Phase Order Line Freq Analog Input Analog Output Run Days Run Hours FUN 02 Meter 2 Meter 2 Starts Ave Volts TruTorque Power Pk Accel Cur Last Start T Zero Seq GF Stator Temp Bearing Temp Other Temp All Temp 72 1 96 1 144 1 288 1 864 1 1320 1 2640 1 2880 1 3900 1 5760 1 FUNO3 P78 CT Ratio CT Ratio 8000 1 14400 1 28800 1 288 1 102 50 5 150 5 250 5 800 5 2000 5 5000 5 208 APPENDIX I PARAMETER TABLES Insensitive e ABC FUN 04 P77 Phase Order Input Phase Sensitivity CBA Insens 102 Single Phase 100 110 120 200 208 220 230 240 350 380 400 415 440 460 480 500 525 575 600 660 FUN 05 P76 Rated Volts Rated RMS Voltage
11. S SOS EEE EU S 18 3 2 Installation 19 2 1 Ote PrepakablObis s 55 acu eire a 19 3 2 2 EMC Installation Guidelines 19 3 2 3 R Rated Motor Starter Fuses 19 3 2 4 Use of Electro Mechanical Brakes 19 32 25 Reversing Contact E 2 22 45 awa ee or SUS Be Oe x 19 3 2 6 Use of Power Factor Capacitors eco 2 u cca gon soe eR RP her EROR Re b 20 3 3 Mounting 5 21 3 3 1 Bypassed Starters lt 2s s sas ca o4 Ca AREER RARER RES PO S S SUN 21 94 Wiring Considerations eese Tran oe e eee et 21 3 4 1 Wiring Practices cos i pee ae ae Ga e cepe a Pup Gee s 21 3 4 2 Considerations for Control and Power Wiring 21 3 4 3 Considerations for Signal Wiring sa s ss sa ss ss sss ss ea 21 SAA Megeering Motor Ls s se s s w 45 4 is Rem s was d es 21 3 45 High Pot Testing ye 52s p e 69 e b ash ew Xd 21 3 9 Typical Wiring Schematics sa aue s mo e OR Rh RO RU RO RR RU E Re 22 3 5 1 Power Wiring Schematic 222 5 fone e ed a 22 3 5 2 EXMVRMD Control Wiring
12. CFN 27 SSpd Kick T Slow Speed Kick Time 0 1 to 10 0 Protection Function Group Display Setting Range PFN 01 P32 Over Cur Lvl Over Current Trip Level ff 50 800 FLA 03 Undr Cur Lvl Under Current Trip Level Off 5 100 FLA or PFN 04 Undr Cur Time Under Current Trip Delay Time Off 0 1 90 0 Seconds 7 PFN 05 Cur Imbl Lvl Current Imbalance Trip Level Off 5 40 p fis 06 Cur Imbl Time Current Imbalance Trip Time 0 1 90 PFN 07 P37 Resid GF Lvl Resid GF Lvl GF Lvl Residual Ground Fault Trip Level Ground Fault Residual Ground Fault Trip Level Level off 5 100 off 5 100 ISI CENA r RU Pra mao pues p pe peu PEN 11 Undr VIt Lvl Under Voltage Trip Level 041 420 1 041 420 40 PFN 13 Ph Loss Time Phase Loss Trip Time Loss Phase Loss Trip Time Time 01 50 1 01 50 5 0 PFN 14 Over Frq Lvl Over Frequency Trip 24 72 MEL PEN 15 E Undr Frq Lvl Under Frequency Trip 23 71 u PFN 16 Frq Trip Time Frequency Trip Time 0 1 90 0 Seconds 01 83 Off 0 80 lag to PF Lvl PF PF Lead Triplet PF Lead Triplet Level 0 01 lead o Je e Off 0 01 lag to TAR ERI i 23 i dia 0 80 lead PFNI9 PFTripTime PFTripTime 01 900 Seconds 100 8 PFN 20 B Backspin Time Backspin Timer Off 1 180 E
13. 27 Phase loss noL No line 29 PORT Timeout A 31 Overcurrent A 34 Undercurrent A 35 PF Too Leading A 36 PF Too Lagging 30024 40024 Alarm Status 2 A 37 Current imbalance A 38 Ground fault A 47 Stack overtemperature A 53 Tach Loss A 60 DI 1 61 DI2 62 DI3 A 63 DIA 185 APPENDIX F MODBUS REGISTER MAP Absolute Register Address A 64 DI5 A 65 DI6 30025 40025 Alarm Status 3 2 A 66 DI7 A 67 18 A 71 Analog Input Trip Motor overload itl Motor PTC RTD Stator it3 RTD Bearing RTD Other it5 Disconnect open 30026 40026 Lockout Status Stack overtemperature it7 Control power RTD Open Short it9 Time between starts Backspin Starts per hour RTD Comm Loss 30027407 PresentFaultCode 30028 40028 Average Current PA O 30029 40029 Current 0048 j 300300030 2 Curent PA 30031 40031 L3 Current 30032 40032 30033 40033 30034 40034 30035 40035 30036 40036 30037 40037 30038 40038 30039 40039 Current Imbalance 2 2 Residual Ground Fault Current 2200 Zero Sequence Ground Fault Current 200 Average Voltage 11 12 Voltage pO 12 13 Voltage L3 LI Voltage I _ Motor Overload N 99 to 100 Power Factor in 16 bit two s compliment signed format Watts lower
14. 800 Curr Based on per cycle RMS values 0 150 Volt Based on per cycle RMS values 0 150 OL Motor Thermal Overload 0 10kWw Based on filtered V and I values 0 100 kW Based on filtered V and I values 0 1 MW Based on filtered V and I values 0 10 MW Based on filtered V and I values 0 100 The output value takes into account the inputs span and offset settings 0 100 Firing Output Voltage to Motor based on SCR firing angle Calibration Calibration full 100 output Description The Analog Output Function parameter selects the function of the analog output The available analog output function selections and output scaling are shown below The analog output is updated every 25msec See Also Analog Output Span parameter I O 22 on page 95 Analog Output Offset parameter 23 on page 95 94 6 PARAMETER DESCRIPTION Analog Output Span YO 22 LCD Display Range 1 125 Default 100 Description The analog output signal can be scaled using the Analog Output Span parameter For a 0 10V output or 0 20mA output a 100 scaling outputs the maximum voltage 10V or current 20mA when the selected output function requests 100 output A scale of 50 outputs 50 voltage current when the analog output function requests a 100 output 3 NOTE For a 4 20mA output set the Analog Output Span to 80 and the Analog Output Offset to 20 3 NOTE The output does not exceed 100 10V or 20mA Example 096 output gt
15. Check motor for jammed or overloaded condition Verify that the combined kick time CFN 12 and acceleration ramp time QST 08 is shorter than the UTS timer QST 09 setting UTS Time Limit Expired Evaluate acceleration ramp settings The acceleration ramp settings may be too low to permit the motor to start and achieve full speed If so revise acceleration ramp settings to provide more motor torque during starting Evaluate UTS timer setting and if acceptable increase UTS timer setting QST 09 Check motor for mechanical failure jammed or overloaded condition Verify the motor thermal overload parameter settings QST 03 and PFN 28 to PFN 35 and motor service factor setting QST 02 Verify that the motor FLA QST 01 and CT ratio FUN 03 settings are correct Motor OL If motor OL trip occurs during starting review acceleration ramp profile settings Verify that there is not an input line power quality problem or excessive line distortion present Verify that PF caps if installed are ahead of CTs Reset overload when content falls below Motor OL Lockout Level PFN 34 Slow Speed Timer Increase Slow Speed Timer CFN 25 u Increase Speed Switch Time PFN 26 Speed Switch Time Limit Expired Accelerate motor faster Check motor cooling fan Motor PTC Overtemperature Clean debris off of motor Reduce Overload Reduce high ambient Verify Stator RTD specifications Allow motor to cool Stat
16. Resetting a Fault A 8 Resetting a Fault To reset from a fault condition press RESET Emergency Overload Reset A 9 Emergency Overload Reset To perform an emergency overload reset press RESET and DOWN pushbuttons together This sets the motor thermal overload content to 0 LED Display 10 LED Display The card mounted LED display can be used to access most of the parameters when the standard remote mounted display is not connected The LED parameter numbers Pxx are shown in the parameter table see Chapter 5 48 Parameter Groups 5 PARAMETER GROUPS Introduction 5 1 5 2 5 2 1 Introduction The EXMVRMX incorporates a number of parameters that allow you to configure the starter to meet the special requirements of your particular application The parameters are divided into groups of related functionality and within the groups the parameters are identified by a short descriptive name They are numbered by the group name followed by an index within the group This chapter lists all of the parameters and their possible values LCD Display Parameters The parameters are subdivided into six groups The groups are QST Quick Start CFN Control Functions PFN Protection Functions I O Input Output Functions RTD Resistance Temperature Device FUN Function FL1 Fault Log and E01 Event Recorder The Quick Start Group provides a collection of the parameters that are most commonly ch
17. Service Factor SF This provides for accurate motor overload protection during a warm start The steady state overload content is calculated by the following formula OLs OL H C Ratio x Current A Current Imbalance Derate Factor The rise or fall time for the overload to reach this steady state is defined by the Motor Overload Cooling Time PFN 32 parameter The default value of 60 for Motor Overload Hot Cold Ratio parameter is typical for most motors more accurate value can be derived from the hot and cold locked rotor times that are available from most motor manufacturers using the following formula Max Hot Locked Rotor Time Max Cold Locked Rotor Time OL H C Ratio J x 100 3 NOTE Consult motor manufacturer data to determine the correct motor overload settings Independent Starting Running Overload parameter PFN 28 on page 86 Motor Running Overload Class parameter PFN 30 on page 87 Motor Starting Overload Class parameter PFN 29 on page 87 Motor Overload Cooling Time parameter PFN 32 on page 88 Relay Output Configuration parameters I O 10 15 on page 91 Theory of Operation section 7 1 6 Hot Cold Motor Overload Compensation on page 116 Motor Overload Cooling Time 32 LCD Display Range Description 88 1 0 999 9 minutes Default 30 0 The Motor Overload Cooling Time parameter is the time to cool from 100 to less than lt 1 When the motor is stopp
18. The National Electrical Code article 430 Part C allows for different overload multiplier factors depending on the motor and operating conditions NEC section 430 32 outlines the allowable service factor for different motors See Also Theory of Operation section 7 2 Motor Service Factor on page 122 Motor Running Overload Class OST 03 LCD Display Range Off 1 40 Default 10 Description The Motor Running Overload Class parameter sets the class of the electronic overload for starting and running if the Indep S R OL PEN 28 parameter is set to Off If separate starting versus running overload classes are desired set the Indep S R OL PEN 28 parameter to On The starter stores the thermal overload value as a percentage value between 0 and 100 with 0 representing a cold overload and 100 representing a tripped overload When the parameter is set to Off the electronic overload is disabled in all states starting and running A separate motor overload protection device must be supplied 3 NOTE Care must be taken not to damage the motor when turning the running overload class off or setting a high value 3 NOTE Consult motor manufacturer data to determine the correct motor overload settings See Also Independent Starting Running Overload PFN 28 on page 86 Motor Starting Overload Class PFN 29 on page 87 Motor Overload Hot Cold Ratio PFN 31 on page 88 Motor Overload Cooling Time PFN 32 on page 88 Motor OL A
19. BYPASS 5 coU LOCATED IN LOW VOLTAGE SECTION MOUNTED IN LOW VOLTAGE DOOR KPMX3LLCD KEYPAD DISPLAY CARD stor Ej ALARM BYPASS nr Y Y pon _ 3 50 60Hz 1 27 2200 6900 VAC 135 7 THEORY OF OPERATION 7 5 6 DC Brake Timing The MX DC injection brake timing is shown below Figure 41 DC Injection Brake Timing DC Brake Delay Time DC Brake Delay after I N Time 1 DC Brake I E I Brake Relay On I I I I Braking Relay Energized Brake Relay Off DC Injection On Starter SCRs On DC Current Applied DC Injection Off time Stop Delay to allow DC Brake Braking Relay Commanded contactor to Time opens after a close before Expired delay to allow applying DC residual DC current current to decay After the DC Brake Time has expired the Braking Relay is held energized to allow the DC current to decay before opening the freewheel path This delay prevents a contactor if used from having to open significant DC current which greatly prolongs the life of the contactor This delay time is based on motor FLA the larger the motor the longer the delay time The delay after DC brake time is approximately Motor FLA Delay after DC Brake Time 10A 0 4 seconds 100A 0 8 seconds 500 A 2 3 seconds 1000 A 4 3 seconds Motor Overload Calculations During DC Injection Braking During DC braking the MX Solid State Motor Overload Pr
20. Bearing Trip Level RTD 23 LCD Display Range 1 200 C Default 200 C Description This parameter sets the bearing trip temperature when a trip will occur Fault delay time is 1 second 3 NOTE Consult motor manufacturer Other Trip Level RTD 24 LCD Display Range 1 200 C Default 200 C Description This parameter sets the other trip temperature when a trip will occur Fault delay time is 1 second 99 6 PARAMETER DESCRIPTION RTD Voting RTD 25 LCD Display Range Disabled Enabled Default Disabled Description RTD Trip voting can be enabled for extra reliability in the event of a RTD malfunction When RTD voting is enabled two 2 RTDs in one assigned group will need to exceed their trip temperature before a fault is declared 36 NOTE If there is only one RTD assigned to a group the RTD voting will be disabled RTD Motor OL Biasing RTD 26 LCD Display Range Off On Default Off Description When RTDs are present active and assigned to the stator group and when RTD biasing is enabled the stator RTD measurements will effect the motor OL content RTD biasing works together with the 1 thermal model ofthe motor In the RTD biasing case a three point approximation of motor overload capacity based on the highest measured stator RTD temperature is used If the RTD motor overload capacity calculation exceeds the t based calculation then the RTD biasing value will be used If the It value is higher t
21. The motor is considered up to speed once the current stabilizes below 175 percent of the FLA value and the ramp time expires 3 NOTE During normal acceleration ramps the up to speed timer has to be greater than the sum of the highest ramp time in use and the kick time The up to speed timer does not automatically change to be greater than the ramp time If a ramp time greater than the up to speed timer is set the starter will declare an up to speed fault every time a start is attempted 3 NOTE When the Start Mode 01 parameter is set to Voltage Ramp the UTS timer acts as an acceleration kick When the UTS timer expires full voltage is applied to the motor This feature can be used to reduce motor oscillations if they occur near the end of an open loop voltage ramp start 3 NOTE When the Starter Type FUN 07 parameter is set to Wye Delta the UTS timer is used as the transition timer When the UTS timer expires the transition from Wye starting mode to Delta running mode takes place if it has not already occurred Fault Code 01 Up to Speed Fault is declared when a stalled motor condition is detected See Also Start Mode 01 on page 63 Ramp Time 1 QST 08 CFN 02 on page 64 Ramp Time 2 CFN 05 on page 65 Kick Time 1 CEN 12 on page 69 Kick Time 2 CEN 14 on page 69 62 6 PARAMETER DESCRIPTION Starter Type FUN 07 on page 103 Application section 7 6 2 Wye Delta on page 139 Theory of Operation
22. When an alarm is present the word Alarm is displayed on the operate screen Pressing the ENTER key displays more information about the alarm Procedure for Setting Data 4 5 Procedure for Setting Data Select a parameter that is to be changed To change Motor FLA from 10 Amps to 30 Amps From the main screen Press UP arrow to change another parameter in QST Press MENU to change another parameter in another group Press LEFT arrow to go back to the main screen 47 4 KEYPAD OPERATION Jump Code 6 Jump Code At the beginning of each parameter group there is a Jump Code parameter By changing the value of this parameter and pressing ENTER you can jump directly to any parameter within that group Restoring Factory Parameter Settings A 7 Restoring Factory Parameter Settings Go to the FUN group by pressing MENU Scroll through to Miscellaneous Commands FUN 22 and press ENTER Now set to Factory Rst and press ENTER The display will return to None but the parameters will be reset to the factory defaults 36 NOTE Ifa factory reset is performed the following minimum parameters will need to be programmed so F47 Stack Overtemp does not occur FUN05 Rated RMS Voltage set to specified equipment rating FUNO3 CT Ratio I O01 08 Digital Inputs I O10 15 Relay Outputs You must consult the wiring schematic for other digital inputs and relay output configuration
23. m en 76 76 Undr Cur Lvl 7 Undr Cur Time Cur Imbl Lvl Cur Imbl Time Resid GF Lvl Under Current Trip Level Off Under Current Trip Delay Time 0 1 Current Imbalance Trip Level Current Imbalance Trip Time 10 Residual Ground Fault Trip Level Off Ground Fault Trip Off 1 0 25 Off Ground Fault Trip Time 0 1 90 0 3 0 Over Voltage Trip Level Off 1 40 Off N S GF Lvl nd Flt Time Over VIt Lvl Undr VIt Lvl Vit Trip Time oo Over Under Voltage Trip Delay 011 900 01 Phase Loss Trip Time 0 1 5 0 0 2 Ph Loss Time Over Frq Lvl Undr Frq Lvl N Over Frequency Trip Level 24 72 72 23 0 1 oo oo oo oo oo oo oO oo CQ tA AJ w _ oo co oo Starts Hour Auto Reset Auto Rst Lim Ctrl Flt En Auto Fault Reset Count Limit Off Controlled Fault Stop OffOn Speed Switch Trip Time Off Motor PTC Trip Time Off Independent Starting Running Overload Cm Motor Overload Class Starting Off 1 4 Auto Fault Reset Time Off 1 900 Off Speed Sw Time 4 Starts per Hour 1 6 Off 5 M PTC Time Indep S R OL Starting OL oo N Motor Overload Class Running Motor Overload Hot Cold Ratio 09 Motor Overload Cooling Time Motor OL Alarm Level Motor OL Lockout Level Motor OL Auto
24. 0 01 lag to 0 80 lead Default Off Description The amount of power factor lag before the specified PF Trip Time PFN 19 fault will occur See Also Power Factor Lead Trip Level PEN 17 on page 83 Power Factor Trip Time PFN 19 on page 83 PF Trip Time PFN 19 LCD Display Range 0 1 90 0 seconds Default 10 0 Description The amount of time that the power factor lead level PFN 17 or lag level PFN 18 conditions must exist beyond the window PFN 19 before a trip will occur See Also Power Factor Lead Trip Level PEN 17 on page 83 Power Factor Lag Trip Level PFN 18 on page 83 83 6 PARAMETER DESCRIPTION Backspin Timer PFN 20 LCD Display Range Off 1 180 minutes Default Off Description The Backspin Timer parameter sets the minimum time between a stop and the next allowed start If the starter is stopped and a time has been set the starter will display a backspin lockout and the time until the next allowed start in the bottom right of the display Time Between Starts 21 LCD Display Range Off 1 180 minutes Default Off Description The Time Between Starts parameter sets the minimum allowed time between starts Once a start command has been given the next start cannot be performed until this time has expired If the starter is stopped and the time between starts has yet to expire the starter will display a time btw starts lockout and the time until the next start is allowed in the bottom
25. NOTE The Slow Speed Time Limit resets when the motor is stopped This timer does not prevent the 138 7 THEORY OF OPERATION operator from stopping and re starting the motor which can result in the slow speed operation time of the motor being exceeded Slow Speed Kick Level The Slow Speed Kick Level sets the short term current level that is applied to the motor to accelerate the motor for slow speed operation The Slow Speed Kick feature is disabled if it is set to off Slow Speed Kick can be used to break loose difficult to start loads while keeping the operating slow speed current level lower This parameter should be set to a midrange value and then the Slow Speed Kick Time should be increased in 0 1 second intervals until the kick is applied long enough to start the motor rotating If the motor does not start rotating with the set Slow Speed Kick Level increase the level and begin adjusting the kick time from 1 0 seconds again If the motor initially accelerates too fast then reduce the Slow Speed Kick Level and or reduce the Slow Speed Kick Time Slow Speed Kick Time The Slow Speed Kick Time parameter sets the length of time that the Slow Speed Kick current level is applied to the motor at the beginning of slow speed operation After the Slow Speed Kick Level is set the Slow Speed Kick Time should be adjusted so that the motor starts rotating when a slow speed command is given If the motor initially accelerates too fast then re
26. The Motor Running Overload Class parameter sets the class of the electronic overload when up to speed and stopping The starter stores the thermal overload value as a percentage value between 0 and 10096 with 0 representing a cold overload and 100 representing a tripped overload See section 7 1 for the overload trip time versus current curves When the parameter is set to Off the electronic overload is disabled when up to speed and a separate motor overload protection device must be supplied 36 NOTE Care must be taken not to damage the motor when turning the running overload class off or setting a high value 3 NOTE Consult motor manufacturer data to determine the correct motor overload settings See Also Independent Starting Running Overload parameter PEN 28 on page 86 Motor Starting Overload Class parameter PFN 29 on page 87 Motor Overload Hot Cold Ratio parameter 31 on page 88 Motor Overload Cooling Time parameter PFN 32 on page 88 Relay Output Configuration parameter I O 10 15 on page 91 Theory of Operation section 7 1 Solid State Motor Overload Protection on page 114 87 6 PARAMETER DESCRIPTION Motor Overload Hot Cold Ratio 31 LCD Display Range Description See Also 0 99 Default 60 The Motor Overload Hot Cold Ratio parameter defines the steady state overload content OL that is reached when the motor is running with a current less than full load current FLA
27. Ue x 146 7 11 2 Modbus Register 4 146 7 113 Cable Specifications s sor se s doa EE A Ye Ex 146 7 114 Terminating Resistors oS GR 9e ee ed a 146 7215 Grounding 2 46 25 xk keep ee ae RE RR R 146 ZALE SMEA iis dete a Beet e east ADR apie be dens 146 TALS WINE es oon Ge a uem om u mada SD ee awe eRe EES 147 8 TROUBLESHOOTING amp 150 8 1 Safety Pr cautions s sk ho sus Oe COE CU ae 150 8 2 Preventative Maintenance 150 8 2 1 General Information s ss esde a dae o s sun a R KUR X s S ERR W Q EE ES 150 8 2 2 Preventative Maintenances Lu sy CE ea bus PS SR 150 8 3 LED Diagnostics 266 646 bee Pk got w 9 ee vow S 151 8 4 General Troubleshooting 153 841 Stack Ov ertemp Lockout ici ees EE ee we ee WS 153 8 4 2 Motor does not start output tomotor 153 8 4 3 During starting motor rotates but does not reach full speed 154 8 4 4 Starter not accelerating as desired 154 8 4 5 Starter not decelerating as 155 8 4 6 Motor s
28. on page 69 Theory of Operation section 7 3 1 Current Ramp Settings Ramps and Times on page 123 Maximum Current 1 OST 07 LCD Display Range Description See Also 100 800 of FLA Default 600 The Maximum Current 1 parameter is set as a percentage of the Motor FLA QST 01 parameter setting This parameter performs two functions It sets the current level for the end of the ramp profile as well as the maximum current that is allowed to reach the motor after the ramp is completed If the ramp time expires before the motor has reached full speed the starter holds the current at the maximum current level until either the UTS timer expires the motor reaches full speed or the overload trips Typically the maximum current is set to 600 unless the power system or load dictates the setting of a lower maximum current Up To Speed Time QST 09 on page 62 Start Mode CFN 01 on page 63 Ramp Time 1 QST 08 CFN 02 on page 64 Initial Current 1 QST 06 03 on page 64 Kick Level 1 11 on page 68 Kick Time 1 CFN 12 on page 69 Theory of Operation section 7 3 1 Current Ramp Settings Ramps and Times on page 123 61 6 PARAMETER DESCRIPTION Ramp Time1 OST 08 LCD Display Range 0 300 seconds Default 15 seconds Description The Ramp Time 1 parameter is the time it takes for the starter to allow the current voltage torque or power depending on the start mode to go from its
29. on page 92 Starter Type FUN 07 on page 103 4 20mA SOURCE 2 4 20 Theory of Operation section 7 11 Phase Control page 145 Theory of Operation section 7 12 Current Follower on page 145 3 11 5 Analog Output The analog output can be configured for Voltage or Current loop The output is shipped in the Voltage loop configuration unless specified in a custom configuration Below TBS is SW1 2 When the switch is in the off position the output is current When it is a Voltage loop output The control is shipped with the Switch on or line power is applied to the analog output 3 NOTE The analog output is a low voltage output maximum of 15VDC The output will be damaged if control power 115VAC The terminals are as follows 5 analog output 6 common Figure 17 Analog Output Wiring Example 761 Al iu 7 shield METER ANALOG INPUT CARD vn See Also Analog Output I O 21 23 on page 94 3 11 6 SW1 DIP Switch Ol O lol The SW1 DIP switch on the card changes the analog input and analog output between 0 10V or 0 20mA The picture below shows how to adjust the switch to select the desired signal 32 3 11 7 3 11 8 3 INSTALLATION Motor PTC Terminal block J7 is for a PTC positive temperature co efficient motor thermistor This input is designed to use standard DIN 44081 or DIN 44082 thermistors The specifications of the
30. 0 10 000 MWh 5 PF 0 01 to 0 01 Lag amp Lead 5 Line Frequency 23 72 Hz 0 1 Hz Ground Fault 5 100 FLA 5 Machine Protection Run Time 3 seconds per 24 hour period Analog Input Accuracy 3 of full scale 10 bit Analog Output Accuracy 2 of full scale 12 bit Zero Seq GF 0 1 25 0 Amps 3 3 NOTE Percent accuracy is percent of full scale of the given ranges Current Motor FLA Voltage 16 000V Watts Volts Amps Watt Hours Motor amp Voltage range 2 2 3 List of Motor Protection Features ANSI 14 Speed Switch and Tachometer Trip ANSI 19 Reduced Voltage Start ANSI 27 59 Adjustable over under voltage protection Off or 1 to 40 time 0 1 to 90 0 sec in 0 1 sec intervals independent over and under voltage levels ANSI 37 Undercurrent detection Off or 5 to 100 and time 0 1 to 90 0 sec in 0 1 sec intervals ANSI 38 Bearing RTD Other RTD Open RTD Alarm NSI 46 Current imbalance detection Off or 5 to 40 NSI 47 Phase rotation selectable ABC CBA Insensitive or Single Phase NSI 48 Adjustable up to speed stall timer 1 to 900 sec in 1 sec intervals NSI 49 Stator RTD NSI 50 Instantaneous electronic overcurrent trip NSI 51 Electronic motor overload Off class 1 to 40 separate starting and running curves available NSI 51 Overcurrent detection Off or 50 to 800 and time 0 1 to 9
31. 3 Years Factory Repair or Exchange Data Sheet FVR Reversing 3 Years Factory Repair or Exchange Data Sheet Motors larger than a T Frame require a supervised start up for the 3 year warranty Factory Repair or Exchange Benshaw will repair or replace at its option all Benshaw manufactured components which fail within the defined warranty period Failures which are caused by unauthorized repairs mechanical electrical or physical abuse and acts of God such as lightning fires or floods are excluded The customer pays freight and any required labor costs Active On Site Time and Parts If Benshaw determines that on site repairs or exchange is necessary Benshaw or an authorized service agent will perform the necessary work on site Benshaw will provide the actual service time and required parts to repair the unit The customer will pay for travel time and living costs to the site and any waiting time to perform the repairs Failures which are caused by unauthorized repairs mechanical electrical or physical abuse and acts of God such as lightning fires or floods are excluded A purchase order must be issued for the non warranty travel and living costs prior to the work being performed Warranty Registration Installation Data Sheet For low voltage products the Benshaw warranty registration form must be completed and returned to Benshaw within five 5 days of startup to activate the 3 year warranty If the data sheet is not compl
32. 30181 40181 Analog Output Function 1 0 100kW O 1IMW O 10MW 1 100 Analog Input 0 100 Firing Calibration full output 100 5 30188 40188 Modbus Timeout Enable 30189 40189 Modbus Timeout 1 120 S 0 72 1 1 96 2 1441 3 2881 4 8641 5 2640 1 6 3900 1 7 57601 30190 40190 CT Ratio 8 8000 1 9 144001 10 28800 1 11 50 5 12 150 5 13 250 5 14 800 5 15 2000 5 16 5000 5 Disabled Start after power applied 30191 40191 Auto Start Start after fault reset Starter after power applied and after fault reset 0 Disabled 30192 40192 Energy Saver Enable dp we 30193 40193 Heater Anti Windmill Enable Us Disabled 1 Enabled 30194 40194 Heater Anti Windmill Level FLA Normal Outside Delta Inside Delta Wye Delta 30195 40195 Starter Type lt Phase Controller Current Follower Across the Line Full Voltage 192 APPENDIX F MODBUS REGISTER MAP Absolute Register Address 30196 40196 LED Display Meter 30197 40197 LCD Display Meter 1 30198 40198 LCD Display Meter 2 900 CY Oy a Status Ave Current L1 Current L2 Current L3 Current Current Imbalance Residual Ground Fault Ave Volts L1 L2 Volts L2 L3 Volts L3 L1 Volts Overload Power Factor Phase Order Line Frequency Analog Input Analog Output Running Days Running Hours Starts TruTorque Power Peak Starting Current Last Star
33. 73 Controlled Fault Stop Enable parameter 25 on page 85 Theory of Operation section 7 5 9 DC Injection Braking Control on page 138 DC Brake Delay 22 LCD Display Range 0 1 3 0 Seconds Default 0 2 Description When the Stop Mode 15 is set to DC brake the DC Brake Delay time is the time delay between when a stop is commanded and the DC braking current is applied to the motor This delay allows the residual magnetic field and motor counter EMF to decay before applying the DC braking current If a large surge of current is detected when DC braking is first engaged increase the delay time If the delay before the braking action begins is too long then decrease the delay time In general low horsepower motors can utilize shorter delays while large horsepower motor may require longer delays See Also Stop Mode parameter CFN 15 on page 70 DC Brake Level parameter CFN 20 on page 72 DC Brake Time parameter CFN 21 on page 73 Theory of Operation section 7 5 9 DC Injection Braking Control on page 138 Preset Slow Speed CFN 23 LCD Display Range Off 1 0 40 0 Default Off 73 6 PARAMETER DESCRIPTION Description See Also The Preset Slow Speed parameter sets the speed of motor operation When set to Off slow speed operation is disabled Slow speed operation is commanded by programming one of the digital inputs to either Slow Speed Forward or Slow Speed Reverse Energi
34. 9 Built In Self Test 5 2 2 171 891 General Informations q a w RAR AA es 171 85 92 Test sige aes k 1G Ree DA oe ee ER AC EE eee ed 171 8 9 3 BIST INOteS 22561 y shua Rae dood TRO t abate de Sch Boab ng 171 894 Conducting a vic ccc sa eos e eG SU Ox Rok TGR EER 173 8 9 5 Begin BIST Test so s wanra A ss atack k ER ON RR 173 8 9 6 RUN relay and In line 3 4 6 6 5 6 S we ete W ahus Xe 173 89 7 UTS relay and Bypass Test 173 8 9 8 Sequential SCR Gate 22525525 woe ae s 174 899 All SCR Gates Firing cs OR Ge ee eed ees 174 8 90 Resets Systems serios ere ueque qe S a qi S a gk odes 175 8 0 T1 BIST Test Cancelled s ie 35 dei x Romo E Se HO 175 S TO High Pot Testing poe GPS wk we te y Rex WA e EHE 4 moe dh SB S 175 Vacuum Contactor sus su cce Pur XXE E E Ee RE NOS N 175 8 12 RTD Module Troubleshooting ees 176 8 13 VACUUM contactor and Power Pole assembly Maintenance 176 APPENDIX A 5 180 APPENDIX B ALARM CODES 181 APPENDIX C FAULT 5 183 APPENDIX D 5
35. Current L1 Current L2 Current L3 Current Curr Imbal Ground Fault FUN 01 P71 Meter 1 E Ave Volts Ave Current L1 L2 Volts L2 L3 Volts L3 L1 Volts Overload Power Factor 101 kW hours MW hours Phase Order Line Freq Analog Input Analog Output Run Days Run Hours FUN 02 Meter 2 Meter 2 Starts Ave Volts TruTorque Power Pk Accel Cur Last Start T Zero Sequence GF Stator Temp Bearing Temp Other Temp All Temp 72 1 96 1 144 1 288 1 864 1 2640 1 3900 1 5760 1 FUN 03 P78 CTRatio i 8000 1 14400 1 288 1 28800 1 50 5 150 5 250 5 800 5 2000 5 5000 5 Insensitive ee ABC FUN 04 P77 Phase Order Input Phase Sensitivity CBA Insens Single Phase 100 110 120 200 208 220 230 240 350 380 400 415 440 460 480 500 525 575 600 660 690 800 1000 1140 FUN 05 P76 Rated Volts Rated RMS Voltage 2200 2300 2400 Vollage 3300 4160 4600 4800 6000 6600 6900 10 00K 11 00K 11 50K 12 00K 12 47K 13 20K 13 80K FUN 06 Motor Rated Power Factor LU Normal Inside Delta Wye Delta FUN 07 74 Starter Type Starter Type Phase Ctl Curr Follow ATL 55 5 PARAMETER GROUPS PORT Fetim PORT mem or Voltage Ramp Fast Recover FUN 12 PORT Recover P O R T Recovery Method Coran Penas Fast Recover 106 Curr Ramp 2 Ramp Select Tach Ramp 13 Tach FS Lvl 1 00 10 00 Volts 5 00 106 Voltage ach Los Tim Tachometer Loss Time 0 1 90 0
36. Default Off Description When using the zero speed stall protection the starter will start monitoring the zero speed input as soon as a run command is given and will recognize a stalled motor if the zero speed time has elapsed before the zero speed signal 15 removed The zero speed input requires a high or low signal to indicate the zero speed condition Fault Code 04 Speed Switch Timer will be displayed when a stalled motor condition is detected 85 6 PARAMETER DESCRIPTION See Also Digital Inputs I O 01 08 on page 90 Motor PTC Trip Time PFN 27 LCD Display Range Off 1 5 seconds Default Off Description The soft starter has the capability to monitor a PTC Positive Temperature Coefficient thermistor signal from the motor The thermistors will provide a second level of thermal protection for the motor There is no PTC input required when set to Off 3 NOTE A motor PTC Fault F05 occurs if resistance exceeds 3 5K ohm 300 ohms The starter is locked out until the resistance drops below 1 65K ohm 150 ohms 3 NOTE Open terminals will give an F05 fault immediately if this parameter is not set to Off The input is designed for DIN44081 and DIN44082 standard thermistors Independent Starting Running Overload PFN 28 LCD Display Range Off On Default Off Description If Off When this parameter is Off the overload defined by the Motor Running Overload Class parameter QST 03 is a
37. F23 F24 F25 F26 F27 F28 F29 0 4 F35 F36 7 F38 F39 F40 F41 F46 F47 F48 F49 F50 F53 F54 F55 F56 F60 F61 F62 F63 Low Line L1 L2 F31 Stack Overtemperature P S Failure Bypass 2M Contactor Fault APPENDIX C FAULT CODES Fault Codes Controlled Fault Stop Shunt Trip Fault Auto Reset Allowed 181 APPENDIX C FAULT CODES Fault Code Semi oled Fault Shunt Trip Fault Auto Reset Allowed N 182 APPENDIX D SPARE PARTS Options and Accessories a LCD Display large KPMX3LLCD H 77mm 3 03 W 127mm 5 Zero Sequence Ground Fault CT CT 2000 1 6 CT100001 01 Po Spare Parts LCD Display large KPMX3LLCD H 77mm 3 03 W 127mm 5 short BIRI 100008 00 3 or meter LCD display cable long BIRI 100009 00 6 or 2meter CT 100001 01 Ground Fault 2000 1 CT 100003 01 150 5 CT 100005 01 250 5 Current Transformers CTs CT 100011 01 800 5 CT 100024 01 50 5 CT 100034 01 2000 5 CT 100108 01 5000 5 Zero Sequence Current Transformer CT 2000 1 6 CT100001 01 22 450100 02 Gate Drive Board BIPC 300003 01 Medium Voltage Fuses Consult Factory MV Stack Power Pole S 450001 02 SCRs S 403005 01 S 403115 05 Fiber Optic eminere fy 183 APPENDIX E EU DECLARATION OF CONFORMITY EU Declaration of Conformity According to the EMC Dir
38. FUN 16 on page 107 Communication Baud Rate parameter FUN 17 on page 107 Communication Timeout parameter FUN 18 on page 107 60 6 PARAMETER DESCRIPTION Initial Current 1 OST 06 LCD Display Range Description See Also 50 600 of FLA Default 100 The Initial Current parameter is set as a percentage of the Motor FLA QST 01 parameter setting This parameter sets the current that is initially supplied to the motor when a start is commanded The initial current should be set to the level that allows the motor to begin rotating within a couple of seconds of receiving a start command To adjust the initial current setting give the starter a run command Observe the motor to see how long it takes before it begins rotating and then stop the unit For every second that the motor doesn t rotate increase the initial current by 20 Typical loads require an initial current in the range of 50 to 175 If the motor does not rotate within a few seconds after a start command the initial current should be increased If the motor accelerates too quickly after a start command the initial current should be decreased The Initial Current 1 parameter must be set to a value that is lower than the Maximum Current 1 QST 07 parameter setting Start Mode CFN 01 on page 63 Ramp Time 1 QST 08 CFN 02 on page 64 Maximum Current 1 QST 07 04 on page 65 Kick Level 1 CFN 11 on page 68 Kick Time 1 CFN 12
39. Hz 45VA required for control card Relay Output SPDT form C NO Contact resistive NC Contact resistive 5A at 250VAC 3A at 250VAC 5A at 125VAC 3A at 125VAC 5A at 30VDC 3A at 30VDC 1250VA 750VA Relay Output SPDT form C NO Contact resistive NC Contact resistive 5A at 250VAC 3A at 250VAC 5A at 125VAC 3A at 125VAC 5A at 30VDC 3A at 30VDC 1250VA 750VA 10A at 250VAC at 125VAC 10A at 30VDC 2500VA Relay Output SPST NO form A Resistive 5A at 250VAC 5A at 125VAC 5A at 30VDC 1250VA Relay Output SPST NO form A Resistive 5A at 250VAC 5A at 125VAC 5A at 30VDC 1250VA Relay Output SPST NO form A Resistive 5A at 250VAC 5A at 125VAC 5A at 30VDC 1250VA 120VAC digital input 2500V optical isolation 4mA current draw Off 0 35VAC On 60 120VAC 120VAC digital input 2500V optical isolation 4mA current draw Off 0 35VAC On 60 120VAC 2 TECHNICAL SPECIFICATIONS Function Terminal Terminal Number Description Block Serial Comm Modbus RTU serial communication port RS 485 interface 19 2k baud maximum 2500V Isolation Analog I O Ain Power Input Ain Voltage or Current Ain Voltage 0 10VDC 67KQ impedance Common Current 0 20mA 500Q impedance Aout Common Output Shield Voltage or Current Voltage 0 10VDC 120mA maximum Current 0 20mA 500Q load maximum PTC Thermistor Input Motor PTC Positive Temperature Coefficient Thermistor Motor PTC
40. Inline Feedback F49 Bypass 2M Feedback F48 Emergency Motor OL Reset Local Remote Control Source Heat Disable Heat Enable Ramp Select Slow Speed Forward Slow Speed Reverse DC Brake Disable DC Brake Enable Speed Switch Normally Open Speed Switch Normally Closed Off Fault Fail Safe Fault Non Fail Safe Running Up To Speed Alarm Ready Locked Out Over Current Alarm Under Current Alarm Overload Alarm Shunt Trip Fail Safe Shunt Trip Non Fail Safe Faulted on Ground Fault In Energy Saver Mode Heating Slow Speed Slow Speed Forward Slow Speed Reverse DC Braking Cooling Fan PORT Tach Loss 191 APPENDIX F MODBUS REGISTER MAP Absolute Register Address 0 Low Fault below preset level 30176 40176 Analog Input Trip Type 1 High Fault above preset level 30177 40177 Analog Input Trip Level 0 100 Im 30178 40178 Analog Input Trip Delay Time 1 900 100 mSec 30179 40179 Analog Input Span 1 100 30180 40180 Analog Input Offset 0 9 ec 0 1 2 3 4 2 6 7 8 30182 40182 Analog Output Span 30183 40183 Analog Output Offset 0 Disabled 30184 40184 Inline Enable 1 Enabled 30185 40185 Inline Delay Time 10 100 100 mSec 30186 40186 Bypass Feedback Time 100 mSec Enabled 30187 40187 Keypad Stop Disabled Disabled Enabled no output 0 200 Current 0 800 Current 0 150 Voltage 0 150 Overload O 10kW
41. Is the temperature of the air water or a surrounding medium where equipment is operated or stored A standard system used for designing the size of electrical conductors Gauge numbers have an inverse relationship to size larger numbers have a smaller cross sectional area However a single strand conductor has a larger cross sectional area than a multi strand conductor of the same gauge so that they have the same current carrying specification Auto Synchronizing of the gate timing pulses matches each phase firing angle to their respective phases The soft start actively tracks minor shifts in the line frequency avoiding nuisance tripping that may happen with conventional gate firing systems In software terms a register or group of register used for temporary storage of data to compensate for transmission rate differences between the transmitter and receiving device In hardware terms an isolating circuit used to avoid the reaction of one circuit with another A method of reversing motor rotation by the use of two separate contactors one of which produces rotation in on direction and the other produces rotation in the opposite direction The contactors are electrically and mechanically interlocked so that both cannot be energized at the same time This is where the microprocessor The CPU Board is attached to the main power and communicates to it and the keypad operator interface via ribbon cables The CPU determines operating functio
42. Operating Environment 40 to 60 C 40 to 140 F up to 95 R H non condensing Terminal Strips Accepts one or two stranded copper wires of the same size oe from 12 to 30 AWG W x 3 4 Hx 2 12 2 TECHNICAL SPECIFICATIONS 2 2 7 Optional Zero Sequence Ground Fault CT The Benshaw BICT 2000 1 6 CT has the following excitation curve Figure 3 BICT2000 1 6 Excitation Curve GROUND FAULT CURRENT TRANSFORMER BICT 2000 1 6 50 0 025A 60Hz MAGNETIZING CURRENT VERSUS VOLTAGE AO 1 0 10 13 2 TECHNICAL SPECIFICATIONS Sample RediStart EXMVRMX3 Unit 2 3 Sample RediStart EXMVRMX Unit POACR TU IPECDHMECT TACH eee aes See voor TT BEESEEES E Bai PASS 5 CONTACTO C i x CABLE CLAMP DISCONNECT j Da AGDER USE COMTACTOR GURAEHT TRAMSF FIBER PHASE ASSEkEG ES DE COWNECT CONTACTOR SEC THOT SLATER SECTION EMV FIGURE 2 3 36 NOTE This is only a sample diagram drawing for component identification purposes Component locations may change to meet end users specifications 14 2 TECHNICAL SPECIFICATIONS Environmental Conditions 2 4 Environmental Conditions Table 7 Environmental Ratings Operating Temperatures 10 C to 40 C 14 F to 104 F enclosed 10 C to 50 C 14 F to 122 F open Storage Temperatures 20 C to 70 C 4 F to 155
43. Schematics Figure 44 Digital Input Simplified Schematic Figure 45 Analog Input Simplified Schematic 100 KQ 100 KQ O e 503 75 Q 100 KQ AIN SWi 1 ON 0 20mA 100 KQ 100 AIN O e W X Y X Figure 46 Analog Output Simplified Schematic 15 KQ 15 KQ 274 KQ 15V W O ON 0 10V O comm 142 7 OF OPERATION Remote Modbus Communications 7 10 7 10 1 7 10 2 7 10 3 7 10 4 7 10 5 7 10 6 Remote Modbus Communications The MX starter provides Modbus R TU to support remote communication The communication interface is RS 485 and allows up to 247 slaves to be connected to one master with repeaters when the number of drops exceeds 31 Please refer to Figures 47 and 48 for connection diagrams Supported Commands The MX supports the following Modbus commands Read Holding Registers 03 hex Read Input Registers 04 hex Preset Single Register 06 hex Preset Multiple Registers 10 hex Up to 64 registers may be read or written with a single command Modbus Register Addresses The Modbus specification defines holding registers to begin at 40001 and input registers to begin at 30001 Holding registers may be read and written Input registers may only be read In MX the register maps are identical for both the holding registers and the input registers For example
44. State Ave Current Average current Default Meter 1 L1 Current Current in phase 1 L2 Current Current in phase 2 L3 Current Current in phase 3 Curr Imbal Current Imbalance Ground Fault Residual Ground Fault FLA Ave Volts Average Voltage L L RMS Default Meter 2 L1 L2 Volts Voltage in L1 to L2 RMS 101 6 PARAMETER DESCRIPTION Description L2 L3 Volts Voltage in L2 to L3 RMS L3 L1 Volts Voltage in L3 to L1 RMS Overload Thermal overload in 96 Power Factor Motor power factor Watts Motor real power consumed VA Motor apparent power consumed vars Motor reactive power consumed kW hours Kilo watt hour used by the motor wraps at 1 000 MW hours Mega watt hour used by the motor wraps at 10 000 Phase Order Phase Rotation Line Freq Line Frequency Analog In Analog Input 96 Analog Out Analog Output 95 Run Days Running time in days wraps at 2 730 days Run Hours Running time in Hours and Minutes wraps at 24 00 Starts Number of Starts wraps at 65 536 TruTorque TruTorque Power Power 95 Pk accel Curr Peak starting current Last Start T Last starting duration Zero Seq GF Zero sequence ground fault Stator Temp Highest Stator temperature Bearing Temp Highest Bearing temperature Other Temp Highest Other temperature All Temp Highest of all temperatures Parameters FUN 01 and FUN 02 configure which meters are displayed on the two lines of the main display screen CT Ratio
45. Temperature 118 7 THEORY OF OPERATION 7 1 8 Overload Auto Lockout This feature prevents an overload trip during the motor start due to insufficient thermal capacity It will automatically calculate the overload content required to start the motor It will lockout the starter if there is not enough overload content available The release value calculated is based on OL content used for the past four 4 successful motor starts A factor of 1 25 is applied as a safety margin Example The OL content used for the past 4 starts were 3096 29 3096 27 step 1 30429430427 4 29 step 2 29 1 25 36 step 3 100 36 64 Therefore 64 is the calculated OL Lockout release level 7 1 9 Separate Starting and Running Motor Overload Settings If desired separate overload classes can be programmed for use during starting and during running The motor overload protection may also be disabled during starting or during normal running In order to enable separate overload settings the Independent Starting Running Overload PFN 28 parameter needs to be set to On to allow independent overload operation Once set to On the individual Motor Starting Overload Class PFN 29 and Motor Running Overload Class PFN 30 parameters can be set to either Off or the desired overload class settings The Motor Starting Overload Class PFN 29 parameter value is used for the motor overload calculations when the starter is starting the motor kick
46. Trip resistance 3 5K 300 Ohms Reset resistance 1 65K 150 Ohms Open terminal voltage is 15V PTC voltage at 4Kohms 8 55V gt 7 5V Response time adjustable between and 5 seconds Maximum cold resistance of PTC chain 1500 Ohms Zero Sequence CT input Zero Sequence Ground Fault Ground Fault 2 CT input CT Type 50 0 025 2000 1 ratio Measurement range 0 1A 25 0 Amps Accuracy 3 Burden at 25Amps 0 0089VA Display RJ45 21 Door Mounted Display Connector SCR SCR 1A F ISO 1 to ISO 18 Fiber Optic connector SCR 2A F SCR 3A F Stack OT Phase 1 LS1 Fiber Optic connector Phase 2 LS2 Phase 3 LS3 Phase C T J10 P Phase CT Connector 5 Amp input Wire Gauge The terminals can support 1 14 AWG wire or 2 16 AWG wires or smaller Torque Rating The terminals on the control cards have a torque rating of 5 0 inch Ib or 0 56Nm This MUST be followed or damage will occur to the terminals 3 NOTE Refer to Control Card Layout starting on page 27 2 TECHNICAL SPECIFICATIONS 2 2 2 Measurements Accuracies Table 2 Measurements and Accuracies Internal ssAssaWcsa i Conversion True RMS Sampling 1 562kHz CT Inputs Range 1 6400A Conversion True RMS Sampling 1 562kHz Line Voltage Inputs Range 10 000 13 800VAC 23 to 72 Hz Metering Current 0 40 000 Amps 3 Voltage 0 16 000 Volts 3 Watts 0 9 999 MW 5 Volts Amps 0 9 999 MVA 5 Watt Hours
47. before the deceleration time has expired increase this parameter value If the motor is still rotating when the deceleration time has expired decrease this parameter value If the value is set too low a Current at Run fault may occur during deceleration 36 NOTE The deceleration end level cannot be set greater than the decel begin level Stop Mode CFN 15 set to TruTorque Deceleration The Decel End Level parameter sets the ending torque level for the TruTorque deceleration ramp profile A typical TruTorque decel end level setting is between 10 and 20 If the motor stops rotating before the deceleration time has expired increase this parameter value If the motor is still rotating when the deceleration time has expired decrease this parameter value See Also Stop Mode CFN 15 on page 70 Decel Begin Level CFN 16 on page 70 Decel Time CEN 18 on page 71 Controlled Fault Stop Enable PFN 25 on page 85 Theory of Operation section 7 4 Deceleration Control on page 131 Decel Time LCD Display Range 1 180 seconds Default 15 sec Description The Decel Time parameter sets the time that the deceleration profile is applied to the motor and sets the slope of the deceleration ramp profile In voltage decel mode this time sets the time to ramp from the initial decel level to the final decel level 36 NOTE If the motor is not up to speed when a stop is commanded the voltage decel profile begins at the lower of either the d
48. can be entered into the Rated Power Factor parameter See Also Meter parameters FUN 01 FUN 02 on page 101 Theory of Operation section 7 3 3 TruTorque Acceleration Control Settings and Times on page 124 Theory of Operation section 7 3 4 Power Control Acceleration Settings and Times on page 126 Starter Type FUN 07 LCD Display Range LCD Description Normal Normal Reduced Voltage Soft Starter RVSS Default Inside Delta Inside Delta RVSS Consult Factory Wye Delta Wye Delta Phase Ctl Open Loop Phase control using external analog input reference Consult Factory 103 6 PARAMETER DESCRIPTION Description See Also Curr Follow Closed Loop Current follower using external analog input reference Consult Factory ATL Across the line Full Voltage The MX has been designed to be the controller for many control applications Solid State Starter both Normal outside Delta and Inside Delta and electro mechanical starters Wye Delta Across the line full voltage starter Phase Control Voltage Follower Current Follower In each case the MX is providing the motor protection and the necessary control for these applications Input Phase Sensitivity parameter FUN 04 on page 102 Theory of Operation section 7 6 2 Wye Delta Operation on page 139 Heater Level FUN 08 LCD Display Range Description 104 Off 1 40 FLA Default Off The Heater Level parameter sets the level of D C current that reaches t
49. contacting Benshaw Name of Company Telephone number where the caller can be contacted Faxnumber of caller Benshaw product name Benshaw model number Benshaw serial number Name of product distributor Approximate date of purchase Voltage of motor attached to Benshaw product FLA of motor attached to Benshaw product A brief description of the application 1 INTRODUCTION Interpreting Model Numbers Figure 1 RediStart EXEXMVRMX Series Model Numbers CFMVRMX36 3500 13 8K 1 1 Nema 1 12 12 Voltage HP 36 10KV 14KV 11 5KV 12KV 12 47KV 13 2KV 13 8KV MV MX Control Combination Fusable Example of Model Number CFMVRMX36 3500 13 8KV 1 A Combination Fusable RediStart starter with MV MX control 13 800 Volts 3500 Horse Power NEMA 1 Enclosure 1 INTRODUCTION General Overview Reduced Voltage Starter General Overview The RediStart EXMVRMX motor starter is a microprocessor controlled starter for three phase motors The starter can be custom designed for specific applications A few of the features are Solid state design Reduced voltage starting and soft stopping Closed loop motor current control power kW control torque control Programmable motor protection Programmable operating parameters Programmable metering Communications Each starter can operate within applied frequency values 23 to 72Hz and l
50. does not reset the overload fault To perform an emergency overload reset simultaneously press the RESET and DOWN buttons on the keypad An emergency overload reset may also be performed by applying 120 Volts to a digital input that is configured as an emergency overload reset input or by setting the emergency overload reset bit in the starter control Modbus register CAUTION This feature should only be used in an emergency Before an emergency reset is performed the cause of the motor overload should be investigated to ensure that the motor is capable of restarting without causing undesired motor or load damage When the emergency motor overload reset is used the accumulated motor overload content is reset back to zero 0 Therefore the MX motor protection functions may not be able to fully protect the motor from damage during a restart after performing an emergency motor overload reset 121 7 THEORY OF OPERATION Motor Service Factor 7 2 General Motor Service Factor 122 The Motor Service Factor QST 02 parameter should be set to the service factor of the motor The service factor is used to determine the pick up point for the overload calculations Ifthe service factor of the motor is not known then the service factor should be set to 1 00 3 NOTE The NEC National Electrical Code does not allow the service factor to be set above 1 40 Check with other local electrical codes for their requirements The National
51. electrical characteristics of balanced voltage digital interface circuits in a point to point link An EIA standard that specifies electrical characteristics of balanced voltage digital interface circuits in a multi point link Resistance Temperature Detector is a temperature measurement device used by passing a low level current through the RTD and measuring the voltage drop The vertical movement of data on a display screen caused by the dropping of one line of display data for each new line added at the opposite end Pertaining to time sequential transmission of storage of or logic operations on data using the same facilities for successive parts When used on a motor nameplate a number which indicates how much above the nameplate rating a motor can be loaded with out causing serious degradation i e a motor with 1 15 S F can produce 15 greater torque than one with 1 0 S F to adjust measured loads in an attempt to compensate for conditions which are difficult to measure or define The soft start contains a firing circuit that includes several unique features that maximize performance without the need for reactors or field installed devices used in other systems regardless of conditions These features include Auto Synchronizing sustained pulse firing closed loop firing control transformer isolation and fiber optic isolation A solid state switch sometimes referred to as a thyristor The SCR has an anode cathode and control
52. element called the gate The device provides controlled rectification since it can be turned on at will the SCR can rapidly switch large currents at high voltage The condition at a particular time of any numerous entities within a system These conditions may be represented by values in a status line The process of absorbing and clipping voltage transients on an incoming AC line or control circuit MOVs Metal Oxide Varistors and specially designed networks are usually used to accomplish this Keeps the firing signal active for 270 electrical degrees ensuring that the DC gate pulse causes the SCR to fire even if line noise is present at a critical moment this provides noise immunity and protects against misfiring enhancing system reliability This is the user connection interface board It is located in the medium voltage section in order to satisfy UL termination requirements but does not actually connect directly to the medium voltage components other than the contactor coils This board contains the user terminal blocks out relays duplicated inputs and control power connections It also contain additional timed relays for interfacing with power factor correction contactors if used and other external devices To switch alternately between two possible selections Prevents the interference from line noise and EMI RFI signals that may be present Specially designed 120 V 3 phase isolation transformers provide potential measurem
53. high noise areas to reduce possible electrical noise pickup Indicates that the starter has lost serial communications Fault occurs when the starter has not received a valid serial communications within the Communication Timeout parameter FUN 18 defined time Verify communication parameter settings FUN 16 FUN 19 Check wiring between the remote network and the MX control card Examine remote system for cause of communication loss Communication between the two MX cards has been lost Verify that both cards are mounted together and that the mounting hardware is not loose Verify that no foreign matter is located between the two boards Consult factory if fault persists Typically occurs when attempting to run a version of application software that is incompatible with the bottom I O card Verify that the software is a correct version for the I O card being used Consult factory for more details Indicates that the I O card self diagnostics have detected a problem with the zero sequence ground fault input If no zero sequence ground fault CT is connected to input verify that parameters ZS GF Lvl PFN 08 is turned Off Verify that no current is flowing through the zero sequence ground fault CT Consult factory is fault persists 161 8 TROUBLESHOOTING amp MAINTENANCE Fault Code Detailed Description of Fault Possible Solutions VO Card Error 4 has detected problem with the Real Time Clock operation Cons
54. horsepower rated and can be used to operate the motor while the power pole is being serviced If this is the case ensure that the power wire for the removed phase is completely removed from the unit and that the control wiring is isolated and will not come into contact with any medium voltage to prevent damage to the starter Physically testing the fans by rotating and observing the fans for noise or binding will indicate if any failure is evident Verify that interlocks functions as intended and have not been forced damaged or removed Verify that all barriers are in place and securely fastened Perform a visual inspection for evidence of damage such as overheating and do a tightness check Consult disconnect switch manufacturers instruction manual included with the starter for addition maintenance requirements 8 TROUBLESHOOTING amp MAINTENANCE NOTES 175 Appendices APPENDIX A EVENT CODES Event Codes Event Number 1 through 99 See starter fault listing for description of faults The event log will only indicate that a fault of a given fault code occurred and a time stamp when it occurred G 105 Energy Saver Exited 180 System Stop Commanded 181 106 107 System Stop Complete 182 User Passcode Enabled 183 User Passcode Disabled Motor OL Warning 184 Factory Control Password Accessed Motor OL Lockout Activated 185 Motor OL Lockout Expired 186 Stack OL Warning 187 Stack
55. in a 0 input reading at 4mA and a 100 input reading at 20mA 3 NOTE Input signal readings are clamped at a 100 maximum Example 4ma 0 input 20ma 100 input Analog Input Reading 10096 gt 12096 Ain Ain Span 80 Offset 2V 4mA i 10V 20mA Input Signal See Also Analog Input Trip Level parameter I O 17 on page 92 Analog Input Trip Time parameter I O 18 on page 93 93 6 PARAMETER DESCRIPTION Analog Input Offset parameter 20 on page 94 Starter Type parameter FUN 07 on page 103 Analog Input Offset I O 20 LCD Display Range 0 99 Default 0 Description The analog input can be offset so that a 0 reading can occur when a non zero input signal is being applied Example Input level of 2V 4mA 0 input In this case the Analog Input Offset parameter should be set to 20 so that the 2V 4mA input signal results in a 0 input reading 36 NOTE For a 4 20mA input set the Analog Input Span to 80 and the Analog Input Offset to 20 96 3 NOTE The measured input reading is clamped at 0 95 minimum See Also Analog Input Trip Level parameter I O 17 on page 92 Analog Input Trip Time parameter I O 18 on page 93 Analog Input Span parameter 1 19 on page 93 Starter Type parameter FUN 07 on page 103 Analog Output Function 21 LCD Display Range LCD Description Off Off Disabled Default 0 200 Curr Based on per cycle RMS values 0
56. left of the display 3 NOTE The TBS timer is not activated by a PORT restart Starts per Hour 22 LCD Display Range Off 1 6 Default Off Description The Starts per Hour parameter will set the number of allowed starts in one hour If the starter has been stopped and the number of starts given in the last hour has exceeded this setting the starter will display a starts per hour lockout and the time until the next start is allowed in the bottom right of the display 3 NOTE The Starts Hour counter does not increment on a PORT restart Auto Fault Reset Time 23 LCD Display Range Off 1 900 seconds Default Off Description The Auto Reset parameter sets the time delay before the starter will automatically reset a fault For the list of faults that may be auto reset refer to Appendix C Fault Codes on page 181 3 NOTE A start command needs to be initiated once the timer resets the fault 3 NOTE If the Auto Reset feature is used CAUTION must be exercised to assure that any restart occurs in a safe manner 84 6 PARAMETER DESCRIPTION See Also Appendix C Fault Codes on page 181 Auto Fault Reset Count Limit parameter PFN 24 on page 85 Auto Fault Reset Count Limit PFN 24 LCD Display Range Off 1 10 Default Off Description The Auto Reset Limit parameter sets the number of times that an auto fault reset may be performed Once the number of auto reset counts have been exceeded th
57. on site training on RediStart EXMVRMX operations and troubleshooting Benshaw technical support personnel are available at no charge to answer customer questions and provide technical support over the telephone For more information about contacting technical support personnel refer to page 4 Benshaw provides all customers with Operations manual Wiring diagram All drawings are produced in AutoCADO format The drawings are available on standard CD DVD or via e mail by contacting Benshaw All RediStart EXMVRMX documentation is available on line at http www benshaw com Spare and replacement parts can be purchased from Benshaw Technical Support This manual pertains to the software version number 1 810023 02 01 2 810024 02 00 This manual pertains to the hardware assembly version number BIPC 450100 02 00 See page 211 Benshaw provides a 1 year standard warranty with its starters An extension to the 3 year warranty is provided when a Benshaw or Benshaw authorized service technician completes the installation and initial start up The warranty data sheet must also be signed and returned The cost of this service is not included in the price of the Benshaw soft starter and will be quoted specifically to each customers needs All recommended maintenance procedures must be followed throughout the warranty period to ensure validity This information is also available by going online to register at www benshaw com 1 INTRO
58. resistance readings are outside of the above specified values consult factory 165 8 TROUBLESHOOTING amp MAINTENANCE SCR Replacement 8 8 SCR Replacement 8 8 1 Card Removal Before the SCRs can be removed the PC boards and Lexan or glastic must first be removed If unsure of any wiring connections to the card write down location of wires on drawings 8 8 2 SCR Clamp The SCR clamp pictured below is typical of the clamp used on all SCRs The larger SCRs have two spring washer stacks and pressure indicating washers These SCR clamps are precision clamps that allows easy installation to the proper SCR clamping pressure They have a pressure indicator s that will become loose once the proper pressure is reached Figure 51 Clamp Assembly Typical E a Glastic Spine 7 Screw Serrated Hex Nut 9 L Finned Heatsink Centering Dowell Pressure Indicating Washer amp Tension Setting Bolt see note below i Insulator Aluminum Brick P SN 3 NOTE Do not adjust pressure indicating washer If it is adjusted or tampered with the clamp is defective and must be returned to factory for calibration 166 8 TROUBLESHOOTING amp MAINTENANCE ATTENTION The Fiber Optic cables can be damaged if struck or bent sharply The edge of the printed circuits board should be held to prevent damage Special equipment is required for working on the fiber optic por
59. rotating increase the kick current by 100 and re adjust the kick time See Also Start Mode on CFN 01 on page 63 Kick Time 1 on CFN 12 on page 68 Theory of Operation section 7 3 2 Programming A Kick Current on page 124 68 6 PARAMETER DESCRIPTION Kick Time 1 CFN 12 LCD Display Range 0 1 10 0 seconds Default 1 0 sec Description The Kick Time 1 parameter sets the length of time that the kick current level is applied to the motor The kick time adjustment should begin at 0 5 seconds and be adjusted by 0 1 or 0 2 second intervals until the motor begins rotating If the kick time is adjusted above 2 0 seconds without the motor rotating start over with a higher kick current setting 3 NOTE The kick time adds to the total start time and must be accounted for when setting the UTS time See Also Up To Speed QST 09 on page 62 Start Mode CFN 01 on page 63 Kick Level 1 CFN 11 on page 68 Theory of Operation section 7 3 2 Programming A Kick Current on page 124 Kick Level 2 CEN 13 LCD Display Range Off 100 800 of FLA Default Off Description The Kick Level 2 parameter sets the current level that precedes any ramp when a start is first commanded when the second ramp is active Refer to the Kick Level 1 CFN 11 parameter on page 68 for description of operation Kick Time 2 14 LCD Display Range 0 1 10 0 seconds Default 1 0 sec Description The Kick Time 2 parameter sets the length o
60. running and the measured PF is lagging the defined threshold but the delay for the fault has not yet expired When the delay expires a Fault 36 occurs Power Factor Lagging This alarm exists while the MX is running and a current imbalance above the defined threshold is detected but the delay for the fault has not yet expired When the delay expires a Fault 37 occurs Current Imbalance This alarm exists while the MX is running and a ground current above the defined threshold is detected but the delay for the fault has not yet expired When the delay expires a Fault 38 occurs a Ground Fault A Stack Overload Alarm This occurs when the stack thermal rises above 105 This occurs when a non valid or tachometer input signal is detected The alarm shall exist until a valid tachometer feedback signal is detected or the fault delay timer has expired When the delay expires a Fault 53 shall occur Tachometer Signal Loss This alarm shall exist if DI 1 is programmed as a fault is in External Alarm on DI 1 Input the fault state but the fault timer has not yet expired When the timer expires a Fault 60 shall occur This alarm shall exist if DI 2 is programmed as a fault is in External Alarm on DI 2 Input the fault state but the fault timer has not yet expired When the timer expires a Fault 61 shall occur This alarm shall exist if DI 3 is programmed as a fault is in External Alarm on DI 3 Input the fault state but the f
61. section 7 3 Acceleration Control on page 123 Jump to Parameter CFN 00 LCD Display Description By changing the value of this parameter and pressing ENTER you can jump directly to any parameter within that group Start Mode 01 LCD Display Range LCD Description Voltage Ramp Open Loop Voltage acceleration ramp Current Ramp Current control acceleration ramp Default TT Ramp TruTorque control acceleration ramp Power Ramp Power kW control acceleration ramp Tach Ramp Tachometer control acceleration ramp Description The Start Mode parameter allows the selection of the optimal starting ramp profile based on the application The closed loop current control acceleration ramp is ideal for starting most general purpose motor applications Ex crushers ball mills reciprocating compressors saws centrifuges and most other applications The closed loop trutorque control acceleration ramp is suitable for applications that require a minimum of torque transients during starting or for consistently loaded applications that require a reduction of torque surges during starting Ex centrifugal pumps fans and belt driven equipment The closed loop power control acceleration ramp is ideal for starting applications using a generator or other limited capacity source In addition to the basic motor and starter setup variables the following needs to be done to use the tachometer feedback control ramp Connect a tachome
62. software must be reloaded in to the control card before normal operation can resume 162 8 TROUBLESHOOTING amp MAINTENANCE Minimum Safety Practices 8 6 Minimum Safety Practices Before performing any tests on electrical equipment make certain all PPE Personal Protective Equipment is worn Check with your Health and Safety co ordinator or for more information see www NFPA ORG Electrical Safety in the workplace Open the disconnect switch and perform lockout and tag procedures After opening the switch and before opening door use the viewing window to ensure that all three Load Break Interrupter Switch blades are open and resting on the ground bar Use a flashlight if necessary see picture There are several interlocks on the switches They are for personal and or equipment protection Under no circumstances should they be made inoperative when the switch is in service To do so could cause bodily injury death and or property damage Prior to commencing any testing procedures ensure that the designated five minute wait period has passed then discharge any power factor correction capacitors if present The wait time allows the charge in the capacitors to dissipate Inspect the LV section first using a voltage sniffer to verify that all voltage has been successfully removed or discharged Next conduct the same tests within the MV section A smell test is then needed to detect a scent of burning or any visual trace
63. speed of the system When this control mode is selected the starter uses a tachometer to provide speed feedback to the starter This mode is commonly used on conveyor belt applications where a smooth controlled start is necessary under various load conditions to prevent belt breakage lifting or excessive stretching The Tachometer controller consists of an inner PID current loop and an outer PI speed control loop 3 NOTE The maximum current limit will override the speed control loop if necessary If the Maximum Current level is not set high enough or the load is too great the starter will limit the motor current to this maximum level When current limiting occurs the speed profile will no longer be linear and the motor s will take longer to accelerate to full speed Therefore if current limiting is undesirable this parameter must be set higher than the peak starting current during a linear speed ramp start In addition to the basic motor and starter setup variables the following needs to done to use the tachometer feedback control ramp 1 Connect a tachometer with appropriate DC output voltage and correct polarity to the MX power card input TB5 2 positive amp 5 3 negative 2 The tachometer feedback Start Mode CEN 01 is selectable as Tach Ramp from the Starter Modes menu 3 Program the appropriate variables in the Tachometer Setup menu FUN 13 Tachometer Full Speed Voltage on page 106 FUN 14 Tachometer Loss T
64. the Motor FLA QST 01 parameter is available both in holding register 40101 and in input register 30101 This is why the register addresses in the Modbus Register Map are listed with both numbers e g 30101 40101 Cable Specifications Good quality twisted shielded communications cable should be used when connecting to the Modbus port on the The cable should contain two twisted pairs and have an overall shield Use one pair of conductors for the A and B signals Use the other pair of conductors for the Common signal The cable should adhere to the following specifications Conductors 2 twisted pair Impedance 100 Ohm to 120 Ohm Capacitance 16 pF ft or less Shield Overall shield or individual pair shields Examples of cables that meet these specifications are Belden part number 9842 and Alpha Wire part number 6412 Terminating Resistors The MX does not have a terminating resistor for the end of the trunk line If a terminating resistor is required the resistor must be wired to the terminal block The purpose of terminating resistors is to eliminate signal reflections that can occur at the end of a network trunk line In general terminating resistors are not needed unless the bit rate is very high or the network is very long In fact terminating resistors place a large load on the network and may reduce the number of drops that may be placed on the network The maximum baudrate of 19 200 supported by the MX i
65. the lowest acceptable frequency When operating on generator power the Under Frequency parameter should be set to the lowest acceptable frequency This will ensure that a generator problem will not cause unnecessarily large fluctuations in the speed of the motor The frequency must be below the under frequency setting for the Frequency Trip Time PFN 16 parameter before the starter will recognize an under frequency condition Once an under frequency condition exists the starter will shut down and display a Fault 12 Low Freq Trip See Also Over Frequency Trip Level PFN 14 on page 82 Frequency Trip Time PFN 16 on page 83 82 6 PARAMETER DESCRIPTION Frequency Trip Time PEN 16 LCD Display Range 0 1 90 0 seconds Default 0 1 Description The Frequency Trip Time parameter sets the time that the line frequency must go above the Over Frequency Trip Level PFN 14 or below the Under Frequency Trip Level PFN 15 parameter before a high or low frequency fault will occur See Also Over Frequency Level PEN 14 on page 82 Under Frequency Level PEN 15 on page 82 PF Lead Trip Level 17 LCD Display Range Off 0 80 lag to 0 01 lead Default Off Description The amount of power factor lead before the specified PF Trip Time PFN 19 fault will occur See Also Power Factor Lag Trip Level PFN 18 on page 83 Power Factor Trip Time PEN 19 on page 83 PF Lag Trip Level PFN 18 LCD Display Range Off
66. to return There is the capability to hold the bypass contactor if present in for a given amount of time Then when power returns PORT shall perform a controlled restart of the motor to prevent current and or torque spikes from occurring The starter will enter PORT when the line voltage drops below the undervoltage trip level if enabled or 30 below rated voltage when undervoltage protection is not enabled 3 NOTE For PORT to operate it is assumed that an UPS Uninterruptible Power Supply will supply the MX control power Also the MX run command needs to be held active during the power outage otherwise the MX will perform a normal stop P O R T Bypass Hold Time FUN 11 LCD Display Range Off 0 1 5 0 seconds Default Off Description When a power outage event is detected and the PORT bypass hold timer is enabled the starter will hold the Bypass contactor in for a user selectable amount of time When the time expires the starter shall open the bypass 105 6 PARAMETER DESCRIPTION P O R T Recovery Method FUN 12 LCD Display Range LCD Description Fast Recover Current acceleration ramp from 100 FLA gt 800 FLA with a ramp time of 1 second Default Current Ramp Current acceleration ramp using the Ramp 1 user parameter settings Current Ramp 2 Current acceleration ramp using the Ramp 2 user parameter settings Ramp Select Current acceleration ramp using the appropriate current ramp selected by the RAMP Se
67. when a stop is commanded decrease this parameter value If there is a sudden drop in motor speed when stop is commanded increase this parameter value Stop Mode 15 set to TruTorque Deceleration Not used when the Stop Mode parameter is set to TruTorque Decel The TruTorque beginning deceleration level is automatically calculated based on the motor load at the time the stop command is given 70 6 PARAMETER DESCRIPTION 3 NOTE It is important that the Rated Power Factor FUN 06 parameter is set properly so that the actual deceleration torque levels are the levels desired See Also Stop Mode CFN 15 on page 70 Decel End Level CFN 17 on page 71 Decel Time CFN 18 on page 71 Controlled Fault Stop Enable PFN 25 on page 85 Rated Power Factor FUN 06 on page 103 Theory of Operation section 7 4 Deceleration Control on page 131 Decel End Level 17 LCD Display Range 1 99 of phase angle firing Default 20 Description Stop Mode CFN 15 set to Voltage Deceleration The voltage deceleration profile utilizes an open loop S curve voltage ramp profile The Decel End Level parameter sets the ending voltage level for the voltage deceleration ramp profile The deceleration ending level is not a precise percentage of actual line voltage but defines an ending point on the S curve deceleration profile A typical voltage decel end level setting is between 10 and 20 If the motor stops rotating
68. 0 0 sec in 0 1 sec intervals ANSI 51G Residual Ground fault detection Off or 5 to 100 of motor FLA Zero Sequence Ground Fault Detection Off 0 1 25Amps ANSI 66 Starts Hour amp Time Between Starts Restart Block Backspin Timer ANSI 74 Alarm relay output available ANSI 81 Over Under Frequency ANSI 86 Overload lockout Single Phase Protection Shorted SCR Detection Mechanical Jam gt gt gt gt gt gt gt 10 2 2 4 2 TECHNICAL SPECIFICATIONS Solid State Motor Overload The control has an advanced I t electronic motor overload OL protection function For optimal motor protection the control has forty standard NEMA style overload curves available for use Separate overloads be programmed one for acceleration and another for normal running operation The overloads can be individual the same or completely disabled if necessary The EXMVRMX motor overload function also implements a NEMA based current imbalance overload compensation RTD Biasing user adjustable hot and cold motor compensation and user adjustable exponential motor cooling Figure 2 Commonly Used Overload Curves 10000 1000 SN 8 RSs 100 5 Class 40
69. 10 and the Analog Input Trip Type parameter is set to Low a fault occurs when the analog input signal level is less than lt or 2mA regardless of what the Analog Input and Analog Input Span parameters values are set to 92 6 PARAMETER DESCRIPTION See Also Analog Input Trip Type parameter 1 16 on page 92 Analog Input Span parameter I O 19 on page 93 Analog Input Offset parameter 20 on page 94 Analog Input Trip Delay Time I O 18 LCD Display Range 0 1 90 0 seconds Default 0 1 Description The Analog Input Trip Time parameter sets the length of time the analog input trip level I O17 must be exceeded before a trip occurs See Also Analog Input Trip Type parameter 16 on page 92 Analog Input Trip Level parameter I O 17 on page 92 Analog Input Span parameter I O 19 on page 93 Analog Input Offset parameter I O 20 on page 94 Analog Input Span 19 LCD Display Range 1 100 Default 100 Description The analog input can be scaled using the Analog Input Span parameter Examples For a 0 10V input or 0 20mA input a 100 Analog Input Span setting results in a 096 input reading with a OV input and a 100 input reading with a 10V input For a 0 5V input a 50 Analog Input Span setting results in a 0 input reading with a input and a 100 input reading with a 5V input For a 4 20mA input a 80 Analog Input Span setting and 20 Analog Input Offset setting results
70. 12 968 5415 BENSHAW Canada 550 Bright Street Listowel Ontario N4W 3W3 Phone 519 291 5112 Fax 519 291 2595
71. 16 bits Watts upper 16 bits VA lower 16 bits VA upper 16 bits vars lower 16 bits in 32 bit two s compliment signed integer vars upper 16 bits format V 0 30040 40040 30041 40041 30042 40042 30043 40043 30044 40044 30045 40045 30046 40046 30047 40047 30048 40048 32 bit unsigned integer format in 32 bit unsigned integer format kW hours lower 16 bits kW hours upper16 bits in 32 bit unsigned integer format ABC 30049 40049 Phase Order CBA SPH Line Frequency 230 720 or 0 if no line in 16 bit two s compliment signed format Starts TruTorque 30050 40050 30051 40051 30052 40052 30053 40053 30054 40054 30055 40055 30056 40056 30057 40057 Power 96 186 APPENDIX F MODBUS REGISTER MAP Deswawss Pek Suing Gane r 30050740059 ast Staring Duration ots Bit Mask Each of the sixteen 16 bits represents an 30079 40079 RTDs Enabled RTD A 1 indicates the RTD is enabled Bit 0 represents RTD 1 Bit 15 represents RTD 16 Bit Mask Each of the sixteen 16 bits represents 20080 400830 RTDs Assigned as Stator RTD A 1 indicates the RTD is assigned to the stator group Bit Mask Each of the sixteen 16 bits represents an 3008140081 RTDs Assigned as Bearing RTD A 1 indicates the RTD is assigned to the bearing group Bit Mask Each of the sixteen 16 bits represents an A 0082 10082 Ass
72. 24 Hour YY MM DD 12 Hour YY MM DD 24 Hour DD MM YY 12 Hour DD MM YY 24 Hour 30230 40230 Current Imbalance Delay Time 100 mSec Disabled 30231 40231 Zero Sequence Ground Fault Trip Enable Enabled 0 Disabled 30238 40238 Power Factor Leading Trip Enable 1 Enabled Squared 30225 40225 PORT Recovery Method 30228 40228 Tachometer Loss Action 30229 40229 Time Date Format 0 1 2 3 0 1 2 3 4 5 x 80 99 0 80 to 0 99 lag 30239 40239 Power Factor Leading Trip Level 100 120 1 00 to 0 80 lead Disabled 30240 40240 Power Factor Lagging Trip Enable Enabled NEN 1 99 0 01 to 0 99 lag 30241 40241 Power Factor Lagging Trip Level 100 120 1 00 to 0 80 lead 30242 40242 Power Factor Delay Time 1 900 100 mSec NN 0 Disabled 30243 40243 Backspin Timer Enable 1 Enabled EM 30244 40244 Backspin Time 1 180 30245 40245 Time Between Starts Enable 0 Disabled l Enabled 30246 40246 1 180 0 Disabled 30247 40247 Starts Hour Enable 1 Enabled 0 Disabled 30249 40249 Speed Switch Enable 1 Enabled 194 APPENDIX F MODBUS REGISTER MAP Absolute Register Address 30250 40250 Speed Switch Delay Time 30251 40251 Motor PTC Enable 30252 40252 Motor PTC Delay Time 30253 40253 PORT Trip Enable 30254 40254 PORT Trip Delay Time 30255 40255 Motor Overload Alarm Level 30256 40256 Motor Overload Lockout Level 30257 40257 Moto
73. 4mA 100 output 20ma Analog Output 10V ____________________ 20mA Aout Span 8096 2V AMA E SSS SSS SSS Seas Aout Offset 0V OmA I 20 Selected Output Selected Output value 0 value 100 See Also Analog Output Offset parameter I O 23 on page 95 Analog Output Offset YO 23 LCD Display Range 0 99 Default 0 Description The analog output signal can be offset using the Analog Output Offset parameter A 50 offset outputs a 50 output 5V in the 10V case when 0 is commanded If the selected variable requests 100 output the span should be reduced to 100 minus offset so that a 100 output request causes a 100 output voltage x96 offset 100 x span 100 3 NOTE For a 4 20mA output set the Analog Output Span to 80 and the Analog Output Offset to 20 See Also Analog Output Span parameter 22 on page 95 95 6 PARAMETER DESCRIPTION Inline Configuration I O 24 LCD Display Range Off 0 10 0 seconds Default 3 0 Description The Inline Configuration parameter controls the behavior of the No Line warning No Line fault and the Ready relay function If the Inline Configuration parameter is set to Off then the MX assumes that there is no Inline contactor and that line voltage should be present while stopped Ifno line is detected then a No Line alarm condition exists and the ready condition does not exist If a start is commanded then a No Line fault is declared If the Inline Configur
74. 8 be ei er LOCATED IN LOW VOLTAGE SECTION i 1 8 TO k q F ret Teese 0 oan enr i i IRR gt s d om LINE VOLTAGE SACT 20001 SENSING DIVIDER INPUT GFCT INPUT scrie CARD 80k i Man AC PHASE 1 STACK OT INPUT POWER sor 28 sor 20 scr 20 t sore t ie 71 ScR2F Be PHASE STACK OT na soraa 0005502 1 sor 28 CARD sorse Lo A RELAY MOTOR OUTPUTS uad 1 CONTACTOR PHASE STACK OT COIL We O uus 1 1 1 lot Tes ANALOG INPUT 10V 00 4 01 RELAY MVIO CARD OUTPUTS 4 TBS ANALOG 1 OUTPUT 1 T 1 f F 4 i MODBUS il stop start bk ale 2 6 Ms SLAVE I i i MEDIUM VOLTAGE n A NAR MX CARD ASSEMBLY KEYPADIDISPLAY CARD DISCONNECT AUXILIARY CONTACT BIPC 450100 01 m Bi stor icopsmar TIT TITEL CONSISTS OF BIPC 300055 02 0 amp 300034 01 Rusu fom ferar OOS PROGRAMMABLE s DIGITAL J5 cow Rm m RESET PARAM DOWN UP ENTER LOCATED IN LOW VOLTAGE SECTION 3 NOTE When in ATL mode the acceleration ramp kick and deceleration parameter settings have no effect on motor oper
75. 9 Once the starter recognizes a ground fault condition it shuts down the motor and declares a Fault 38 Ground Fault Alarm Fault FLA Condition Trip Residual Gnd Fault Level PFN 07 Ground Fault Trip Time PEN 09 If a programmable relay 01 08 is set to Ground Fault the starter energizes the relay when the condition exists A typical value for the ground fault current setting is 10 to 20 of the full load amps of the motor 36 NOTE This type of protection is meant to provide machine ground fault protection only It is not meant to provide human ground fault protection 38 NOTE The EXMVRMX residual ground fault protection function is meant to detect ground faults on solidly grounded systems Use on a high impedance or floating ground power system may impair the usefulness of the EXMVRMX residual ground fault detection feature 36 NOTE Due to uneven CT saturation effects and motor and power system variations there may be small values of residual ground fault currents measured by the EXMVRMX during normal operation See Also Ground Fault Trip Time parameter PFN 09 on page 80 Auto Reset parameter PFN 23 on page 84 Controlled Fault Stop Enable parameter 25 on page 85 Relay Output Configuration parameters I O 10 15 on page 91 79 6 PARAMETER DESCRIPTION Zero Sequence Ground Fault Trip Level PFN 08 LCD Display Range Off 1 0 25 0 amps Default Off Description T
76. Acceleration Ramp Control on page 128 65 6 PARAMETER DESCRIPTION Maximum Current 2 07 LCD Display Range 100 800 of FLA Default 600 Description The Maximum Current 2 parameter is set as a percentage of the Motor FLA QST 01 parameter setting when the second ramp is active Refer to the Maximum Current CFN 04 on page 65 parameter for description of operation See Also Maximum Current 1 CFN 04 on page 65 Digital Input Configuration I O 01 08 on page 90 Theory of Operation section 7 3 1 Current Ramp Settings Ramps and Times on page 123 Theory of Operation section 7 3 6 Dual Acceleration Ramp Control on page 128 Initial Voltage Torque Power CEN 08 LCD Display Range 1 100 of Voltage Torque Power Default 25 Description Start Mode CEN 01 set to Open Loop Voltage Acceleration This parameter sets the starting point for the voltage acceleration ramp profile A typical value is 2596 If the motor starts too quickly or the initial current is too high reduce this parameter If the motor does not start rotating within a few seconds after a start is commanded increase this parameter Start Mode CFN 01 set to Current Control Acceleration Not used when the Start Mode parameter is set to Current control acceleration Refer to the Initial Current 1 QST 06 CEN 03 parameter to set the initial current level Start Mode CEN 01 set to TruTorque Control Acceleration This parameter s
77. C We 890034 06 00 Motor Starter Card Set BIPC 450100 02 01 Software Version 1 810023 02 01 Software Version 2 810024 01 01 Gate Driver Card BIPC 300003 01 Gate Power Distributor Card BIPC 300007 02 2006 Benshaw Inc Benshaw retains the right to change specifications and illustrations in text without prior notification The contents of this document may not be copied without the explicit permission of Benshaw ADVANCED CONTROLS amp DRIVES Important Reader Notice Congratulations on the purchase of your new Benshaw RediStart EXMVRMX Solid State Starter This manual contains the information to install and program the Solid State Starter This manual may not cover all of the applications for the RediStart EXMVRMX Also it may not provide information on every possible contingency concerning installation programming operation or maintenance specific to the RediStart EXMVRMX Series Starters The content of this manual will not modify any prior agreement commitment or relationship between the customer and Benshaw The sales contract contains the entire obligation of Benshaw The warranty enclosed within the contract between the parties is the only warranty that Benshaw will recognize and any statements contained herein do not create new warranties or modify the existing warranty in any way Any electrical or mechanical modifications to Benshaw products without prior written consent of Ben
78. Check if motor may have been driven by the load a regeneration condition Check Gate and Cathode connections to MX for loose connections Check for inline contactor or disconnect A shorted or open SCR condition has been detected Verify that all SCR gate leads wires are properly connected at the SCR devices and the MX control card Check all SCRs with ohmmeter for shorts Verify that the Input Phase Sensitivity parameter setting FUN 04 is correct Verify that the Starter Type parameter setting FUN 07 is correct Verify the motor wiring Verify dual voltage motors for correct wiring configuration Motor current was detected while the starter was not running Examine starter for shorted SCRs Examine bypass contactor if present to verify that it is open when starter is stopped Verify that the motor FLA QST 01 and CT ratio FUN 03 settings are correct A signal on the disconnect digital input 01 I O 08 was not present when a start was commanded Verify that disconnect feedback wiring is correct Verify that disconnect is not faulty 159 8 TROUBLESHOOTING amp MAINTENANCE Fault Code Detailed Description of Fault Possible Solutions The MX electronic power stack OL protection has detected an overload condition Stack Protection Fault stack Check motor for jammed or overloaded condition thermal overload Verify that the CT ratio FUN 03 is correct Motor load exceeds power stack rating Co
79. DUCTION Contacting Benshaw Contacting Benshaw Information about Benshaw products and services is available by contacting Benshaw at one of the following offices Benshaw Inc Corporate Headquarters 1659 E Sutter Road Glenshaw PA 15116 Phone 412 487 8235 Tech Support 800 203 2416 Fax 412 487 4201 Benshaw Canada Controls Inc 550 Bright Street East Listowel Ontario N4W 3W3 Phone 519 291 5112 Tech Support 877 236 7429 BEN SHA W Fax 519 291 2595 Benshaw West 14715 North 78th Way Suite 600 Scottsdale AZ 85260 Phone 480 905 0601 Fax 480 905 0757 Benshaw High Point EPC Division 645 McWay Drive High Point NC 27263 Phone 336 434 4445 Fax 336 434 9682 Benshaw Mobile CSD Division 5821 Rangeline Road Suite 202 Theodor AL 36582 Phone 251 443 5911 Fax 251 443 5966 Benshaw Pueblo Trane Division 1 Jetway Court Pueblo CO 81001 Phone 719 948 1405 Fax 719 948 1445 Technical support for the RediStart EXMVRMX Series is available at no charge by contacting Benshaw s customer service department at one of the above telephone numbers A service technician is available Monday through Friday from 8 00 a m to 5 00 p m EST 3 NOTE An on call technician is available after normal business hours and on weekends by calling Benshaw and following the recorded instructions To help assure prompt and accurate service please have the following information available when
80. ESCRIPTION Passcode FUN 26 LCD Display Description The MX provides a means of locking parameter values so that they may not be changed Once locked the parameters values may be viewed on the display but any attempt to change their values by pressing the UP or DOWN keys is ignored Viewing the Passcode parameter indicates whether or not the parameters are locked If they are locked the Passcode parameter displays On If they are not locked the Passcode parameter displays Off To lock the parameters press the ENTER key while viewing the Passcode parameter This allows entry ofa 4 digit number Press the UP or DOWN keys and ENTER for each of the four digits After entering the fourth digit the number is stored as the passcode and the parameters are locked Once parameters are locked the same 4 digit number must be re entered into the Passcode parameter in order to unlock them Any other 4 digit number entered will be ignored 3 NOTE To re establish password protection after it has been cleared the password must be entered again Fault Log 9 LCD Display Range FLI FL9 Description When a fault occurs the fault number is logged in non volatile memory The most recent fault is in FL1 and the oldest fault is in FL9 Pressing ENTER toggles through the Starter data recorded at the time of the fault See section 4 4 5 for more information See Also Appendix C Fault Codes on page 181 Event Reco
81. Electrical Code article 430 Part C allows for different overload multiplier factors depending on the motor and operating conditions NEC section 430 32 outlines the allowable service factor for different motors as follows Motor Overload Multiplier Service factor 1 15 or more 1 25 Motor temp rise 40 C or less 1 25 All others 1 15 NEC section 430 34 permits further modifications if the service factor is not sufficient to start the motor Motor Overload Multiplier Service factor 1 15 or more 1 40 Motor temp rise 40 C or less 1 40 All others 1 30 Although the NEC does not address the effect of the ambient temperature of the motor location guidance can be derived by examining NEC limits If the motor is operating in an ambient temperature that is less than 40 C then the overload multiplier can be increased while still protecting the motor from exceeding its maximum designed temperature The following curve gives the ambient temperature versus the correction factor Temperature vs Correction Factor Temperature Correction Factor Example If a motor operates at 0 C then a 1 36 correction factor could be applied to the overload multiplier This could give a theoretical overload multiplier of 1 36 x 1 25 or 1 70 The highest legal NEC approved value of overload multiplier is 1 40 so this could be used 7 THEORY OF OPERATION Acceleration Control 7 3 Acceleration Control 7 3 1 Current
82. F Humidity 0 to 95 non condensing Altitude 1000m 3300ft without derating Maximum Vibration 5 9m s 19 2ft s2 0 66 Cooling Natural convection Fans optional Altitude Derating 2 5 Altitude Derating Benshaw s starters are capable of operating at altitudes up to 3 300 feet 1000 meters without requiring altitude derating Table 6 provides the derating percentage to be considered when using a starter above 3 300 feet 1000 meters Table 6 Altitude Derating Altitude Percent Derating Amps 3300 Feet 1006 meters 0 0 4300 Feet 1311 meters 3 0 5300 Feet 1615 meters 6 0 6300 Feet 1920 meters 9 0 1 7300 Feet 2225 meters 2 0 8300 Feet 2530 meters 15 0 9300 Feet 2835 meters 18 0 For derating above 10 000 feet consult Benshaw Inc Real Time Clock 2 6 Real Time Clock The MX comes with a real time clock The user can enter the actual time and the starter will use this time when it logs faults in the fault recorder as well as events in the event recorder This can help with troubleshooting The system clock does not recognize daylight savings time Accuracy 1 minute per month Range 1 1 1972 to 1 1 2107 with automatic leap year compensation 2 7 Approvals MX Control Card Set is UL cUL Recognized Certificate of Compliance 2 8 Certificate of Compliance CE Mark see Appendix E on page 184 15 2 TECHNICAL SPECIFICATIONS NOTES POACR TU IPECDHMECT TACH J e
83. FUN 03 LCD Display Range Description 72 1 96 1 144 1 288 1 864 1 2640 1 3900 1 5760 1 8000 1 14400 1 28800 1 50 5 150 5 250 5 800 5 2000 5 5000 5 Default 288 1 The CT Ratio parameter must be set to match the CTs current transformers supplied with the starter This allows the starter to properly calculate the current supplied to the motor 36 NOTE It is very important that the CT ratio is set correctly Otherwise many starter functions will not operate correctly Input Phase Sensitivity FUN 04 LCD Display Range Description 102 LCD Description Insensitive Runs with any three phase sequence Default ABC Only runs with ABC phase sequence CBA Only runs with CBA phase sequence Single phase Single Phase The Phase Order parameter sets the phase sensitivity of the starter This can be used to protect the motor from a possible change in the incoming phase sequence If the incoming phase sequence does not match the set phase rotation the starter displays an alarm while stopped and faults if a start is attempted 6 PARAMETER DESCRIPTION Rated RMS Voltage FUN 05 LCD Display Range 100 110 120 200 208 220 230 240 350 380 400 415 440 460 480 500 525 575 600 660 690 800 1000 1140 2200 2300 2400 3300 4160 4600 4800 6000 6600 6900 10 00K 11 00K 11 50K 12 00K 12 47K 13 20K 13 80K Default 480 Description The Rated Voltage parameter sets the line volta
84. Fault Current 15 ach Los Act Tachometer Loss Action TruTorque KW Com Drop Communication Address 110247 7 4 9 S Fault 106 a E ri S 8 L i 1200 2400 4800 17 Com Baud rate Communication Baud Rate 9600 19200 19200 107 1 5 5 6 7 8 Even 1 Stop Bit Communications Byte Odd 1 Stop Bit P Com Parity Framing None 1 Stop Bit Even 1 Stop 108 None 2 Stop Bit 0 Software 1 Software Part Number 1 Display Only EE 108 Software 2 Software Part Number 2 Display Only fo Reset Reset kWh ise Reflash Mode P67 Miscellaneous Commands Store Parameters None 108 Command Load Parameters Factory Reset Std BIST Powered BIST mm dd yy 12h mm dd yy 24h T D Format Time and Date Format 1 m 109 dd mm yy 12h dd mm yy 24h N N ER 109 Fa Paste T To mi N 5 2 7 Fault Group Page Cou D V1 v2 v kw Number Description State Time 210 5 2 8 Event Log Group Event Group Event Number 3 Condition Date Description 56 Parameter Description 6 PARAMETER DESCRIPTION Parameter Descriptions 6 1 Parameter Descriptions The detailed parameter descriptions in this chapter are organized in the same order as they appear on the LCD display Each parameter has a detailed description that is disp
85. I3 120VAC NEUTRAL 120VAC NEUTRAL DIGITAL INPUT WIRING 3 WIRE START STOP BUTTONS DI1 SET TO STOP OFF HAND 4 AUTO PLC 120VAC LIVE olo k OUTPUT CONTACT START 120VAC LIVE o l iue Te 120VAC NEUTRAL 120VAC NEUTRAL 2 WIRE ON OFF SELECTOR SWITCH HAND OFF AUTO SELECTOR SWITCH DI1 SET TO STOP ON OFF ON OFF 120VAC LIVE 120 LIVE SLOW SPEED AE m TRIP A 120VAC NEUTRAL 120VAC NEUTRAL SLOW SPEED CONTROL BUTTON EXTERNAL TRIP INPUT DI2 SET TO SSPD SLOW SPEED 013 SET TO FL FAULT LOW See Also Digital Input Configuration I O 01 08 on page 90 31 3 INSTALLATION 3 11 4 Analog Input The analog input can be configured for voltage or current loop The input is shipped in the voltage loop configuration unless specified in a custom configuration Below TBS is SW1 1 When the switch is in the on position the input is current loop When off it is a voltage input The control is shipped with the switch in the off position 3 NOTE The analog input is a low voltage input maximum of 15VDC The input will be damaged if control power 115VAC or line power is applied to the analog input The terminals are as follows 1 10VDC Power for POT Figure 16 Analog Input Wiring Examples 2 input 3 input 4 common 7 shield 4 5 A 5K 10Kohm 9 O 9 POTENTIOMETER See Also Analog Input I O 16 20
86. ISO 1 OVERTEMP CHANNEL 1 1502 OVERTEMP CHANNEL 2 ISO3 OVERTEMP CHANNEL 3 GATE POWER OK LED GATE POWER DISTRIBUTOR CARD BIPC 300007 02 ATTENTION The Fiber Optic cables can be damaged if struck or bent sharply The edge of the printed circuit board should be held to prevent damage 150 8 TROUBLESHOOTING amp MAINTENANCE General Troubleshooting Charts 8 4 General Troubleshooting Charts The following troubleshooting charts can be used to help solve many of the common issues that may occur 8 4 1 Stack Overtemp Lockout Check wiring to the OTR from the Gate OTP overtemperature relay is not energized Power Distributor Cards Enter the equipment specified rated voltage in Rated Voltage FUNOS Enter the value of the CTs supplied with the MVRMX3 into the CT Ratio Factory reset in FUN 22 was entered parameter FUN 03 Display screen displays what is shown above Set DI 2 1 002 to inline confirm Set DI 3 1 003 to disconnect Set Relay 3 I O12 to running Set r time betw tarts to all Time between starts set too short e Dee OSUWON stats LOW heat sink cooling Fiber Optic connectionon Distributor Reconnect the Fiber Optic Cables Display screen displays what is shown above plus OTS OK 2 acted and secondary fuses LED on any of the Distributor Transformer T3 supply to Distributor cards bad Card is NOT lit Check wiring to Distributor Cards and correct as n
87. LA Ramp Time 2 UTS Time 30120 40120 Initial V T P 30121 40121 Max T P Coast Voltage Decel 30122 40122 Stop Mode TruTorqu Decel DC Brake 0 Disabled 30129 40129 Kick Enable 1 1 Enabled 30130 40130 Kick Current Level 1 100 800 FLA 30131 40131 Kick Time 1 1 100 100 mSec 0 Disabled 2 30132 40132 Kick Enable 2 1 Enabled 30133 40133 Kick Current Level 2 100 800 FLA 30134 40134 Kick Time 2 1 100 100 mSec 0 Disabled 30135 40135 Slow Speed Enable 1 Enabled EM Sec Sec 0 0 188 APPENDIX F MODBUS REGISTER MAP 0 30136 40136 Slow Speed 30137 40137 Slow Speed Current Level 10 400 0 Disabled 30138 40138 Slow Speed Time Limit Enable 1 Enabled S 30139 40139 low Speed Time Limit 1 900 1 0 Disabled 30140 40140 low Speed Kick Enable 1 Enabled S 30141 40141 Slow Speed Kick Level 100 800 FLA 30142 40142 Slow Speed Kick Time 1 100 100 mSec 189 APPENDIX F MODBUS REGISTER MAP Absolute Register Address po SON ee StS 30143 40143 Rated RMS Voltage 30144 40144 Input Phase Sensitivity 30145 40145 Motor Rated Power Factor 1 100 0 Disabled 30146 40146 Overcurrent Enable 1 Enabled 30147 40147 50 800 FLA 0 Disabled 30148 40148 Overcurrent Delay Time Enable i Enabled 30149 40149 Overcurrent Delay Time 1 900 100 mSec 0 Disabled 30150 40150 Undercurrent Trip Enab
88. Lockout Level of Awo Running OL OL H C Ratio OL Cool Time OL Alarm Lvl OL Lock Lvl OL Lock Calc Under Voltage Trip Level Off 1 40 0 Off 10 10 30 15 Off B oo 5 PARAMETER GROUPS 5 2 4 Group lump Code twa I O 01 DI 1 Config Digital Input 1 Configuration Off Slow Spd Fwd m Stop Slow Spd Rev I O 02 DI 2 Config Digital Input 2 Configuration Fault High Brake Disable T O 03 DI 3 Config Digital Input 3 Configuration Fault Low Brake Enable 04 E DI 4 Config Digital Input 4 Configuration Fault Reset Speed Sw NO Disconnect Speed Sw NC 1 0 05 DI 5 Config Digital Input 5 Configuration Inline Cnfrm I O 06 ERE DI 6 Config Digital Input 6 Configuration a aia eset I O 07 I 1 DI 7 Config Digital Input 7 Configuration ocaV Remote Heat Disable T O 08 DI 8 Config Digital Input 8 Configuration Heat Enable Ramp Select I O 09 Dig Trp Time Digital Fault Input Trip Time 0 1 to 90 0 Relay Output 1 Fault FS Ground Fault Relay Output 2 VO 11 R2 Config Contisuration FaultNFS Energy Saver Off Running Heating 012 Ps4 R3 Config a UTS Slow Spd Off onfiguration Alarm Slow Spd Fwd Relay Output 4 Ready Slow Spd Rev Relay O m Overcurrent Cool Fan Ctl I O 14 m R5 Config d a Undercurrent PORT Off OL Alarm Tach Loss hunt F VO 15 p R6 Config pe Su Shunt hs off I O 16 55 Ain Trp Analo
89. N17 set improperly End levels Decel time seems correct but motor surges oscillates at beginning of deceleration 1 Begin Level CFN16 set too high cycle Decrease Decel Begin Level until surging is eliminated Increase Decel End Level until End Level CFN17 set too low motor just stops at the end of the deceleration cycle Decel End Level CFN17 set too high Decrease Pecel Level until R water hammer is eliminated Water hammer still occurs at end of cycle Decel Time CFN18 too short If possible increase Decel Time to decelerate system more gently Increase the Decel Begin Level until Motor speed drops sharply before decel Decel Begin Level CFN16 too low drop inspaed is eliminated 8 4 6 Motor stops unexpectedly while running Fault Displayed Fault Occurred See fault code troubleshooting table for more details Verify start command input signal is present or serial communications start command is present Check any permissive that may be wired into the run command Start Stop Control volt bsent Check for proper control voltage input Display Blank Heartbeat LED on MX kE VO TAER Verify wiring and fuses card not blinking control card problem Consult factory Decel time seems correct but motor stops before end of deceleration cycle Ready Displayed Start command lost 153 8 TROUBLESHOOTING amp MAINTENANCE 8 4 7 Metering incorrect Verify correct CT wi
90. NO3 Relay 3 normally open 8 RC3 Relay 3 common 9 NC3 Relay 3 normally closed Terminal block J3 is for output relays R4 R5 and R6 These relays connect as follows 1 RAA Relay 4 common 2 R4B Relay 4 open 3 RSA Relay 5 common 4 R5B Relay 5 open 5 ROA Relay 6 common 6 R6B Relay 6 open Figure 14 Relay Wiring Examples 120 LIVE s 120 NEUTRAL MA TRIP gt 120VAC NEUTRAL X RUN 120VAC LIVE vx STOP TRIP PILOT LIGHT RUN amp STOPPED PILOT LIGHT RELAY 1 SET TO FLFS FAULT FAILSAFE RELAY 2 SET TO RUN See Also Relay Output Configuration I O 10 15 on page 91 30 3 INSTALLATION 3 11 3 Digital Input TB3 is for digital inputs Start DI2 and These digital inputs use 120 These digital inputs connect as follows 1 Start Start Input 2 DII Digital Input 1 3 012 Digital Input 2 4 DI3 Digital Input 3 5 Com 120VAC neutral Terminal block J6 is for digital inputs DI4 to DI8 These digital inputs use 120VAC These digital inputs connect as follows 1 DI4 Digital input 4 2 DIS Digital input 5 3 DI6 Digital input 6 4 DI7 Digital input 7 5 DI8 Digital input 8 6 Com 120VAC neutral Figure 15 Digital Input Wiring Examples START START 120VAC LIVE E 120VAC LIVE xp o o 012 D
91. OL Lockout Activated 188 Stack OL Lockout Expired 190 Emergency OL Reset Performed 191 RTD Stator Warning 92 Low Control a when RTD Bearing Warning 193 RTD Other Warning 194 Disconnect Opened N ele Hin HR w 178 APPENDIX B ALARM CODES Alarm Codes The following is a list of all MX alarm codes The alarm codes correspond to associate fault codes In general an alarm indicates a condition that if continued will result in the associated fault Alarm 522 Motor Overload Alarm Motor PTC Alarm Stator RTD Alarm Bearing RTD Alarm Other RTD Alarm Phase Rotation not ABC Phase Rotation not CBA Low Line Frequency High Line Frequency Input power not single phase Input power not three phase This occurs when the motor thermal content reaches the Motor OL Alarm Level PFN33 The MX trips when it reaches 100 The alarm continues until the overload trip lockout is reset This occurs when the Motor PTC thermistor input indicates that the motor is overheated but before the fault trip time has expired This occurs when a RTD assigned to the Stator group reaches its alarm level This occurs when a RTD assigned to the Bearing group reaches its alarm level This occurs when a RTD assigned to the other group reaches its alarm level This alarm exists while the MX is stopped line voltage is detected and phase sensitivity parameter is set to ABC Ifa sta
92. R ERR Deme PFN 23 Reset Reset Auto Fault Reset Time Reset Time off 1 900 1 off 1 900 PEN 24 Auto Rst Lim 2 EIS en Count Limit PFN 25 Ctrl Flt En Controlled Fault Stop ff OffOn PFN 26 EN Speed Sw Time Speed Switch Trip Time Off 1 250 Seconds of 85 PEN 27 a MPTCTime Motor PTC Trip Time Off 1 5 mjo PFN 28 Indep S R OL Independent Starting Running Off On Overload SS RETE 205 APPENDIX I PARAMETER TABLES PFN 32 OL Cool Time Motor Overload Cooling Time 1 0 999 9 Minutes 30 8 Press n p wm fd Ems 9 T O Group messe iem 2 T r VO 01 DI 1 Config 2 NM V O 02 DI 2 Config d rand ai Off Heat Disable Digital Input 3 V0 03 DI 3 Config Configuration Stop Heat Enable Fault High Ramp Select I O 04 DI 4 Config Digital Input 4 Fault Low Slow Spd Fwd Configuration Fault Reset Slow Spd Rev Digital Input 5 Disconnect Brake Disable Bypass Cnfrm Speed Sw NO 06 DI 6 Config Digital Input 6 E OL Reset Speed Sw NC Configuration Local Remote vo 07 017 Config Pistia 97 ER VO 08 m DI 8 Config emn m 1 0 09 Dig Trp Time Digital Fault Input Trip Time 0 1 to 90 0 Seconds 91 Relay Ou
93. Ramp Settings Ramps and Times General The current ramp sets how the motor accelerates The current ramp is a linear increase in current from the initial setting to the maximum setting The ramp time sets the speed of this linear current increase The following figure shows the relationships of these different ramp settings Figure 32 Current Ramp Current Start command Kick Current Initial Current Motor FLA L 21 2 2 2 2 224p 2 2 222 22e2d Time Kick Time lt gt Ramp Time gt Up To Speed Timer d Initial Current The initial current should be set to the level that allows the motor to begin rotating within a couple of seconds of receiving a start command To adjust the initial current setting give the starter a run command Observe the motor to see how long it takes before it begins rotating and then stop the unit For every second that the motor doesn t rotate increase the initial current by 2096 Typical loads require an initial current in the range of 50 to 175 Maximum Current For most applications the maximum current can be left at 600 This ensures that enough current is applied to the motor to accelerate it to full speed The maximum current can also be set to a lower current limit This is usually done to limit the voltage drop on the power system or to limit the torque the motor produces to help prevent damage to the driven load 3 NOTE Th
94. Schematics 3 5 1 Power Wiring Schematic Figure 6 EXMVRMX Power Wiring Schematic 22 3 6 3 6 1 3 6 2 3 6 3 3 6 4 3 INSTALLATION Power Wiring Input Line Requirements The input line source needs to be an adequate source to start the motor generally 2 times the rating of the motor FLA This may not apply in some cases such as being connected to a generator Recommended Wire Gauges The wire gauge selection is based on the FLA of the motor Refer to NEC table 310 16 or CEC Part 1 Table 2 or local code requirements for selecting the correct wire sizing Ensure appropriate wire derating for temperature is applied If more than three current carrying conductors are in one conduit ensure NEC table 310 15 B 2 or CEC Part 1 Table 5 is adhered to In some areas local codes may take precedence over the NEC Refer to your local requirements Power Wire Connections Attach the motor cables Usethe 1 2 and T3 terminals Use lugs crimps or terminals lugs and crimps are to be provided by the user Attach the power source cables Use the L1 L2 and L3 terminals Use lugs crimps or terminals lugs and crimps are to be provided by the user Motor Lead Length The standard starter can operate a motor with a maximum of 600 feet of properly sized cable between the T leads of the starter and that of the motor For wire runs greater than 600 feet contact Benshaw Inc for application assist
95. See NFPA 70E Turn off all power before working on or inside equipment Use a properly rated voltage sensing device to confirm that the power is off Before performing visual inspections tests or maintenance on the equipment disconnect all sources of electric power Assume that circuits are live until they have been completely de energized tested and tagged Pay particular attention to the design of the power system Consider all sources of power including the possibility of backfeeding Replace all devices doors and covers before turning on power to this equipment Failure to follow these instructions will result in death or serious injury 1 INTRODUCTION Benshaw Services General Information Start Up Services On Site Training Services Technical Support Documentation On Line Documentation Replacement Parts Software Number Hardware Number Publication History Warranty Benshaw offers its customers the following Start up services On site training services Technical support Detailed documentation Replacement parts 3 NOTE Information about products and services is available by contacting Benshaw refer to page 4 Benshaw technical field support personnel are available to customers with the initial start up of the RediStart EXMVRMX Information about start up services and fees are available by contacting Benshaw Benshaw technical field support personnel are available to conduct
96. Selection parameter determines whether or not a transition from low to high is required on the Start input for a start to occur after either a power up or a fault reset This applies to lockout conditions being cleared as well The behavior for a lockout clearing is the same as for a fault being reset Jump to Parameter RTD 00 LCD Display Description By changing the value of this parameter and pressing ENTER you can jump directly to any parameter within that group RTD Module 1 Address RTD 01 LCD Display Range Off 16 to 23 Default Off Description The module 1 address parameter has to be set to the Modbus address of the first RTD module attached to the soft starter The address of the RTD module can be verified by checking the rotary switch on the top of the RTD module 97 6 PARAMETER DESCRIPTION RTD Module 2 Address RTD 02 LCD Display Range Off 16 to 23 Default Off Description The module 2 address parameter has to be set to the Modbus address of the second RTD module attached to the soft starter The address of the RTD module can be verified by checking the rotary switch on the top of the RTD module Ensure that module 2 is not set to the same address as module 1 RTD Group RTD 03 RTD 18 LCD Display RTD number menu index number Range LCD Description Off RTD channel not read Stator RTD included in Stator metering group Bearing RTD included in Bearing metering group Other RTD acts i
97. Sensor LEM The optional Hall Effect Current sensor can be used when a more precise measurement of braking current is necessary This can occur if the DC injection braking is applied when the source supply has a very high short circuit capability very stiff or in special instances when more precise braking current control is required The appropriate brake type and feedback method is preset from the factory Please consult Benshaw for more information if changes need to be made Maximum Load Inertia The following table shows maximum load inertia NEMA MGI parts 12 and 20 It is recommended a thermistor or RTD be installed to protect the motor from overheating Speed RPM 3600 1800 mo 39 60 54 Inertia Ib ft2 133 7 THEORY OF OPERATION 7 5 1 7 5 2 7 5 3 7 5 4 DC Injection Braking Standard Duty The MX Standard Duty Braking allows up to approximately 250 FLA current to be applied to the motor The MX Standard Duty package consists of an extra braking contactor that shorts motor terminals 2 and 3 together while braking as DC current is applied by the MX starter to provide moderate braking torque CAUTION Contactor MUST NOT short phase 1 and phase T3 3 NOTE Contactor sizing requires ACI contactor rating Motor FLA 1 6 The three contacts must be paralleled DC Injection Braking Heavy Duty The MX Heavy Duty Braking allows up to 400 FLA current to be applied to the motor for maximum brakin
98. Starts per Hour Time between Starts PORT Power Outage Ride Through 16 RTD with Biasing D C Injection Braking 2 Technical Specifications 2 TECHNICAL SPECIFICATIONS Technical Specifications 2 1 General Information The physical specifications of the starter vary depending upon its configuration The applicable motor current determines the configuration and its specific application requirements Specifications are subject to change without notice This document covers the control electronics and several power sections MX Control Card Set Power Stacks with inline and bypass vacuum contactors 22 Electrical Ratings 2 2 1 Terminal Points and Functions Relay 3 R3 Digital Inputs Digital Inputs Table 1 Terminals Function Terminal Terminal Number Description Block Relay 1 R1 Relay 2 R2 G ground N 120VAC neutral N 120VAC neutral L 120VAC line L 120VAC line NO1 Normally Open Contact RC1 Common NC1 Normally Closed Contact NO2 Normally Open Contact RC2 Common Contact NC2 Normally Closed Contact NO3 Normally Open Contact RC3 Common Contact NC3 Normally Closed Contact R4A Normally Open Contact R4B Normally Open Contact RSA Normally Open Contact RSB Normally Open Contact R6A Normally Open Contact R6B Normally Open Contact Start DII DD2 DI3 Common DIA DIS DI6 DI7 DI8 Common 96 144 VAC input 50 60
99. State Motor Overload Protection is fully active During slow speed operation the Running Motor overload setting is used 3 NOTE When the motor is operating at slow speeds its cooling capacity can be greatly reduced Therefore the running time of the motor at a given current level is dependant on the motor s thermal capacity Although the Motor OL is active if it has not been intentionally disabled during slow speed operation it is recommended that the motor temperature be monitored if slow speed is used for long periods of time Slow Speed Cyclo Converter Parameters Slow Speed The Slow Speed parameter selects the speed of motor operation when slow speed is selected When set to Off slow speed operation is disabled Slow Speed Current Level The Slow Speed Current Level parameter selects the level of current applied to the motor during slow speed operation The parameter is set as a percentage of motor full load amps FLA This value should be set to the lowest possible current level that will properly operate the motor Slow Speed Time Limit The Slow Speed Time Limits parameter sets the amount of time that continuous operation of slow speed may take place When this parameter is set to Off the timer is disabled This parameter can be used to limit the amount of continuous slow speed operation to protect the motor and or load 3 NOTE The Slow Speed Time Limit includes the time used for the Slow Speed Kick if kick is enabled 3
100. Status Green light that blinks once per second The RTD module connects to the top of the MX I O card There should be a Red TX and Green RX blinking in the J1 connection where the two devices connect 36 NOTE For more details see Remote RTD Module Manual Pub 890010 00 X Figure 56 RTD Module SPR 100P ane Remote 77 oon 444444 7 Flashes when module is transmitting data Remote RTD Module Flashes when module is receiving data SPR 100P 8 13 VACUUM contactor and Power Pole assembly Maintenance General During the life of the it may be necessary to perform routine maintenance on the unit The following sections describe how to change a VACUUM contactor and power pole assembly Attention Servicing energized equipment can be hazardous Sever injury or death may result from electrical shock or burn due to improper use of the equipment It is recommended that the equipment is disconnected and a lock out command is enacted prior to any maintenance that is performed Remember to allow any stored energy in the capacitors to dissipate If it is necessary to work in the vicinity of energized as well as de energized equipment the work practices of NFPA 70E Electrical Safety Requirements for Employee Workplace must be followed Periodical Inspection Benshaw controls require only periodical inspections These inspections can be visual for physical tr
101. T Energized when the starter is in the Power Outage Ride Through mode Tach Loss Energized when the starter has faulted on a Tachometer Loss of Signal Fault 91 6 PARAMETER DESCRIPTION Description Parameters I O 10 12 configure which functions are performed by the R1 to R3 relays located on MX card Parameters I O 13 15 configure which functions are performed by the R4 to R6 relays located on I O card See Also Up To Speed Time parameter QST 09 on page 62 Over Current Level parameter PFN 01 on page 76 Under Current Level parameter PFN 03 on page 77 Residual Ground Fault Level parameter PFN 07 on page 79 Inline Configuration parameter I O 24 on page 96 Heater Level parameter FUN 08 on page 104 Energy Saver parameter FUN 09 on page 106 Theory of Operation section 7 1 Motor Overload Operation on page 114 Theory of Operation section 7 6 2 Wye Delta Operation on page 139 Theory of Operation section 7 7 Across The Line Full Voltage Starter on page 140 Appendix C Fault Codes on page 181 Analog Input Trip Type I O 16 LCD Display Range LCD Description Off Off Disabled Default Low Level Low Fault if input signal below preset trip level High Level High Fault if input signal above preset trip level Description The analog input is the reference input for a starter configured as a Phase Controller or Current Follower In addition the Analog Input Trip parameter allows the user to set a High or Low
102. T ratio parameter is set incorrectly correctly Verify correct CT wiring and verify that not reading correctly CTs installed iredi d the CTs are installed with all the White dots towards the input line side CT1 L1 CT2 L2 CT3 L3 2 GF Metering nof reading CT installed or wired incorrectly Verify CT installation Verify that Rated Voltage parameter is set correctly CTs installed or wired incorrectly Residual Ground Fault Current Metering 154 8 4 8 Other Situations 8 TROUBLESHOOTING amp MAINTENANCE Motor Rotates in Wrong Direction Erratic Operation Motor Overheats Starter cooling fans do not operate When Present Analog Output not functioning properly Remote Keypad does not operate correctly Cannot change parameters If input phasing correct exchange any two output wires Phasing incorrect If input phasing incorrect exchange any two input wires Shut off all power and check all Loose connections connections Motor over Motor overloaded Reduce motor load motor load Allow for adequate motor cooling between starts Set Hot Cold ratio higher or lengthen cooling time Too many starts per hour Reduce ambient temperature or provide for better cooling Set OL class lower to compensate for ambient temperature Reduce starting load and or review Acceleration time too long acceleration ramp settings Incorrect motor OL settings Revi
103. TOR COIL R2 INLINE CONTACTOR COIL DC Injection Brake Wiring Example 7 THEORY OF OPERATION Figure 40 DC Injection Brake Wiring Example G G G G m B pen 800 wm Y x GND FLT 5 J10 J8 LINE VOLTAGE SENSING DIVIDER INPUT 1 CARD 120 INPUT POWER BIPC 300055 02 I LL MecAnD TB2 RELAY OUTPUTS 8 amp m x J3 I BIPC 300034 01 I RELAY MVIO CARD OUTPUTS lt bt 1 E w MEDIUM VOLTAGE OPTO MX CARD ASSEMBLY INPUTS BIPC 450100 01 CONSISTS OF BIPC 300055 02 TOP amp BIPC 300034 01 BOTTOM J6 PROGRAMMABLE DIGITAL INPUTS p m El ONE 2000 1 GFCT INPUT LEDS LED3 MODBUS RS485 Tx sor J15 sme Es sor 10 sore E sor iF Ez phase 1 stack 1571 sor 2a Far sor 28 E sor 2c E sor zo sz sor 2e 57 scr 2F 2 5 f scr aa s scr as So scnap sor se 57 serar Phase astack or IN CONNECTOR Or C J1 RJ45 9 AN power C ane an G 7 TBS ANALOG INPUT 10 MAX TBS ANALOG 4 OUTPUT GJ com G TB4 SLAVE g sj acc mne 1 2 5 BYPASS sy J5 d
104. The Motor Starting Overload Class parameter sets the class of the electronic overload when starting The starter stores the thermal overload value as a percentage value between 0 and 100 with 0 representing a cold overload and 100 representing a tripped overload The starting overload class is active during Kicking and Ramping when the Independent Starting Running Overload parameter is set to On When the Motor Starting Overload Class parameter is set to Off the electronic overload is disabled while starting the motor 36 NOTE Care must be taken not to damage the motor when turning the starting overload class off or setting to a high value 36 NOTE Consult motor manufacturer data to determine the correct motor OL settings See Also Independent Starting Running Overload parameter PEN 28 on page 86 Motor Running Overload Class parameter PFN 30 on page 87 Motor Overload Hot Cold Ratio parameter 31 on page 88 Motor Overload Cooling Time parameter PFN 32 on page 88 Relay Output Configuration parameters I O 10 15 on page 91 Theory of Operation section 7 1 Solid State Motor Overload Protection on page 114 Motor Running Overload Class PFN 30 LCD Display Range Off 1 40 Default 10 Description The Motor Running Overload Class parameter sets the class for starting and running if the parameter is set to Off If separate starting versus running overload classes are desired set the parameter to On
105. To Speed Time QST 09 on page 62 Start Mode CFN 01 on page 63 Ramp Time 1 QST 08 CFN 02 on page 64 Initial Current 1 QST 06 CFN 03 on page 64 Kick Level 1 CFN 11 on page 68 Kick Time 1 CFN 12 on page 69 Theory of Operation section 7 3 1 Current Ramp Settings Ramps and Times on page 123 Ramp Time 2 CFN 05 LCD Display Range 0 300 seconds Default 15 seconds Description The Ramp Time 2 parameter sets the time it takes for the starter to allow the current to go from the initial current to the maximum current when the second ramp is active Refer to the Ramp Time 1 QST 08 CFN 02 for description of operation See Also Ramp Time 1 QST 08 CFN 02 on page 64 Digital Input Configuration 1 01 08 on page 90 Theory of Operation section 7 3 1 Current Ramp Settings Ramp and Times on page 123 Theory of Operation section 7 3 6 Dual Acceleration Ramp Control on page 128 Initial Current 2 CFN 06 LCD Display Range 50 600 of FLA Default 100 Description The Initial Current 2 parameter is set as a percentage of the Motor FLA QST 01 parameter setting when the second ramp is active Refer to the Initial Current 1 CFN 03 parameter for description of operation See Also Initial Current 1 CFN 03 on page 64 Digital Input Configuration 1 01 08 on page 90 Theory of Operation section 7 3 1 Current Ramp Settings Ramps and Times on page 123 Theory of Operation section 7 3 6 Dual
106. Use only UL or CSA recognized wire Grounding must be in accordance with NEC CEC or local codes If multiple starters are installed near each other each must be connected to ground Take care to not form a ground loop The grounds should be connected in a STAR configuration 3 4 3 Considerations for Signal Wiring Signal wiring refers to the wires connected to the control terminal strip that are low voltage signals below 15V Shielded wire is recommended to prevent electrical noise interference from causing improper operation or nuisance tripping Signal wire rating should carry as high of a voltage rating as possible normally at least 300V Routing of signal wire is important to keep as far away from control and power wiring as possible 3 4 4 Meggering a Motor If the motor needs to be meggered remove the motor leads from the starter before conducting the test Failure to comply may damage the SCRs and WILL damage the control board which WILL NOT be replaced under warranty 3 4 5 High Pot Testing If the starter needs to be high pot tested perform a DC high pot test The maximum high pot voltage must not exceed 2 0 times rated RMS voltage 2000VAC High pot to 75 of factory Failure to comply WILL damage the control board which WILL NOT be replaced under warranty An example to find the maximum high pot voltage is 2 0 rated RMS voltage 2000 0 75 3 INSTALLATION Typical Wiring Schematics 3 5 Typical Wiring
107. a motor thermal value based on the highest stator RTD measurement The motor thermal overload content is set to this calculated value if this calculated value is higher than the motor thermal overload content The RTD biasing is calculated as follows Max measured stator RTD temp lt RTD Bias Min Level RTD27 BiasOL 0 RTD Bias Min Level RTD27 lt Max measured stator RTD temp lt RTD Bias Mid Point Level RTD28 RTD max MinBiasTemp MidBiasTemp MinBiasTemp BiasOL x Hot Cold Ratio RTD Bias Mid Point Level RTD28 lt Max measured stator RTD temp lt RTD Bias Max Level RTD29 RTD max MidBiasTemp MaxBiasTemp MidBiasTemp BiasOL x 99 9 hot_ cold _ ratio hot_ cold _ ratio RTD Bias Max Level RTD29 lt Max measured stator RTD temp BiasOL 99 9 The RTD Biasing levels are generally set by using the motor data as follows RTD Bias Min Level RTD27 This parameter is typically programmed to the ambient temperature rating of the motor RTD Bias Mid Level RTD28 This parameter is typically programmed to the temperature rise rating of the motor RTD Bias Max Level RTD29 This parameter is typically programmed to insulation rating of the motor Figure 30 RTD Bias Curve RTD Bias Curve RTD BiasMax 100 90 80 60 50 30 RTD Bias Value oe RTD BiasMid Hot Cold Ratio RTD BiasMin 9 50 0 50 100 150 200 250 Maximum RTD
108. aces of dust dirt or visible damage Circuit boards should be physically tested to ensure that all the cables are connected properly Remember cleaning solvents should not come in contact with circuit or PC boards If filters or blowers are used they should be cleaned or replaced as specified in the NEMA Standards Publication No ICS 1 1 1987 Static While performing maintenance on the certain preventative measures must be taken when handling or touching static sensitive components in the enclosure Most circuit boards and SCRs can be damaged by Electro Static Discharge ESD If persons make contact with an ESD sensitive component during maintenance they must be grounded Grounding should be accomplished with a wrist strap which is connected to an approved ground 173 8 TROUBLESHOOTING amp MAINTENANCE ATTENTION Maintenance Records Vacuum Contactor Vacuum Bottles Power Pole Fans Interlocks Barriers Disconnect Switch 174 Using other than factory recommended test equipment and instructions on the controls may result in personal injury and damage or failure of equipment Keeping good maintenance records will be helpful in locating possible intermittent problems by pointing to a particular area of recurring trouble within the system To remove either of the contactors perform the following steps Ensure that the main disconnect is open and the grounding blades are seated Di
109. ad trips 36 NOTE Setting the ramp time to a specific value does not necessarily mean that the motor will take this time to accelerate to full speed The motor and load may achieve full speed before the ramp time expires if the application does not require the set ramp time and maximum current to reach full speed Alternatively the motor and load may take longer than the set ramp time to achieve full speed Up To Speed Time QST 09 on page 62 Start Mode 01 on page 63 Initial Current 1 QST 06 CEN 03 on page 64 Maximum Current 1 QST 07 CFN 04 on page 65 Kick Level 1 CFN 11 on page 68 Kick Time 1 CEN 12 on page 69 Theory of Operation section 7 3 1 Current Ramp Settings Ramps and Times on page 123 Initial Current 1 CFN 03 LCD Display Range Description See Also 64 50 600 95 of FLA Default 100 The Initial Current 1 parameter is set as a percentage of the Motor FLA QST 01 parameter setting The Initial Current 1 parameter sets the current that is initially supplied to the motor when a start is commanded The initial current should be set to the level that allows the motor to begin rotating within a couple of seconds of receiving a start command To adjust the initial current setting give the starter a run command Observe the motor to see how long it takes before it begins rotating and then stop the unit For every second that the motor doesn t rotate increase the initial current b
110. ae 480 103 4600 4800 6000 6600 6900 10000 11000 11500 12000 12470 13200 13800 Normal Inside Delta _ _ Wye Delta FUN07 P74 Starter Type Starter Type Phase Ctl Normal Curr Follow ATL Luxe Pra omon or 7 Voltage Ramp Fast Recover P O R T Recovery Current Ramp Fast FUN 12 PORT Resover Method Curr Ramp 2 Recover de Ramp Select Tach Ramp Voltage meters Sew 15 Fault FUN 15 Tach Los Act Tachometer Loss Action Fault CA Fri rw mm B B Communication Even 1 Stop Bit Communications Byte Odd 1 Stop Bit PUNA ee Com Parity Framing None 1 Stop Bit None 2 Stop Bit P80 FUN 20 Software Part Number 1 Display Only FUN21 Software Part Number2 Display Only None Reset RT Reset kWh Miscellaneous Rattan Mode P67 Misc Command Commands ae Parameters oad Parameters Factory Reset Std BIST Powered BIST 209 APPENDIX I PARAMETER TABLES mm dd yy 12h mm dd yy 24h 5 yy mm dd 12h mm dd yy FUN 23 T D Format Time and Date Format yy mm dd 24h 12h 109 dd mm yy 12h dd mm yy 24h Time Date Fault Group Fault Starter Eug 210 Publication History 12 15 06 Initial Release ADVANCED CONTROLS 8 DRIVES BENSHAW 615 Alpha Drive Pittsburgh PA 15238 Phone 412 968 0100 Fax 4
111. al Input Configuration parameter on page 90 Relay Output Configuration 10 15 LCD Display Range LCD Description Off Off Not Assigned May be controlled over Modbus Default R 2 3 4 5 6 Fault FS Faulted Fail Safe operation Energized when no faults present de energized when faulted Default R1 Fault NFS Faulted Non Fail Safe operation Energized when faulted Running Running starter running voltage applied to motor UTS Up to Speed motor up to speed or transition to for Wye Delta Operation Alarm Alarm any alarm condition present Ready Ready starter ready for start command Locked Out Locked Out OverCurrent Over Current Alarm over current condition detected UnderCurrent Under Current Alarm under current condition detected OL Alarm Overload Alarm Shunt FS Shunt Trip Relay Fail Safe operation energized when no shunt trip fault present de energized on shunt trip fault Shunt NFS Shunt Trip Relay Non Fail Safe operation de energized when no shunt trip fault present energized on shunt trip fault Ground Fault A Ground Fault trip has occurred Energy Saver Operating in Energy Saver Mode Heating Motor Heating starter applying heating pulses to motor Slow Spd Starter operating in slow speed mode Slow Spd Fwd Starter operating in slow speed forward mode Slow Spd Rev Starter operating in slow speed reverse mode Braking Starter is applying DC brake current to motor Cool Fan Ctl Heatsink fan control POR
112. ameters I O 01 08 on page 90 Theory of Operation section 7 6 2 Wye Delta Operation on page 139 Keypad Stop Disable I O 26 LCD Display Range LCD Description Disabled Keypad Stop does not stop the starter Enabled Keypad Stop does stop the starter Default Description If Disabled When this parameter is set to Disabled the keypad Stop button is de activated This should be done with caution as the STOP will not stop the starter 96 6 PARAMETER DESCRIPTION If the keypad is selected as local or remote control sources the STOP key cannot be disabled If Enabled When this parameter is set to Enabled the keypad stop button is enabled and stops the starter regardless of the selected control source keypad terminal or serial See Also Local Source parameter QST 04 on page 59 Remote Source parameter QST 05 on page 60 Auto Start Selection 27 LCD Display Range LCD Description Disabled When Disabled the Start Input must always transition from low to high for a start to occur Default Power When set to Power a start will occur if the Start input is high while control power is applied Fault When set to Fault a start will occur if the Start input is high when a fault is reset Power Fault When set to Power and Fault a start will occur if the Start input is high while control power is applied and a start will occur if the Start input is high when a fault is reset Description The Auto Start
113. amp start If a surge occurs near the end of the ramp set the UTS timer to expire at this time and restart the motor If the surge still occurs set the UTS time to a lower time until the surging subsides If motor surging continues to be a problem it is recommended that one of the other standard MX closed loop starting profiles be used Figure 36 Effect of UTS Timer on Voltage Ramp Voltage Full Voltage 4 Start 7 command Initial Voltage Optional Kick Current Time Kick Time lt gt Ramp Time 7 3 6 Dual Acceleration Ramp Control General Two independent current ramps and kick currents may be programmed The use of two different starting profiles can be very useful with applications that have varying starting loads such as conveyors that can start either loaded or unloaded The Current Ramp 1 profile is programmed using the parameters Initial Current 1 Maximum Current 1 and Ramp Time 1 The Current Ramp 2 is programmed using the parameters Initial Current 2 Maximum Current 2 and Ramp Time 2 Kick Current 1 profile is programmed using the parameters Kick Level 1 and Kick Time 1 Kick Current 2 profile is programmed using the parameters Kick Level 2 and Kick Time 2 7 3 7 Tachometer Ramp Selection Description Tachometer Requirements 128 The Tachometer control ramp profile provides a method to linearly ramp the
114. ance If shielded cable is used consult factory for recommended length Compression Lugs The following is a list of the recommended crimp on wire connectors manufactured by Penn Union Corp for copper wire Table 8 Single Hole Compression Lugs LU LU LU LU LU LU BLU BLU BLU BLU LU U LU Table 9 Two Hole Compression Lugs U anu j 23 3 INSTALLATION 3 6 5 Torque Requirements for Power Wiring Terminations Table 10 Slotted Screws and Hex Bolts Tightening torque pound inches N m Wire size installed in conductor H 1 head ext 1 dri ket ete ae ne Slot width 0 047 inch Slot width over 0 047 1 2mm or less and inch 1 2mm or slot AWG kemil mm slot length inch length over 1 4 inch Split bolt connectors Other connectors 6 4mm or less 6 4mm or less 5 7 gt 1 de is d 7 5 325 9 EM NN 1 0 2 0 53 5 64 4 3 0 4 0 85 0 107 2 250 350 127 177 600 750 304 380 5 6 1000 113 0 800 1000 406 508 5 6 1100 124 3 56 5 1250 2000 635 1010 67 8 36 NOTE For a value of slot width or length not corresponding to those specified above the largest torque value associated with the conductor size shall be marked Slot width is the nominal design value Slot length is measured at the bottom of the slot Table 11 Tightenin
115. and the decel time can be used to adjust the deceleration rate If the motor is coming to a stop too quickly or if the starter continues to apply current to the motor after the motor has stopped this parameter can be increased in 5 increments to fix this The decel time sets how quickly the motor decelerates Usually a time of 30 seconds is a good starting point To make the motor take longer to decelerate increase this parameter or to make the motor decelerate quicker decrease this parameter 36 NOTE Deceleration control provides a smoother stop However the motor will take longer to stop than if it was just allowed to coast to stop 131 7 THEORY OF OPERATION 7 4 2 TruTorque Deceleration Overview TruTorque deceleration control is a closed loop deceleration control This allows TruTorque deceleration to be more consistent in cases of changing line voltage levels and varying motor load conditions TruTorque deceleration is best suited to pumping and compressor applications where pressure surges such as water hammer must be eliminated The MX linearly reduces the motor s torque to smoothly decelerate the motor and load TruTorque deceleration is very easy to use with only two parameters to set Figure 39 TruTorque Deceleration Motor Torque Stop command Motor Torque Before Stop Command End Torque Level Time Decel Time gt Ending Level The Decel End Level parameter sets the ending torque level for the Tr
116. anged when commissioning a starter Many of the parameters in the Quick Start group are duplicates of the same parameters in other groups The following shows the menu structure for the LCD display as well as the text that is displayed for the parameters on the display If the LCD is not connected most parameters shown on the LED display will turn on when LCD is unplugged Quick Start Group MotorFLA Motor FLA 1 to 6400 e QST 03 Running OL Motor Overload Class Running Off 1 to 40 a o j 59 Terminal i Terminal Po picui a pr Maxcurt MaximumCurett 100030 wmA e or esr RawTme aro m eee enero 50 5 2 2 5 PARAMETER GROUPS Control Function Group Voltage Ramp Current Ramp Current CFN 01 Start Mode Start Mode TT Ramp Ramp 63 Power Ramp Tach Ramp m rampini RamTmei f ooo is 6 ceo po MoorCurener oo 100 ot Lem Pr Max Cort Mesum Motor Caren 1 0010800 oo p Max Cor Maximum moror Cunem2 10010800 e P pav Linear CFN 10 Accel Prof Acceleration Ramp Profile Squared Linear 67 S Curve Pon p Kiki om Tomi ms scs o ms KickL
117. arter Status Register Initializing or Faulted and decelerating or Faulted and Braking or Faulted and Stopped or Lockout Otherwise 1 Bit 1 Running 1 22 Bit 0 Ready 0 Not UTS Bit 2 UTS 1 UTS Bit 3 Alarm 0 alarm conditions 1 more alarm conditions 0 No Fault Condition Bit 4 Fault 1 Fault Condition Start or Fault Reset not locked out Bit 5 Lockout Start or Fault Reset locked out Possible causes are Overload Lockout State Watts VA vars and kW hour Registers Meter registers present 32 bit meters in two consecutive 16 bit registers The least significant 16 bits are in the first register followed by the most significant 16 bits in the second register Reading the least significant register latches data into the most significant register so that the data remains synchronized between the two Parameter Registers For those parameters that can be set either to Off or some value within a range many of the protection parameters for example there are two Modbus registers One is an enable register and the other sets the value within the range 198 APPENDIX G APPLICATION GLOSSARY A AC Ambient Temperature American Wire Gauge Auto Synchronizing B Buffer Contactor Reversing CPU Board Cursor Cycle D DeviceNet Disable Duty Cycle DV DT E Enable F Fault Fiber Optic Isolation G Gate Gate Drive Boards Alternating Current
118. ary Power RTD Module s js SOCKEL Phase Connector J2 STAT FBK I SCR 1A to 1F J3 6 4 F Phase 1 Relay 1 Fiber Optic Outputs TB1 R4 to R6 un ontro J6 Power Digital Input Inputs DIA to DI8 TB2 J7 Relay SCR 2A to 2F MOT PTC Outputs Phase 2 Motor R1 to R3 Fiber Optic Thermistor TB3 J8 Digital LINE Inputs Voltage Divider DI1 to DI3 Card TB4 J9 Modbus LINE PTs Slave SCR 3A to 3F RS485 Phase 3 Fiber Optic J10 J2 Phase CTs Remote Keypad J15 J13 RJ45 Socket Zero LOAD Sequence Voltage Divider TB5 Ground Card Analog I O Fault CT J14 LOAD PTs Phase 1 to 3 Stack O T Fiber Optic 29 3 INSTALLATION Control Wiring 3 11 Control Wiring 3 11 1 Control Power The 120VAC control power is supplied to TB1 The connections are as follows 1 Ground 2 Neutral 3 Neutral 4 Line 120VAC 5 Line 120VAC Figure 13 Control Power Wiring Example lt l 6 Al OL a i QI 120VAC NEUTRAL A OY If IA d NI 120VAC LIVE 14 20VAC LI E IGI Le Z d 3 11 2 Output Relays TB2 is for output relays R1 R2 and R3 These relays connect as follows 1 NOI Relay 1 normally open 2 Relay 1 common 3 NCI Relay 1 normally closed 4 NO2 Relay 2 normally open 5 RC2 Relay 2 common 6 NC2 Relay 2 normally closed 7
119. ating within a few seconds after a start is commanded increase this parameter If the value is set too low a No Current at Run fault may occur This parameter CFN 09 sets the final or maximum torque level that the motor produces at the end of the acceleration ramp time For a loaded motor the maximum torque value initially should be set to 10096 or greater If the maximum torque value is set too low the motor may not produce enough torque to reach full speed and may stall On lightly loaded motors this parameter may be reduced below 100 to produce smoother starts If the motor can be started by using the default TruTorque acceleration parameter values or another ramp profile the Maximum Torque level can be determined more precisely so that the motor comes up to speed in approximately the preset ramp time In this case while the motor is running fully loaded display the TruTorque percent TT meter on the display Record the value displayed The Maximum Torque level should then be set to the recorded full load value of TT plus an additional 10 Restart the motor with this value to verify correct operation 3 NOTE When setting the Maximum Torque value the motor must be monitored to ensure that the torque level is high enough to allow the motor to reach full speed under worst case load conditions 3 NOTE Depending on loading the motor many achieve full speed at any time during the TruTorque ramp This means that the Maximum Torque leve
120. ation 3 NOTE When in ATL mode the SCR gate outputs are disabled 140 7 THEORY OF OPERATION Start Stop Control with a Hand Off Auto Selector Switch 7 8 Start Stop Control with a Hand Off Auto Selector Switch Often times a switch is desired to select between local or Hand mode and remote or Auto mode In most cases local control is performed as 3 wire logic with a normally open momentary contact Start pushbutton and a normally closed momentary contact Stop pushbutton while remote control is performed as 2 wire logic with a Run Command contact provided by PLC The MX can perform both 2 wire start stop logic and 3 wire start stop logic With 2 wire logic the starter starts when a run command is applied to the Start input It continues to run until the run command is removed from the Start input With 3 wire logic the starter starts when a start command is momentarily applied to the Start input and continues to run until an input programmed as a Stop input goes low The MX automatically determines whether to use 2 wire logic or 3 wire logic by the presence of a high level on a Stop input If there is an input programmed as a Stop input and that input is high when the Start input goes high then 3 wire start stop logic is used Otherwise 2 wire start stop logic is used This feature eliminates the need for external logic relays often used to seal in the momentary Start and Stop pushbuttons creating a 2 wire
121. ation Address FUN 16 on page 107 Communication Baud Rate FUN 17 on page 107 Communication Timeout FUN 18 on page 107 Remote Source OST 05 LCD Display Range LCD Description Keypad The start stop control is from the keypad Terminal The start stop control is from the terminal strip inputs Default Serial The start stop control is from the network Description The EXMVRMX can have three sources of start and stop control Terminal Keypad and Serial Two parameters Local Source QST 04 and Remote Source QST 05 select the sources of the start and stop control If a digital input is programmed as Local Remote then that input selects the control source When the input is low the local source is used When the input is high the remote source is used If no digital input is programmed as Local Remote then the local remote bit in the Modbus starter control register selects the control source The default value of the bit is Local 0 Figure 26 Local Remote Source Local Source e Keypad Terminal I Serial v e Start Source Remote Source e Keypad e Terminal Bene Local Remote Input DI8 configured by Parameter T O 01 T O 08 Serial Modbus Starter Control Register Local Remote Bit See Also Local Source parameter QST 04 on page 59 Digital Input Configuration parameters 1 01 08 on page 90 Keypad Stop Disable parameter 1 26 on page 96 Communication Address parameter
122. ation is in place Apply only the voltage that is specified in this manual to the terminals to prevent damage Transportation and Installation Use proper lifting gear when carrying products to prevent injury Make certain that the installation position and materials can withstand the weight of the soft starter Refer to the installation information in this manual for correct installation B Ifparts are missing or soft starter is damaged do not operate the RediStart EXMVRMX Do not stand or rest heavy objects on the soft starter as damage to the soft starter may result Do not subject the soft starter to impact or dropping Make certain to prevent screws wire fragments conductive bodies oil or other flammable substances from entering the soft starter Trial Run Check all parameters and ensure that the application will not be damaged by a sudden start up Emergency Stop To prevent the machine and equipment from hazardous conditions if the soft starter fails provide a safety backup such as an emergency brake Disposing of the RediStart EXMVRMX Never dispose of electrical components via incineration Contact your state environmental agency for details on disposal of electrical components and packaging in your area TABLE OF CONTENTS Table of Contents J INTRODUCTION y 9 9 wmm Row win w W W RON RURSUS TR S 2 2 TECHNICAL SPECIFICATIONS 8 2 1 General Informa
123. ation parameter is set to a time delay then the assumes that there is an Inline contactor and that line voltage need not be present while stopped If no line is detected then the No Line alarm condition does not exist and the ready condition does exist If a start is commanded and there is no detected line voltage for the time period defined by this parameter then a noL No Line fault is declared In order to control an inline contactor program a relay as a Run relay 3 NOTE This fault is different than over under voltage since it detects the presence of NO line See Also Relay Output Configuration parameters I O 10 15 on page 91 Bypass Feedback Time I O 25 LCD Display Range 0 1 5 0 seconds Default 2 0 Description The starter contains a built in dedicated bypass feedback input that is enabled when the dedicated stack relay is factory programmed to bypass The programmable inputs DI 1 DI 2 DI 3 DI4 DIS DI6 DI7 or DI8 may also be used to monitor an auxiliary contact from the bypass contactor s or in the case of a wye delta starter the 2M contactor The digital input is expected to be in the same state as the UTS relay If it is not the trips on Fault 48 Bypass Fault The Bypass Confirmation input must be different from the UTS relay for the time period specified by this parameter before a fault is declared There is no alarm associated with this fault See Also Digital Input Configuration par
124. ault timer has not yet expired When the timer expires a Fault 62 shall occur This alarm shall exist if DI 4 is programmed as a fault is in External Alarm on DI 4 Input the fault state but the fault timer has not yet expired When the timer expires a Fault 63 shall occur This alarm shall exist if DI 5 is programmed as a fault is in External Alarm on DI 5 Input the fault state but the fault timer has not yet expired When the timer expires a Fault 64 shall occur This alarm shall exist if DI 6 is programmed as a fault is in External Alarm on DI 6 Input the fault state but the fault timer has not yet expired When the timer expires a Fault 65 shall occur This alarm shall exist if DI 7 is programmed as a fault is in External Alarm on DI 7 Input the fault state but the fault timer has not yet expired When the timer expires a Fault 66 shall occur This alarm shall exist if DI 8 is programmed as a fault is in External Alarm on DI 8 Input the fault state but the fault timer has not yet expired When the timer expires a Fault 67 shall occur This alarm exists if the analog input exceeds the defined A Analog Input Level Trip Alarm threshold but the delay for the fault has not yet expired When the delay expires a Fault 71 occurs A29 A31 A34 A35 A36 A37 A38 A47 A53 A60 A61 A62 A63 A64 A65 A66 A67 71 180 Fault Code F00 F01 F02 F03 F04 F05 F06 F07 F08 F10 F12 F13 F14 F15 F21 F22
125. be damaged or the operational life can be reduced Wiring Considerations 3 4 Wiring Considerations 3 4 1 Wiring Practices When making power and control signal connections the following should be observed Never connect input AC power to the motor output terminals T1 U T2 V or T3 W Power wiring to the motor must have the maximum possible separation from all other wiring Do not run control wiring in the same conduit this separation reduces the possibility of coupling electrical noise between circuits Minimum spacing between metallic conduits containing different wire groups should be three inches 8cm Minimum spacing between different wiring groups in the same tray should be six inches Wire runs outside an enclosure should be run in metallic conduit or have shielding armor with equivalent attenuation Whenever power and control wiring cross it should be at a 90 degree angle Different wire groups should be run in separate conduits With a reversing application the starter must be installed in front of the reversing contactors 3 NOTE Local electrical codes must be adhered to for all wiring practices 3 4 2 Considerations for Control and Power Wiring Control wiring refers to wires connected to the control terminal strip that normally carry 24V to 115V and Power wiring refers to wires connected to the line and load terminals that normally carries 10 000 to 13 800 respectively Select power wiring as follows
126. ck motor wiring for short circuits or ground faults LO C Check motor for short circuits or ground faults Instantaneous Over current Check if power factor or surge capacitors are installed on the motor side of the starter Verify that the motor FLA QST 01 and CT ratio FUN 03 settings are correct Check motor for a jammed or an overload condition Motor current dropped under the Under Current Trip Level setting PEN 03 for Undercurrent longer than the Under Current Trip Delay time setting PFN 04 Check system for cause of under current condition Motor current exceeded the Over Current Trip Level setting PFN 01 for longer Over current than the Over Current Trip Delay Time setting PFN 02 No input voltage was detected for longer than the Inline Configuration time delay parameter setting I O 24 when a start command was given to the starter F28 No Ling Check input supply for open disconnects open fuses open circuit breakers or disconnected wiring 158 8 TROUBLESHOOTING amp MAINTENANCE Fault Code Detailed Description of Fault Possible Solutions Power Factor Leading Power Factor Lagging Current Imbalance 1 Ground Fault F35 F36 F37 F38 F39 F40 F41 46 No Current at Run Shorted Open SCR Current at Stop Disconnect Open The motor power factor went above the PF leading trip level Verify loading of motor On synchronous motors verify field supply current The motor power fa
127. comparator based on the analog input If the type is set to Low then a fault occurs if the analog input level is below the trip level for longer than the trip delay time If the type is set to High then a fault occurs if the analog input level is above the trip level for longer than the trip delay time This function is only active when the motor is running This feature can be used in conjunction with using the analog input as a reference for a control mode in order to detect an open 4 20mA loop providing the reference Set the Analog Input Trip Type parameter to Low and set the Analog Trip Level parameter to a value less than lt 20 See Also Analog Input Trip Level parameter I O 17 on page 92 Analog Input Trip Time Level parameter I O 18 on page 93 Analog Input Span parameter 19 on page 93 Analog Input Offset parameter I O 20 on page 94 Starter Type parameter FUN 07 on page 103 Analog Input Trip Level I O 17 LCD Display Range 0 100 Default 50 Description The Analog Input Trip Level parameter sets the analog input trip or fault level This feature can be used to detect an open 4 20mA loop by setting the Analog Input Trip Type I O 16 parameter to Low and setting the Analog Input Trip Level I O 17 parameter to a value less than lt 20 36 NOTE The analog input trip level is NOT affected by the Analog Input Offset or Analog Input Span parameter settings Therefore if the trip level is set to
128. contains the digital I O relays and interfaces to the terminal for user interface See terminal and control It also controls the sequencing of the isolation and bypass contactors with the SCR firing This board generates all firing signals for the SCR stacks and receives feedback signals from the fiber optic transmitters It converts analog levels to digital signals for the CPU These firing pulses are via fiber optic signals to isolate them from the medium voltage environment Control electronics are located in the medium voltage section of the soft start The main line power must be disconnected before accessing these electronics which include the TCB terminal and control board gate drive and temp CT current transformer board A registered based multi point network A selected method of operation For example run A set of contacts on a relay or switch that are closed when the relay is de energized or the switch is de activated They are open when the relay is energized or the switch is activated A set of contacts on a relay or switch that are open when the relay is de energized or the switch is de activated They are closed when the relay is energized or the switch is activated Power outage ride through A measurement of the time phase difference between the voltage and current in an AC circuit It is represented by the cosine of the angle of this phase difference Power factor is the ratio of Real Power kW to total kVA or the ra
129. ctive in all states If On When this parameter is On the starting and running overloads are separate with each having their own settings The starting overload class is used during motor acceleration and acceleration kick The running overload class is used during all other modes of operation If both the running overload and the starting overload classes are set to Off then the existing accumulated motor OL is erased and no motor overload is calculated in any state If the starting overload class is set to Off and the running overload class is set to On then the motor overload does NOT accumulate during acceleration kick and acceleration ramping states However the existing accumulated OL remains during starting and the hot cold motor compensation is still active The OL is capped at 99 during starting Although there is really no reason to do so the starting overload class could be set to On and the running overload class set to Off See Also Motor Starting Overload Class parameter PFN 29 on page 87 Motor Running Overload Class parameter PFN 30 on page 87 Motor Overload Hot Cold Ratio parameter PFN 31 on page 88 Motor Overload Cooling Time parameter PFN 32 on page 88 Theory of Operation section 7 1 9 Separate Starting and Running Motor Overload Settings on page 119 86 6 PARAMETER DESCRIPTION Motor Starting Overload Class PFN 29 LCD Display Range Off 1 40 Default 10 Description
130. ctor went below the PF lagging trip level Verify loading of motor On synchronous motors verify field supply current A current imbalance larger than the Current Imbalance Trip Level parameter setting PFN 05 was present for longer than the Curr Imbal Trip Time PFN 06 Check motor wiring for cause of imbalance Verify dual voltage and 6 lead motors for correct wiring configuration Check for large input voltage imbalances that can result in large current imbalances Check motor for internal problems Ground current above the Ground Fault Trip level setting PFN 07 PFN 08 has been detected for longer than the delay time PFN 09 setting Check motor wiring for ground faults Check motor for ground faults Megger motor and cabling disconnect from starter before testing Verify that the motor FLA QST 01 and CT ratio FUN 03 settings are correct Verify that the CTs are installed with all the White dots towards the input line In Single phase applications verify that only two CTs are being used that they are installed with all the White dots or Xs in the correct direction and that the CTs are connected to the L1 and L3 CT inputs on the MX control card Motor current went below 1096 of FLA while the starter was running Verify Motor Connections Verify the CT wiring to the MX control card Verify that the motor FLA QST 01 and CT ratio FUN 03 settings are correct Check if load is still connected to starter
131. current sets a constant current level that is applied to the motor before the ramp begins The kick current is only useful on motor loads that are hard to get rotating but then are much easier to move once they are rotating An example of a load that is hard to get rotating is a ball mill The ball mill requires a high torque to get it to rotate the first quarter turn 90 Once the ball mill is past 90 of rotation the material inside begins tumbling and it is easier to turn The kick current parameter is usually set to a low value and then the kick time is adjusted to get the motor rotating If the kick time is set to more than 2 0 seconds without the motor rotating increase the kick current by 100 and re adjust the kick time The kick time adjustment should begin at 0 5 seconds and be adjusted by 0 1 or 0 2 second intervals until the motor begins rotating If the kick time is adjusted above 2 0 seconds without the motor rotating start over with a higher kick current setting TruTorque Acceleration Control Settings and Times 124 TruTorque acceleration control is a closed loop torque based control The primary purpose of TruTorque acceleration control is to smoothly start motors and to reduce the torque surge that can occur as an AC induction motor comes up to speed This torque surge can be a problem in applications such as pumps and belt driven systems In pumping applications this torque surge can result in a pressure peak as the motor com
132. d of the ramp time For a loaded motor the maximum power value initially should be set to 100 or greater If the maximum power level is set too low the motor may not produce enough torque to reach full speed and may stall On lightly loaded motors this parameter may be reduced below 100 to provide for smoother starts 3 NOTE It is important that the Rated Power Factor FUN 06 parameter is set properly so that the actual maximum power level is achieved See Also Start Mode CFN 01 on page 63 Ramp Time 1 CEN 02 QST 08 on page 64 Maximum Current 1 QST 07 CFN 04 on page 65 Initial Voltage Torque Power 08 on page 66 Initial Current 1 CFN 03 on page 64 Rated Power Factor FUN 06 on page 103 Theory of Operation section 7 3 Acceleration Control on page 123 Acceleration Ramp Profile 10 LCD Display Range Linear Square S Curve Default Linear Description Linear The linear profile linearly increases the control reference voltage current torque power speed from the initial acceleration ramp value to the final acceleration ramp value The linear profile is the default profile and is recommended for most acceleration and deceleration situations Linear End Torque 67 6 PARAMETER DESCRIPTION Squared The squared profile increases the control reference voltage current torque power speed in a squared manner squared acceleration profile can be useful when using TruTorque c
133. defined as the time that it takes for the motor to cool from 100 overload content to less than 1 overload content Sometimes a motor manufacturer may provide a cooling time constant t or tau value In these cases the Motor Overload Cooling Time PFN 32 parameter should be set to five 5 times the specified time constant value Motor Cooling While Running When the motor is running the Motor Overload Cooling Time PFN 32 parameter and the Motor Overload Hot Cold Ratio PFN 31 parameter settings control the motor OL content If the motor overload content is above the steady state OL running level See section 7 1 6 Hot Cold Motor Overload Compensation for more details the motor OL exponentially cools to the appropriate steady state OL level When the motor is running the cooling time is adjusted based on the measured current level and current imbalance level at which the motor is operating Measured Running Current 1 Motor FLA Current Imbalance Derate Factor Cooling Time Running Cooling Time Stopped In all cases the running motor cooling time is shorter motor will cool faster than when the motor is stopped The faster cooling results because it is assumed that when a motor is running cooling atr is being applied to the motor Emergency Motor Overload Reset The MX has an emergency motor overload reset feature that allows the user to override the overload starter lockout This resets the motor overload content to 0 It
134. duce the Slow Speed Kick Level and or reduce the Slow Speed Kick Time 139 7 THEORY OF OPERATION Across The Line Starter 7 7 Across The Line Full Voltage Starter When the Starter Type parameter is set to ATL the MX is configured to operate an electro mechanical full voltage or across the line ATL starter In the ATL configuration the MX assumes that the motor contactor 1M is directly controlled by a digital output relay that is programmed for the RUN function Therefore when a start command is given the RUN programmed relay energizes the motor contactor which applies power to the motor When the MX determines that the motor is at full speed the up to speed UTS condition is indicated by energizing the UTS programmed relays When configured as an ATL starter all MX motor and starter protective functions except bad SCR detection and power stack overload are available to provide full motor and starter protection Figure 42 A Typical ATL Starter Schematic with the EXMVRMX CT4 GFCT ZERO SEQUENCE GROUND FAULT CT 23 OPTIONAL M 3 50 60Hz 3 50 60Hz 2200 6900 VAC 2200 6900 VAC Gos P d 8 BIPC 450100 01 222 DIB SS MEET POE 88 id Bo jm 1 L ds 19
135. e Transition Time 1 900 Seconds 20 2 Control Function Group Voltage Ramp Current Ramp CFN 01 Start Mode Start Mode TT Ramp Current Ramp Power Ramp Tach Ramp 02 Time 1 Time 1 0 to 300 08 Init V T P Initial Voltage Torque Power 1 to 100 Ca ae ES 09 Max Maximum Torque Power 10 to 325 1 15 Linear CEN 10 Accel Prof Acceleration Ramp Profile Squared Linear S Curve osu ws ores oma on 14 Tonia P sees 19 Penis ras Dor Tonia KickTine 010100 ro e Coast Volt Decel CFN 15 15 Stop Mode Stop Mode TT Decel Coast DC Brake wer m mr estre 901 a lo nj mw Dee Time sea as zj Decel Ram Linear CFN 19 Decel Prof P Squared Linear Profile S Curve P paraq ocene crar 5 204 APPENDIX I PARAMETER TABLES P21 Brake Dey DC Beke bey f seos oz sss sewsee or s gr enc Ka umasa CFN25 25 SSpd Timer Slow Speed Timer Slow Speed Timer Timer Off 1t0900 1 Off 1t0900 900 Seconds
136. e Digital Fault Input Trip Time I O 09 Analog Input Level Fault Trip RTD Module Communications Fault Modbus Timeout Fault MX to I O Card Communication Fault Interboard fault I O Card SW version Fault I O Card Current Offset Error Keypad Communication Fault Based on the Analog Input parameter settings the analog input level has either exceeded or dropped below the Analog Input Trip Level setting I O 17 for longer than the Analog Input Trip Delay time 18 Measure value of analog input to verify correct reading Verify settings of all Analog Input parameters I O 16 I O 20 Verify correct positioning of input switch SW1 1 Voltage or Current on the MX control card Verify correct grounding of analog input connection to prevent noise or ground loops from affecting input Communications with the RTD module s has been lost Verify RS 485 wiring between RTD module s and MX card set Verify RTD module 24VDC power supply Verify that the RTD module s are set to the same address as the MX module address parameters RTD 01 and RTD 02 Indicates that communication has been lost with the remote keypad This fault normally occurs if the remote keypad is disconnected while the MX control card is powered up Verify that the remote keypad cable has not been damaged and that its connectors are firmly seated at both the keypad and the MX control card Route keypad cables away from high power and or
137. e available parameter groups When viewing a parameter pressing MENU jumps to the top of the menu When a parameter is being edited and MENU is pressed the change is aborted and the parameter s old value is displayed The STOP RESET key halts the operation of the starter Stop Key Ifa fault has occurred the STOP RESET key is used to clear the fault Reset Key The STOP RESET key always halts the operation of the starter if the control source is set to Keypad If the Control Source QST 04 QST 05 is not set to Keypad the STOP RESET key may be disabled using the Keypad Stop Disable I O 26 parameter 4 KEYPAD OPERATION Alphanumeric Display 4 4 4 4 1 4 4 2 Alphanumeric Display The remote LCD keypad and display uses a 32 character alphanumeric LCD display All starter functions can be accessed by the keypad The keypad allows easy access to starter programming with parameter descriptions on the LCD display Power Up Screen On power up the software part numbers are displayed for a few seconds Pressing any key immediately changes the display to the operate screen Operate Screen The operate screen is the main screen The operate screen is used to indicate the status of the starter if it s running what state it s in and display the values of Meter 1 and Meter 2 which are selectable The Operate Screen is divided into five sections Sections A and B display status information S
138. e firing of the SCRs There is one gate drive board for each pair of SCRs in each stack 199 APPENDIX G APPLICATION GLOSSARY Interface Board J Jogging Jumper K Keypad L LCD Locked Rotor Torque Low Voltage M Main Power Board Medium Voltage ModBUS Mode N Normally Closed Contacts Normally Open Contacts Port Power Factor Preset Speed Programmable Controller Protocol 9 R Ramp Ramp Time 200 This circuit board take line side and load side voltage feedback signals from the voltage feedback board and passes them via pin cables to the processor Is a means of accomplishing momentary motor movement by repetitive closure of a circuit using a single push button or contact element A short conductor with which you connect two parts Is 2 line x 16 character LCD display with backlighting for low ambient conditions The display reads out in truncated english and can show multiple data points in each screen Liquid crystal display which is a reflective visual readout device commonly used in digital watches and laptop computers The minimum torque that a motor will develop at rest for all angular positions of the rotor with rated voltage applied at rated frequency Low Voltage electronics include the keypad operator interface CPU main power PC board and are located in isolated low voltage compartments of the enclosure This is also referred to as the firing board It
139. e motor may achieve full speed at any time during the current ramp This means that the maximum current setting may not be reached Therefore the maximum current setting is the most current that could ever reach the motor and not necessarily the maximum current that reaches the motor 3 NOTE When setting a current limit the motor must be monitored to ensure that the current is high enough to allow the motor to reach full speed under worst case load conditions 123 7 THEORY OF OPERATION Ramp Time 7 3 2 General The ramp time is the time it takes for the current to go from the initial current to the maximum current To make the motor accelerate faster decrease the ramp time To make the motor accelerate slower increase the ramp time If the ramp time expires before the motor reaches full speed the starter maintains the maximum current level until either the motor reaches full speed the Up to Speed time expires or the motor thermal overload trips 36 NOTE Setting the ramp time to specific value does not necessarily mean that the motor will take this time to accelerate to full speed The motor and load may achieve full speed before the ramp time expires if the application does not require the set ramp time and maximum current to reach full speed Alternatively the motor and load may take longer than the set ramp time to achieve full speed Programming A Kick Current Kick Level Kick Time 7 3 3 General The kick
140. e starter will lockout until a manual fault reset is performed If less than the maximum number of auto resets occur and the starter does not fault for 15 minutes after the last auto fault reset occurred the counter will be set back to zero The auto reset counter is also set back to zero when a manual fault reset occurs See Also Appendix C Fault Codes on page 181 Auto Reset Limit parameter PFN 23 on page 84 Controlled Fault Stop Enable 25 LCD Display Range Off On Default On Description A Controlled Fault Stop Enable can occur if this parameter is On The controlled stop will occur before the starter trips During a controlled fault stop the action selected by the Stop Mode parameter is performed before the starter is tripped This prevents the occurrence of water hammer etc in sensitive systems when a less than fatal fault occurs 36 NOTE All relays except the UTS relay are held in their present state until the stop mode action has been completed 36 NOTE Only certain faults can initiate a controlled fault stop Some faults are considered too critical and cause the starter to stop immediately regardless of the Controlled Fault Stop Enable parameter Refer to Appendix C Fault Codes to determine if a fault may perform a controlled stop See Also Stop Mode parameter CFN 15 on page 70 Appendix C Fault Codes on page 181 Speed Switch Trip Time PFN 26 LCD Display Range Off 1 250 seconds
141. e stopped in a controlled manner Voltage Decel TT Decel or D C Braking instead of being allowed to coast to a stop when this occurs This may be achieved by setting the Controlled Fault Stop PFN 25 parameter to On Be aware however that not all fault conditions allow for a controlled fault stop See Also Decel Begin Level CFN 16 on page 70 Decel End Level CFN 17 on page 71 Decel Time CFN 18 on page 71 Deceleration Ramp Profile CFN 19 on page 72 DC Brake Level CFN 20 on page 72 DC Brake Time CFN 21 on page 73 DC Brake Delay CFN 22 on page 73 Controlled Fault Stop Enable PFN 25 on page 85 Digital Input Configuration I O 01 08 on page 90 Relay Output Configuration 10 15 on page 91 Theory of Operation Deceleration Control on page 131 Theory of Operation Braking Controls on page 133 Decel Begin Level CEN 16 LCD Display Range 1 100 of phase angle firing Default 40 Description Stop Mode CEN 15 set to Voltage Deceleration The voltage deceleration profile utilizes an open loop S curve voltage ramp profile The Decel Begin Level parameter sets the initial or starting voltage level when transferring from running to deceleration The deceleration beginning level is not a precise percentage of actual line voltage but defines a point on the S curve deceleration profile A typical voltage decel begin level setting is between 30 and 40 If the motor initially surges oscillates
142. e viewed by changing the two meter parameters FUN 01 FUN 02 there are 19 Meter Pages that are easily accessed to view all of the meter information These meter pages are scrolled through by pressing the UP or DOWN down arrows from the operate screen 36 NOTE Run Hours 00 00 23 59 Run Days 0 2730 days or 7 5 years kWatt Hours 0 999 MWatt Hours 0 9999 Starts 0 65535 RS Gnd Cur motor FLA 44 4 KEYPAD OPERATION 4 4 5 Fault Log Screen Information regarding each fault is available through the remote MX LCD display FL Fault Log Number FL1 is the most recent fault and FL9 is the oldest fault Fault Fault Code NNN Fault Name or the condition when the fault occurred Press MENU until you get to the FL1 parameter Pressing the UP and DOWN keys navigates through older and newer faults in the log When you get to your fault on the screen begin pressing the ENTER key repeatedly This will rotate through the steps below to show the conditions the starter was in when the fault occurred EnterStep S O 1 Fault Description 2 Status when the fault occurred Run Stopped Accel ete 3 curentatthe time ofthe fault j 4 The L2currentatthe time ofthe fault 5 The L3 current at the time ofthe fault y U 2 4 4 6 Fault Screen When a Fault occurs the main screen is r
143. ecel begin level setting or at the motor voltage level when the stop is commanded Although the profile may be adjusted the deceleration time remains the same In the TruTorque deceleration mode the decel time sets the time between when a stop is commanded and when the decel end torque level is applied 71 6 PARAMETER DESCRIPTION If the motor stops rotating before the decel time expires decrease the Decel Time CFN 18 parameter If the motor is still rotating when the decel time expires increase the Decel Time CFN 18 parameter A typical decel time is 20 to 40 seconds 3 NOTE Depending on the motor load and the Decel parameter settings the motor may or may not be fully stopped at the end of the deceleration time Refer to section 7 4 Deceleration Control on page 131 See Also Stop Mode CFN 15 on page 70 Decel Begin Level CFN 16 on page 70 Decel End Level CFN 17 on page 71 Controlled Fault Stop PFN 25 on page 85 Theory of Operation section 7 4 Deceleration Control on page 131 Decel Ramp Profile 19 LCD Display Range Linear Squared S Curve Default Linear Description See Accel Prof CFN 10 on page 67 for details See Also Stop Mode CFN 15 on page 70 DC Brake Level CFN 20 LCD Display Range 10 100 of available brake torque Default 25 Description When the Stop Mode CFN 15 is set to DC brake the DC Brake Level parameter sets the level of DC current applied to the motor dur
144. eceleration Control 7 4 Deceleration Control TAA Voltage Control Deceleration Overview The deceleration control on the MX uses an open loop voltage ramp The MX ramps the voltage down to Beginning Level Ending Level Decel Time decelerate the motor The curve shows the motor voltage versus the decel setting Figure 38 Motor Voltage Versus Decel Level 5 op 1 KE gt E op 1 2 sa Wm Ay LETTE A EERESEPAN 100 90 80 70 60 50 40 30 20 10 0 Programmed Decel Level This sets the starting voltage of the deceleration ramp Most motors require the voltage to drop to around 60 or lower before any significant deceleration is observed Therefore a good first setting for this parameter is 35 To adjust this parameter it is necessary to observe the motor operation as soon as a stop is commanded If the motor hunts speed oscillations at the beginning of the deceleration then lower the parameter by 5 If the motor has a big drop in speed as soon as a stop is commanded then raise the parameter by 5 Some motors are very sensitive to the adjustment of this parameter If a 5 adjustment changes the motor from hunting to dropping in speed then a smaller change of 1 or 2 may be necessary This sets the final voltage for the deceleration ramp In most cases this parameter can be set to 10
145. ecommended Figure 35 Voltage Ramp Voltage Full Voltage Start command Optional Kick Current Initial Voltage Time Kick Time 4 4 Ramp Time This parameter sets the initial voltage level that is applied to the motor To adjust the starting voltage level give the starter a run command and observe the motor operation If the motor starts too quickly reduce the initial voltage level If the motor does not start rotating immediately or starts too slowly then increase the initial voltage level until the motor just starts to rotate when a start command is given If the initial voltage level is set too low a Fault 39 No Current at Run may occur In this case increase the initial voltage level to permit more current to initially flow to the motor The ramp time setting is the time that it takes for the applied voltage to go from the initial voltage level to the full voltage 100 level To make the motor accelerate faster decrease the ramp time To make the motor accelerate slower increase the ramp time 127 7 THEORY OF OPERATION UTS Timer When the start mode is set to open loop voltage ramp acceleration the UTS Timer acts as an acceleration kick When the UTS timer expires full voltage is applied to the motor This feature can be used to reduce motor surging that may occur near the end of an open loop voltage r
146. ections C and D display the meters selected by the Meter 1 and 2 parameters see FUN 01 02 Section S displays the source for the start command Figure 25 Operate Screen SECTION A SECTION C D ti T m SECTION SECTION B SECTION D Table 14 Operate Screen Section NoL Description L1 L2 L3 not present Starter ready to run A fault condition is present If it continues a fault occurs Starter is running Run 42 4 KEYPAD OPERATION Table 15 Operate Screen Section B Description Display Starter is stopped and no Faults Run UTS Wye Run Starter is in Run mode and Ramp f UTS StarterisUpToSpeed Wye In Wye delta control indicates motor is accelerating in Wye mode Table 16 Operate Screen Section S D Description Keypad Control Terminal Block Wiring Control Serial Communication Connection Control 4 4 3 Parameter Group Screens From the operate screen the parameter group screens are accessed by pressing either the menu or the left arrow keys The parameter group screens display the different parameter groups QST PFN I O RTD FUN FL1 E01 MMM Parameter Group MI Menu Index PPP Parameter Name VVV Parameter Value and Units Refer to Chapter 5 for a listing of the parameters and their ranges 4 KEYPAD OPERATION 4 4 4 Meter Pages Although any meter may b
147. ective 89 336 EEC as Amended by 92 31 EEC and 93 68 EEC Product Category Product Type Model Number Manufacturer s Name Manufacturer s Address Motor Controller Reduced Voltage Solid State Motor Controller CFMVRMX36 3500 13200 1 Example of Model Number CFMVRMX36 3500 13200 1 1 1 3R Nema 3R 12 Nema 12 Voltage HP 36 10 000 Volts 11 000 Volts 11 500 Volts 12 000 Volts 12 470 Volts 18 200 Volts 13 800 Volts MV MX Control Combination Fusable A Combination Fusable RediStart starter with control 13 200 Volts 3500 Horsepower NEMA 1 Enclosure Benshaw Inc 659 East Sutter Road Glenshaw PA 15116 United States of America The before mentioned products comply with the following EU directives and Standards Electromagnetic Compatibility N 61000 6 4 2001 Emissions Radiated Conducted N 55011 05 98 A1 1999 N 61000 4 2 Electrostatic Discharge N 61000 4 3 Radiated RF N 61000 4 4 Electrical Fast Transient Burst N 61000 4 5 Surge N 61000 4 6 Injected Currents N 61000 4 8 Magnetic E E E E E E E E E EN 61000 4 11 Voltage Dips N 61000 6 2 2001 Immunity Susceptibility which includes The products referenced above are for the use of control of the speed of AC motors The use in residential and commercial premises Class B requires an optional EMC series filter Via internal mechanisms and Quality Control it is verified that these p
148. ed the overload content reduces exponentially based on Motor Overload Cooling Time parameter Refer to the following equation 5 OL Content 2 OL Content when Stopped CoolingTime So a motor with a set cooling time of 30 minutes 1800 sec with 100 accumulated OL content cools to lt 1 OL content in 30 minutes 36 NOTE Consult motor manufacturer data to determine the correct motor cooling time 6 PARAMETER DESCRIPTION See Also Independent Starting Running Overload parameter PFN 28 on page 86 Motor Running Overload Class parameter PFN 30 on page 87 Motor Starting Overload Class parameter PFN 29 on page 87 Motor Overload Hot Cold Ratio parameter PFN 31 on page 88 Theory of Operation section 7 1 10 Motor Cooling While Stopped on page 120 Theory of Operation section 7 1 11 Motor Cooling While Running on page 121 Motor OL Alarm Level PEN 33 LCD Display Range 1 100 Default 90 Description An overload alarm condition is declared when the accumulated motor overload content reaches the programmed OL Alarm Level An output relay can be programmed to change state when a motor overload alarm condition is present to warn of an impending motor overload fault See Also Relay Output Configuration parameters I O 10 15 on page 91 Theory of Operation section 7 1 Solid State Motor Overload Protection on page 114 Motor OL Lockout Level PEN 34 LCD Display Range 99 Default 15 Description Afte
149. ed when input asserted 120V applied Slow Spd Fwd Operate starter in slow speed forward mode Slow Spd Rev Operate starter in slow speed reverse mode Brake Disabl Disable DC injection braking Brake Enabl Enable DC injection braking Speed Sw NO Speed Switch Normally Open applied See PFN 26 on page 85 Speed Sw NC Speed Switch Normally Closed 120V applied See PFN 26 on page 85 Description I O 01 03 parameters configure which features are performed by the DI 01 to DI 03 terminals I O 04 08 parameters configure which features are performed by the DI 04 to DI 08 terminals 90 6 PARAMETER DESCRIPTION See Also Local Source parameter QST 04 on page 59 Remote Source parameter QST 05 on page 60 Bypass Feedback Time parameter 1 25 on page 96 Heater Level parameter FUN 08 on page 104 Theory of Operation section 7 1 12 Emergency Motor Overload Reset on page 121 Theory of Operation section 7 3 6 Dual Acceleration Ramp Control on page 128 Theory of Operation section 7 6 2 Wye Delta Operation on page 139 Theory of Operation section 7 8 Start Stop Control with a Hand Off Auto Selector Switch on page 141 Digital Fault Input Trip Time I O 09 LCD Display Range 0 1 90 0 Seconds Default 0 1 Sec Description The Digital Fault Input Trip Time parameter sets the length of time the digital input must be high or low before a trip occurs This delay time only functions for fault high and fault low See Also Digit
150. ee ees See NET TTIINEEER Pass UUITPAIT Pita CONTACTO T5 MOTOR ECONNECT i a CABLE CLAMPS ee d FOS CusTOMES USE a 5 AEE DS COMHECT SEGCTEOH CONTAC TOR SECTIONS SIARTER SECTION EMV FIGURE 2 3 36 NOTE This is only a sample diagram drawing for component identification purposes Component locations may change to meet end users specifications 16 Installation 3 INSTALLATION Before You Start 3 1 3 1 1 18 Before You Start Installation Precautions Inspection Before storing or installing the RediStart EXMVRMX Series Starter thoroughly inspect the device for possible shipping damage Upon receipt Remove the starter from its package and inspect exterior for shipping damage If damage is apparent notify the shipping agent and your sales representative Open the enclosure and inspect the starter for any apparent damage or foreign objects Ensure that all of the mounting hardware and terminal connection hardware is properly seated securely fastened and undamaged Ensure all connections and wires are secured Read the technical data label affixed to the starter and ensure that the correct horsepower and input voltage for the application has been purchased General Information Installation of some models may require halting production during installation If applicable ensure tha
151. eeded OT Switch wiring to Gate Driver Card bad Check wiring at TB Gate Driver Card and correct as needed 8 4 2 Motor does not start no output to motor Control volt bsent Check for proper control voltage input Display Blank CPU Heartbeat LED on voltage absent Verify fuses and wiring MX board not blinking 3 MX control board problem Consult factory Feult Displayed Fault Occurr d See fault code troubleshooting table for more details Start Stop control input problems Verify that the start stop wiring and start Start command given but nothing input voltage levels are correct happens Control Source parameters QST 04 05 Verify that the parameters are set not set correctly correctly Check input supply for inline contactor open disconnects open fuses open circuit breakers or disconnected wiring Verify that the SCR gate wires are properly connected to the MX control board On medium voltage systems verify wiring of the voltage feedback measurement circuit See fault code troubleshooting table for more details NOL or No Line is displayed and a start No line voltage has been detected by the command is given it will fault in F28 MX when a start command is given 151 8 TROUBLESHOOTING amp MAINTENANCE 8 4 3 During starting motor rotates but does not reach full speed Fault Displayed Fault Occurred See fault code troubleshooting table for more details ea Motor
152. ent firing board power and gate power systems while isolated from the line voltage High isolation ring transformers are used to reduce the voltage down to 28 Vac for the sustained pulse firing circuit providing further isolation for the SCR gates Additional magnetic isolation is provided via a separate control power transformer CPT which powers the low voltage controls and the CPU A momentary deviation in an electrical or mechanical system Canadian Underwriters Laboratories an approval agency 201 APPENDIX H 3 YEAR WARRANTY 3 Year Warranty Benshaw s standard warranty is one 1 year from date of shipment Benshaw will extend this warranty to three 3 years from date of shipment when done by a supervised start up by a Benshaw Technician See attached Warranty Statement and Terms of Conditions STARTER INFORMATION Date of Startup Benshaw Model Benshaw Serial USER INFORMATION OWNER Company Name Address Contact Purchased from Distributor MOTOR INFORMATION WoundRotor Synchronous L Other SF Field Voltage Secondary Volts TS Field Amps Secondary Amps Field Resistor Secondary Resistance x KVACo LOAD INFORMATION Type of driven load POWER SYSTEM INFORMATION Power cable run from source to starter L Approximate or 1 Actual Power Factor Caps Surge Caps Lightning Arrestors moved to line side of solid state starter or removed DANGER Equipment may be dama
153. ents a patented Slow Speed algorithm that can be used to rotate a three phase AC motor with control of the stator current at speeds less than the rated synchronous speed of the motor The algorithm is used with a standard three phase six switch SCR based soft starter The advantages of the MX starter algorithm over other jogging techniques are that the low speed motor rotation is done without any additional hardware such as additional mechanical contactors and or extra SCRs the peak phase currents are reduced compared with other jogging techniques motor heating is minimized and higher shaft torque can be generated Operation Slow speed forward and reverse operation is achieved by energizing a digital input that has been programmed to either Slow Speed Forward or Slow Speed Reverse refer to the Digital Input Configuration parameters on page 90 for more information The active control source Local Source or Remote Source must be set to terminal Slow Speed Start Stop control is not available from the LCD keypad The starter must be in the idle state in order to enter slow speed operation Relay outputs can be programmed to energize during slow speed operation refer to the Relay Output Configuration parameters on page 91 for more information This feature can be used to disable mechanical brakes or energize clutches during slow speed operation Motor Overload Calculations During Slow Speed Operation During Slow Speed Operation the MX Solid
154. eplaced with a fault screen The screen shows the fault number and the name of the fault The main status screen is not shown until the fault is reset When a fault occurs the STOP LED flashes 3 NOTE For a list of the Faults refer to Appendix C Fault Codes on page 181 4 4 7 Event Recorder An event is anything that changes the present state of the starter Examples of events include a start a stop an overload alarm or a fault The event recorder stores the last 99 events Press MENU until you get to the E01 parameter Pressing UP or DOWN will scroll through the last 99 events and displays the event or fault code on top and the event or fault that changed the starter s state on the bottom Pressing ENTER gives the starter state condition at the time of event Press ENTER again to give you the time of the event Press ENTER again to give you the date that the event occurred 36 NOTE After pressing ENTER you can shift through all the different starter states times and dates by using the UP and DOWN arrows 4 KEYPAD OPERATION 4 4 8 Lockout Screen When a lockout is present one of the following screens will be displayed The main status screen is not shown until the lockout is cleared The overload lockout displays the overload content and the time until reset if an overload occurs 3 NOTE XX XX is the time remaining until the lockout releases 46 4 KEYPAD OPERATION 4 4 9 Alarm Screen
155. erload curves in steps of one available for use Separate overload classes can be programmed for acceleration and for normal running operation and individually or completely disabled if necessary The MX motor overload function also implements a NEMA based current imbalance overload compensation adjustable hot and cold motor compensation and adjustable exponential motor cooling CAUTION If the motor overload protection is disabled during any mode of operation external motor overload protection must be provided to prevent motor damage and or the risk of fire in the case of a motor overload Setting Up The MX Motor Overload Motor overload protection is easily configured through seven parameters please refer to the descriptions of each parameter in section 6 of this manual for additional parameter information Motor FLA QST 01 Motor Service Factor QST 02 Motor Running Overload Class QST 03 Motor Starting Overload Class PFN 29 Independent Starting Running Overload PFN 28 Motor Overload Hot Cold Ratio PFN 31 Motor Overload Cooling Time PEN 32 DIGNUM EO E The Motor FLA and Service Factor parameter settings define the motor overload pickup point For example if the motor service factor is set to 1 00 the motor overload begins accumulating or incrementing when the measured motor current is gt 100 FLA 100 1 00 The overload will NOT trip if the motor current is 10096 If the motor service factor i
156. es not operate normally until reflash mode is exited Reflash mode may be exited by cycling control power The Store Parameters command allows the user to copy the parameters into non volatile memory as a backup If changes are being made store the old set of parameters before any changes are made If the new settings do not work the old parameter values can be loaded back into memory The Load Parameters command loads the stored parameters into active memory The Factory Reset command restores all parameters to the factory defaults The default values can be found in chapter 5 The standard BIST command will put the starter into the unpowered BIST test See section 8 9 on page 168 3 NOTE The powered BIST test is only offered in the Low Voltage systems Time and Date Format FUN 23 LCD Display Range LCD Description mm dd yy 12h month day year 12 hour mm dd yy 24h month day year 24 hour yy mm dd 12h year month day 12 hour yy mm dd 24h year month day 24 hour dd mm yy 12h day month year 12 hour dd mm yy 24h day month year 24 hour Description Sets the date display format and 12 hour or 24 hour time display 3 NOTE The system clock does not recognize daylight savings time Time FUN 24 LCD Display Description Sets the present time See Also Time and Date parameter FUN 23 on page 109 Date FUN 25 LCD Display Description Sets the present date See Also Time and Date parameter FUN 23 on page 109 109 6 PARAMETER D
157. es up to speed In most situations this small pressure peak is not a problem However in selected cases even a small pressure rise can be highly undesirable In belt driven applications TruTorque can prevent the slipping of belts as the motor reaches full speed Figure 33 TruTorque Ramp Motor Torque Max Torque Motor Running 4228222 ea Se secede Mia qawa asas Qa EAE Torque Start command Optional Kick Current Initial Torque Time Kick Time Je Ramp Time gt Up Speed Timer gt TruTorque acceleration control can be very useful for a variety of applications However it is best used to start centrifugal pumps fans and other variable torque applications TruTorque generally should not be used in applications where the starting load varies greatly during the start such as with a reciprocating compressor where the starting load is very low or where the starting load varies greatly from one start to another TruTorque control is not recommended for the starting of AC synchronous motors Initial Torque Maximum Torque Ramp Time 7 THEORY OF OPERATION This parameter CFN 08 sets the initial torque level that the motor produces at the beginning of the starting ramp profile A typical value is 10 to 20 Ifthe motor starts too quickly or the initial motor torque is too high reduce this parameter If the motor does not start rot
158. eted and returned the warranty will be 12 months from date of shipment All recommended maintenance procedures must be followed throughout the warranty period Motors larger than a T Frame require a Benshaw authorized representative to start the equipment to activate the 3 year warranty Warranty Registration Benshaw Startup Service For Medium Voltage products Benshaw or an authorized service agent must startup the equipment and complete the installation data sheet to activate the 3 year warranty from date of shipment If the data sheet is not completed and returned the warranty will be 12 months from date of shipment The cost of this service is not included in the price of the Benshaw equipment and will be quoted separately to the customer All recommended maintenance procedures must be followed throughout the warranty period 12 18 Month Warranty These warranties are 12 months from date of startup or 18 months from date of shipment whichever is sooner WN0001 03 3 Year Warranty Data Sheet Revision Nov 06 doc Page 2 of 2 203 APPENDIX I PARAMETER TABLES Parameter Table Following is the parameter table for both the LED and LCD Display The last column is a convenient place to write down parameter settings Quick Start Group Lew Meera Masna femsas oe Mowrseniceracor s Eesti IE Terminal Terminal P9 05709 UTS Time UTS Tim
159. ets the initial torque level that the motor produces at the beginning of the starting ramp profile A typical value is 10 to 20 If the motor starts too quickly or the initial torque level is too high reduce this parameter If the motor does not start rotating within a few seconds after a start is commanded increase this parameter If the value is set too low a No Current at Run fault may occur during acceleration 36 NOTE It is important that the Rated Power Factor FUN 06 parameter is set properly so that the actual initial torque level is the value desired Start Mode CEN 01 set to KW Power Control Acceleration This parameter sets the initial motor power KW level that will be achieved at the beginning of the starting ramp profile A typical value is 10 to 30 If the motor starts too quickly or the initial power level is too high reduce this parameter If the motor does not start rotating within a few seconds after a start is commanded increase this parameter If the value is set too low a No Current at Run fault may occur during acceleration 36 NOTE It is important that the Rated Power Factor FUN 06 parameter is set properly so that the actual initial power level is the value desired See Also Start Mode 01 on page 63 Ramp Time 1 CFN 02 on page 64 Initial Current 1 CFN 03 QST 06 on page 64 Maximum Torque Power CFN 09 on page 66 Rated Power Factor FUN 06 on page 103 Theory of Operation
160. evel parameter sets the level of DC current applied to the motor during braking The desired brake level is determined by the combination of the system inertia system friction and the desired braking time Ifthe motor is braking too fast the level should be reduced If the motor is not braking fast enough the level should be increased Brake Time The DC Brake Time parameter sets the time that DC current is applied to the motor The desired brake time is determined by the combination of the system inertia system friction and the desired braking level If the motor is still rotating faster than desired at the end of the brake time increase the brake time if possible Ifthe motor stops before the desired brake time has expired decrease the brake time to minimize unnecessary motor heating Brake Delay The DC Brake Delay Time is the time delay between when a stop is commanded and the DC braking current is applied to the motor This delay allows the residual magnetic field and motor counter EMF to decay before applying the DC braking current If a large surge of current is detected when DC braking is first engaged increase the delay time If the delay before the braking action begins is too long then decrease the delay time In general low horsepower motors can utilize shorter delays while large horsepower motor may require longer delays Slow Speed Cyclo Converter 7 6 7 6 1 7 6 2 Slow Speed Cyclo Converter The MX Soft Starter implem
161. ew and correct if necessary motor OL settings Motor cooling obstructed damaged Remove cooling air obstructions Check motor cooling fan Fan power supply lost Verify fan power supply check fuses Fan wiring problem Check fan wiring Voltage Current output switch SW1 2 Set SW1 2 to give correct output not set correctly Analog Output Function parameter Verify that the Analog Output Function 1 21 set incorrectly parameter is set correctly Analog Output Offset and or Span parameters 1 023 and 1 022 set incorrectly Verify load on analog output meets the Load om analog output too high MX analog output specifications Verify correct grounding of analog output connection to prevent noise and or ground loops from affecting output High ambient temperature Verify that the Analog Output Span and Offset parameters are set correctly Ground loop or noise problems Verify that the remote keypad cable has not been damaged and that it is properly seated at both the keypad and the MX control card Heater Level FUNOS is set to On Keypad cable not plugged in properly or cable is damaged 155 8 TROUBLESHOOTING amp MAINTENANCE Fault Code Table 8 5 Fault Code Table The following is a list of possible faults that can be generated by the MX starter control Fault Code Detailed Description of Fault Possible Solutions Motor did not achieve full speed before the UTS timer QST 09 expired
162. ewt om KickTine Sew amp 10 Coast Volt Decel CFN 15 15 Stop Mode Stop Mode TT Decel Coast 70 DC Brake 16 Decel Begin Decel Begin Level 100to1 Linear CFN 19 Decel Prof Decel Ramp Profile Squared Linear 72 S Curve CFN 20 Brake Level DC Brake Level 10 to 100 CEN 22 Brake Delay DC Brake Delay 0 1 to 3 0 CFN 23 SSpd Speed Slow Speed Off 1 40 24 SSpd Curr Slow Speed Current Level 10 to 400 FLA CEN 25 SSpd Timer Slow Speed Time Limit Off 1 to 900 CEN 26 SSpd Kick Curr Slow Speed Kick Level Off 100 to 800 FLA CEN 27 SSpd Kick T Slow Speed Kick Time 0 1 to 10 0 51 5 PARAMETER GROUPS 5 2 3 Protection Group PFN 01 Over Cur Lvl Over Current Trip Level Off 50 800 FLA of PEN 02 Over Current Trip Delay Time Off 0 1 90 0 0 1 PFN 04 PFN 05 PFN 06 PFN 0 PFN 0 PFN 0 PFN 10 1 d Z PFN 12 PFN 13 PFN 14 FN 15 16 Frq Trip Time Frequency Trip Time 0 1 90 0 PEN 19 PF Trip Time PF Trip Time 0 1 90 0 10 0 PEN20 Backspin Time Backspin Timer Off 1 180 Off PFN 21 Time Btw St Time Between Starts Off 1 180 Off PFN 23 PFN 24 PFN 25 PFN 26 PFN 2 PFN 2 PFN 2 PFN 30 PFN 31 PFN 32 PFN 33 PFN 34 PFN 35 52 E P40 PFN 17 PF Lead Lvl PF Lead Trip Level UU off PEN 18 EN PF Lag Lvl PF Lag Trip Level ee ALES CO UL LA Off
163. f time that the kick current level is applied to the motor when the second ramp is active Refer to the Kick Time 1 CFN 12 parameter on page 69 for description of operation See Also Kick Level 1 CFN 11 on page 68 Digital Input Configuration I O 01 08 on page 90 Theory of Operation section 7 3 2 Programming A Kick Current on page 124 Theory of Operation section 7 3 6 Dual Acceleration Ramp Control on page 128 69 6 PARAMETER DESCRIPTION Stop Mode CFN 15 LCD Display Range LCD Description Coast Coast to stop Default Volt Decel Open loop voltage deceleration TT Decel TruTorque deceleration DC Brake DC Braking Description Coast A coast to stop should be used when no special stopping requirements are necessary example crushers balls mills centrifuges belts conveyor The bypass contactor is opened before the SCRs stop gating to reduce wear on the contactor contacts Voltage Decel In this mode the starter linearly phases back the SCRs based on the parameters Decel Begin Level CFN 16 Decel End Level CFN 17 and Decel Time CFN 18 TruTorque Decel In this mode the starter linearly reduces the motor torque based on the parameters Decel End Level CFN 17 and Decel Time CFN 18 DC Brake In this mode the starter provides D C injection for frictionless braking of a three phase motor 38 NOTE The EXMVRMX stops the motor when any fault occurs Depending on the application it may be desirable for the motor to b
164. g 3 NOTE Consult motor manufacturer for high inertia applications 72 6 PARAMETER DESCRIPTION 36 NOTE Not to be used as an emergency stop When motor braking is required even during a power outage an electromechanical brake must be used See Also Stop Mode parameter CFN 15 on page 70 DC Brake Time parameter CFN 21 on page 73 DC Brake Delay parameter CFN 22 on page 73 Controlled Fault Stop Enable parameter PFN 25 on page 85 Digital Input parameters I O 01 08 on page 90 Theory of Operation section 7 1 Solid State Motor Overload Protection on page 114 Theory of Operation section 7 5 1 DC Injection Braking Control on page 134 DC Brake Time 21 LCD Display Range 1 180 Seconds Default 5 Description When the Stop Mode CFN 15 parameter is set to DC brake the DC Brake Time parameter sets the time that DC current is applied to the motor The required brake time is determined by the combination of the system inertia system friction and the desired braking level If the motor is still rotating faster than desired at the end of the brake time increase the brake time if possible If the motor stops before the desired brake time has expired decrease the brake time to minimize unnecessary motor heating See Also Motor Running Overload Class parameter QST 03 on page 59 Stop Mode parameter CFN 15 on page 70 DC Brake Level parameter CFN 20 on page 72 DC Brake Delay parameter CFN 22 on page
165. g Input Trip Low Level Off 09 High Level Luo p Anoma ow fo Off 0 200 Curr 0 800 Curr 0 150 Volt 0 150 OL f 0 10 kW I O 21 Aout Fctn Analog Output Function 0 100 kW Off 94 0 1 MW 0 10 MW 0 100 Ain 0 10095 Firing Calibration 1025 e AwOme ow 95 PG imine Conte nine Configuration Om 10100 Pos 2 oroso Seems 20 Duos Pes Keypad Siop Disable 5 Disabled Power I O 27 Auto Start Power On Start Selection Fault Disabled 97 Power Fault 5 PARAMETER GROUPS 5 2 5 RTD Group npo RTD Module 2 Address Addr RTD 08 RTD6 Group RTD6 Group RTD 11 RTD9 Group RTD9 Group Bearing Other RTD 03 RTDI Group RTDI Group RTD 04 RTD2 Group RTD2 Group RTD 05 RTD3 Group RTD3 Group RTD 06 RTD4 Group RTD4 Group RTD 09 RTD7 Group RTD7 Group Off Off 98 RTD 12 RTD10 Group RTD10 Group amo RTD Module 1 Address Off 16 23 Off RTD 07 RTDS Group RTDS Group RTD 10 RTD8 Group RTD8 Group Stator RTD 13 RTD11 Group RTD11 Group RTD 19 Stator Alarm Level RTD 20 Bearing Alrm Bearing Alarm Level 200 RTD 21 Other Alrm Other Alarm Level ieai 200 RTD29 RTD Bias Max RTD Bias Maximum Level 105 200 155 101 200 54 5 2 6 5 PARAMETER GROUPS Function Group Ave
166. g Torque for Inside Hex Screws oem em o _ 6G wo sy 36 NOTE For screws with multiple tightening means the largest torque value associated with the conductor size shall be marked Slot length shall be measured at the bottom of the slot 24 3 INSTALLATION Current Transformers 3 7 3 7 1 3 7 2 3 7 3 Current Transformers CT Mounting If the CTs are shipped loose they need to be mounted on the power wiring Thread the power wire through the CT and supplied sleeving ensuring the polarity mark is towards the line side The polarity marks may be a white or yellow dot an X on the side of the CT or the white wire Each phase has its own CT The CT must then be attached to the power wiring using two tie wraps CT Polarity The CT has a polarity that must be correct for the starter to correctly measure Watts kW Hours Power Factor and for the Power and TruTorque motor control functions to operate properly Each CT has a dot on one side of the flat surfaces This dot normally white in color must be facing in the direction of the line must be on Line L1 CT2 must be on Line L2 CT3 must be on Line L3 Zero Sequence Ground Fault Current Transformer The Zero Sequence Ground Fault CT can be installed over the three phase conductors for sensitive ground current detection or for use with high resistance grounded systems Figure 7 BICT 2000 1 6 Mechanical Dimensio
167. g performance The MX Heavy Duty braking package includes a freewheel current path between phases 1 and 3 that consists of a fuse and a 7 SCR with gating card In combination with the applied DC current from the MX starter the freewheeling current path greatly enhances available braking torque When Braking the stop must be counted as another motor start when looking at the motor starts per hour limit 38 NOTE Semi Conductor Fuse and 7th SCR supplied by Benshaw Braking Output Relay To utilize DC injection braking one of the user output Relays needs to be programmed as a Braking relay Refer to the Relay Output Configuration parameters on page 91 for more information The output of a Braking relay is needed to control the contactor and or gm SCR gating control card used during braking 3 NOTE Verify that the correct output relay is programmed to Braking and that the wiring of this relay is correct Damage to the starter can result if the braking relay is not programmed and or wired properly Stand Alone Overload Relay for emergency ATL Across The Line Operation Due to the currents being drawn on Line 1 and Line 3 for braking this stand alone overload relay will cause nuisance current imbalance trips For a solution consult factory 134 7 5 5 2 2200 6900 L3 s o 58 gt ou 5 5 o s TO 120VAC 4 NEUTRAL aruma t F F R1 BRAKING CONTAC
168. ge that is used when the starter performs Over and Under line voltage calculations This value is the supply voltage NOT the motor utilization voltage 3 NOTE Settings above 1140 are for medium voltage applications 3 NOTE Rated Voltage must be set properly for the starter to operate properly See Also Over Voltage Level parameter PFN 10 on page 81 Under Voltage Level parameter PFN 11 on page 81 Voltage Trip Time parameter PFN 12 on page 81 Meter parameter FUN 01 FUN 02 on page 101 Motor Rated Power Factor FUN 06 LCD Display Range 0 01 lag to 1 00 unity Default 0 92 Description The Motor Rated Power Factor parameter sets the motor power factor value that is used by the starter for TruTorque and Power control calculations and metering calculations If TruTorque or Power acceleration and or deceleration control is used it is very important to properly set this parameter to the motor s full load rated power factor usually available on the motor nameplate or from the motor manufacturer For a typical induction motor this value is between 0 80 and 0 95 If the motor rated power factor is not available from either the motor nameplate or the motor manufacturer the value can be obtained by viewing the power factor meter With the motor running at full name plate current view the power factor meter by pressing the UP arrow key until the Motor PF meter is displayed using the LCD display The meter value
169. ged or personal injury may result if equipment is started with lightning arrestors power factor capacitors or surge capacitors connected on the load side of the solid state motor controls STARTUP PROCEDURES All procedures are found in your instruction manual U Pre startup procedures followed L Connection procedures followed 0 Startup procedures followed Proper cable size All Connections tig WARRANTY STATUS For Benshaw Office Use Only e Please return to Benshaw Canada 550 Bright Street E Listowel Ontario Canada N4W 3W3 Attn Warranty Department Fax 519 291 2595 Complete the warranty registration on line at http www benshaw com WN0001 03 3 Year Warranty Data Sheet Revision Nov 06 doc Page of 2 202 APPENDIX H 3 YEAR WARRANTY General Conditions All warranties are provided in accordance with Benshaw Inc Terms and Conditions of Sale Benshaw warrants it s products including printed circuit boards power electronic assemblies and integral bypass contactors per the periods and warranty types listed below Other manufacturer s products which are included in the Benshaw equipment such as circuit breakers fuses transformers relays pilot devices and other power control components are warranted per the terms and conditions of the manufacturer s original equipment warranty All warranty periods for Benshaw manufactured products are based on the date of shipment unless
170. guration parameters I O 10 15 on page 91 Under Current Trip Level PFN 03 LCD Display Range Off 5 100 of FLA Default Off Description If the MX detects a one cycle average current that is less than the level defined an under current alarm condition exists and any relays programmed as alarm will energize The under current timer starts a delay time If the under current still exists when the delay time expires the starter Under Current Trips F34 and any relay programmed as fault relay changes state The Under Current Trip is only active in the UTS state Energy Saver state Current follower or while in the Phase Control mode A relay can be programmed to change state when an under current alarm condition is detected Alarm Fault 94 Current Condition Trip Motor FLA QST 01 Under Level 03 Time lt lt Under Current Trip Delay Time PFN 04 See Also Under Current Time parameter PFN 04 on page 77 Auto Reset parameter PFN 23 on page 84 Controlled Fault Stop Enable parameter PFN 25 on page 85 Relay Output Configuration parameters I O 10 15 on page 91 Under Current Trip Delay Time PEN 04 LCD Display Range Off 0 1 90 0 seconds Default 0 1 sec Description The Under Current Time parameter sets the period of time that the motor current must be less than the Under Current Level PFN 03 parameter before an under current fault and trip occurs If Off is selected the unde
171. he Zero Sequence Ground Fault parameter sets a ground fault current trip or alarm level that can be used to protect the system from a ground fault condition In isolated or high impedance grounded systems core balanced current sensors are typically used to detect low level ground faults caused by insulation breakdowns or entry of foreign objects Detection of such ground faults can be used to interrupt the system to prevent further damage or to alert the appropriate personnel to perform timely maintenance Ground Fault Trip The EXMVRMX will trip with a ground fault indication if No other fault currently exists Ground fault current is equal to or greater than the GF Trip Level for a time period greater than the GF Trip Delay PFN 09 Once the starter recognizes a ground fault condition it will shut down the motor and display a fault F38 Ground Fault Alarm Fault Amps Condition Trip Zero Sequence Gnd Fault Level TLF 7 PFN 08 1 Time 4 Ground Fault Trip Time PFN 09 If a programmable relay 1 O 10 15 is set to Ground Fault the starter energizes the relay when the condition exists 38 NOTE The zero sequence ground fault detection consists of installing a Cat No BICT 2000 1 6 50 0 025 amps core balance current transformer to terminal J15 Gnd Flt located on the I O card See Also Ground Fault Trip Time PEN 09 on page 80 Auto Reset parameter PFN 23 o
172. he installation site inspect the electrical connections more frequently 148 8 TROUBLESHOOTING amp MAINTENANCE LED Diagnostics 8 3 LED Diagnostics There are several LEDs located on the EXMVRMX circuit cards These LEDs can be used to help troubleshoot problems with the starter Refer to the circuit card layouts for LED locations Assembly BIRC 50100 02 00 Gate Driver Card On when gate x is on LED3 SCRy is firing On when gate y is on Gate Power Distributor I LED GATE OPTIONAL RTD Modules Remote transmitting data RTD Module Flash twice per second when card is Status Green Flash once per second DC Power Supply DC ON Green DC voltage is On Stays on when R TD module has power 3 NOTE The SCR Gate Firing LEDs RED LED 7 8 9 10 11 12 are always turned off expect during the BIST test and start up 149 8 TROUBLESHOOTING amp MAINTENANCE RediStart EXMVRMX3 Gate Driver Card lt SCRxGATE POWER SWITCH WIRES a SCRrON LED BACK OF CARD SCRx GATE WHITE LEAD CATHODE RED LEAD 15O1 SCRx FIBER OPTIC CABLE METTI 1502 OT CIRCUIT FIBER OPTIC CABLE VOLTAGE ACROSS SCRs LED lt BACK OF CARD lt SCRy ON LED SCRy BACK OF CARD GATE WHITE LEAD CATHODE RED LEAD 7 1503 SCRy FIBER OPTIC CABLE 4 SCRy GATE POWER GATE DRIVER CARD BIPC 301003 01 OTS OK LED
173. he list When a list of faults is displayed it moves from one fault to the next When a list of events is displayed it moves from one event to the next When the starter is in the Operate Mode pressing UP allows you to change which group of meter values is monitored Decrease the value of a numeric parameter Select the previous value of an enumerated parameter It scrolls backward through a list of parameters within a group when the first parameter is displayed it scrolls to the end of the list When a list of faults is displayed it moves from one fault to the previous fault When a list of events is displayed it moves from one event to the previous event When the starter is in the Operate Mode pressing DOWN allows you to change which group of meter values is monitored When editing a numeric parameter the LEFT arrow key moves the cursor one digit to the left If cursor is already at the most significant digit it returns to the least significant digit on the right When in Menu mode the LEFT arrow allows groups to be scrolled through in the opposite direction of the MENU Key Stores the change of a value When in Fault History ENTER key scrolls through information logged when a fault occurred When in Event History ENTER key scrolls through information logged when an event occurred When an alarm condition exists ENTER scrolls through all active alarms MENU scrolls between the operate screen and th
174. he motor when the motor winding heater anti windmilling brake is enabled The motor winding heater anti windmilling brake can be used to heat a motor in order to prevent internal condensation or it can be used to prevent a motor from rotating 38 NOTE The motor can still slowly creep when the anti windmilling brake is being used If the motor has to be held without rotating a mechanical means of holding the motor must be used The motor winding heater anti windmilling brake operation may be controlled by a digital input and by a heater disable bit in the starter control Modbus register There are two methods of using the digital inputs either the input is an enable or disable Enabled When the DI 1 2 3 4 5 6 7 8 inputs are programmed as Heat Enable Inputs the input may be used to control when heating anti windmilling is applied The Heater Level parameter must be set the starter stopped and this input must be high for heating to occur Disabled When the DI 1 2 3 4 5 6 7 8 inputs are programmed as Heat Disable Inputs the input may be used to control when heating anti windmilling is applied The Heater Anti Windmill Level parameter must be set and this input must be low for heating to occur If no digital inputs are programmed as heater enabled or disabled and HEATER LEVEL is programmed greater than 0 the heater is applied at all times when the motor is stopped The level of D C current applied to the motor during this operat
175. hen the value will be used RTD Bias Curve 400 RTD BiasMax 90 80 nd 8S ed Setpoints 5 a RTD27 Bias Minimum Level Setpoint 8 RTD28 Bias Midpoint Level Setpoint 4 RTD29 Bias Maximum Level Setpoint k 30 4 299 RTD BiasMid 20020 SR Hot Cold Ratio 0 RID BiasMin 50 0 50 100 150 200 250 Maximum RTD Temperature C See Also RTD Biasing OL group in section 7 1 7 on page 118 RTD Bias Minimum Level RTD 27 LCD Display Range 100 0 198 C Default 40 C 6 PARAMETER DESCRIPTION Description Typically set to ambient conditions 40 C See Also RTD Biasing OL group in section 7 1 7 on page 118 RTD Bias Midpoint Level RTD 28 LCD Display Range 1 199 C Default 130 C Description Typically set at the rated motor running temperature 88 NOTE Consult motor manufacturer for information See Also RTD Biasing OL group in section 7 1 7 on page 118 RTD Bias Maximum Level RTD 29 LCD Display Range 105 200 C Default 155 C Description The stator insulation maximum temperature rating 88 NOTE Consult motor manufacturer for information See Also RTD Biasing OL group in section 7 1 7 on page 118 Jump to Parameter FUN 00 LCD Display Description By changing the value of this parameter and pressing ENTER you can jump directly to any parameter within that group Meter FUN 01 02 LCD Display Range LCD Description Status Running
176. hen the fault has 30629 40629 occurred 3063 1 4063 1 to 30639 40639 30641 40649 to 30649 40649 30651 40651 L1 L2 Voltages The line voltage that is to present between lines 1 and 2 when a fault 30659 40659 Occurs 30661 40661 L2 L3 Voltages The line voltage that is to present between lines 2 and 3 when a fault 30669 40669 Occurs 30671 40671 L1 Voltages The line voltage that is to present between lines 3 and 1 when a fault 30679 40679 Occurs 30681 40681 to 30689 40689 30691 40691 Line Periods The line period to 1 frequency that is present when a fault microseconds 30699 40699 Occurs 30701 40701 PPP MEM x ing time meter when a fault occurs Hours 30709 40709 running Run Time Counts The value of the 30711 40711 272 s hi io running time meter when a fault occurs resets to 0 each time the running time 10 cownts sec The running counts provides more hours increments at 35 999 30713 40719 resolution than the running time hours L2 Currents The current that the load is drawing from Line 2 when a fault occurs L3 Currents The current that the load is drawing from Line 3 when a fault occurs Kilowatts The power that the load is drawing when a fault occurs Event Codes Bit 15 indicates whether a 15 event or fault 1 indicates fault and 0 indicates event The sdb remaining 15 bits contain the code 30901 40901 newest to 4 theeyentor
177. hm Meter Testing A few reasons for an SCR Test Procedure would be if the starter is receiving shorted SCR trips current imbalance trips or ground fault trips basically the SCR is not turning on properly If any cards have been replaced it is also recommended to do a BIST test see BIST testing A ohmmeter will be needed to perform the following tests For accurate results it is important to use the same ohmmeter throughout the tests and for each SCR in the starter If all ohm readings are within specified limits then the SCRs can be considered good and this procedure completed Fuse Tests Perform ohmmeter resistance across both power and control fuses Verify fuses for continuity Shorted SCR Test This will test the anode to cathode integrity of the SCR Use the following table and figure to place the ohmmeter probes You should not need to remove components to perform the ohmmeter tests 3 NOTE Figure 49 is the heat sinks that are underneath the 3 separate cards Place the leads of the ohmmeter on the heat sinks behind the gate driver card Figure 49 Heat sinks RIVER CARDS lt S 450001 XX Table 17 Ohmmeter Position From position 1 to position 2 From position 1 to position 3 If all values are greater than 50K ohms proceed to the SCR Gate to Cathode Test If an SCR measures less than 50K ohms but not 0 ohms the SCR still may be good Contact Benshaw for further assistance If any of the reco
178. igned as Other RTD A 1 indicates the RTD is assigned to the other group Bit Mask Each of the sixteen 16 bits represents 20053 40083 R TDS ith RTD A 1 indicates the RTD has an open lead Bit Mask Each of the sixteen 16 bits represents an RTD A 1 indicates the RTD has shorted leads 30085 40085 Remaining Lockout Time PO See 30086 40086 Date Time lower 16 bits in 32 bit unsigned integer format Sec 30087 40087 Date Time upper 16 bits 30101 40101 Motor FLA 1 6400 30102 40102 100 199 30103 40103 Independent Start Run Motor Overloads O Dil 1 Enabled r 0 Disabled 30104 40104 Motor Overload Running Enable i Enabled 30084 40084 RTDs with Shorted Leads APPENDIX F MODBUS REGISTER MAP Absolute Register Address 0 Disabled 30106 40106 Motor Overload Starting Enable 1 Enabled 30108 40108 Motor Overload Hot Cold Ratio 0 99 l 30109 40109 Motor Overload Cooling Time 10 9999 0 1 Min 30110 40110 Local Source Keypad Terminal 30111 40111 Serial Remote Source Open Loop Voltage Ramp Closed Loop Current Ramp TruTorque Ramp Power Ramp Tach Ramp Initial Motor Current 1 50 600 FLA Maximum Motor Current 1 100 800 FLA Ramp Time 1 0 300 Sec 30112 40112 Start Mode TIO e Be 30113 40113 30114 40114 30115 40115 30116 40116 30117 40117 30118 40118 30119 40119 Initial Motor Current 2 FLA Maximum Motor Current 2 F
179. igure 22 Remote RTD Module Mechanical Layout EL HOUSING LIGHTS A S ole RER 2 32e REF i 25 3 543 69 69 69 69 69 69 69 69 69 69 69 amp Modbus Address Set the rotary switch on the top of the Remote RTD Module to the desired Modbus address Up to 2 modules can be connected to the EXMVRM starter The address set by the rotary switch must match the setting in RTD 01 or RTD 02 For example setting both the rotary switch and RTD 01 to 16 would make the connected module be module 1 The connected RTDs would then represent 1 to 8 in the RTD programming Power Connections The 24VDC power source is connected to the following terminals 24VDC Negative connection to 24VDC power supply 24VDC Positive connection to 24VDC power supply Chassis ground connection RS 485 Communication The RS 485 communications wiring should use shielded twisted pair cable The shield should only be terminated at one end The connections are as follows MX RJ45 Module Description pin 5 A RS 485 negative communications connection pin 4 B RS 485 positive communications connection pin 8 Com RS 485 common connection 36 3 13 5 3 13 6 RTD Co
180. ime on page 106 FUN 15 Tachometer Loss Action on page 106 4 Setthe Initial Current QST 06 CFN 03 level to the desired starting current on page 64 5 Set the Maximum Current QST 07 04 level to the desired maximum current limit on page 65 Acceleration Ramp Selection 7 OF OPERATION Current Ramp 2 and Kick Current 2 starting profiles are selected by programming a digital input to the Ramp Select function and then energizing that input by applying 120 Volts to it When a digital input is programmed to Ramp Select but de energized Current Ramp 1 and Kick Current 1 are selected When no digital inputs are programmed to the Ramp Select function the Ramp 1 profile is used The Ramp Select input only affects the starting profile when using a current ramp profile and during a kick The Ramp Select input does not affect the TruTorque ramp Power ramp or the Voltage ramp profile unless kicking is enabled at the beginning of those ramps The following table summarizes which parameters affect the starting profile when a digital input is programmed to the Ramp Select function and that input is either energized or de energized Ramp Modes Ramp Select De energized Initial Current 1 Ramp Select Energized Initial Current 2 Maximum Current 1 Maximum Current 2 Current Ramp Ramp Time 1 Ramp Time 2 Kick Level 1 Kick Level 2 Kick Time 1 Kick Time 2 I
181. imit the power kW drawn from the power system and to reduce the power surge that may occur as an AC induction motor comes up to speed This power surge can be a problem in applications that are operated on generators or other limited or soft power systems Power control also reduces the torque surge that can also occur as an AC induction motor comes up to speed Figure 34 Power Ramp Motor Input Power Max Power Start command Current Initial Power Time Kick Time 44000 Ramp Time gt Up To Speed Timer gt Power control acceleration can be very useful for a variety of applications Power control generally should not be used in applications where the starting load varies greatly during the start such as with a reciprocating compressor Power control is not recommended for starting of AC synchronous motors This parameter sets the initial power level that the motor draws at the beginning of the starting ramp profile A typical value is usually 10 to 30 Ifthe motor starts too quickly or the initial power level is too high reduce this parameter If the motor does not start rotating within a few seconds after a start is commanded increase this parameter If this value is set too low a No Current at Run fault may occur This parameter sets the final or maximum power level that the motor produces at the end of the acceleration ramp For a loaded motor the maximum power level initially should be se
182. in both the open and closed state If the feedback does not match the state of the RUN relay within the amount of time set by the Inline Config I O 24 parameter an Inline fault Fault 49 will occur 3 NOTE If no digital input is assigned as an Inline Confirm input this test will always pass 3 NOTE If the Inline Config I O 24 parameter on page 96 is set to Off this test will be skipped During the in line contactor test the EXMVRMX will display the following UTS relay and Bypass Test In this test the dedicated bypass relay if assigned and UTS assigned relays are cycled on and off once and the feedback from a bypass contactor is verified In order to have a valid bypass contactor feedback the dedicated bypass confirm input and any other inputs set to bypass confirm needs to be wired to an auxiliary contact of the bypass contactor The feedback is checked in both the open and closed state If the feedback does not match the state of the UTS relay within the amount of time set by the Bypass Feedback I O 25 parameter a Bypass 2M Fault Fault 48 will occur 3 NOTE If the dedicated bypass relay is set to fan and if no digital inputs are assigned as a Bypass Confirm input this test will always pass 170 8 9 8 8 9 9 8 TROUBLESHOOTING amp MAINTENANCE Sequential SCR Gate Firing The SCR gate outputs are fired sequentially in this test This test is used to verify that the fiber optic gate driver cards are
183. ine voltage of 10 000 to 13 800VAC The starter can be programmed for any motor FLA and all of the common motor service factors It enables operators to control both motor acceleration and deceleration The RediStart EXMVRMX can also protect the motor and its load from damage that could be caused by incorrect phase order wiring The starter continually monitors the amount of current being delivered to the motor This protects the motor from overheating or drawing excess current Features The enhanced engineering features of the starter include Multiple frame sizes Universal voltage operation Universal frequency operation Programmable motor overload multiplier Controlled acceleration and deceleration Phase rotation protection Regulated current control Electronic motor thermal overload protection Electronic over under current protection Single phase protection Line to line current imbalance protection Stalled motor protection Programmable metering Passcode protected Programmable Relays Analog output with digital offset and span adjustment Analog input with digital offset and span adjustment Voltage and Current Accuracy of 3 Slow speed Cyclo Conversion 1 0 40 0 forward and reverse Motor Winding Heater Anti Condensation Anti windmilling brake PTC Thermistor 99 Event Recorder 9Fault Log Real Time Clock Zero Sequence Ground Fault Backspin Timer
184. ing braking The desired brake level is determined by the combination of the system inertia system friction and the desired braking time If the motor is braking too fast the level should be reduced If the motor is not braking fast enough the level should be increased Refer to Nema MGI Parts 12 and 20 for maximum load inertias A PTC Thermistor or RTD MUST be installed to protect the motor DC Brake Function Programming Steps 1 The DC Brake function may be enabled by setting the Stop Mode CFN 15 parameter to DC Brake 2 Once this function is enabled a relay output configuration I O 10 15 must be used to control the DC brake contactor or 7th SCR gate drive card during braking It is recommended to use Relay R3 1 012 because it is a higher rated relay 3 NOTE Standard duty braking For load inertias less than 6 x motor inertia Heavy duty braking For NEMA MGI parts 12 and 20 maximum load inertias 3 NOTE When DC injection braking is utilized discretion must be used when setting up the DC Brake Level Motor heating during DC braking is similar to motor heating during starting Even though the Motor OL is active if not set to Off during DC injection braking excessive motor heating could still result if the load inertia is large or the brake level is set too high Caution must be used to assure that the motor has the thermal capacity to handle braking the desired load in the desired period of time without excessive heatin
185. initial to the maximum value To make the motor accelerate faster decrease the ramp time To make the motor accelerate slower increase the ramp time A typical ramp time setting is from 15 to 30 seconds If the ramp time expires before the motor reaches full speed the starter maintains the maximum current level until either the motor reaches full speed the UTS timer expires or the motor thermal overload trips 36 NOTE Setting the ramp time to a specific value does not necessarily mean that the motor will take this time to accelerate to full speed The motor and load may achieve full speed before the ramp time expires if the application does not require the set ramp time and maximum current to reach full speed Alternatively the motor and load may take longer than the set ramp time to achieve full speed See Also Up To Speed Time QST 09 on page 62 Start Mode 01 on page 63 Initial Current 1 QST 06 CEN 03 on page 64 Maximum Current 1 QST 07 CFN 04 on page 65 Kick Level 1 CFN 11 on page 68 Kick Time 1 CEN 12 on page 69 Theory of Operation section 7 3 1 Current Ramp Settings Ramps and Times on page 123 Up To Speed Time OST 09 LCD Display Range 1 300 seconds Default 20 sec Description The Up To Speed Time parameter sets the maximum acceleration time to full speed that the motor can take A stalled motor condition is detected if the motor does not get up to speed before the up to speed timer expires
186. input are as follows Figure 18 SW1 DIP Switch Settings ANALOG INPUT ANALOG OUTPUT sw1 1 SW1 2 ON 0 20mA ON 0 10V OFF 0 10V OFF 0 20mA Trip resistance 3 5K 300 Ohms Reset resistance 1 65K 150 Ohms Open terminal voltage is 15V PTC voltage at 4Kohms 8 55v gt 7 5V Response time adjustable between 1 and 5 seconds Maximum cold resistance of PTC chain 1500 Ohms An example of the thermistor wiring is shown below in Figure 19 See Also Motor PTC Trip Time PFN 27 on page 86 RTD Module Connector Connector is for the connection of Benshaw Remote RTD Modules These modules can be mounted at the motor to reduce the length of the RTD leads The connector is a standard RJ 45 The wires connect as follows 4 B 5 A 8 common 33 3 INSTALLATION Remote LCD Keypad Display 3 12 Remote LCD Keypad Display The display has a NEMA 13 IP65 service rating The display is available in 2 versions a small display as P N KPMX3SLCD and large display as P N KPMX3LLCD 3 12 1 Remote Display The LCD keypad is mounted remotely from the MX Control via a straight through display cable which connects between the MX RJ45 terminal and remote display s RJ45 terminal Figure 20 Mounting Remote Keypads CLIP t ENCLOSURE DOOR MX DISPL Y 34 3 12 2 3 12 3 3 INSTALLATION
187. ion needs to be monitored to ensure that the motor is not overheated The current level should be set as low as possible and then slowly increased over a long period of time While this is being done the temperature of the motor should be monitored to ensure it is not overheating The motor should be labeled as being live even when not rotating The heater feature should not be used to dry out a wet motor 3 NOTE When this function is On all of the other parameters cannot be programmed until this parameter is turned Off 6 PARAMETER DESCRIPTION Energy Saver FUN 09 LCD Display Range On Off Default Off THIS FUNCTION IS NOT AVAILABLE FOR MEDIUM VOLTAGE Description The Energy Saver parameter lowers the voltage applied to a lightly loaded motor It continues to lower the voltage until it finds the point where the current reaches its lowest stable level and then regulates the voltage around this point If the load on the motor increases the starter immediately returns the output of the starter to full voltage 3 NOTE This function does not operate if a bypass contactor is used 36 NOTE In general Energy Saver can save approximately 1000 watts per 100 HP Consult Benshaw for further detail P O R T Fault Time FUN 10 LCD Display Range Off 0 1 90 0 seconds Default Off Description The purpose of PORT is to not fault when all line power has been lost and to wait for a predetermined amount of time for power
188. ite must be prepared The customer is responsible for Providing the correct power source Providing the correct power protection Selecting the control mechanism Obtaining the connection cables lugs and all other hardware Ensuring the installation site meets all environmental specifications for the enclosure NEMA rating Installing and connecting the motor Power Cables The power cables for the starter must have the correct NEC CSA current rating for the unit being installed Depending upon the model the power cables can range from a single 2 AWG conductor to four 750 MCM cables Consult local and national codes for selecting wire size Site Requirements The installation site must adhere to the applicable starter NEMA CEMA rating For optimal performance the installation site must meet the appropriate environmental and altitude requirements EMC Installation Guidelines General In order to help our customers comply with European electromagnetic compatibility standards Benshaw Inc has developed the following guidelines Attention This product has been designed for Class A equipment Use of the product in domestic environments may cause radio interference in which case the installer may need to use additional mitigation methods Enclosure Install the product in a grounded metal enclosure Grounding Connect a grounding conductor to the screw or terminal provided as standard on each controller Refer to layout power
189. l many never be achieved Therefore the maximum torque level is the maximum TruTorque level that is permitted However the motor torque may not necessarily reach this value during all starts When in TruTorque acceleration mode the ramp time setting is the time it takes for the torque to go from the initial torque setting to the maximum torque setting To make the motor accelerate faster decrease the ramp time To make the motor accelerate slower increase the ramp time If the ramp time expires before the motor reaches full speed the starter maintains the Maximum Torque level until either the motor reaches full speed UTS timer expires or the motor thermal overload protection trips 3 NOTE Setting the ramp time to a specific value does not necessarily mean that the motor takes that exact amount of time to accelerate to full speed The motor and load may achieve full speed before the ramp time expires if the load does not require the set ramp time or set torque level to reach full speed Alternately the motor and load may take longer than the set ramp time to achieve full speed depending on the parameter settings and load level 125 7 THEORY OF OPERATION 7 3 4 Power Control Acceleration Settings and Times General Initial Power Maximum Power 126 Motor Running Power Level Optional Kick Power control is a closed loop power based acceleration control The primary purpose of Power controlled acceleration is to control and l
190. larm Level PFN 33 on page 89 Motor OL Lockout Level PFN 34 on page 89 Motor OL Auto Lockout Level PFN 35 on page 89 Relay Output Configuration I O 10 15 on page 91 Theory of Operation section 7 1 Solid State Motor Overload Protection on page 114 Local Source OST 04 LCD Display Range LCD Description Keypad The start stop control is from the keypad Terminal The start stop control is from the terminal strip inputs Default Serial The start stop control is from the network Description The have three sources of start and stop control Terminal Keypad and Serial Two parameters Local Source QST 04 and Remote Source QST 05 select the source of the start and stop control If digital input is programmed as Local Remote then that input selects the control source When the input is low the local source is used When the input is high the remote source is used If no digital input is 59 6 PARAMETER DESCRIPTION programmed as Local Remote then the local remote bit in the starter control Modbus register selects the control source The default value of the bit is Local 0 3 NOTE By default the STOP key is always enabled regardless of selected control source It may be disabled though using the Keypad Stop Disable I O 26 parameter See Also Remote Source QST 05 on page 60 Digital Input Configuration I O 01 08 on page 90 Keypad Stop Disable 26 on page 96 Communic
191. layed with the following format Parameter Name LCD Display Range Parameter Value Default Constant OR LCD Keypad Description The description of the function See Also Cross references to related parameters or other chapters Jump to Parameter OST 00 LCD Display Description By changing the value of this parameter and pressing ENTER you can jump directly to any parameter within that group Motor FLA QST 01 LCD Display Range 1 6400 Amps RMS Default 10A Description The Motor FLA parameter configures the motor full load amps and is obtained from the nameplate on the attached motor If multiple motors are connected the FLA of each motor must be added together for this value 3 NOTE Incorrectly setting this parameter prevents proper operation of the motor overload protection motor over current protection motor undercurrent protection ground fault protection and acceleration control Motor Service Factor OST 02 LCD Display Range 1 00 1 99 Default 1 15 58 6 PARAMETER DESCRIPTION Description The Motor Service Factor parameter should be set to the service factor of the motor The service factor is used for the overload calculations If the service factor of the motor is not known then the service factor should be set to 1 00 3 NOTE The NEC National Electrical Code does not allow the service factor to be set above 1 40 Check with other local electrical codes for their requirements
192. lculated current imbalance is greater than the current imbalance level for the Current Imbalance Delay Trip Time PFN 06 the starter shuts down the motor and declares a Fault 37 Current Imbalance Alarm Fault Condition Trip Imbalance Current Imbl Lvl PFN 05 Time Current Imbalance Trip Time PFN 06 See Also Current Imbalance Trip Time PFN 06 on page 78 Auto Reset parameter PFN 23 on page 84 Controlled Fault Stop Enable parameter PFN 25 on page 85 Current Imbalance Trip Time PFN 06 LCD Display Range 0 1 90 0 seconds Default 10 0 sec 78 6 PARAMETER DESCRIPTION Description The Imbalance Delay parameter sets the time that the current imbalance must be greater than the Percent Imbalance PFN 05 parameter before a trip will occur See Also Current Imbalance Trip Level PFN 05 on page 78 Residual Ground Fault Trip Level PFN 07 LCD Display Range Off 5 100 FLA Default Off Description The Residual Ground Fault parameter sets a ground fault current trip or indicate level that can be used to protect the system from a ground fault condition The starter monitors the instantaneous sum of the three line currents to detect the ground fault current Ground Fault Trip The EXMVRMX will trip with a ground fault indication if No other fault currently exists Ground fault current is equal to or greater than the GF Trip Level for a time period greater than the GF Trip Delay PFN 0
193. le Enabled 30151 40151 Undercurrent Trip Level 5 100 FLA 0 Disabled 30152 40152 Undercurrent Trip Delay Time Enable 1 Enabled 30153 40153 Undercurrent Trip Delay Time 1 900 100 mSec 0 Disabled 30154 40154 Current Imbalance Trip Enable 1 Enabled 190 APPENDIX F MODBUS REGISTER MAP Absolute Register Address 0 Disabled Residual Ground Fault Trip Enable 1 Enabled EE 30157 40157 Residual Ground Fault Trip Level 5 100 0 Disabled 30158 40158 Over Voltage Trip Enable 1 Enabled 30159 40159 Over Voltage Trip Level 0 Disabled 30160 40160 Under Voltage Trip Enable l Enabled a 30161 40161 Under Voltage Trip Level 30162 40162 Over Under Voltage Delay Time 1 900 100 mSec 30163 40163 Digital Input Trip Delay Time 1 900 100 mSec 30156 40156 30164 40164 30165 40165 30166 40166 30167 40167 30168 40168 30169 40169 30170 40170 30171 40171 30172 40172 30173 40173 30174 40174 Auto Fault Reset Enable Auto Fault Reset Delay Time 1 900 Auto Fault Reset Count Enable Auto Fault Reset Count Controlled Fault Stop DI 1 Configuration DI 2 Configuration DI 3 Configuration R1 Configuration R2 Configuration R3 Configuration 0 1 0 1 22 0 1 Disabled 30175 40175 Analog Input Trip Enable Enabled Disabled Enabled Disabled Enabled Fault High Fault Low Fault Reset Disconnect
194. lect digital input Tach Ramp Speed controlled acceleration ramp Ramp starts at motor speed measured at start of recovery and accelerates motor at same slope acceleration rate as a normal tachometer start from zero speed would do Description The PORT Recovery parameter sets how the starter will re accelerate the motor when power returns Tachometer Full Speed Voltage FUN 13 LCD Display Range 1 00 10 00 V in 0 01 volt increments Default 5 00V Description The Tachometer Full Speed Voltage parameter sets the tachometer input voltage at full speed This value should be set at full unloaded motor speed Ex A tachometer rated at 0 0033 volts per rpm is mounted on a 4 pole 1800 rpm motor Therefore the FS Volts should be set to 0 0033 1800 5 94 volts Tachometer Loss Time FUN 14 LCD Display Range 0 1 90 0 seconds Default 1 5 Description The Tachometer Loss Time is the allowable time the starter will operate when a tachometer signal is lost If the signal is lost the starter will perform the action set by the Tach Loss Action parameter 3 NOTE Nuisance tachometer loss faults at start can be prevented by setting the initial current parameter to a value that allows the motor to begin rotating soon after a start is commanded Tachometer Loss Action FUN 15 LCD Display Range LCD Description Fault The starter will shutdown and indicate a tachometer loss fault Current Acceleration If the tachometer signal is lost the starter will faul
195. logic signal The key is to have the Stop input be high when the Hand Off Auto switch is in the Hand position but be low when the switch is in the Auto position The following wiring diagram illustrates a possible implementation In this example DI 1 on the MX is programmed as a Stop input Figure 43 Example of Start Stop with a Hand Off Auto Selector Switch OFF HAND 4 AUTO 120 LIVE OUTPUT CONTACT STOP START o SELECTOR SWITCH 120VAC NEUTRAL When the Hand Off Auto selector switch is in the Hand position current flows to the Stop push button contact and to the Stop input on the MX If the Stop is not pressed and the Start push button is pressed the starter starts This is a typical 3 wire control The seal for the Start push button input is accomplished in software When the stop is pressed the starter stops When the Hand Off Auto selector switch is in the Auto position current flows to the user supplied run contact but the Stop input remains low When the user supplied run contact closes and the stop input is low no power applied the starter is in 2 wire control CAUTION It is important that the Stop push button be wired in front of the Start push button otherwise the starter could be started when the Stop bush button is pressed and the Start button is pressed 141 7 THEORY OF OPERATION Simplified I O Schematics 7 9 Simplified I O
196. lso Local Source parameter QST 04 on page 59 Remote Source parameter QST 05 on page 60 Communication Address parameter FUN 16 on page 107 Communication Timeout parameter FUN 18 on page 107 Communication Byte Framing parameter FUN 19 on page 108 Communication Timeout FUN 18 LCD Display Range Off 1 120 seconds Default Off Description The Communication Timeout parameter sets the time that the starter continues to run without receiving a valid Modbus request If a valid Modbus request is not received for the time that is set the starter declares an F82 Modbus Time Out The starter performs a controlled stop See Also Local Source parameter QST 04 on page 59 Remote Source parameter QST 05 on page 60 Stop Mode parameter CFN 15 on page 70 Controlled Fault Stop Enable parameter PFN 25 on page 85 Communication Address parameter FUN 16 on page 107 Communication Baud Rate parameter FUN 17 on page 107 107 6 PARAMETER DESCRIPTION Communication Byte Framing FUN 19 LCD Display Range Even 1 Stop Default Odd 1 Stop None 1 Stop None 2 Stop Description The Communication Byte Framing parameter sets both the parity and number of stop bits See Also Communication Address parameter FUN 16 on page 107 Communication Baud Rate parameter FUN 17 on page 107 Communication Timeout parameter FUN 18 on page 107 Software Version 1 FUN 20 LCD Display Description This parameter sho
197. lts per division and a 2 millisecond time scale See the figure below for a sample voltage measurement using an oscilloscope Figure 55 Gate voltage of a proper SCR Vertical data Verbal data 171 8 TROUBLESHOOTING amp MAINTENANCE During this test the display will show the following Press ENTER pushbutton to complete BIST procedure 36 NOTE If the LED gate indicators do not all light during this test then consult Benshaw Do not attempt to operate the starter as SCR damage will occur 8 9 10 Resetting System After the completion of the BIST Test the EXMVRMX registers an event 195 BIST Passed in the event recorder and automatically resets the system 8 9 11 BIST Test Cancelled If for any reason during the test the disconnect is closed power is applied or the BIST command is removed the EXMVRMX will stop the test and log the fault number and name of event that caused the BIST to be cancelled High Pot Test 8 10 High Pot Testing Consult Factory Vacuum Contactor 8 11 Vacuum Contactor Consult manual for vacuum contactor See also page 173 for more information 172 8 TROUBLESHOOTING amp MAINTENANCE Optional RTD Module Troubleshooting 8 12 RTD Module Troubleshooting If the system includes optional RTD Modules verify that all three LED indicator lights on the remote RTD units are toggling There is a TX Red amp RX Green that will flash when the module is communicating and a
198. may occur This alarm exists while the MX is stopped and high line voltage is detected If a start is commanded a Fault 25 may occur This alarm exists while the MX is stopped and high line voltage is detected If a start is commanded a Fault 26 may occur This alarm exists while the MX is running and a phase loss condition is detected but the delay for the fault has not yet expired When the delay expires a Fault 27 occurs No Line This alarm exists while the MX needs to be synchronized or is trying to sync to the line and no line is detected 179 APPENDIX B ALARM CODES Alarm Sis This alarm exists while the MX is in Power Outage Ride P O R T Timeout Through mode and it is waiting for line power to return When the PORT fault delay expires a Fault 29 shall occur This alarm exists while the MX is running and the average Over current current is above the defined threshold but the delay for the fault has not yet expired When the delay expires a Fault 31 occurs This alarm exists while the MX is running and the average Undercurrent current is below the defined threshold but the delay for the fault has not yet expired When the delay expires a Fault 34 occurs This alarm exists while the MX is running and the measured PF is leading the defined threshold but the delay for the fault has not yet expired When the delay expires a Fault 35 occurs Power Factor Leading This alarm exists while the MX is
199. mode acceleration and running before up to speed has been declared Once the motor has reached full speed and during deceleration or braking the Motor Running Overload Class PFN 29 is used for the motor overload calculations As the motor protection curves shift from the acceleration curve to the running curve the accumulated overload content is retained to provide a seamless transition from one mode of operation to the other Disabling the Starting OL function or using a higher OL class for the Starting OL can be useful on extremely high inertial loads such as large centrifuges or high friction loads that require very long starting periods 36 NOTE When the Independent Starting Running Overload PFN 28 parameter is set to Off the running OL is used at all times 36 NOTE When one or the other overload is disabled the Hot Cold motor compensation is still active Therefore the motor overload content may still slowly increase or decrease depending on the measured motor current However if the motor overload is disabled in one of the operating modes the motor overload content is limited in that mode to a maximum of 99 Therefore a motor overload trip can not occur CAUTION When both overloads are disabled the accumulated overload content is set to zero 096 and the starter does not provide any motor overload protection External motor overload protection must be provided to prevent motor damage and or the risk of fire in the case of a mo
200. mp MAINTENANCE 36 NOTE If the gate power LED does not light up check and verify the 24 VAC Transformer If the transformer is functional then the gate power distributor card has failed Figure 54 Fiber Optic Driver Card Location BIPC 300003 xx SCR ASSEMBLY GATE POWER STARTER DISTRIBUTOR CARDS SECTION 169 8 TROUBLESHOOTING amp MAINTENANCE 8 9 4 8 9 5 8 9 6 8 9 7 Conducting a BIST To conduct a BIST Test follow these steps Press the MENU button six times to scroll to th FUN group Press the DOWN button five times to get to FUN 22 Press the ENTER button Press the UP button seven times to set parameter to Std BIST Press the ENTER button to begin the BIST test Begin BIST Test Once started the EXMVRMX will log an event log 193 Std BIST Enter in the event recorder and check the state of the disconnect switch If the disconnect switch is closed the EXMVRMX will display RUN relay and In line Test The EXMVRMX will begin the test sequence by operating the in line contactor and monitoring the 120VAC feedback for proper operation The RUN assigned relays are cycled on and off once and the feedback from an inline contactor is verified In order to have a valid inline contactor feedback a digital input I O 01 08 needs to be set to Inline Confirm and the input needs to be wired to an auxiliary contact of the inline contactor The feedback is checked
201. n 8 8 5 Re Test SCR s Once the SCR s have been replaced perform another SCR Test Procedure 8 8 6 Re Assemble Unit When the SCR readings are correct re install the PC boards RC snubber and Lexan or glastic Make certain that all wiring is done correctly and re install the phase in the unit it was taken from 167 8 TROUBLESHOOTING amp MAINTENANCE Built In Self Test BIST 8 9 Built In Self Test BIST 8 9 1 General Information The EXMVRMX starter has the capability to perform a test sequence to ensure it is operating properly The test will operate the vacuum contactors and fire the SCR gates so that proper operation can be determined The standard BIST tests are designed to be run with no line voltage applied to the starter When a disconnect switch is used the disconnect switch must be opened before starting the standard tests Standard BIST mode can be entered by entering the appropriate value into the Miscellaneous Command user parameter CAUTION In order to prevent backfeeding of voltage through the control power transformer if used control power must be carefully applied to the control card and contactors so that self testing can occur safely The user must verify that the applied test control power cannot be fed backwards through the system Run Test isolation switches test power plugs and wiring diagrams are available from Benshaw N CAUTION Verify that line voltage is not applied to the line
202. n page 84 Controlled Fault Stop PFN 25 on page 85 Relay Outputs I O 10 15 on page 91 Ground Fault Trip Time PFN 09 LCD Display Range 0 1 90 0 seconds Default 3 0 Description The Ground Fault Trip Time parameter can be set from 0 1 to 90 0 seconds in 0 1 second intervals See Also Residual Ground Fault Trip Level PFN 07 on page 79 Zero Sequence Ground Fault Trip Level PFN 08 on page 80 80 6 PARAMETER DESCRIPTION Over Voltage Trip Level 10 LCD Display Range Off 1 40 Default Off Description If the EXMVRM detects a one cycle input phase voltage that is above the over voltage level the over under voltage alarm is shown and the voltage trip timer begins counting The delay time must expire before the starter faults 36 NOTE For the over voltage protection to operate correctly the Rated Voltage parameter FUN 05 must be set correctly 36 NOTE The voltage level is only checked when the starter is running See Also Under Voltage Level parameter PFN 11 on page 81 Voltage Trip Time parameter PFN 12 on page 81 Auto Reset parameter PFN 23 on page 84 Controlled Fault Stop Enable parameter 25 on page 85 Rated Voltage parameter FUN 05 on page 103 Under Voltage Trip Level 11 LCD Display Range Off 1 40 Default Off Description If the EXMVRMX detects a one cycle input phase voltage that is below the under voltage level the over under voltage ala
203. ndependently Description Each of the 16 available RTD input channels has a parameter to assign that RTD channel to a grouping 36 NOTE RTD 1 8 is on module 1 RTD 9 16 is on module 2 Stator Alarm Level RTD 19 LCD Display Range 200 C Default 200 Description The Stator Alarm Level parameter selects its Alarm temperature level When an RTD in this group reaches Alarm level an alarm condition will be declared This parameter sets the alarm level for any RTD set to Stator 36 NOTE Consult motor manufacturer Bearing Alarm Level RTD 20 LCD Display Range 200 C Default 200 C 98 6 PARAMETER DESCRIPTION Description The Bearing Alarm Level parameter selects its Alarm temperature level When an RTD in this group reaches Alarm level an alarm condition will be declared This parameter sets the alarm level for any RTD set to Bearing 88 NOTE Consult Motor Manufacturer Other Alarm Level RTD 21 LCD Display Range 1 200 C Default 200 C Description The Other Alarm Level parameter selects its Alarm temperature level When an RTD in this group reaches Alarm level an alarm condition will be declared This parameter sets the alarm level for any RTD set to Other 36 NOTE Consult motor manufacturer Stator Trip Level RTD 22 LCD Display Range 1 200 C Default 200 C Description This parameter sets the stator trip temperature when a trip will occur Fault delay time is 1 second
204. nitial Voltage Torque Power Maximum Torque Power TruTorque Ramp Ramp Time 1 Kick Level 1 Kick Level 2 Kick Time 1 Kick Time 2 Initial Voltage Torque Power Maximum Torque Power Power KW Ramp Ramp Time 1 Kick Level 1 Kick Level 2 Kick Time 1 Kick Time 2 Initial Voltage Torque Power Ramp Time 1 Voltage Ramp Kick Level 1 Kick Level 2 Kick Time 1 Kick Time 2 Tachometer Ramp Initial Current 1 Initial Current 2 Maximum Current 1 Maximum Current 2 Ramp Time 1 Ramp Time 2 Kick Level 1 Kick Level 2 Kick Time 1 Kick Time 2 129 7 THEORY OF OPERATION Changing Ramp Profiles The selected ramp profile may be changed during starting by changing the Ramp Select input When the Ramp Select input changes during ramping control switches to the other profile as if it were already in progress It does not switch to the beginning of the other profile Refer to the following example below 38 NOTE Once the motor has achieved an up to speed status UTS changes to the Ramp Select input have no effect on the motor operation Figure 37 Changing Ramps During Acceleration Example Ramp Profile 1 Kick Level 1 Maximum 1 Initial Current 1 Kick Time 1 Ramp Profile 2 Maximum Current 2 Kick Level 2 Initial Current 2 Kick Time 2 Ramp Select Changed During Start Ramp Time 2 130 7 THEORY OF OPERATION D
205. nnections 3 INSTALLATION Each Remote RTD Module has connections for up to 8 RTDs The terminals for the RTD wires are as follows R RTD return wire C RTD compensation wire H RTD hot wire Each RTD is connected to the three terminals with the common number For example RTD number 5 connects to the terminals numbered 5R 5C and 5H Figure 23 Remote RTD Module Wiring RTD1 RTD2 RTD3 RTD4 PINS BLU WHT J1 PIN4 BLU TE RTD MODULE CABLE PINB BRN RTD CONNECTOR N MX STARTER STARTE com EA EA REMOTE MODULE SPR 100P Ge STATUS RX D POWER SUPPLY E RTD5 3 120 RTD Temperature vs Resistance 1000 Pt D6 RTD7 RTD8 DIN STEM 05 100 10 16104 17 is 36 16847 L 3 6 mwa s 18347 o w mos 44 905 pte 29 19408 37 Keypad Operation 4 KEYPAD OPERATION Introduction 4 1 Introduction The MX has a 2x16 character back lit LCD display keypad that is mounted remotely from the MX control card The remote keypad is NEMA 13 IP65 when mounted directly on the door of an enclosure wi
206. not set to Off during slow speed operation it is recommended that the motor temperature be monitored if slow speed is used for long periods of time See Also Motor Running Overload Class QST 03 parameter on page 59 Slow Speed Current Level CFN 24 parameter on page 74 Motor PTC Trip Time PFN 27 parameter on page 86 Theory of Operation section 7 6 Slow Speed Operation on page 138 Slow Speed Kick Level CFN 26 LCD Display Range Off 100 800 FLA Default Off Description The Slow Speed Kick Level sets the short term current level that is applied to the motor to accelerate the motor for slow speed operation If set to Off the Slow Speed Kick feature is disabled Slow speed kick can be used to break loose difficult to start loads while keeping the normal slow speed current level at a lower level This parameter should be set to a midrange value and then the Slow Speed Kick Time CFN 27 parameter should be increased in 0 1 second intervals until the kick is applied long enough to start the motor rotating If the motor does not start rotating then increase the Slow Speed Kick Level and begin adjusting the kick time from 1 0 seconds again If the motor initially accelerates too fast then reduce the Slow Speed Kick Level and or reduce the Slow Speed Kick Time CFN 27 See Also Kick Level 1 parameter CFN 11 on page 67 Slow Speed Kick Time parameter CFN 27 on page 75 Motor PTC Trip Time PFN 27 on page 86 The
207. ns 10 32 SCREW TERMINALS 2 PLACES gt p WM Ed 4 A 9 LABEL gat o 1 ALUMINUM BRACKET 25 3 INSTALLATION The correct installation of the current transformer on the motor leads is important The shield ground wire should also be passed through the CT window if the motor conductors use shielded cable Otherwise capacitive coupling of the phase current into the cable shield may be measured as ground fault current See Figure 8 below for proper installation 3 NOTE Power cable must be covered with voltage rated sleeving tubing extending a minimum of 8 past both sides of the CT Figure 8 Zero Sequence CT Installation Using Unshielded Cable LUGS TO LOAD TERMINALS STARTER O O o E 50 0 025 CORE BALANCE CT GROUND WIRE DOES Lage PASS THROUGH CT GROUND ON STARTER CORE BALANCE SECONDARY J15 MX CARD POWER CABLE TO MOTOR Figure 9 Zero Sequence CT Installation Using Shielded Cable LUGS TO LOAD TERMINALS STARTER STRESS CONES GROUND GROUND WIRE MUST PASS THROUGH CT WINDOW 50 0 025 CORE CORE BALANCE BALANCE CT CT SECONDARY CONNECTION TO J15 ON CARD GROUND ON STARTER POWER CABLE TO MOTOR 26 3 INSTALLATION Control Card Layout 3 8 Control Card Layout
208. ns stores user programming and acts on feedback signals for faults metering and historical data This board also contains the flash EEPROM and SRAM memory The intensified or blinking element in a video display A means for indication where data entry or editing occurs A sequence of operations that is repeated regularly The time it take for one sequence of operations to occur A producer consumer based high speed multi node network To inhibit logic from being activated The relationship between the operation and rest time or repeatable operation at different loads The DV DT boards are used to reduce voltage transients across the stack assemblies To allow an action or acceptance of data by applying an appropriate signal to the appropriate input Any malfunction that interferes with normal system operation Is provided for all signal interfaces between the medium and low voltage systems The control element of an SCR silicon controlled rectifier commonly referred to as a thyristor When a small positive voltage is applied to the gate momentarily the SCR will conduct current when the anode is positive with respect to the cathode of the SCR Current conduction will continue even after the gate signal is removed Are located directly on the SCR stacks These boards communicate to the main power board via fiber optic cables They amplify the gate pulse signals with power from the ring transformer to create two sustained puls
209. nsult factory A digital input has been programmed as a Bypass 2M Contactor Feedback input and an incorrect bypass feedback has been detected for longer than the Bypass Confirm time parameter setting I O 25 Verify that the bypass 2M contactor coil and feedback wiring is correct Verify that the relay connected to the bypass 2M contactor s is programmed as Bypass 2M Contactor Fault the UTS function I O 10 I O 15 Verify that the bypass 2M contactor power supply is present J4 Verify that the appropriate Digital Input Configuration parameter I O 01 08 has been programmed correctly Verify that the bypass contactor s are not damaged or faulty The in line contactor did not close Check wiring to coil of contactor Inline Contactor Fault Check feedback wiring from auxiliary contactor to digital input 01 08 Check in line fault delay I O 24 Low control power below 90V has been detected while running Verify that the control power input level is correct especially during starting when there may be significant line voltage drop Pan Contol Power Low Check control power transformer tap setting if available Check control power transformer fuses if present Check wiring between control power source and starter Indicates that the MX control card self diagnostics have detected a problem with one or more of the current sensor inputs Verify that the motor FLA QST 01 and CT ratio FUN 03 are correct Curren
210. nsure that the installation site meets all of the required environmental conditions refer to Site Preparation page 19 LOCK OUT ALL SOURCES OF POWER Install circuit disconnecting devices 1 circuit breaker fused disconnect or non fused disconnect if they were not previously installed by the factory as part of the package Install short circuit protection i e circuit breaker or fuses if not previously installed by the factory as part of the package Follow all NEC National Electrical Code and or C S A Canadian Standards Association standards or Local Codes as applicable Remove any foreign objects from the interior of the enclosure especially wire strands that may be left over from installation wiring Ensure that a qualified electrician installs wiring Ensure that the individuals installing the starter are wearing ALL protective eyewear and clothing Ensure the starter is protected from debris metal shavings and any other foreign objects The opening of the branch circuit protective device may be an indication that a fault current has been interrupted To reduce the risk of electrical shock current carrying parts and other components of the starter should be inspected and replaced if damaged Installation Considerations 3 2 3 2 1 3 2 2 3 2 3 3 2 4 3 INSTALLATION Installation Considerations Site Preparation General Information Before the starter can be installed the installation s
211. of burn damage to the system Follow all grounding procedures set forth by the health and safety co ordinator If no such procedures are available contact NFPA 70E for the proper procedure Never energize a switch without the arc chutes and barriers installed in place For more details refer to Powercon PIF or Micro Rupter Load Break Interrupter Switch Instruction Book with the switch model number supplied with the starter DANGER HAZARD OF ELECTRIC SHOCK EXPLOSION OR ARC FLASH Only qualified personnel familiar with medium voltage equipment are to perform work described in this set of instructions Apply appropriate personal protective equipment PPE and follow safe electrical work practices See NFPA 70E Turn off all power before working on or inside equipment Use a properly rated voltage sensing device to confirm that the power is off Before performing visual inspections tests or maintenance on the equipment disconnect all sources of electric power Assume that circuits are live until they have been completely de energized tested and tagged Pay particular attention to the design of the power system Consider all sources of power including the possibility of backfeeding Replace all devices doors and covers before turning on power to this equipment Failure to follow these instructions will result in death or serious injury 163 8 TROUBLESHOOTING amp MAINTENANCE Ohm Meter Testing 8 7 8 7 1 8 7 2 O
212. ontrol on a load with a squared torque characteristic such as pumps and fans squared torque profile can provide a more linear speed profile during acceleration and deceleration Squared End Torque S Curve The S curve profile slowly increases the control reference s rate of change at the beginning of the ramp profile and an slowly decreases the rate of change of the reference at the end of the ramp profile This profile can be useful when using closed loop tach control to smooth the starting and ending of the acceleration profile It can also be useful with other types of control methods that require extra smooth starts S Curve See Also Start Mode 01 on page 63 Kick Level 1 CEN 11 LCD Display Range Off 100 800 of FLA Default Off Description The Kick Level 1 parameter sets the current level that precedes any ramp when a start is first commanded The kick current is only useful on motor loads that are hard to get rotating but then are much easier to move once they are rotating An example of a load that is hard to get rotating is a ball mill The ball mill requires a high torque to get it to rotate the first quarter turn 90 Once the ball mill is past 90 of rotation the material inside begins tumbling and it is easier to turn The kick level is usually set to a low value and then the kick time is adjusted to get the motor rotating If the kick time is set to more than 2 0 seconds without the motor
213. or RTD Overtemperature Clean debris off of motor Reduce Overload Reduce high ambient Verify Bearing RTD specifications Replace bearings Bearing RTD Overtemperature Reduce load on bearings Reduce high ambient Reduce high vibrations Verify Other RTD specifications Other RTD Overtemperature Reduce load Reduce high ambient Verify PTC thermistor specifications Allow motor to cool this will reset motor PTC thermistors F05 156 8 TROUBLESHOOTING amp MAINTENANCE Fault Code Detailed Description of Fault Possible Solutions Input phase rotation is not ABC and Input Phase Sensitivity parameter FUN 04 is set to ABC only Phase Rotation Error not ABC Verify correct phase rotation of input power Correct wiring if necessary Verify correct setting of Input Phase Sensitivity parameter FUN 04 Input phase rotation is not CBA and Input Phase Sensitivity parameter FUN 04 is set to CBA only u High Line Frequency Three phase power has been detected when the starter is expecting single phase power Verify that input power is single phase Input power not single phase Verify that single phase power is connected to the L1 and L2 inputs Correct wiring if necessary Verify that the SCR gate wires are properly connected to the MX control card Single phase power has been detected when the starter is expecting three phase power Verify that input power is three phase Correct wiring if necessary 15 Inp
214. orrection capacitors or surge capacitors must be connected ahead of the starter and sequenced into the power circuit after the start is completed A programmable relay can be configured as an up to speed UTS relay and then used to pull in a contactor to connect the capacitors after the motor has reached full speed Figure 4 Separate Power Factor Correction Disconnect POWER BUS FAULT MAKE LOAD BREAK DISCONNECT SWITCH FAULT MAKE LOAD BREAK DISCONNECT SWITCH FUSE MOTOR FUSE POWER FACTOR VACUUM CONTACTOR REACTOR INLINE VACUUM CONTACTOR CAPACITOR FUSE SILICON BYPASS CONTROLLED VACUUM FACTOR RECTIFIERS CONTACTOR CORRECTION CAPACITOR ONE 87 MOTOR 3 NOTE If the motor manufacturer supplies surge capacitors they must be removed before starting Figure 5 Integral Power Factor Correction Disconnect POWER BUS FAULT MAKE LOAD BREAK DISCONNECT SWITCH INLINE VACUUM CONTACTOR MOTOR FUSE SILICON CONTROLLED RECTIFIERS VACUUM CONTACTOR Lx is I x d MOTOR 20 POWER FACTOR VACUUM CONTACTOR REACTOR CAPACITOR FUSE POWER FACTOR CORRECTION CAPACITOR 3 INSTALLATION Mounting Considerations 3 3 Mounting Considerations 3 3 1 Bypassed Starters Provisions should be made to ensure that the temperature inside the enclosure never rises above 50 C If the temperature inside the enclosure is too high the starter can
215. ory of Operations section 7 6 Slow Speed Operation on page 138 Slow Speed Kick Time 27 LCD Display Range 0 1 10 0 seconds Default 1 0 sec Description The Slow Speed Kick Time parameter sets the length of time that the Slow Speed Kick Current Level 24 is applied to the motor at the beginning of slow speed operation After the Slow Speed Kick Level CFN 26 is set the Slow Speed Kick Time should be adjusted so that the motor starts rotating when a slow speed command is given If the motor initially accelerates too fast then reduce the Slow Speed Kick Level CFN 26 and or reduce the Slow Speed Kick Time See Also Preset Slow Speed CEN 23 on page 73 Slow Speed Kick Level parameter CFN 26 on page 75 Motor PTC Trip Time PEN 27 on page 86 Theory of Operations section 7 6 Slow Speed Operation on page 138 15 6 PARAMETER DESCRIPTION Jump to Parameter PFN 00 LCD Display Description By changing the value of this parameter and pressing ENTER you can jump directly to any parameter within that group Over Current Trip Level PFN 01 LCD Display Range Off 50 800 of FLA Default Off Description If the MX detects a one cycle average current that is greater than the level defined an over current alarm condition exists and any relays programmed as alarm will energize The over current timer starts a delay time If the over current still exists when the delay timer expires the sta
216. otection is fully active During braking the Running Motor overload setting is used The MX adjusts the overload calculations based on whether Standard Duty or Heavy Duty braking is used The overload calculations are also adjusted based on whether the standard Current Transformers CTs are used for current feedback or if the optional Hall Effect Current sensor is used for current feedback 3 NOTE Discretion must be used when DC injection braking Motor heating during DC injection braking is similar to motor heating during starting Although the Motor OL is active if it has not been intentionally disabled excessive rotor heating could still result if the load inertia is very large braking level is high or the brake time is set too long Caution must be used to assure that the motor has the thermal capacity to brake the desired load in the desired period of time without excessive heating 7 5 7 DC Injection Brake Enable and Disable Digital Inputs Digital inputs can be programmed to either a Brake enable or a Brake Disable In the Brake Enable case the digital input must be energized for DC braking to occur The braking will immediately stop if the brake enable is de energized In the Brake Disable case DC braking will occur unless the Brake Disable digital input is energized DC braking will cease if the brake disable is energized 136 7 5 8 7 THEORY OF OPERATION Once DC Braking is stopped due to a digital input state change no fur
217. otherwise specified Solid State Reduced Voltage Products Warranty Period Warranty Type Warranty Registration RC2 Non Reversing 3 Years Factory Repair or Exchange Data Sheet RC3 Non Reversing 3 Years Factory Repair or Exchange Data Sheet RCM Non Reversing 3 Years Factory Repair or Exchange Data Sheet RB2 Non Reversing with Bypass 3 Years Factory Repair or Exchange Data Sheet RB3 Non Reversing with Bypass 3 Years Factory Repair or Exchange Data Sheet RBX Non Reversing with Bypass 3 Years Factory Repair or Exchange Data Sheet RBM Non Reversing with Bypass 3 Years Factory Repair or Exchange Data Sheet 8 10 Reversing Starter 3 Years Factory Repair or Exchange Data Sheet RSM10B Reversing Bypass 3 Years Factory Repair or Exchange Data Sheet RSM11 Reversing DC Brake 3 Years Factory Repair or Exchange Data Sheet RSMIIB Reversing Brake Bypass 3 Years Factory Repair or Exchange Data Sheet MVRSM Medium Voltage All Types 3 Years Active On Site Startup Service MVRMX Medium Voltage All Types 3 Years Active On Site Startup Service WRSM6 Wound Rotor Starter 3 Years Factory Repair or Exchange Data Sheet SMRSM6B Synchronous Starter 3 Years Factory Repair or Exchange Data Sheet Brakes Products Warranty Period Warranty Type Warranty Registration DCB3 DC Injection Brake 3 Years Factory Repair or Exchange Data Sheet Full Voltage Products Warranty Period Warranty Type Warranty Registration FVNR Non Reversing
218. otor overload content is greater than the calculated running OL content level the overload exponentially cools down or decreases to the appropriate running overload content level The rate of the running motor overload heating or cooling is controlled by the Motor Overload Cooling Time PFN 32 parameter The following diagram illustrates how the current and the Motor Overload Hot Cold Ratio PFN 31 parameter determine the steady state overload content It assumes there is no current imbalance Figure 29 Motor Overload H C Ratio Example 100 FLA Motor 0 Current SO FLA O FLA OL Ratio Motor Overload Content At time TO the motor current is 100 FLA and the OL H C Ratio is set at 30 It is assumed that the motor has been running for some time and the motor overload content has reached a steady state value of 30 30 H C Ratio x 100 FLA 30 At time T1 the motor current drops to 50 FLA The motor overload content exponentially cools to a new steady state value of 15 30 H C Ratio x 50 FLA 15 At time T2 the OL H C Ratio is set to 80 The motor overload content exponentially rises to a new steady state value of 40 80 H C Ratio x 50 FLA 40 At time T3 the motor current rises back up to 100 FLA The motor overload content exponentially rises to a new steady state value of 80 80 H C Ratio x 100 FLA 80 117 7 THEORY OF OPERATION 7 1 7 RTD Overload Biasing The RTD biasing calculates
219. ough the Motor OL is active if not set to Off during slow speed operation it is recommended that the motor temperature be monitored when slow speed is used for long periods of time Motor Running Overload Class parameter QST 03 on page 59 Slow Speed Time Limit parameter 25 on page 74 Motor PTC Trip Time PFN 27 on page 86 Theory of Operation section 7 6 Slow Speed Operation on page 138 Slow Speed Time Limit CEN 25 LCD Display Range Description 74 Off 1 900 Seconds Default 10 sec The Slow Speed Time Limit parameter sets the amount of time that continuous operation of slow speed may take place When this parameter is set to Off the timer is disabled This parameter can be used to limit the amount of slow speed operation to protect the motor and or load 3 NOTE The Slow Speed Time Limit includes the time used for the Slow Speed Kick Time CFN27 parameter if kick is enabled 38 NOTE The Slow Speed Time Limit resets when the motor is stopped Therefore this timer does not prevent the operator from stopping slow speed operation and re starting the motor which can result in the operation time of the motor being exceeded 38 NOTE When the motor is operating at slow speeds its cooling capacity can be greatly reduced Therefore the running time of the motor at a given current level is dependant on the motor s thermal capacity 6 PARAMETER DESCRIPTION Although the Motor OL is active if
220. properly connected and functional The gate output LEDs must be monitored during this test to verify proper operation When the MX is performing this test it will display the following This display will indicate a gate number from 1 to 6 in the order G6 G3 G5 G2 G4 and Gl The medium voltage starter uses series SCR strings instead of a single SCR so each gate number indicates a series SCR string being fired in sequence The firing pattern is shown in the table below Ensure that the starter steps through this sequence triggering the SCRs in the order shown below Table 19 Gate Firing Sequence x s eS Watch the sequence of the gate LEDs while this test is operating If the SCR gates are fired out of sequence than check the fiber optics for improper installation Press ENTER pushbutton to move to the next BIST step 36 NOTE Ifthe SCR gate indicators do not light in the proper sequence during this test then consult Benshaw Do not attempt to operate the starter as SCR damage will occur SCR Gates Firing The SCR gate outputs are all fired in this test This test allows easy measurement of the gate voltages The gate voltages can be measured with a DC voltage meter or with an oscilloscope The voltages should be between 0 5 VDC and 2VDC when measured with a DC voltage meter Connect the positive lead to the white gate wire and the negative lead to the red gate wire to measure the gate waveform with an oscilloscope Use 2 vo
221. r Overload Auto Lockout Calculation 30258 40258 Motor Overload RTD Biasing Enable 30259 40259 Motor Overload RTD Biasing Min 30260 40260 Motor Overload RTD Biasing Mid 30261 40261 30264 40264 30268 40268 30270 40270 RTD Module 1 Enable 30271 40271 RTD Module 1 Address 30272 40272 RTD Module 2 Enable RTD 10 Group 30289 40289 30290 40290 30291 40291 30292 40292 30293 40293 30294 40294 30295 40295 30296 40296 RTD Voting Enable 1 250 0 Disabled Enabled 0 Disabled Enabled 900 100 mSec 1 100 0 Disabled 1 Enabled 0 Disabled Enabled 0 198 1 199 105 200 Same as DI 1 through DI 3 configuration in register 30169 40169 Same as R1 through R3 configuration in register 30172 40172 0 Disabled Enabled 0 Disabled Enabled Off Stator Bearing Other 1 200 0 Disabled 1 Enabled 195 APPENDIX F MODBUS REGISTER MAP Absolute Register Address 30601 40601 Fault Code newest fault to to Refer to page 181 30609 40609 Fault Code oldest fault Initializing Locked Out Faulted Stopped Heating Kicking Ramping Slow Speed System States The state that the starter Not UTS was in when the fault has occurred UTS up to speed Phase Control Current Follower Decelling Braking Wye PORT BIST Shorted SCR Test Open SCR Test 30611 40611 to 30619 40619 cO ON U E eS 30621 40621 L1 Currents The current that the load is to drawing from Line 1 w
222. r current timer does not operate and the starter does not trip It energizes any relay set to undercurrent until the current rises See Also Under Current Level parameter PFN 03 on page 77 Relay Output Configuration parameters I O 10 15 on page 91 Auto Reset parameter PFN 23 on page 84 Controlled Fault Stop Enable parameter PFN 25 on page 85 77 6 PARAMETER DESCRIPTION Current Imbalance Trip Level PFN 05 LCD Display Range Off 5 40 Default 15 Description The Current Imbalance Level parameter sets the imbalance that is allowed before the starter shuts down The current imbalance must exist for the Current Imbalance Delay Trip Time PEN 06 before a fault occurs At average currents less than or equal to full load current FLA the current imbalance is calculated as the percentage difference between the phase current that has the maximum deviation from the average current Imax and the FLA current The equation for the current imbalance if running at current lt FLA ave Imax FLA imbalance x 100 At average currents greater than full load current FLA the current imbalance for each phase is calculated as the percentage difference between the phase current that has the maximum deviation from the average current Imax and the average current lave The equation for the current imbalance if running at current gt FLA Clave Imax imbalance 100 lave If the highest ca
223. r tripping on an overload restarting is prevented and the starter is locked out until the accumulated motor overload content has cooled below the programmed Motor OL Lockout Level See Also Theory of Operation section 7 1 Solid State Motor Overload Protection on page 114 Motor OL Auto Lockout Level 35 LCD Display Range Off Auto Default Off Description The MX has the capability to automatically calculate a motor OL lockout release level This level shall be calculated so that the OL lockout is cleared when there is enough OL content available to start the motor without tripping the OL This prevents the motor from being started if the O L will trip during the start The value shall be calculated based on OL content used for the past four 4 successful motor starts A factor of 1 25 shall be applied as a safety margin Example The OL content used for the past 4 starts were 3096 29 30 27 Average OL content used is 29 using integer math Multiply result by 1 25 gt 36 The new calculated motor OL lockout release level will be 100 36 gt 64 The starting OL content shall be latched when a start command is given A value for OL content used 89 6 PARAMETER DESCRIPTION during a start shall only be added to the list if the motor start fully completes the start i e the starter reaches up to speed 3 NOTE This feature should not be used on systems where the starting load varies greatly from start to star
224. rameters sms as seek 50 5 2 Quick Start Group oe sia e wee GE EEG 50 5 22 Control Function Groups se u e s o m OS SS REN EE EEG 51 5 2 3 Protection Groups awe Ep aE eS abe SS SUR Dh E 52 52 4 s s sa n do o h E ee her awn debe E Ro 53 5 2 5 RTD Group tc S y p w fect k lead nci attt he Se ail ak S 54 52 6 Furiction Group i a Boe des bee Ta er we aa e 55 52 7 Fault Group 6462824 e o ds oy Rhee ee Ped ee 56 5 2 8 Event Log Group ze Ao bebe vas ache Dede SRS AEDES OE SE S Q 56 6 PARAMETER 5 58 61 Parameter Descriplions eH Ro RAGS Eee Roe bee N 58 7 THEORY OF OPERATION ss rans w k a RI OR 3 114 7 1 Solid State Motor Overload Protection 114 7 11 Overview c qu sana S PUR u k He Won ak hd e der 114 7 1 2 Setting Up The MX Motor Overload 114 7 1 3 Motor Overload 115 7 1 4 Current Imbalance Negative Sequence Current Compensation 116 7 15 Harmonic Compensation sve i a ok e ee m n p eS 116 7 1 6 Hot Cold Motor Overload
225. rded values are 0 ohms then one or more of the SCRs in that phase has failed An ohmmeter can only determine failed devices an SCR tester is required to verify proper operation of the device 36 NOTE If at any time during this procedure it is necessary to remove any of the red and white SCR gate leads from the firing card care must be taken to insure that these leads are reconnected to the terminal they were removed from Alternative Shorted SCR Test 164 8 TROUBLESHOOTING amp MAINTENANCE 8 7 3 SCR Gate to Cathode Test To perform the gate to cathode test attach the ohmmeter to SCRs like in the picture shown below to measure the resistance between the red and white SCR gate leads Figure 50 SCR Gate Test 5 GATE WHITELEAD CATHODE RED LEAD DRIVER CARD 302003 01 Table 18 Ohmmeter Position for SCR Gate Test Gate to cathode for each SCR Less 8 or more than 50 If an SCR measures less than 8 ohms but not 0 ohms the SCR still may be good If any of the recorded values are 0 ohms then that SCR has failed An ohmmeter can only determine failed devices an SCR tester is required to verify proper operation of the device 36 NOTE If at any time during this procedure it is necessary to remove any of the red and white SCR gate leads from the firing card care must be taken to insure that these leads are reconnected to the terminal they were removed from 36 NOTE If at any time these
226. rder E01 E99 Range E01 E99 Description An event is anything that changes the present state of the starter Some examples of events would be an operation fault a Start command or a Stop command The event recorder stores the last 99 events When an event occurs the event number is logged in non volatile memory The most recent event is in E01 and the oldest event is in E99 See Also Appendix A Event Codes on page 178 Appendix C Fault Codes on page 181 LCD Display The first screen displayed in the event recorder gives the starter state on the second line of the screen See below 110 See Also 6 PARAMETER DESCRIPTION Pressing ENTER will now display the starter state at the time of the event on the bottom line of the screen See below Pressing ENTER for a 2nd time will display the time of the event on the bottom line of the screen See below Pressing ENTER for a 3rd time will display the date of the event on the bottom line of the screen See below Pressing ENTER again returns to the first display screen Appendix A Event Codes on page 178 111 6 PARAMETER DESCRIPTION NOTES 112 Theory of Operation 7 THEORY OF OPERATION Motor Overload 7 1 7 1 1 7 1 2 Solid State Motor Overload Protection Overview The MX contains an advanced I t electronic motor overload OL protection function For optimal motor protection the MX has forty standard NEMA style ov
227. ring and verify that the CTs are installed with all the White dots towards the input line side Power Metering not reading correctly CT1 L1 CT2 L2 CT3 L3 CT ratio parameter FUNO3 set Verify that the CT ratio parameter is set incorrectly correctly Verify correct CT wiring and verify that PF Meter not reading correctly CTs installed or wired incorrectly the CTs are installed with all the White dots towards the input line side Energy Saver active Turn off Energy Saver if not desired Shut off all power and check all Loose connections connections Verify that the SCRs gate leads are SCR fault connected properly and the SCRs are ok i Verify that the load is actually steady Load actually is not steady and that there are not mechanical issues Other equipment on same power feed causing power fluctuations and or distortion CTs installed or wired incorrectly Motor Current or Voltage meters fluctuating with steady load Fix cause of power fluctuations and or distortion In medium voltage systems Rated Voltage Metering not reading correctly Voltage parameter FUN05 set incorrectly CT ratio parameter FUN03 set Verify that the CT ratio FUN03 incorrectly parameter is set correctly Current Metering not reading correctly Verify correct CT wiring and verify that the CTs are installed with all the White dots towards the input line side CT1 L1 CT2 L2 CT3 L3 CT ratio parameter FUNO3 set Verify that the C
228. rm is shown and the voltage trip timer begins counting The delay time must expire before the starter faults 36 NOTE For the under voltage protection to operate correctly the Rated Voltage parameter FUN 05 must be set correctly 36 NOTE The voltage level is only checked when the starter is running See Also Over Voltage Level parameter PFN 10 on page 81 Voltage Trip Time parameter PFN 12 on page 81 Auto Reset parameter PFN 23 on page 84 Controlled Fault Stop Enable parameter 25 on page 85 Rated Voltage parameter FUN 05 on page 103 Over Under Voltage Trip Delay Time 12 LCD Display Range 0 1 90 0 seconds Default 0 1 Description The Voltage Trip Time parameter sets the period of time that either an over voltage or under voltage condition must exist before a fault occurs See Also Over Voltage Level parameter PFN 10 on page 81 Under Voltage Level parameter PFN 11 on page 81 Auto Reset parameter PFN 23 on page 84 Controlled Fault Stop Enable parameter PFN 25 on page 85 81 6 PARAMETER DESCRIPTION Phase Loss Trip Time 13 LCD Display Range 0 1 5 0 seconds Default 0 2 Description The Phase Detect Delay parameter sets the delay time on Fault 27 Phase Loss This fault detects a loss of proper phase timing even when the phasing remains valid example loss of line when the motor back generates a voltage This allows a much faster detection than low line or no c
229. roducts conform to the requirements of the Directive and applicable standards Glenshaw PA USA 1 October 2003 Neil Abrams Quality Control Manager 184 APPENDIX F MODBUS REGISTER MAP Modbus Register Map Following is the Modbus Register Map Note that all information may be accessed either through the Input registers 30000 addresses or through the Holding registers 40000 addresses Bit Mask Bit0 Run Stop Bitl Fault Reset Bit2 Emergency Overload Reset Bit3 Local Remote Bit4 Heat Disable 30020 40020 Starter Control Bit5 Ramp Select Bit 10 Relay 6 Bit 11 Relay 5 Bit 12 Relay 4 Bit 13 Relay 3 Bit 14 Relay 2 Bit 15 Relay 1 Bit Mask Bit0 Ready Bitl Running 30021 40021 Starter Status Bit2 UTS Bit3 Alarm Bit4 Fault Bit5 Lockout Bit Mask Bit0 OL Motor overload Bitl 5 Motor PTC Bit2 6 Stator RTD Bit3 7 Bearing RTD Bit4 8 Other RTD Bit 5 10 Phase rotation not ABC Bit 6 A 11 Phase rotation not CBA 30023 40023 Alarm Status 1 Bit 7 12 Low Line Frequency Bit8 A 13 High Line Frequency Bit9 14 Phase rotation not IPH Bit 10 A 15 Phase rotation not 3PH Bit 11 A 21 Low line L1 L2 Bit 12 22 Low line L2 L3 Bit 13 23 Low line L3 L1 Bit 14 A 24 High line L1 L2 Bit 15 A 25 High line L2 L3 A 26 High line L3 L1
230. rotation opposite the motor rotation and are typically at two times the line frequency Due to the negative sequence currents opposite rotation and higher frequency these currents can cause a significant increase in rotor heating The overload curves provided by a motor manufacturer are based on balanced motor operation Therefore if a current imbalance is present the MX motor overload compensates for the additional heating effect by accumulating overload content faster and tripping sooner to protect the motor The current imbalance compensation also adjusts the Hot Cold motor protection as described below in section 7 1 6 The MX derating factor is based on NEMA 1 14 35 specifications and is shown in Figure 28 Figure 28 Overload Derating for Current Imbalance MX Motor OL derating vs current imbalance 0 9 Derating Factor 0 8 0 5 10 15 20 25 30 Current imbalance Harmonic Compensation The MX motor overload calculation automatically compensates for the additional motor heating that can result from the presence of harmonics Harmonics can be generated by other loads connected to the supply such as DC drives AC variable frequency drives arc lighting uninterruptible power supplies and other similar loads Hot Cold Motor Overload Compensation If a motor has been in operation for some time it will have heated up to some point Therefore there is typically less overload conten
231. rt is commanded a Fault 10 occurs This alarm exists while the MX is stopped line voltage is detected and phase sensitivity parameter is set to CBA Ifa start is commanded a Fault 11 occurs This alarm exists when the MX has detected a line equency below the user defined low line frequency level The alarm continues until either the line frequency changes to be in range or the fault delay timer expires This alarm exists when the MX has detected a line frequency above the user defined high line frequency level The alarm continues until either the line frequency changes to a valid frequency or the fault delay timer expires This alarm exists while the is stopped set to single phase mode and line voltage is detected that is not single phase Ifa start is commanded a Fault 14 occurs This alarm exists while the MX is stopped set to a three phase mode and single phase line voltage is detected Ifa start is commanded a Fault 15 occurs This alarm exists while the MX is stopped and low line voltage is detected If a start is commanded a Fault 21 may occur This alarm exists while the MX is stopped and low line voltage is detected If a start is commanded a Fault 22 may occur This alarm exists while the MX is stopped and low line voltage is detected If a start is commanded a Fault 23 may occur This alarm exists while the MX is stopped and high line voltage is detected If a start is commanded a Fault 24
232. rter Over Current Trips F31 any relay programmed as fault relay changes state The Over Current Trip is only active in the UTS state Energy Saver state Current follower or while in the Phase Control mode A relay can be programmed to change state when an over current alarm condition is detected Alarm Boule Current Condition 1 Over Cur Level PFN 01 Motor FLA QST 01 Time Current Trip Delay Time PFN 02 See Also Over Current Time parameter PFN 02 on page 76 Auto Reset parameter PFN 23 on page 84 Controlled Fault Stop Enable parameter PFN 25 on page 85 Relay Output Configuration parameters 1 10 15 on page 91 Over Current Trip Delay Time PFN 02 LCD Display Range Off 0 1 90 0 seconds Default 0 1 sec Description The Over Current Time parameter sets the period of time that the motor current must be greater than the Over Current Level PFN 01 parameter before an over current fault and trip occurs If Off is selected the over current timer does not operate and the starter does not trip It energizes any relay 76 6 PARAMETER DESCRIPTION set to Over current until the current drops or the starter trips on an overload A shear pin function can be implemented by setting the delay to its minimum value See Also Over Current Level parameter PFN 01 on page 76 Auto Reset parameter PFN 23 on page 84 Controlled Fault Stop Enable parameter PFN 25 on page 85 Relay Output Confi
233. s oe weg e genes 133 7 5 1 DC Injection Braking Standard Duty 134 7 5 2 DC Injection Braking Heavy 134 7 5 3 Braking Output Relay ens k W lt S Rx S w doe S 134 7 5 4 Stand Alone Overload Relay for emergency ATL Across The Line Operation 134 7 5 5 DC Injection Brake Wiring 135 756 DC Brake Timing siae paa S eR Re EEE eR ed 136 7 5 7 DC Injection Brake Enable and Disable Digital Inputs 136 7 5 8 Use of Optional Hall Effect Current 137 7 5 9 DC Injection Braking Parameters v s esas hun h hoa w m 138 7 6 Slow Speed Cyclo 138 7 61 ODBOrali li a gone s qos oed ues Yee wee 4 queue 138 7 6 2 Slow Speed Cyclo Converter Parameters 138 7 7 WyeDeltaStarter cu doe pe RR eR Oe ee VOR 140 7 8 Across The Line Full Voltage Starter saa lees 143 7 9 Start Stop Control with a Hand Off Auto Selector Switch 144 7 10 Simplified I O Schematics 2 145 7 11 Remote Modbus Communications asa 146 7 111 Supported Commands x 22 ues iussis ace
234. s not high enough to warrant a terminating resistor unless the network is extremely long 3 000 feet or more A terminating resistor should only be installed on the MX if signal reflection is known to be a problem and only if the MX is at the end of the network Terminating resistors should never be installed on nodes that are not at the end of the network Grounding RS 485 buses with isolated nodes are most immune to noise when the bus is not connected to earth ground at any point If electrical codes require that the bus be connected to earth ground then the Common signal should be connected to earth ground at one point and one point only If the Common signal is connected to earth ground at more than one point then significant currents can flow through the Common signal when earth ground potentials are different at those points This can cause damage to devices attached to the bus Shielding The shield should be continuous from one end of the trunk to the other The shield must be tied to the RS 485 Common signal at one point and one point only If the shield is not tied to Common at any point or is tied to Common at more than one point then its effectiveness at eliminating noise is greatly reduced 143 7 THEORY OF OPERATION 7 10 7 Wiring Figure 47 shows the wiring of TB4 to a Modbus 485 Network If the starter is the end device in the network a 120Q 1 4W terminating resistor may be required Please refer to Figure 48 for wire and
235. s set to 1 15 the overload starts accumulating content when the motor current 211596 FLA 100 1 15 The overload will NOT trip if the measured motor current is 11596 of rated FLA The available overload classes are based on the trip time when operating at 600 of rated motor current For example a Class 10 overload trips in 10 seconds when the motor is operating at 60096 rated current a Class 20 overload trips in 20 seconds when the motor is operating at 600 rated current The equation for the standard overload curves after the pick up point has been reached is Time to Trip seconds 35 86conds 5 Current Imbal Derate Factor 1 Motor Measured Current 114 7 1 3 Seconds to Trip 7 THEORY OF OPERATION Figure 27 Commonly Used Overload Curves 10000 1000 N N 5 Eee 100 LE S Class 40 Lo Class 35 Class 30 P Class 15 Class 10 Class 5 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 Current FLA Visit the web at www benshaw com for an automated overload calculator Motor Overload Operation Overload Heating When the motor is operating in the overloaded condition motor current greater than FLAxSF the motor overload content accumulates based on the star
236. sconnect all power wire or bus going to the VACUUM contactor poles Remove the control wire harness from the contactor Undo the four mounting bolts and remove the contactor Replacement of the contactor is the reverse of the removal Test the contactor before installing to ensure proper operation A contactor manual is provided with each starter and should be referred to when disassembling and reassembling the contactor If required contact Benshaw for a manual The contacts in a vacuum bottle can not be seen or examined directly They rely on a vacuum to operate properly and to interrupt current Consult contactor manufacturers instruction manual included with the starter for addition maintenance requirements High pot testing of vacuum bottles creates radiation Personnel should be no closer than 10 feet and behind a metal barrier Keep test times to a minimum To remove a SCR assembly perform the follow steps Ensure that the main disconnect is open and the grounding blades are seated Disconnect all power bus and control wires and fiber optic cables going to the assembly Remove the bolts holding the assembly to the shelf Carefully slide the assembly from the enclosure using caution to avoid damage to the control wiring Once removed contact Benshaw to have the phase serviced or exchanged The installation of the power pole is the opposite of the removal process The bypass contactor in the package is
237. section 7 3 Acceleration Control on page 123 66 6 PARAMETER DESCRIPTION Maximum Torque Power CFN 09 LCD Display Range 10 325 of Torque Power Default 105 Description Start Mode CFN 01 set to Open Loop Voltage Acceleration Not used when the Start Mode CFN 01 parameter is set to open loop voltage acceleration When in open loop voltage acceleration mode the final voltage ramp value is always 100 or full voltage Start Mode CFN 01 set to Current Control Acceleration Not used when the Start Mode CFN 01 parameter is set to current control acceleration mode Refer to the Maximum Current 1 CFN 04 parameter to set the maximum current level Start Mode CFN 01 set to TruTorque Control Acceleration This parameter sets the final or maximum torque level that the motor produces at the end of the acceleration ramp time For a loaded motor the maximum torque value initially should be set to 100 or greater If the maximum torque value is set too low the motor may not produce enough torque to reach full speed and may stall On lightly loaded motors this parameter may be reduced below 100 to produce smoother starts 3 NOTE It is important that the Rated Power Factor FUN 06 parameter is set properly so that the desired maximum torque level is achieved Start Mode CEN 01 set to Power Control Acceleration This parameter sets the final or maximum power KW consumption level that will be achieved at the en
238. setting to the maximum power setting To make the motor accelerate faster decrease the ramp time To make the motor accelerate slower increase the ramp time If the ramp time expires before the motor reaches full speed the starter maintains the Maximum Power level until either the motor reaches full speed the UTS timer expires or the motor thermal overload protection trips 36 NOTE Setting the ramp time to a specific value does not necessarily mean that the motor takes that exact amount of time to accelerate to full speed The motor and load may achieve full speed before the ramp time expires if the load does not require the set ramp time or set power level to reach full speed Alternately the motor and load may take longer than the set ramp time to achieve full speed depending on the parameter settings and load level 7 3 5 Open Loop Voltage Ramps and Times General Initial Voltage Ramp Time The open loop voltage ramp provides soft starting of a motor by increasing the voltage applied to motor from the Initial Voltage setting to full 100 line voltage The ramp time sets the speed at which the voltage is increased Because this is an open loop control profile the motor current during starting tends to be reduced however the current is not limited to any particular level This starting mode old is not commonly used except in special circumstances In most applications the use of one of the other closed loop starting profiles is r
239. shaw will void all warranties and may also void cUL listing or other safety certifications unauthorized modifications may also result in product damage operation malfunctions or personal injury Incorrect handling of the starter may result with an unexpected fault or damage to the starter For best results on operating the RediStart MX starter carefully read this manual and all warning labels attached to the starter before installation and operation Keep this manual on hand for reference Do not attempt to install operate maintain or inspect the starter until you have thoroughly read this manual and related documents carefully and can use the equipment correctly Do not use the starter until you have a full knowledge of the equipment safety procedures and instructions This instruction manual classifies safety instruction levels under WARNING and CAUTION Electrical Hazard that could result in injury or death Caution that could result in damage to the starter Highlight marking an important point in the documentation Please follow the instructions of both safety levels as they are important to personal safety High Voltage Motor control equipment and electronic controllers are connected to hazardous line voltages When servicing starters and electronic controllers there may be exposed components with housings or protrusions at or above line potential Extreme care should be taken to protect against shock Stand on an insula
240. side of the inline contactor before the test is performed Otherwise the inline test will apply line voltage to the starter and a BIST test fault will occur CAUTION Before starting the Built In Self Test ensure that the disconnect is open This test should not be performed until it has been verified that all three phases of the disconnect are open and the disconnect is locked out CAUTION After the BIST is completed the operator must wait 15 minutes before performing another BIST or starting the starter 8 9 2 Test Setup To perform the BIST open the control panel door to connect 120VAC to the test plug Move the Test Run switch to the Test Position and verify that the 120VAC control power is present h e J Figure 53 Test Run Switch Open the medium voltage door and verify the operation of the LEDs on each of the gate driver cards and the gate power distributor cards The Gate Power LED and the OTS OK LED on all of the Distributor Cards should be lit 8 9 3 BIST Notes The display will indicate step by step the activity of the BIST operation throughout the test To skip or move to the next activity of the BIST before the predetermined time has elapsed press the ENTER button until the desired activity is present on the display screen The normal length of a BIST is 285 seconds At the completion of the test the display will briefly read the display below and then return to the home screen 168 8 TROUBLESHOOTING a
241. surement circuit 157 8 TROUBLESHOOTING amp MAINTENANCE Fault Code Description Detailed Description of Fault Possible Solutions High voltage above the Over voltage Trip Level parameter setting PFN 10 was detected for longer than the Over Under Voltage Trip delay time PFN 12 detected for longer than the Over Under Voltage Trip delay time PFN 12 detected for longer than the Over Under Voltage Trip delay time PFN 12 The MX has detected the loss of one or more input or output phases when the starter was running Can also be caused by line power dropouts Check input supply for open fuses Check power supply wiring for open or intermittent connections Phase Loss Check motor wiring for open or intermittent connections On medium voltage systems verify wiring of the voltage feedback measurement circuit Check Gate and Cathode connections to MX card If an inline contactor is being used verify that the setting of the Inline Configuration time delay parameter I O 24 allows enough time for the inline contactor to completely close Verify that the SCR gate wires are properly connected to the MX control card On medium voltage systems verify wiring of the voltage feedback measurement circuit PORT fault timer timed out before line power returned PORT Timeout Extend PORT fault time parameter FUN 10 if possible During operation the MX detected a very high level of current in one or more phases Che
242. t See Also Motor OL Lockout Level PFN 34 on page 89 Theory of Operation 7 1 Solid State Motor Overload Protection on page 114 Jump to Parameter I O 00 LCD Display Description By changing the value of this parameter and pressing ENTER you can jump directly to any parameter within that group Digital Input Configuration 01 08 LCD Display Range LCD Description Off Off Not Assigned Input has no function Default DI02 DI08 Stop Stop Command for 3 wire control Default DI 1 Fault High Fault High Fault when input is asserted 120V applied See I O 09 on page 91 Fault Low Fault Low Fault when input is de asserted OV applied See I O 09 on page 91 Fault Reset Reset when input asserted 120V applied Disconnect Disconnect switch monitor Inline Cnfrm Inline contactor feedback Bypass Cnfrm Bypass 2M bypass contactor feedback 2M contactor feedback in full voltage or Wye delta E OL Reset Emergency Motor Overload content reset After an OL trip has occurred Reset when input asserted 120V applied Local Remote Local Remote control source Selects whether the Local Source parameter or the Remote Source parameter is the control source Local Source is selected when input is de asserted 0V applied Remote Source selected when input asserted 120V applied Heat Disable Heater disabled when input asserted 120V applied Heat Enable Heater enabled when input asserted 120V applied Ramp Select Ramp 2 is enabl
243. t However the start mode parameter will be set to Current control acceleration so that when the fault is reset the starter will start in current control mode 106 6 PARAMETER DESCRIPTION TruTorque Accel If the tachometer signal is lost the starter will fault However the start mode parameter will be set to TruTorque control acceleration so that when the fault is reset the starter will start in Current control mode KW Power If the tachometer signal is lost the starter will fault However the start mode parameter will be set to KW Power so that when the fault is reset the starter will start in Current control mode Description If the tachometer detects the feedback signal is not valid one of the above actions will be taken depending on the value of the Tach Loss Action user parameter Communication Address FUN 16 LCD Display Range 1 247 Default 1 Description The Communication Address parameter sets the starter s address for Modbus communications See Also Local Source parameter QST 04 on page 59 Remote Source parameter QST 05 on page 60 Communication Baud Rate parameter FUN 17 on page 107 Communication Timeout parameter FUN 18 on page 107 Communication Byte Framing parameter FUN 19 on page 108 Communication Baud Rate FUN 17 LCD Display Range 1200 2400 4800 9600 19200 bps Default 19200 Description The Communication Baud Rate parameter sets the baud rate for Modbus communications See A
244. t available in the case where a motor is restarted immediately after it has been running when compared to the situation where a motor has been allowed to cool down before restarting The MX provides adjustable hot motor overload compensation to fully protect the motor in these cases If the hot and cold maximum locked rotor times are provided the MX Hot Cold Ratio parameter value can be calculated as follows Hot Locked Rotor Time 1 Cold Locked Rotor Time x100 116 7 THEORY OF OPERATION If motor information is available a Hot Cold ratio value of 60 is usually a good starting point The MX adjusts the actual motor overload content based on the programmed Hot Cold Ratio set point and the present running current of the motor so that the accumulated motor overload content accurately tracks the thermal condition of the motor If the motor current is constant the overload content eventually reaches a steady state value This value is derived as follows Current 1 OL H C Ratio x x LA Current Imbalance Derate Factor The running OL content is also adjusted based on the derating factor due to the presence of any current imbalances and or harmonics If the existing motor overload content is less than the calculated running OL content the motor overload exponentially increases the overload content until the appropriate running overload content level is achieved If the existing m
245. t Sensor Offset Error E Verify that no actual current is flowing through any of the starter s CTs when the starter is not running Consult factory if fault persists No tachometer signal detected during start or run Verify tachometer wiring and level of signal Tachometer Signal Loss Verify tachometer Full Speed Voltage FUN 13 setting Extend Tachometer Loss Time FUN 14 to allow time for motor to start turning Increase Initial Current to make sure motor starts turning immediately after the start command is given The Build In Self Test was cancelled The disconnect if present was closed during standard BIST testing BIST Fault Line voltage and or phase current was detected during standard BIST testing During powered BIST testing the disconnect was opened during testing During powered BIST testing line voltage was lost during testing During powered BIST testing the starter detected that one or more CTs are located BIST CT Fault on the incorrect phases or one or more CT s polarities are reversed Verify CT wiring positioning and direction An open or shorted RTD was detected RTD Open or Shorted Verify the condition and wiring of the RTD 160 8 TROUBLESHOOTING amp MAINTENANCE Fault Code Detailed Description of Fault Possible Solutions DI 01 08 170 01 08 has been programmed as a fault type digital input and the input indicates a fault condition is present External Fault on DI 8 input Increas
246. t the starter is installed when production can be halted long enough to accommodate the installation Before installing the starter ensure The wiring diagram supplied separately with the starter is correct for the required application starter is the correct current rating and voltage rating for the motor being started All of the installation safety precautions are followed The correct power source is available The starter control method has been selected The connection cables have been obtained lugs and associated mounting hardware The necessary installation tools and supplies are procured The installation site meets all environmental specifications for the starter NEMA CEMA rating The motor being started has been installed and is ready to be started Any power factor correction capacitors PFCC are installed on the power source side of the starter and not on the motor side Failure to remove power factor correction or surge capacitors from the load side of the starter will result in serious damage to the starter that will not be covered by the starter warranty The capacitors must be connected to the line side of the starter The up to speed UTS contact can be used to energize the capacitors after the motor has reached full speed Safety Precautions To ensure the safety of the individuals installing the starter and the safe operation of the starter observe the following guidelines E
247. t to 100 or greater If the maximum power level value is set too low the motor may not produce enough torque to reach full speed and may stall On lightly loaded motors this parameter may be reduced below 100 to produce smoother starts If the motor can be started by using the default Power acceleration parameter values or the Current control ramp the Maximum Power level can be determined more precisely so that the motor comes up to speed in approximately the preset ramp time In this case while the motor is running fully loaded display the Power percent K W meter on the display Record the value displayed The Maximum Power level should then be set to the recorded full load value of KW plus an additional 5 to 10 Restart the motor with this value to verify correct operation 38 NOTE When setting the Maximum Power level the motor must be monitored to ensure that the starting power is high enough to allow the motor to reach full speed under worst case load conditions Ramp Time 7 THEORY OF OPERATION 36 NOTE Depending on loading the motor may achieve full speed at any time during the Power ramp This means that the Maximum Power level may not be reached Therefore the maximum power level is the maximum power level that is permitted However the motor power may not necessarily reach this value during all starts When in Power acceleration mode the ramp time setting is the time it takes for the power to go from the initial power
248. ter s operating mode at a rate established by the overload protection class chosen The accumulated overload content can be viewed on the display or over the communications network Overload Alarm An overload alarm condition is declared when the accumulated motor overload content reaches the Motor OL Alarm Level PFN 33 An output relay can be programmed to change state when a motor overload alarm condition is present to warn of an impending motor overload fault Overload Trip The starter trips when the motor overload content reaches 100 protecting the motor from damage The starter first performs the defined deceleration or DC braking profile before stopping the motor if the controlled fault stop feature of the MX is enabled The motor overload trip time accuracy is 0 2 seconds or 3 of total trip time Overload Start Lockout After tripping on an overload restarting is prevented and the starter is locked out until the accumulated motor overload content has cooled below the Motor OL Lockout Level PFN 34 115 7 THEORY OF OPERATION 7 1 4 7 1 5 Current Imbalance Negative Sequence Current Compensation The MX motor overload calculations automatically compensate for the additional motor heating which results from the presence of unbalanced phase currents There can be significant negative sequence currents present in the motor when a current imbalance is present These negative sequence currents have a
249. ter with appropriate DC output voltage and correct polarity to the MX power card input TB5 2 input TB5 3 input The Start Mode CFN 01 is to be selected as Tach Ramp Program Tachometer Full Speed Voltage FUN 13 see page 106 Program Tachometer Loss Time FUN 14 see page 106 Program Tachometer Loss Action FUN 15 see page 106 Set the Initial Current Level CFN 03 see page 64 to the desired current limit Set the Maximum Current Level CFN 04 see page 65 to the desired maximum current limit See Also Initial Voltage Torque Power CFN 08 on page 66 Maximum Torque Power CFN 09 on page 67 Acceleration Ramp Profile CFN 10 on page 67 Theory of Operation section 7 3 Acceleration Control on page 123 63 6 PARAMETER DESCRIPTION Ramp Time1 CFN 02 LCD Display Range Description See Also 0 300 seconds Default 15 seconds The Ramp Time 1 parameter is the time it takes for the starter to allow the current voltage torque or power depending on the start mode to go from its initial to the maximum value To make the motor accelerate faster decrease the ramp time To make the motor accelerate slower increase the ramp time A typical ramp time setting is from 15 to 30 seconds If the ramp time expires before the motor reaches full speed the starter maintains the maximum current level until either the motor reaches full speed the UTS timer expires or the motor thermal overlo
250. termination practices Figure 47 TB4 Connector B A COM Figure 48 Modbus Network Wiring Example Mx 2 ve H MODBUS SLAVE MODBUS SLAVE PLC COMPUTER 7 OQ Qm 2 Drm 1200 ele W 1200 WOO e Woo I 144 7 THEORY OF OPERATION NOTES 145 7 THEORY OF OPERATION 146 Troubleshooting amp Maintenance 8 TROUBLESHOOTING amp MAINTENANCE Safety Precautions 8 1 Safety Precautions For safety of maintenance personal as well as others who might be exposed to electrical hazards associated with maintenance activities the safety related work practices of NFPA 70E Part II should always be followed when working on electrical equipment Maintenance personnel must be trained in the safety practices procedures and requirements that pertain to their respective job assignments WARNING To avoid shock hazard disconnect main before working on controller starter motor or control devices such as start stop pushbuttons Procedures which require parts of the equipment to be energized during troubleshooting testing etc must be performed by properly qualified personnel using appropriate work practices and precautionary measures as specified in NFPA70 Part II CAUTION Disconnect the controller starter from the motor before measuring insulation resistance IR or the motor windings Voltages used for ins
251. th the correct gasket Figure 24 Remote LCD Keypad Sp BENSHAW Description of the LEDs on the Keypad 2 4 Description of the LEDs on the Keypad The keypad provides three LED indicators in addition to the 2x16 character display The LEDs provide starter status information Table 12 Remote Keypad LED Functions Faulted On Running and up to speed DNE Tu Flashing Running and not up to speed ramping decelerating braking etc ARM Flashing Alarm condition exists If condition persists a fault occurs 3 NOTE By default the STOP key is always active regardless of selected control source Local Source and Remote Source parameters It may be disabled though using the Keypad Stop Disable I O 26 parameter For more information refer to the Keypad Stop Disable I O 26 parameter on page 96 40 4 KEYPAD OPERATION Description of the Keys on the Remote LCD Keypad 4 3 Description of the Keys on the Remote LCD Keypad Table 13 Function of the Keys on the LCD Keypad Function This key causes the starter to begin the start sequence The direction is dependent on wiring and phase selection In order for this key to work the Local Source QST 04 parameter must be set to Keypad Increase the value of a numeric parameter Select the next value of an enumerated parameter It scrolls forward through a list of parameters within a group when the last parameter is displayed it scrolls to the beginning of t
252. ther DC braking will take place and the starter will return to the idle state Use of Optional Hall Effect Current Sensor The Hall Effect Current Sensor should be located on Phase 1 of the motor output wiring The sensor should be located so that the sensor measures both the applied DC current from the starter as well as the freewheel current The sensor is connected to the analog input of the MX card along with a burden resistor The analog input must be set to be a 0 10V voltage input for correct operation The sensor scaling and burden resistance are factory selected Please consult factory if changes to either the sensor scaling or burden resistance is required 4 A 4 i 24VDC 30W POWER SUPPLY 3 5820 03024 5 9 5 24VDC 30W POWER SUPPLY GND S82K 03024 6 6 N ha TB5 x AN POWER 8 7 n 7 AN 2 27 5 RESISTOR 5 z an 3 8 L i owG z 6 7 4 5 5 ES T1 20 0 o 5 XM 5 e z sHieLo G 5000 1 LEM E T2 LT 2005 S gt e v GSS T3 4 e 36 NOTE Hall effect current sensor must be used when load inertia exceeds motor manufactures recommended specifications 36 NOTE Hall effect current sensor must be protected with high voltage sleeving 137 7 THEORY OF OPERATION 7 5 9 DC Injection Braking Parameters Brake Level The DC Brake L
253. ting Duration Zero Sequence Ground Current Hottest Stator RTD Temperature Hottest Bearing RTD Temperature Hottest Other RTD Temperature Hottest RTD Temperature Ave Current L1 Current L2 Current L3 Current Current Imbalance Residual Ground Current Ave Volts L1 L2 Volts L2 L3 Volts L3 L1 Volts Overload Power Factor Watts VA vars kW hours MW hours Phase Order Line Frequency Analog Input Analog Output Running Days Running Hours Starts TruTorque Power Peak Starting Current Last Starting Duration Zero Sequence Ground Current Stator RTD Temperature Bearing RTD Temperature Other RTD Temperature Hottest RTD Temperature 193 APPENDIX F MODBUS REGISTER MAP Absolute Register Address 0 None 1 Reset Run Time 2 Reset kWh 3 Enter Reflash Mode 30199 40199 Misc Commands 4 Store Parameters 5 Load Parameters 6 Factory Reset 7 Standard BIST 8 Powered BIST pa 2 a 30221 1 Acceleration Profile Linear 3002240222 Deceleration Profle Profile S Curve 0 Disabled 30223 40223 PORT Bypass Enable 1 Enabled 30224 40224 PORT Bypass Delay Time 100 mSec Voltage Ramp Fast Recover Current Ramp Current Ramp 2 Ramp Select Tach Ramp 30226 40226 Tachometer Full Speed Voltage 100 1000 30227 40227 Tachometer Loss Delay Time 1 900 100 mSec Fault Closed Loop Current Ramp TruTorque Ramp Power Ramp MM DD YY 12 Hour MM DD YY
254. ting pad and make it a habit to use only one hand when checking components Always work with another person in case an emergency occurs Disconnect power before checking controllers or performing maintenance Be sure equipment is properly grounded Wear safety glasses whenever working on electronic controllers or rotating machinery TRADEMARK NOTICE BENSHAW Benshaw and are registered trademarks of Benshaw Incorporated UL is a trademark of Underwriters Laboratories Incorporated SAFETY PRECAUTIONS Safety Precautions Electric Shock Prevention While power is on or soft starter is running do not open the front cover You may get an electrical shock This soft starter contains high voltage which can cause electric shock resulting in personal injury or loss of life Be sure all AC power is removed from the soft starter before servicing Do not connect or disconnect the wires to or from soft starter when power is applied Make sure ground connection is in place Always install the soft starter before wiring Otherwise you may get an electrical shock or be injured Operate the switches with dry hands to prevent an electrical shock Risk of Electric Shock More than one disconnect switch may be required to de energize the equipment before servicing Injury Prevention Service only by qualified personnel Make sure power up restart is off to prevent any unexpected operation of the motor Make certain proper shield install
255. tio of actual power W to apparent power volt amperes Refers to one or more speeds at which the drive will operate A solid state system that has user programmable memory for storage of instructions to implement specific functions such as I O control logic timing counting report generation communication arithmetic and data file manipulation A controller consists of a central processor input output interface and memory A controller is designed as an industrial control system A set of conventional governing the format and timing of data between communication devices Is the charted path that the torque current power follows will achieving maximum torque Is the time it takes for the torque to go from the initial torque current power setting to the maximum torque current power setting Remote I O RS 232 C RS 422 RS 485 RTD S Scrolling Serial Service Factors SCR Gate Firing Circuit Silicon Controlled Rectifier SCR Status Surge Protection Sustained Pulse Firing T Terminal and Control Board Toggle Transformer Isolation Transient APPENDIX G APPLICATION GLOSSARY I O connected to a processor across a serial link With a serial link remote I O can be located long distances from the processor An EIA standard that specifies electrical mechanical and functional characteristics for serial binary communication circuits in a point to point link An EIA standard that specifies
256. tion s sasso eb are Ae ee qw 8 2 2 Electrical Ratings odes 16 6 uta AL BLASER OS be we es 8 2 2 1 Terminal Points and 8 2 2 Measurements and 10 2 2 3 List of Motor Protection 10 2 24 Solid State Motor 11 2 2 CT Rats s A e E oat art amend weet kosa 12 2 2 6 Optional RTD Module Specifications 12 2 2 7 Optional Zero Sequence Ground 13 2 3 Sample RediStart EXMVRMX3 Unit u leere 14 2 4 Environmental 5 15 2 5 Altitude Detating 9 G s w Wa ee ES dede 15 2 6 Real Time Clock 2 eee yz as poe tee ae a EU 15 27 Approvals tnu e pr eR EO EG aw ee ee a waite 15 2 8 Certificate of Compliance 22 55 u s OR E Y Rok RR RR Ed 15 3 INSTALLATION 43 xem SA ew OS BSS 18 Before Yow Start ae ae Ae a ei A Ed 18 3 1 1 Installation 5 18 3 12 Safety Preca tiOnS s pom En o
257. tion of the starter Please contact Benshaw for service this area 8 8 3 SCR Removal To remove the SCR from heatsink loosen the two bolts at each end of the clamp body The SCR has a dowel pin centering it in the heat sink so the two bolts have to be loosened enough to allow it to clear this pin DO NOT loosen the nut on indicator washer This will change the clamping pressure of the clamp and the clamp will be rendered defective 8 8 4 SCR Installation To install an SCR use Benshaw approved SCR s Note that the SCR grade must match the grades of the rest of the SCRs in that phase Coat the faces of the SCR s to be installed with a thin layer of electrical joint compound EJC Place the SCR s onto the dowel pins refer to Figure 52 for proper SCR position The SCR symbol has a triangle that points to the cathode Assemble the insulator cups washers and bolts as shown in the clamp diagram Finger tighten the bolts until they are snug ensuring that the bolts are evenly tightened and the clamp body is parallel to the heat sink Tighten each bolt in 1 8 turn increments until the pressure indicator s can be turned on the bolt This ensures the proper clamping pressure on the SCR Figure 52 GATE DRIVER CARDS S 450001 XX 403005 XX 36 NOTE For clamps with two washer stacks it may be necessary to adjust tighten or loosen one or both bolts until both indicators are even allowing both washers to spi
258. tops unexpectedly while 155 8 4 7 Metering incorrect v v vs same m RB or OS Sw Dew Shee es 156 8 4 8 Other Situations amp eG UR Oe OR Wa DS LG EGE RE RUE Re S X 157 Fault Code Table Su PES op RSE bug em Je dp eos 158 8 6 Minimum Safety Practices u s sa sop mk RE RR we eR 165 TABLE OF CONTENTS 8 7 Ohm Meter Testing s t sumaya eoe RAR Sere up sa 166 8 71 Fuse bea bua SESS S 51 Noe SiS 166 0 72 Shorted SCR Wests 5 L as sac o Lac ue epe wS 166 8 73 Alternative Shorted SCR 167 9 74 Shorted SCR wo ak ie kG Ge eek eh dece do e cu 167 8 7 5 SCR Gate to Cathode 168 8 8 SCR Replacement s i sess a ee hk deg e Eee SUN ea UR 169 8 81 Card Removal ee Rd de 169 882 SCR Nue es eee 169 8 83 SCR Removal io 64 bss Shae waa ee S WD k WR E 170 8 84 SCR Installation srra yl OS 170 8 85 Re Test SCR Se abe doe eee Ba eae ee d cem eas 9 wa s 170 8 8 6 Re Assemble Unit 170 8
259. tor overload 119 7 THEORY OF OPERATION 7 1 10 Motor Cooling While Stopped The Motor Overload Cooling Time PFN 32 parameter is used to adjust the cooling rate of the motor overload When the motor is stopped and cooling the accumulated motor overload content is reduced in an exponential manner 5 OL Content OL Content when Stopped e rete When the motor is stopped the motor overload cools as shown in the following Figure 31 Figure 31 Motor Cooling While Stopped Curves MX Motor OL Cooling Motor Stopped 100 90 4 80 4 70 60 50 40 Remaining OL Content j 20 10 0 t T 0 200 400 600 800 1000 1200 1400 1600 1800 2000 Time sec 120 7 1 11 7 1 12 7 THEORY OF OPERATION If the motor manufacturer does not specify the motor cooling time the following approximations for standard TEFC cast iron motors based on frame size can be used Frame Size Cooling Time 180 30 min 280 60 min 360 90 min 400 440 120 min 500 180 min Larger frames Manufacturer For motors less than 300hp another approximation based on allowable motor starts per hour can also be used to set an initial value of the Motor Overload Cooling Time PFN 32 parameter 60 minutes Motor Cooling Time minutes Starts per hour 3 NOTE The Motor Overload Cooling Time PFN 32 parameter is
260. tput VO 10 Config 41 Configuration Off Ground Fault Fault FS Fault FS Energy Saver 1011 P53 R2Config Relay Output 2 Fault NFS Heating Off Configuration Running Slow Spd Relay Output 3 UTS Slow Spd Fwd Ready Braking R4 Config Relay Output 4 Locked Out Cool Fan Ctl Off Configuration Overcurrent PORT 01 R5 Confi Relay Output 5 Undercurrent Tach Loss Off es Configuration OL Alarm Shunt FS VO 1 Re Config Relay Output 6 Shunt NFS off Configuration 1 I O 16 Off Ain Trp Type Analog Input Trip Type Low Level High Level Ain Trp Lvl Analog Input Trip Level 0 to 100 5 1 vol oo Aa qayma ATOS mon Tip Daley 0 1 to 90 0 Seconds 0 Time 0 019 58 AinSpan Analog Input Span 1 to 100 0 93 1020 59 Ain Offset Analog Input Offset 206 APPENDIX I PARAMETER TABLES Off 0 200 Curr 0 800 Curr 0 150 Volt 0 150 OL Analog Output 0 10kWw Aout Hot Function 0100 kW 0 1 MW 0 10MW 0 100 Ain 0 100 Firing Calibration 022 P61 Analog Output Span 1 to 125 100 I O 23 62 Aout Offset Analog Output Offset 024 P63 Inline Confg Inline Configuration Off 1 0 to 10 0 3 0 1 to 5 0 I 2 P64 Bypass 2M Confirm 0 1 to 5 0 2 I O 2 65 KpdStop Keypad Stop Disable Enabled Disabled ipm Disabled 1 O 27 Auto Start Power On Start Selection Power and Fault RTD Group RTD 01 RTD Addr RTD Module 1 Address
261. tult refer to address 30611 30619 30999 40999 oldest kusaka 30801 40801 newest refer to page 178 100011001 2 registers 32 bit unsigned integer event seconds since 01 01 1972 01 01 2107 to Time and Date Stamp 31198 41198 196 APPENDIX F MODBUS REGISTER MAP Starter Control Register 0 Stop 0 No action Bit 1 Fault Reset 1 Fault Reset 0 No action Bit 2 Emergency Overload Reset 1 Emergency Overload Reset 0 1 1 Remote 0 Heater Enabled Bit 4 Heat Disabled Heater Disabled 0 Ramp 1 Bit 5 Ramp Select 1 Ramp 2 0 Energize d Relays 1 De energize d Bit 11 Relay 5 Bit 12 Relay 4 Bit 13 Relay 3 The control source must be serial for the starter to be started through Modbus The Run Stop bit must transition from 0 to 1 for a start to occur If the starter stops due to a fault the action of the starter depends on the state of the Auto Start parameter I O 27 The fault reset bit must transition from 0 to 1 for a fault to be reset If any of the programmed digital inputs are programmed as Local Remote inputs then the local Remote bit has no effect When the relays are programmed as the relay bits may be written in order to control the relays When the relays are programmed for any function other than Off Fault Run UTS for example then the relay bits may be read to determine the state of the relays APPENDIX F MODBUS REGISTER MAP St
262. uTorque deceleration ramp profile A typical TruTorque decel end level setting is between 10 and 20 Ifthe motor stops rotating before the deceleration time has expired increase this parameter value If the motor is still rotating when the deceleration time has expired decrease this parameter value Decel Time The decel time sets the ramp time between the motor torque level when stop was commanded and the decel end torque level If the motor stops rotating before the decel time has expired decrease the decel time parameter If the motor is still rotating when the decel time expires increase the decel time parameter 132 7 THEORY OF OPERATION Braking Controls 7 5 Braking Controls Overview When the Stop Mode parameter is set to DC Brake the MX starter provides DC injection braking for fast and friction braking of a three phase motor The MX starter applies a controlled DC current to the motor in order to induce a stationary magnetic field that then exerts a braking torque on the motor s rotating rotor The braking current level and braking time required depends on the motor characteristics the load inertia and the friction in the system The MX starter supports two different levels of DC injection braking 1 Standard Duty Brake For less than 6 x motor inertia 2 Heavy Duty Brake For NEMA specified inertia and two motor current feedback methods a Standard Current Transformers CTs b Optional Hall Effect Current
263. ulation resistance testing can cause failure of SCR s Do not make any measurements on the controller with an IR tester megger 3 NOTE Blades against ground bar Preventative Maintenance 8 2 8 2 1 Preventative Maintenance General Information Preventative maintenance performed on a regular basis will help ensure that the starter continues to operate reliably and safely The frequency of preventative maintenance depends upon the type of maintenance and the installation site s environment 3 NOTE A trained technician should always perform preventative maintenance Preventative Maintenance During Commissioning Torque all power connections during commissioning This includes factory wired equipment Check all of the control wiring in the package for loose connections If fans are installed ensure proper operation One month after the starter has been put in operation Re torque all power connections during the month This includes factory wired equipment Inspect the cooling fans after two weeks to ensure proper operation After the first month of operation Re torque all power connections every year Cleanany accumulated dust from the starter using a clean source of compressed air or a vacuum cleaner Inspect the cooling fans every three months to ensure proper operation Cleanor replace any air vent filters on the starter every three months 36 NOTE If mechanical vibrations are present at t
264. ult I O Card Error I O card has detected an internal CPU problem Consult factory I O Card SW Watchdog I O card has detected an internal software problem Consult factory I O Card Error I O card has detected an internal CPU problem Consult factory F91 VO Card Programi EPROM T O card has detected an internal CPU problem Consult factory Checksum Typically occurs when attempting to run a version of control software that is incompatible with the MX control card hardware being used Verify that the software is a correct version for the MX control card being used Consult factory F94 CPU Error SW Fault for more details Fault can also occur if the MX control has detected an internal software problem Consult factory The MX found the non volatile parameter values to be corrupted Typically occurs when the MX is re flashed with new software CPU Error Parameter EEPROM Cliecksum Fault Perform a Factory Parameter reset and then properly set all parameters before resuming normal operation If fault persists after performing a Factory Parameter reset consult factory CPU Error The MX has detected an internal CPU problem Consult factory CPU Error SW Watchdog Fault The MX has detected an internal software problem Consult factory CPU Error The MX has detected an internal CPU problem Consult factory The non volatile program memory has been corrupted CPU Error Program EPROM 5 Checksum Fault Consult factory Control
265. urrent at run faults Over Frequency Trip Level PFN14 LCD Display Range 24 72 Hz Default 72 Description The Over Frequency Trip Level parameter sets the highest line frequency that the starter will operate on When operating on line power the default setting will usually suffice If the application is speed sensitive or the line power is suspect the Over Frequency Trip Level parameter can be set to the highest acceptable frequency When operating on generator power the Over Frequency Trip Level parameter should be set to the highest acceptable frequency This will ensure that a generator problem will not cause unnecessarily large fluctuations in the speed of the motor The frequency must be above the over frequency trip level setting for the Frequency Trip Time PFN 16 parameter before the starter will recognize a high frequency condition Once a high frequency condition exists the starter will shut down and display a Fault 13 High Freq Trip See Also Under Frequency Trip Level PFN 15 on page 82 Frequency Trip Time PFN 16 on page 83 Under Frequency Trip Level PFN 15 LCD Display Range 23 71 Hz Default 23 Description The Under Frequency Trip Level parameter sets the lowest line frequency that the starter will operate on When operating on line power the default setting will usually suffice If the application is speed sensitive or the line power is suspect the Under Frequency parameter can be set to
266. ut power not three phase Verify that the SCR gate wires are properly connected to the MX control card On medium voltage systems verify wiring of the voltage feedback measurement circuit Low voltage below the Under voltage Trip Level parameter setting PFN 11 was detected for longer than the Over Under Voltage Trip delay time PFN 12 Verify that the actual input voltage level is correct Low Line L1 L2 Verify that the Rated Voltage parameter FUN 05 is set correctly Check input supply for open fuses or open connections On medium voltage systems verify wiring of the voltage measurement circuit Low voltage below the Under voltage Trip Level parameter setting PFN 11 was detected for longer than the Over Under Voltage Trip delay time PFN 12 Verify that the actual input voltage level is correct Low Line L2 L3 Verify that the Rated Voltage parameter FUN 05 is set correctly Check input supply for open fuses or open connections On medium voltage systems verify wiring of the voltage feedback measurement circuit Low voltage below the Under voltage Trip Level parameter setting PFN 11 was detected for longer than the Over Under Voltage Trip delay time PFN 12 Verify that the actual input voltage level is correct Low Line L3 L1 Verify that the Rated Voltage parameter FUN 05 is set correctly Check input supply for open fuses or open connections On medium voltage systems verify wiring of the voltage feedback mea
267. wiring schematic for grounding provision location Wiring Refer to Wiring Practices on page 21 Filtering To comply with Conducted Emission Limits CE requirement a high voltage 1000V or greater 0 1 uF capacitor should be connected from each input line to ground at the point where the line enters the cabinet Use of Electro Mechanical Brakes If an electro mechanical brake is used with the starter it must be powered from the line side of the starter to ensure full voltage is applied to the brake during a start so it will properly release A programmable relay can be configured as a run relay and then used to pull in a contactor to power the brake whenever the starter is providing power to the motor Reversing Contactor If the application requires a reversing contactor it should be connected on the output side load of the soft starter The contactor must be closed before starting the soft starter The soft starter must be off before switching the direction of the reversing contactor The reversing contactor must never be switched while the soft starter is operating 19 3 INSTALLATION 3 2 5 Use of Power Factor Capacitors Power factor correction capacitors and surge capacitors CAN NOT be connected between the starter and the motor These devices can damage the SCRs during ramping These devices appear like a short circuit to the SCR when it turns on which causes a di dt level greater than the SCR can handle If used power factor c
268. ws the software version 1 The software version is also displayed on power up Software Version 2 FUN 21 LCD Display Description This parameter shows the software version 2 The software version is also displayed on power up Miscellaneous Commands FUN 22 LCD Display Range LCD Description None No commands Default Reset RT Reset Run Time Meter Reset kWh Reset kWh MWh Meters Reflash Mode Activate Reflash Mode Store Parms The current parameter values are stored in non volatile memory Load Parms All parameter are retrieved from non volatile memory Factory Rst All parameters are restored to the factory defaults Std BIST Built In Self Test with no line voltage applied to the starter Powered BIST Built In Self Test with line voltage applied to the starter 3 NOTE Powered BIST not available on medium voltage starters 108 6 PARAMETER DESCRIPTION Description The Miscellaneous Commands parameter is used to issue various commands to the MX starter The Reset Run Time command resets the user run time meters back to zero 0 The Reset kWh command resets the accumulated kilowatt hour and megawatt hour meters back to zero 0 The Reflash Mode command puts the MX into a reflash program memory mode The reflash mode can only be entered if the MX starter is idle When the reflash mode is entered the MX waits to be programmed The onboard LED display shows FLSH The remote display is disabled after entering reflash mode The MX do
269. y 20 Typical loads require an initial current in the range of 50 to 175 If the motor does not rotate within a few seconds after a start command the initial current should be increased If the motor takes off too quickly after a start command the initial current should be decreased The Initial Current 1 parameter must be set to a value that is lower than the Maximum Current 1 QST 07 CFN 04 parameter setting Start Mode 01 on page 63 Ramp Time 1 QST 08 CFN 02 on page 64 Maximum Current 1 QST 07 CFN 04 on page 65 Kick Level 1 CFN 11 on page 68 Kick Time 1 CEN 12 on page 69 Theory of Operation section 7 3 1 Current Ramp Settings Ramps and Times on page 123 6 PARAMETER DESCRIPTION Maximum Current 1 CFN 04 LCD Display Range 100 800 of FLA Default 600 Description The Maximum Current 1 parameter is set as a percentage of the Motor FLA QST 01 parameter setting and performs two functions It sets the current level for the end of the ramp profile It also sets the maximum current that is allowed to reach the motor after the ramp is completed If the ramp time expires before the motor has reached full speed the starter holds the current at the maximum current level until either the UTS timer expires the motor reaches full speed or the overload trips Typically the maximum current is set to 600 unless the power system or load dictates the setting of a lower maximum current See Also Up
270. zing the Slow Speed Input when the starter is idle will initiate slow speed operation 38 NOTE When the motor is operating at slow speeds its cooling capacity can be greatly reduced Therefore the running time of the motor at a given current level is dependant on the motor s thermal capacity Although the Motor OL is active if not set to Off during slow speed operation it is recommended that the motor temperature be monitored when slow speed is used for long periods of time Slow Speed Current Level parameter CFN 24 on page 74 Slow Speed Time Limit parameter CFN 25 on page 74 Motor PTC Trip Time PFN 27 on page 86 Digital Input Configuration parameters I O 01 08 on page 90 Relay Output Configuration parameter I O 10 15 on page 91 Theory of Operation section 7 6 Slow Speed Operation on page 138 Preset Slow Speed Current Level CEN 24 LCD Display Range Description See Also 10 400 FLA Default 100 The Preset Slow Speed Current Level parameter selects the level of current applied to the motor during slow speed operation The parameter is set as a percentage of motor full load amps FLA This value should be set to the lowest possible current level that will properly operate the motor 36 NOTE When the motor is operating at slow speeds its cooling capacity can be greatly reduced Therefore the running time of the motor at a given current level is dependant on the motor s thermal capacity Alth

EX MV MX3 User Manual [May16].vp

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