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RediStartTM

1. Model A B C D E F RB3 27 65A 14 10 12 5 8 43 0 84 0 31 77 964 15 10 15 5 8 43 0 84 0 31 RB3 838A 27 75 26 6 23 5 8 7 N A 0 31 L F o E D Model A B C D E F RB3 125A 19 5 12 27 13 25 4 0 5 0 31 RB3 156 180A 21 25 12 27 15 25 4 0 5 0 31 180 302A 22 75 12 27 16 75 4 0 5 0 31 RB3 361A 23 87 13 09 18 63 4 31 0 5 0 31 23 2 TECHNICAL SPECIFICATIONS 2 4 2 Figure 6 RB3 414 838A E s o gu RC3 Chassis with no Bypass Figure 7 RC3 0 124A B T 2 T P 24 Model A B 414 590A 28 29 18 5 26 25 N A 0 31 RB3 720A 30 04 18 5 28 6 N A 0 31 RB3 838A 27 75 26 6 23 5 8 7 N A 0 31 Model A B 27 52 14 9 875 3 375 4 69 8 32 65 77 18 10 4 375 4 75 4 20 RC3 96 124A 27 10 5 313 475 4 20 TAP 2 TECHNICAL SPECIFICATIONS Figure 8 RC3 156 590A B D y Model A B C D E RC3 156 180 18 15 17 13 5 0 3 RC3 240A 24 15 23 13 5 0 5 ns RC3 302 361A 28 17 25 27 15 75 0 5 RC3 477A 28 20 27 18 5 0 5 590A 35 20 34 18 5 0 5 Le Environmental Conditions 2 5 Environmental Conditions Table 11
2. MX Current Follower Mode 100 5 90 E 80 o S 70 60 50 5 40 8 30 20 5 10 0 10 20 30 40 50 60 70 80 90 100 Analog Input A reference input value of 0 results in no output A reference input value of 100 results in a current output equal to the Motor FLA setting The actual voltage or current input that results in a given output can be adjusted through the use of the Analog Input Offset and Analog Input Span parameters 36 NOTE The power stack must be rated for continuous non bypassed duty in order to operate in Current Follower mode 3 NOTE When operating in Current Follower mode the acceleration ramp kick and deceleration settings have no effect on operation 3 NOTE The following motor starter protective functions are available when in Current Follower mode Current Imbalance Over Current Under Current Over Voltage Under Voltage Over Frequency Under Frequency Phase Loss Phase Rotation Current while Stopped Motor OL Residual Ground Fault Instantaneous Over Current IOC 175 7 THEORY OF OPERATION Start Stop Control with a Hand Off Auto Selector Switch 7 13 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
3. 101 00 3 98 50 50 50 50 1 99 1 99 Ry 51 85 BN Ry 1 Figure 28 Large Display Keypad Mounting Dimensions Part KPMX3LLCD 127 00 5 00 63 50 63 50 2 50 2 50 gu 77 00 3 03 38 50 1 52 3 INSTALLATION RTD Module Installation 3 13 RTD Module Installation 3 13 1 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 Figure 29 Remote RTD Module Mechanical Layout p LIGHTS A SOME REF 3 543 REF 3 13 2 Modbus Address HOUSING 2 322 REF 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 MX starter The address set by the rotary switch must match the setting RTD 01 RTD 02 For exampl
4. Ramp Modes Ramp Select De energized Ramp Select Energized Initial Current 1 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 Initial 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 Initial Current 1 Initial Current 2 Maximum Current 1 Maximum Current 2 Tachometer Ramp Ramp Time 1 Ramp Time 2 Kick Level 1 Kick Level 2 Kick Time 1 Kick Time 2 155 7 THEORY OF OPERATION 7 3 9 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 44 Changing Ramps During Acceleration Example Ramp Profile 1 Kick Level 1
5. a 56 443 Parameter Group Screens gs sie ve Sow bee wd Wee a e rece gi ee 57 AAA Meter Pages sure xe Ro exer hg RC OR Mom BEE Ro NUR pekctum p EY 58 SCHOOL 25 UP dore co Wein Roseto ere ded Bed ar a a ode a 59 4 46 Fault Screen we GRE Gor S RU C S RVG Had Sos sU Gees aS 59 447 BventRecorder 3 tas p ve be P Wb Pe ES EEE GEE OES HRM 59 448 Lockout Sereen s zu eee uos OE UP vU RV QURE ECL 60 449 Alarmicreen koe d RR obe eR Rum d URS AUS NUUS RR Rue e UR dee 61 4 5 Procedure for Setting Data ii 6s pw a dass PAG 61 26 MP RITE 62 4 7 Restoring Factory Parameter Settings si eA 62 4 8 Resetting a Fault RR XE ee 62 TABLE OF CONTENTS 49 Emergency Overload Reset wess RR dene cem Ro eee m ee 62 LED Display S Decret eed x dena dead tud 62 5 PARAMETER GROUPS 64 51 Introduction ssp mx Reps Rb Pedic n REOR UR EROR REGERE una pda 64 52 LCD Display Parameters Roe rmx exu EROR Ro RR eS ES 64 521 Quick Start Group i aee uer p ber d eub de S 64 522 Contro Fun
6. 24 P42 Auto Rst Lim Amo sen Off 1 10 Count Limit Ta a Se SS SE Rn omis ___ seme om w _ 28 P44 Indep S OL Independent Searing vanity Off On off 105 Overload rms s sanno omr fo ef Cmm kimning OL Monor Overend Cass Rumes ff mm ot no aio 09 s o o 223 APPENDIX PARAMETER TABLES PEN 32 OL Cool Time Motor Overload Cooling Time 1 0 999 9 Minutes 30 108 rum __ trea voorr roont fs pm mus omamo _ or Group yoor P48 DI1Config Digital Input 1 Configuration 9 02 P4 DI 2 Config Off Heat Disable Stop Heat Enable Fault High Ramp Select Digital Input 4 Fault Low Slow Spd Fwd Configuration Fault Reset Slow Spd Rev Digital Input 5 Disconnect Brake Disable Configuration Inline Cnfrm Brake Enable Bypass Cnfrn Speed Sw NO Digital Input 6 E OL Reset Speed Sw NC Configuration Local Remote Digital Input 47 Configuration Digital Input 8 Configuration Digital Fault Input Trip Time 0 1 to 90 0 Seconds 01 112 Relay Output Z1 Configuration Off Shunt NFS Fault FS Relay Output 42 Fault FS Ground Fault Fault NFS Energy Saver Off Running Heating Relay Output 3 UTS Slow Spd Off Configura
7. 25 SSpd Timer Slow Speed Time Limit Off 1 to 900 26 SSpd Kick Curr Slow Speed Kick Level Off 100 to 800 FLA 27 SSpd Kick T Slow Speed Kick Time 0 1 to 10 0 65 5 GROUPS 5 2 3 Protection Group 01 Over Cur Lvl Over Current Trip Level Off 50 800 04 05 06 0 0 0 1 11 12 14 15 16 1 1 20 21 22 23 24 25 26 2 2 oo 2 30 31 32 PEN 33 34 35 66 E 40 02 Over Current Trip Delay Time Off 0 1 90 0 0 1 P41 P42 P43 P44 P45 P46 P47 92 93 S GF Lvl Ground Fault Trip Off 1 0 25 Off nd Flt Time Ground Fault Trip Time 0 1 90 0 3 0 Over Vlt Lvl Over Voltage Trip Level Off 1 40 Off Vit Trip Time Ove pader Voltage Trip Delay 0 1 90 0 0 1 Ph Loss Time Phase Loss Trip Time 0 1 5 0 0 2 ele ej Over Over Frequency Trip Level 24 72 12 Undr Lvl Under Frequency Trip Level 23 Frq Trip Time Frequency Trip Time 0 1 90 0 0 1 PF Lead Lvl PF Lead Trip Level is 0 80 lag to 0 01 EE Off F Lag Lvl PF Lag Trip Level om E Off P o 4 Ctrl Flt En Cont
8. 172 7 THEORY OF OPERATION Phase Control 7 11 Output Voltage Phase Control When the Starter Type parameter FUNO7 is set to Phase Control the MX is configured to operate as a phase controller or voltage follower This is an open loop control mode When a start command is given the RUN programmed relays energize The firing angles of the SCRs are directly controlled based on voltage or current applied to the Analog Input Figure 55 Phase Control Mode Output Voltage vs Analog Input 100 90 10 20 30 40 50 60 70 80 90 100 Analog Input A reference input value of 0 results in no output A reference input value of 100 results in full 10096 output voltage The actual input voltage current that results in a given output can be adjusted through the use of the Analog Input Offset and the Analog Input Span parameters 3 NOTE The power stack must be rated for continuous non bypassed duty in order to operate in Phase Control mode continuously NO BYPASS 38 NOTE When operating in Phase Control mode the acceleration ramp kick and deceleration settings have no effect on operation 38 NOTE When in Phase Control mode the following motor starter protective functions are available Residual Ground Fault Instantaneous Over Current IOC Phase Rotation Phase Loss Under Frequency Current Imbalance Over Current Current while Stopped Under Current
9. J15 Zero Sequence Ground Fault CT 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 19 Control Power Wiring Example AT 3 11 2 Output Relays TB2 is for output relays R1 R2 and R3 These relays connect as follows 1 NO1 Relay 1 normally open 2 RCI Relay 1 common 3 NC1 Relay 1 normally closed 4 NO2 Relay 2 normally open 5 RC2 Relay 2 common 6 NC2 Relay 2 normally closed 7 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 R4A Relay 4 common 2 R4B Relay 4 open 3 R5A Relay 5 common 4 R5B Relay 5 open 5 R6A Relay 6 common 6 R6B Relay 6 open Figure 20 Relay Wiring Examples 120VAC LIVE ve 120VAC NEUTRAL A TRIP 120VAC NEUTRAL 120VAC LIVE 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 112 44 3 11 3 Digital Input 3 INSTALLATION TB3 is for digital inputs Start DI2 and DI3 These digital inputs use 120VAC These digital inputs connect as follows 1 Start Start Input 2 DII Digital Input 1 3
10. 1 GROUND 5 i g BIPC 300055 03 Rs NEUTRAL Z MX3 CARD 1 1 ug ya J9 NEUTRAL 1 G Pwr cru L LIVE LIVE E BIPC 500034 02 Ll MX3 CARD 2 gt g anf 0 Q 5 Li 5V PWR CPU SZ 55 L 2 s 782 Oai i power C PROGRAMMABLE 5 RCI RELAY RI an 2 75 An 782 CH 58 aout ie 55 3 PROGRAMMABLE ST RCD REY R2 g 6 19 SHIELD 7 82 55 TBA 5 Lai B PROGRAMMABLE 2 ax 5 RC RELAY R3 go Se e ic3 S con us ED procrauwaste RELAY R4 FED procrauuasre RELAY R5 3 59 45 4 EED procraumnare 5 RELAY R6 H s B3 U24 1 start 5 5 5 5 5 W W SW Wi RD Pert on RESET PARAM DOWN UP ENTER ag 8 o2 28 LEDS IN CONNECTOR Dos 6 538 RX TX eou ed 28 6 Fr 00 5 BIPC 400100 01 o 854 CARD ASSEMBLY 05 2 CONSISTS OF BIPC 300055 03 TOP amp BIPC 300034 02 BOTTOM 3 2 o7 amp os L com 50 95 1 3 INSTALLATION T1 12 din 7 15 7 alc T SWITCH fred a TO DVDT 3 5 S
11. Ground Fault Trip Time 09 If a programmable relay 10 15 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 3 NOTE The 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 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 MX during normal operation Ground Fault Trip Time PFN09 on page 98 Auto Reset parameter PFN23 on page 102 Controlled Fault Stop Enable parameter PFN25 on page 103 Relay Output Configuration parameters I O 10 15 on page 112 6 PARAMETER DESCRIPTION Zero Sequence Ground Fault Trip Level 08 LCD Display Range Off 1 0 25 0 amps Default Off Description The Zero Sequence Ground Fault Trip Level 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 cur
12. Over Current Trip Delay Time PFN 02 Over Current Time parameter 2 on page 93 Auto Reset parameter PFN23 on page 102 Controlled Fault Stop Enable parameter PFN25 on page 103 Relay Output Configuration parameters I O 10 15 on page 112 Over Current Trip Delay Time 02 LCD Display Range Description See Also Off 0 1 90 0 seconds Default 0 1 The Over Current Trip Delay Time parameter sets the period of time that the motor current must be greater than the Over Current Trip Level PFNO1 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 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 Over Current Level parameter PFNO1 on page 92 Auto Reset parameter PFN23 on pagel02 Controlled Fault Stop Enable parameter PFN25 on page 103 Relay Output Configuration parameters I O 10 15 on page 112 Under Current Trip Level 03 LCD Display Range Off 5 100 of FLA Default Off 93 6 PARAMETER DESCRIPTION Description See Also 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 s
13. 7 shield Figure 23 Analog Output Wiring Example S Tes 2 OU g i oli 4 9 gt TO METER ANALOG INPUT CARD vn I G c g GJ ae Z E y See Also Analog Output I O 21 23 on page 116 46 3 11 6 3 11 7 3 11 8 3 INSTALLATION SW1 DIP Switch 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 Figure 24 SW1 DIP Switch Settings ANALOG INPUT ANALOG OUTPUT SW1 1 SW1 2 ON 0 20mA ON 0 10V OFF 0 10V OFF 0 20mA 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 input are as follows 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 chain 1500 Ohms An example of the thermistor wiring is shown below Figure 25 PTC Thermistor Wiring ZH See Also Motor PTC Trip Time PFN27 on page 104 RTD Module Connector Connector J1 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 i
14. 9 19 0 OM 0 v OV A009 f OSIVZOE 0 OM 0 0 6 L 1 L 0 0 0 4 OSsIVOrc 0 7444 081 OSIVOSI 0 E E Luc wc se OvVIVOS 0 OU 056 S6r 09 VAZH acoddo 9 S87 VICE VS7C acoddo 0 VSCI VOOT gHt 9q3D 5 001 W001 V IOOT 1001 001 possedig 5507 HEM 8 5 5 VXCV VOOT gHt 9q3D lt M e VAOS V IOOT VAOS V IOOT Suey 11045 Acr V09 VATY V09 suyey HOS Jaquiny snd du IILI Supu JUN v 3 urnurxe A suney Suprug JUM DIL OV A009 f gel sng OV A009 f OV A009 f DL OV A009 f TAY L OV A009 f 112019 Jomod 112019 Jomod 12019 OV A009 f 12018 moq OV A009 f 15018 DAYAL OV A009 f 15019 mod 5909 proT ena L S L S Y 8 9 S L S T Or 96 ES ER EN ES EN a a a a a a ES EN EN COD 8 SCF OVIVSCI 0 Ot VrcI 0 OM OtIV960 0 OM 0 0 OU OZIVS90 0 OW OcIVCcS0 0 OU OIIVOT
15. to T of if the gate in an SCR is shorted or open An SCR could also still be damaged even though the measurements are within the above specifications 8 5 2 Voltage When the starter is running the operation of the SCRs can be confirmed with a voltmeter Extreme caution must be observed while performing these checks since the starter has lethal voltages applied while operating While the starter is running and up to speed use an AC voltmeter check the voltage from L to T of each phase The voltage should be less than 1 5 Volts If the starter has a bypass contactor the voltage drop should be less than 0 3 volts Using a DC voltmeter check between the gate leads for each SCR red and white twisted pair The voltage should between 0 5 and 2 0 volts 8 5 3 Integral Bypass RB3 A voltage check from L to T of each phase of the RediStart starter should be preformed every 6 months to confirm the bypass contactors are operating correctly Extreme caution must be observed while performing these checks since the starter has lethal voltages applied while operating While the starter is running and Up to Speed use an AC voltmeter check the voltage from L to T of each phase The voltage drop across the contactor contacts should be less than 300mV The bypass should be serviced if the voltage drop is greater that 300mV It may be necessary to clean the contact tips or replace the contactor Built In Self Test Functions 8 6 Bu
16. 12 Relay 4 13 Relay 3 Bit 14 Relay 2 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 Bit2 6 Stator RTD Bit3 7 Bearing RTD Bit4 8 Other RTD Bit5 10 Phase rotation not ABC Bit6 11 Phase rotation not 30023 40023 Alarm Status 1 Bit 7 A 12 Low Line Frequency Bit8 13 High Line Frequency Bit9 A 14 Phase rotation not Bit 10 A 15 Phase rotation not 3PH Bit 11 21 Low line LI L2 Bit 12 22 Low line L2 L3 Bit 13 A 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 A 27 Phase loss noL No line A 29 PORT Timeout A 31 Overcurrent 34 Undercurrent 35 PF Too Leading A 36 Too Lagging 30024 40024 Alarm Status 2 37 Current imbalance A 38 Ground fault 47 Stack overtemperature 53 Tach Loss 60 DI I 61 DI2 62 DI3 A 63 DIA 209 APPENDIX MODBUS REGISTER Absolute Register Address A 64 DI 5 A 65 DI 6 30025 40025 Alarm Status 3 it2 A 66 DI 7 A
17. E ra 9 CPU 52 1 1 L 2 1 782 4 S 185 Ao HS POWER 1 1 PROGRAMMABLE i RCI RELAY RI an 2 1 1 4 22 an 3 i ge 1 1 2 1 602 55 5 1 1 ES 1 PROGRAMMABLE 8T RCZ RELAY R2 1 22 SHIELD 7 1 1 p 1 2 5e 1 gt Cal La ye 8 Qj 1 1 PROGRAMMABLE n 55 1 i ECI RELAY R3 g SERIAL COMMUNICATION 3 Bg s 0 Bo O s 65485 5V g 2 ES 3 33 1 1 1 1 RAN i 691 OVERTEMP SWITCH MTD ON HEATSINK i i pee 1 1 1 FED proceamns e 2 1 1 RELAY 65 R56 f HEATSINK FANS 1 1 i Ros PROGRAMMABLE 5 1 TWO WIRE CONTROL 1 LAY T pq Pu BEBA D pui Sas E jg STOP START eo pep ala t sw2 SWS SW4 505 SW6 i RESET PARAM DOWN UP ENTER 1 1 a3 1 es 1 LEDS IN CONNECTOR g 1 oO 2 59 1 0 o 2 1 Bu io Eg i ES 1 aS 6 Mow zs BIPC 400100 01 8e CARD ASSEMBLY 05 2 CONSISTS OF 300055 03 TOP amp BIPC 300034 02 06 DISPLAY 17 oL 8 g osav 1 e CABLE e 8 ow L 34 3 6 3 6 1 3 6 2 3 6 3 3 6 4 3 INSTALLATION Power Wiring Recommended Incoming Line Protection Fuses or Circuit Breaker refer t
18. Heh Se te 8 2 2 Blectrical Ratings ooo e eae Oh eR TREE Be a eds 8 2 2 1 Terminal Points and Functions a dde dae ee hr nn 8 2 2 2 Measurements and Accuracies ss e bs es e be 9 a cer LE 10 2 23 Listof Motor Protection Features s s zoe ae exe Gee le QR Forced PSs 10 2 24 Solid State Motor Overload eg ea uy ea EAA RR Ge ew 11 225 CF RAOS D a RE eae Oe RES owe BASS Ow oe aS 12 2 2 6 Optional RTD Module s pers 2 13 2 2 7 Zero Sequence Ground Fault CT 2 2 4 we ease hed ele We ga oe aod 14 23 Starter Power Ratings iss e r uce Re eae ae Ress e OR RO a TRO n 14 2 3 1 Standard Duty 350 for 30 sec Ratings syo tyro cebi rene tee uka eek 15 2 3 2 Heavy Duty 500 current for 30 sec Ratings 2 16 2 3 3 Severe Duty 600 current for 30 sec Ratings eee 17 2 3 4 Inside Delta Connected Standard Duty 350 for 30 sec 18 2 3 5 Power Stack Ratings and Protection Requirements 19 2 3 6 Power Stack Input Ratings with Protection Requirements for Separate Bypass 20 2 3 7 Power Stack Input Ratings with Protection Requirements for RC No Bypass 21 2 3 8 Starter Control Power Requirements 22 2 3 9 RC3 Starter Control Power Requirements
19. Ws 890034 02 00 December 2006 Motor Starter Card Set BIPC 400100 01 03 Software Version 1 810023 02 01 Software Version 2 810024 01 01 Gate Driver Card 300047 01 Rev 13 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 lt BENSHAW ADVANCED CONTROLS amp DRIVES Important Reader Notice Congratulations on the purchase of your new Benshaw RediStart Mx Solid State Starter This manual contains the information to install and 3 program the MX Solid State Starter This manual may not cover all of the applications for the RediStart MX Also it may not proyide information on every possible contingency concerning installation programming operation or maintenance specific to the RediStart MX 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 Benshaw will void all warranties and may also vo
20. 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 8 Input Voltage 24 Volts DC 20 2 5W Communication Type Modbus RTU RS 485 19 2Kbps Modbus Addresses 16 to 23 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 from 12 to 30 AWG Dimensions 5 2 Listing cUL 13 2 TECHNICAL SPECIFICATIONS 2 2 7 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 oM woo do Starter Power Ratings 2 3 Starter Power Ratings Each RB3 model starter is rated for three different starting duties For example a starter can operate a 300HP motor for a standard duty start 350 for 30 seconds Or 200HP for a heavy duty start 500 for 30 seconds Or 150HP motor for a class 30 start 600 for 30 seconds Or 450HP motor when connected to the inside delta of a motor for a class 10 start 35096 for 30 seconds 14 2 3 1 Standard Duty 350 for 30 sec Ratings 2 TECHNICAL SPECIFICATIONS Table 5 Standard Duty Horsepower Ratings Standard Duty 350
21. Motor Torque Stop command Motor Torque Before Stop Command End Torque Level Time Decel Time Ending Level 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 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 158 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 non friction braking of a three phase motor The 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 Stand
22. Over Voltage Under Voltage e Motor OL Over Frequency 173 7 THEORY OF OPERATION 7 11 1 Phase Controller Phase control can be used to directly control the voltage applied to motors resistive heaters etc When in Phase Control mode the phase angle of the SCRs and hence the voltage applied is directly controlled based on the analog input signal The reference command can be generated from any 0 10V 0 20mA or similar source such as a potentiometer another or an external controller such as a PLC 7 11 2 Master Slave Starter Configuration In the master slave configuration one master starter can directly control the output of one or more slave starters To utilize the master slave configuration one starter needs to be defined as the master starter The Starter Type parameter of the master starter should be configured appropriately as a Soft Starter normal or ID Phase Controller or Current Follower If configured as a soft starter the acceleration and deceleration profiles need to be configured for proper operation To configure a master slave application I The analog output of the master MX control card needs to be connected to the analog input s of the slave card s 2 The master MX analog output needs to be configured Set the Analog Output Function parameter to option 10 or 0 100 firing The Analog Output Span parameter should be set to provide a 0 10V or 0 20 milliamp output to the
23. Power Pk Accel Cur Last Start T Zero Seq GF Stator Temp Bearing Temp Other Temp Temp Insensitive ABC 72 1 96 1 144 1 288 1 864 1 2640 1 3900 1 5760 1 CT Ratio CT Ratio 8000 1 14400 1 288 1 28800 1 50 5 150 5 250 5 800 5 2000 5 5000 5 Insens Single Phase 100 110 120 200 208 220 230 240 350 380 400 415 440 460 480 500 525 5775 600 660 690 800 1000 1140 S FUN 05 P76 Rated Volts Rated RMS Voltage 2200 2300 2400 4 3300 4160 4600 4800 6000 6600 6900 10 00 11 00K 11 50K 12 00 12 47 13 20 13 80 Normal Inside Delta FUN 07 P74 Starter Type Starter Type Wys Delta Normal Phase Ctl Curr Follow ATL FUN 04 Phase Order Input Phase Sensitivity 69 5 GROUPS routiers PORT Fak Tine omerces or 1 PORT Bsn Tin PORT Bypass Hod Time Omoi so Seconds om 130 Voltage Ramp Fast Recover Current FUN 12 PORT Recover P O R T Recovery Method Ramp Curr Ramp 2 Fast Recover 130 Ramp Select Tach Ramp FUN 13 Tach FS Lvl Tachometer Speed 1 00 10 00 Volts 5 00 130 Voltage Fault FUN 15 Tach Los Act Tachometer Loss Action Current Fault 131 FUN16 Po Com Drop Communication Address 1 to 247 1200 2400 4800 Even 1 Stop Bit E Communications Byte Odd 1 Stop Bit FUN 19 P71 Com Parity Framing None 1 Stop Bit Even 1 Stop 132 N
24. 100 RTD BiasMax 80 70 50 40 RTD Bias Value 96 a RTD BiasMid Hot Cold Ratio RTD BiasMin 9 50 0 50 100 150 200 250 Maximum RTD Temperature C 143 7 THEORY OF OPERATION 7 1 8 7 1 9 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 30 27 step 1 30429 30427 4 29 step 2 29 1 25 36 step 3 100 36 64 Therefore 64 is the calculated OL Lockout release level 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 PFN28 parameter needs to be set to On to allow independent overload operation Once set to On the individual Motor Starting Overload Class PFN29 and Motor Running Overload Class PFN30 parameters can be set to eithe
25. 24V 0C san r r bd b 4 bd EI d RTD5 RTD6 RTD7 RTD8 POWER SUPPLY x TO 120 VAC 51 3 INSTALLATION 3 13 6 RTD Temperature vs Resistance DIN 43760 80 176 130 89 240 464 190 45 52 4 KEYPAD OPERATION Introduction 4 1 Introduction The MX has a 2x16 character back lit LCD display keypad that may be mounted remotely from the Mx control card The remote LCD keypad has menu enter up down left start and stop reset keys The display has keys such as START STOP and a LEFT arrow for moving the cursor around in the LCD display Status indicators provide additional information for the starter operation Extended parameters are also added The remote keypad is NEMA 13 IP65 when mounted directly on the door of an enclosure with the correct gasket Figure 31 Remote LCD Keypad S um DBENSHAW Description of the LEDs on the Keypad 4 2 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 18 Remote Keypad LED Functions Dus me eee Stopped ert Faulted On __ Running and up to speed Flashing Running and not up to speed ramping decelerating braking etc ALARM Flashing Alarm condition exists If condition persists a fault occurs 3 NOTE
26. 36 D 5 400100 01 Bo CARD ASSEMBLY CONSISTS OF BIPC 300055 03 TOP 300034 02 BOTTOM ici DISPLAY nu Oco OOOO y 3 NOTE When in ATL mode the acceleration ramp kick and deceleration parameter settings have no effect on motor operation 3 NOTE When in ATL mode the SCR gate outputs are disabled 171 7 THEORY OF OPERATION 7 10 Single Phase Soft Starter There are times a single phase motor may need to be started using a soft starter This can be accomplished with any 3 phase starter with the following modifications to the starter Connect Line power to terminals L1 and L3 Remove gate leads from J8 and J9 and tie off so the leads will not touch anything Remove gate leads from J6 and reinstall to J8 from J7 and reinstall to J9 e Change Input Phase Sensitivity FUN04 to SPH Single Phase Connect motor to terminals T1 and T3 Figure 54 Power Schematic for RB3 Integral Bypass Power Stack for Single Phase Operation L1 SCRE seed Fs 100 600 gt 1050 60Hz y CUSTOMER SUPPLIED 120 m m fe J12 J15 1 FUNOS GND FLT 1 1 PFNOB GROUND 5 BIPC 300055
27. 5V 3 OVERTEMP SWITCH MTO ON HEATSINK ii 3 A5 6 529 d g 58 Hi HE zi O amp e CD 0 GO p HEAVY DUTY 161 7 THEORY OF OPERATION 7 5 6 DC Brake Timing The MX DC injection brake timing is shown below Figure 48 DC Injection Brake Timing DC Brake Delay Time DC Brake Delay after I Time DC Brake Braking Relay Energized Brake Relay Off DC Injection On Starter SCRs On DC Current Applied DC Injection Off time Stop Delay to allow DCBrake 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 Solid State Motor Overload Protection i
28. 7 1 4 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 starter 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 PFN33 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 Tri The MX 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 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 PFN34 Current Imbalance Negative Sequence Current Compensation The motor overload calculations automatically compensate for the additional motor heating which results from the presence of unbalanced phase currents Th
29. LA pL wr osror Maximum MoiorCuneneT 19 89 ma woods Dm Ramptiner Semi 236 sro urs Tierras ie 1 90 1 Control Function Group Voltage Ramp Current Ramp CEN 01 P10 Start Mode Start Mode TT Ramp Current Ramp Power Ramp Tach Ramp 04 Maximum Motor Current 1 100 to 800 FLA CEN 06 Initial Motor Current 2 50 to 600 FLA 80 08 Init Initial Voltage Torque Power 110100 09 Maximum Torque Power 10 to 325 15 10 BE Accel Prof Acceleration Ramp Profile dm ES TUN E NE NN RR Lawn m kaime Dorm ur Lem _ 04100 seos 10 5 Coast Volt Decel 15 Stop Mode Stop Mode TT Decel Coast DC Brake CEN 16 16 Decel Begin Decel Begin Level 100 to 1 Decel Ram oss CFN 19 Decel Prof p Squared Profile S Curve CEN 20 Brake Level DC Brake Level 10 to 100 222 APPENDIX G PARAMETER TABLES Cenaa sind Cur Sow Speed Cuneta 10830 wna ww cos ra spd Timer Stow Speed Timer Ores Sema Jaf cras P30 Stow Speed Kiek Level om ows ov __ Psi Slow Speed Kie me __ 010100 seem 10 Protection Function Group 01 Over Cur Lvl
30. STOP key may be disabled using the Keypad Stop Disable I O26 parameter 55 4 KEYPAD OPERATION Alphanumeric Display 44 4 4 1 4 4 2 56 Alphanumeric Display The remote LCD keypad and display uses a 32 character alphanumeric LCD display 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 MX and I O software part numbers are displayed for five 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 Sections C and D display the meters selected by the Meter 1 and 2 parameters see FUN 01 02 Section 5 displays the source for the start command Figure 32 Operate Screen SECTION A SECTION S SECTION noL iac STOPPER Homo Bu SECTION i L SECTION D Table 20 Operate Screen Section A Display L1 L2 L3 not present Starter ready to run A fault condition is present If it continues a fault occurs Starter is running 443 4 KEYPAD OPERATION Table 21 Operat
31. Spare Parts small KPMX3SLCD H 63mm 2 48 W 101mm 4 1 LCD Display large KPMX3LLCD H 77mm 3 03 W 127mm 5 short RI 100008 00 3 or lm 2 PCD Display Cable long RI 100009 00 6 2m Current Transformer CTs Zero Sequence CT CT 2000 1 6 CT100001 01 MX Assembly PC 400100 01 02 9 DV DT Board PC 300048 01 02 BISCR5016x BISCR10016x BISCR13216x BISCR16116x 10 SCRs BISCR25016x BISCR66018x BISCR88018x BISCR150018x RSC 9 6AC120 RSC 100 4120 RSC 12 6AC120 RSC 125 4120 RSC 18 6AC120 RSC 150 4120 RSC 22 6AC120 RSC 180 4120 11 Contactors RSC 32 6AC120 RSC 220 4120 RSC 40 6AC120 RSC 300 4120 RSC 50 6AC120 RSC 400 4120 RSC 75 6AC120 RSC 600 4120 RSC 85 6AC120 RSC 800 4120 RSC 85 4 6AC 120 7 3 Starter 6 Starter 5 CH D 207 APPENDIX E EU DECLARATION OF CONFORMITY EU Declaration of Conformity According to the EMC Directive 89 336 EEC as Amended by 92 31 EEC and 93 68 EEC Product Category Motor Controller Product Type Reduced Voltage Solid State Motor Controller Model Number 3 1 5 0774130 RB3 LS ISA ISC RBI ESMTTA ITC RCESONATSC rosaa RCEESSIA PRC3 S 125A 40_ ROS 15 302A 15C_ RC3 FS 590A 18C_ Rens Issac RC3 15 361A 16C Rensi kersaan Roasio forssan Manufacturer s Name Benshaw Inc Manufacturer s Address 1659 East Sutter Road Glenshaw
32. cycle Decrease Decel Begin Level until surging is eliminated Increase Decel End Level until 1 End Level 17 set too low motor just stops at the end of the deceleration cycle Decel End Level CFN17 set too high Decrease Decel End 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 iivapeed is eliminated 8 3 5 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 VOS Verify wiring and fuses card not blinking MX control card problem Consult factory Decel time seems correct but motor stops before end of deceleration cycle Ready Displayed Start command lost 185 8 TROUBLESHOOTING amp MAINTENANCE 8 3 6 Metering incorrect Verify correct CT wiring 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 C
33. 10 32 EW TERMINALS _ s 2 PLACES e w aae FAL 20 AT pA LABEL 77 c ad 1PIECE ALUMINUM BRACKET 4 Ae 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 below for proper installation Figure 14 Zero Sequence CT Installation Using Unshielded Cable LUGS TO LOAD TERMINALS ON STARTER Q os E A Re 50 0 025 CORE CORE BALANCE IR BALANCE CT CT SECONDARY CONNECTION TO J15 ON MX CARD GROUND WIRE DOES PASS THROUGH CT 2 GROUND ON STARTER POWER CABLE TO MOTOR 39 3 INSTALLATION 40 Figure 15 Zero Sequence CT Installation Using Shielded Cable LUGS TO LOAD TERMINALS ON 4 STARTER STRESS CONES O O O GROUND CORE BALANCE CT SECONDARY CONNECTION TO J15 ON MX CARD POWER CABLE TO MOTOR GROUND WIRE MUST PASS THROUGH CT window 50 0 025 CORE BALANCE CT GROUND ON STARTER 3 INSTALLATION Control Card Layout 3 8 m Control Card Layout Figure 16 Control Card Layout 120 VAC
34. 141 74 7 RID Overload Biasing s es HR RR Eum RUBRA XU EAR HERES 143 71 8 Overload Auto Lockout 2 34 hae kek xq EUM RS A AES DS 144 7 1 9 Separate Starting and Running Motor Overload Settings 144 7 1 10 Motor Cooling While Stopped ne serr e ER RE UR e EROR E Ur Roms 145 7111 Motor Cooling While Running e cte c cac e ecaa doe a ha a kao a y ha e toasoe 146 7 412 Emergency Motor Overload RESELE i eiss ai am i aiia 2 G ey 146 7 2 Motor Service Factor cus kee ee eR eR Ae eM n RU e 147 7 9 Accelerdtiote Control 2 8 28 sation Be 148 7 3 1 Current Ramp Settings Ramps Times 22A 148 7 9 2 Programming A Kick Currents p sac u OFS FERRE GI ROG 149 7 3 3 TruTorque Acceleration Control Settings and 149 7 3 4 Power Control Acceleration Settings and 151 7 3 5 Open Loop Voltage Ramps Times ee 152 7 3 6 Tachometer Ramp Selection oh 153 7 3 7 Dual Acceleration Ramp Control 24 uos Re d E ERR qoe a 154 7 3 8 Acceleration Ramp Selection eh hh hok hh 155 7 3 9 C hanesine Ramp Profiles
35. 3 NOTE When the Start Mode parameter CFNO1 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 parameter FUNO7 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 Start Mode CFNO1 on page 78 Ramp Time 1 QSTOS 2 on page 78 Ramp Time 2 5 on page 80 Kick Time CFN12 on page 84 Kick Time 2 CFN 14 on page 85 Starter Type FUN07 on page 128 Theory of Operation section 7 3 Acceleration Control on page 148 Theory of Operation section 7 8 Wye Delta on page 168 Jump to Parameter CEN 00 LCD Display Description By changing the value of this parameter and pressing ENTER you can jump directly to any parameter within the group TI 6 PARAMETER DESCRIPTION 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
36. 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 1 026 parameter For more information refer to the Keypad Stop Disable 1 O26 parameter on page 119 54 4 KEYPAD OPERATION Description of the Keys on the Remote LCD Keypad 4 3 Description of the Keys on the Remote LCD Keypad Table 19 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 QST04 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 the 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 faul
37. Environmental Ratings 10 C to 40 C 14 F to 104 F enclosed Operating Temperatures 10 C to 50 C 14 F to 122 Storage Temperatures 20 C to 70 C 4 F to 155 F Humidity 0 to 95 non condensing Altitude 1000m 3300ft without derating Maximum Vibration 5 9m s 19 2ft s 0 6G RC Natural convection Cooling RB Bypassed 2 TECHNICAL SPECIFICATIONS Altitude Derating 2 6 Altitude Derating Benshaw s starters are capable of operating at altitudes up to 3 300 feet 1000 meters without requiring altitude derating Table 12 provides the derating percentage to be considered when using a starter above 3 300 feet 1000 meters Table 12 Altitude Derating Altitude Percent Derating Amps 3300 Feet 1006 meters 0 0 4300 Feet 1311 meters 3 096 5300 Feet 1615 meters 6 0 6300 Feet 1920 meters 9 0 7300 Feet 2225 meters 12 0 8300 Feet 2530 meters 15 0 9300 Feet 2835 meters 18 0 Real Time Clock 231 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 Approvals 2 8 Approvals MX Contr
38. FUNOS and Starter Type FUNO7 The powered BIST tests comprise of Step 1 LCD Display Go to FUN22 misc commands and press ENTER Increment up to Powered BIST and press ENTER Powered BIST test will commence Step 2 Shorted SCR and Ground Fault Test In this test each power pole is energized individually If current flow is detected the controller attempts to differentiate whether it is a shorted SCR shorted power pole condition or a ground fault condition and either a SCR Fault or Ground Fault will occur Step 3 Open SCR and Current Transformer CT Test In this test a low level closed loop controlled current is selectively applied to various motor phases to verify that the motor is connected all SCRs are turning on properly and that the CTs are wired and positioned properly If current is detected on the wrong phase then a BIST CT Fault fault will be declared If an open motor lead open SCR or non firing SCR is detected then a SCR Fault will occur 3 NOTE When this test is in progress audible humming or buzzing maybe heard from the motor Pressing ENTER on the keypad at any time will abort the current test in progress and proceed to the next BIST test 36 NOTE If line voltage is lost during the powered tests a BIST Abnormal Exit fault will occur 36 NOTE The powered BIST tests will verify that the input phase order is correct If the measured phase order is not the s
39. Ground Fault 5 10096 FLA 5 Machine Protection Zero Seq GF 0 1 25 0 Amps 3 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 3 NOTE Percent accuracy is percent of full scale of the given ranges Current Motor FLA Voltage 1000V Watts Volts Amps Watt Hours Motor amp Voltage range 2 2 3 List of Motor Protection Features e ANSI 14 Speed Switch and Tachometer Trip e ANSI 19 Reduced Voltage Start e 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 e 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 90 0 sec in 0 1 sec intervals ANSI 51G Residual Ground fault detection Off or 5 to 100 of mo
40. Maximum Current 1 B 2 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 1 Selected Ramp 2 Selected 156 7 THEORY OF OPERATION Deceleration Control 7 4 Deceleration Control 7 4 1 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 45 Motor Voltage Versus Decel Level Motor Voltage of Line Voltage TET TTT 100 90 50 70 60 40 30 20 10 Programmed Decel Level o 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 adjustmen
41. Ramps and Times on page 148 Theory of Operation section 7 3 7 Dual Acceleration Ramp Control on page 154 Initial Voltage Torque Power 8 LCD Display Range Description See Also 1 100 of Voltage Torque Power Default 25 Start Mode CFNO1 set to Open Loop Voltage Acceleration This parameter sets the starting point for the voltage acceleration ramp profile A typical value is 25 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 set to Current Control Acceleration Not used when the Start Mode parameter is set to Current control acceleration Refer to the Initial Current 1 parameter to set the initial current level Start Mode CFNO01 set to TruTorque Control Acceleration This parameter sets the initial torque level that the motor produces at the beginning of the starting ramp profile A typical value is 1096 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 FUN06 Rated Power Factor parameter is set properly so that the actual init
42. cold overload and 100 representing a tripped overload See section 7 1 for the overload trip time versus current curves on page 138 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 106 6 PARAMETER DESCRIPTION See Also Independent Starting Running Overload parameter PFN28 on page 105 Motor Starting Overload Class parameter PFN29 on page 106 Motor Overload Hot Cold Ratio parameter PFN31 on page 107 Motor Overload Cooling Time parameter PFN32 on page 108 Relay Output Configuration parameter I O 10 15 on page 112 Theory of Operation section 7 1 Solid State Motor Overload Protection on page 138 Motor Overload Hot Cold Ratio PEN 31 LCD Display Range 0 99 Default 60 Description 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 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 Current 1 x OLs OL H C Ratio x FLA Current Imbalanc
43. 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 in single phase mode the heater function is disabled 3 NOTE When this function is on all of the other parameters cannot be programmed until this parameter is turned off LCD Display Range Description Energy Saver FUN 09 On Off Default Off 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 36 NOTE This function does not operate if a bypass contactor is used 85 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 Description Off 0 1 90 0 seconds Default Off 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 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 shal
44. running overload class PFN30 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 Dt 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 Motor Running Overload Class parameter PFN30 on page 106 Motor Starting Overload Class parameter PFN29 on page 106 Motor Overload Hot Cold Ratio parameter PFN31 on page 107 Motor Overload Cooling Time parameter PFN32 on page 108 Theory of Operation section 7 1 9 Separate Starting and Running Motor Overload Settings on page 144 105 6 PARAMETER DESCRIPTION Motor Starting Overload Class 29 LCD Display Range Off 1 40 Default 10 Description 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 an
45. s compliment signed format Starts Truorque o e _______ _ _ _____ 30050 40050 30051 40051 30052 40052 30053 40053 30054 40054 30055 40055 30056 40056 30057 40057 Power 96 210 APPENDIX MODBUS REGISTER 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 an 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 as Other RTD A 1 indicates the RTD is assigned to the other group Bit Mask Each of the sixteen 16 bits represents an 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 S 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
46. uoneorddy v3joq Sunew KI0 o es VD VD 5 pessed g Supnew dug T Surg wa VPA ILAJ PMY osnq mores amuen a NUN puejsuprA uono2ouuo xun OV SII Power Stack Input Ratings with Protection Requirements for Separate Bypass 2 TECHNICAL SPECIFICATIONS 2 3 6 20 2 TECHNICAL SPECIFICATIONS Power Stack Input Ratings with Protection Requirements for RC No Bypass 2 3 7 Vico V009 00 gcodro V009 q 9q 15 V00r g8codro V0Or 9 voor gcoq4o VOST H8t 904D VSTC 9 VASO VASO VASO VAS9 VAOS 0007 V IOOT 0091 VAOS 0007 VAOOI 0091 001 0091 3001 0091 1001 V IOOT V IOOT 1001 V IOOI 001 j nsuoo SZULI QTV 194314 104 p C4t 9215 xX20 q 19 0d 8 ZH 9215 IIM 8 OH 9215 YOOT_ PAL A009 erma DIL OV A009 f sng rma DIL OV A009 f sng qeLsng DIL OV A009 f sng rma DL OV A009 f qersng J6IVOr8 0 OU L O8IVOCL 0 OU S 081 065 0 OU OLIVLLY 0 OU 4 6 L
47. 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 21 Digital Input Wiring Examples START 120VAC LIVE o o om 120VAC NEUTRAL DIGITAL INPUT WIRING 120VAC LIVE 120VAC NEUTRAL 2 WIRE ON OFF SELECTOR SWITCH 120VAC LIVE 14 SLOW SPEED L o 120VAC NEUTRAL SLOW SPEED CONTROL BUTTON DI2 SET TO SSPD SLOW SPEED START STOP 120VAC LIVE 120VAC NEUTRAL 3 WIRE START STOP BUTTONS DI1 SET TO STOP OFF 4 HAND AUTO 1 120VAC LIVE Lo To OUTPUT CONTACT STOP START zip ko BE 120VAC NEUTRAL g HAND OFF AUTO SELECTOR SWITCH SET TO STOP ON OFF TB3 120VAC LIVE ot NNNNA QoooQ 120VAC NEUTRAL EXTERNAL TRIP INPUT DI3 SET TO FL FAULT LOW See Also Digital Input Configuration I O 01 08 on page 111 45 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
48. 1 70 The highest legal NEC approved value of overload multiplier is 1 40 so this could be used 147 7 THEORY OF OPERATION Acceleration Control 7 3 Acceleration Control 7 3 1 Current 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 Current Maximum Current 148 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 39 Current Ramp Current Max Current Start command Kick Current Initial Current Motor FLA 4 4 Time Kick Time lt Up To Speed Timer 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 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 s
49. 67 DI18 A 71 Analog Input Trip Motor overload it 1 Motor PTC RTD Stator it 3 RTD Bearing RTD Other it 5 Disconnect open 30026 40026 Lockout Status Stack overtemperature it 7 Control power RTD Open Short it 9 Time between starts Backspin Starts per hour RTD Comm Loss 30027 40027 Present Fault Code 30028 40028 Average Current PA O 30029 40029 Current Ame ___ 300300030 ____ me ___ 30031 40031 L3 Current A 30032 40032 30033 40033 30034 40034 30035 40035 30036 40036 30037 40037 30038 40038 30039 40039 pO Current Imbalance 2 2 Residual Ground Fault Current Zero Sequence Ground Fault Current Average Voltage pO 1112 Voltage pO 12 13 Voltage pO L3 L1 Voltage nm Motor Overload _ 99 to 100 Power Factor in 16 bit two s compliment signed format Watts lower 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 V 0 30040 40040 30041 40041 30042 40042 30043 40043 30044 40044 30045 40045 30046 40046 30047 40047 30048 40048 in 32 bit unsigned integer format in 32 bit unsigned integer format kW hours lower 16 bits KW hours 16 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
50. Cable Specifications Good quality twisted shielded communications cable should be used when connecting to the Modbus port on the MX The cable should contain two twisted pairs and have an overall shield Use one pair of conductors for the A and signals Use the other pair of conductors for the Common signal The cable should adhere to the following specifications e 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 is not high enough to warrant a terminating resistor unless the network is extremely long 3 000 feet more A terminating resistor should only be installed on the if signal reflection is known to be a problem an
51. 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 If no 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 Configuration parameter is set to a time delay then the MX 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 112 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 DI8 may also be used to monito
52. 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 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 or less 1 25 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 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 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 100 8 60 Temperature 0 0 50 1 00 1 50 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
53. Factor Lagging Trip Enable 1 Enabled 1 99 0 01 10 0 99 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 au 0 Disabled 30243 40243 Backspin Timer Enable 1 Enabled 30244 40244 Backspin Time 1 180 30245 40245 Time Between Starts Enable Disabled 1 Enabled 0 Disabled 30247 40247 Starts per Hour Enable l Enabled EM 218 APPENDIX F Absolute Register Address 30249 40249 Speed Switch Enable 30250 40250 Speed Switch Delay Time 30251 40251 Motor PTC Enable 30252 40252 Motor PTC Delay Time 30253 40253 PORT Trip Enable 30254 40254 30255 40255 30256 40256 PORT Trip Delay Time Motor Overload Alarm Level Motor Overload Lockout Level 30257 40257 Motor Overload Auto Lockout Calculation 30258 40258 Motor Overload RTD Biasing Enable 30259 40259 30260 40260 30261 40261 30262 40262 30263 40263 30264 40264 30265 40265 DI7 Configuration 30270 40270 RTD Module 1 Enable Motor Overload RTD Biasing Min Motor Overload RTD Biasing Mid Motor Overload RTD Biasing Max DI4 Configuration DI5 Configuration DI6 Configuration 30271 40271 RTD Module 1 Address 30272 40272 RTD Module 2 Enable 30273 40273 30274 40274 30275 40275 30276 40276 30277 40277 30278 40278 30279 40279 30280 40280 30281 40281 30282 40282 30283 40283 30284 40284 30285 40285 30286 40286 RTD Module 2 Address RTD 1 Group RTD 2 Gr
54. Factor Trip Time 19 on page 101 PF Trip Time 19 LCD Display Range 0 1 90 0 seconds Default 10 0 Description The amount of time that the power factor lead level PFN17 or lag level PFN18 conditions must exist beyond the window 19 before a trip will occur 101 6 PARAMETER DESCRIPTION See Also Power Factor Lead Trip Level PFN17 on page 101 Power Factor Lag Trip Level PFN18 on page 101 Backspin Timer 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 18 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 PEN 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 right of the display 3 NOTE The TBS timer is not activated by a PORT restart Starts per Hour PEN 22 LCD Display Range Off 1 6 Default Off Description The Starts per Hour parameter
55. Figure 60 Analog Output Simplified Schematic 15 KQ 15 274 15V 0 3 JL 100 WW aout 500 Q AOUT Z swi 2 ON 0 10V 177 7 THEORY OF OPERATION Remote Modbus Communications 7 15 7 15 1 7 45 2 7 15 3 7 15 4 7 15 5 7 15 6 Remote Modbus Communications The starter provides Modbus RTU 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 62 and 61 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 Inthe MX the register maps are identical for both the holding registers and the input registers For example 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
56. Initial Current 1 CFN03 QST06 on page 79 Maximum Current 1 QSTO7 CFN04 on page 79 Initial Voltage Torque Power CFN08 on page 81 Rated Power Factor FUN06 on page 127 Theory of Operation section 7 3 Acceleration Control on page 148 6 PARAMETER DESCRIPTION Acceleration Ramp Profile 10 LCD Display Range Linear Default Square S Curve 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 Squared The squared profile increases the control reference voltage current torque power speed squared manner A squared acceleration profile can be useful when using TruTorque control on a load with a squared torque characteristic such as pumps and fans A squared torque profile can provide a more linear speed profile during acceleration and deceleration Squared 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 ty
57. LCD Display Range Description See Also Off 100 800 FLA Default Off 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 PFN27 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 Kick Level 1 parameter CFN11 on page 83 Slow Speed Kick Time parameter CFN27 on page 91 Motor PTC Trip Time PFN27 on page 104 Theory of Operations section 7 6 Slow Speed Operation on page 164 91 6 PARAMETER DESCRIPTION Slow Speed Kick Time 27 LCD Display Range 0 1 10 0 seconds Default 1 0 Description The Slow Speed Kick Time parameter sets the length of time that the Slow Speed Kick current level CFN26 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 sh
58. O 00 LCD Display Description By changing the value of this parameter and pressing ENTER you can jump directly to any parameter within the group 110 6 PARAMETER DESCRIPTION Digital Input Configuration I O 01 YO 08 LCD Display Range Description See Also LCD Description Off Off Not Assigned Input has no function Default 0102 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 Fault Low Fault Low Fault when input is de asserted OV applied See I O 09 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 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 enabled when input asserted 120V applied Slow Spd Fwd Operate starter in slow speed forward mode S
59. OL group in section 7 1 7 on page 143 RTD Bias Maximum Level RTD 29 LCD Display Range 105 200 C Default 155 C Description The stator insulation maximum temperature rating 3 NOTE Consult motor manufacturer for information See Also RTD Biasing OL group in section 7 1 7 on page 143 124 6 PARAMETER DESCRIPTION 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 the group Meter FUN 01 02 LCD Display LCD Range Ave Current 11 Current L2 Current L3 Current Curr Imbal Ground Fault Ave Volts 11 12 Volts L2 L3 Volts L3 L1 Volts Overload Power Factor Watts VA vars kW hours MW hours Phase Order Line Freq Analog In Analog Out Run Days Run Hours Starts TruTorque Power 96 Pk accel Curr Last Start T Zero Seq GF Stator Temp Bearing Temp Other Temp Temp Description screen Description Average current Default Meter 1 Current in phase 1 Current in phase 2 Current in phase 3 Current Imbalance Residual Ground Fault FLA Average Voltage L L RMS Default Meter 2 Voltage in L1 to L2 RMS Voltage in L2 to L3 RMS Voltage in L3 to LI RMS Thermal overload in Motor power factor Motor real power consumed Motor apparent power consumed Motor reactive power consumed Kilo watt hour used by the motor wraps at 1 000 Mega watt hour used by the
60. Otherwise when the inline test is performed the inline contactor will be energized applying line voltage to the starter and a BIST test fault will occur The standard BIST tests comprise of Step 1 LCD Display Go to parameter FUN22 misc commands and press ENTER Press UP button until it reads Std BIST and press ENTER 195 8 TROUBLESHOOTING amp MAINTENANCE Std BIST test will commence 3 NOTE Designed to run with no line voltage applied Step 2 RUN relay test and Inline Feedback Test Inthis test 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 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 in both the open and closed state If the feedback does not match the state ofthe RUN relay within the amount of time set by the Inline Config 024 parameter an Inline fault 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 1 024 parameter page 118 is set to Off this test will be skipped Step 3 UTS relay test and Bypass Feedback 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 t
61. Outside Delta Inside Delta Wye Delta 30195 40195 Starter Type Phase Controller Current Follower Across the Line Full Voltage Enabled 30190 40190 CT Ratio x 1 30193 40193 Heater Anti Windmill Enable 0 Disabled Enabled 216 APPENDIX F MODBUS REGISTER Absolute Register Address 30196 40196 LED Display Meter 30197 40197 LCD Display Meter 1 30198 40198 LCD Display Meter 2 ON B M Le Status Ave Current L1 Current L2 Current L3 Current Current Imbalance 96 Residual Ground Fault 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 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 96 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 Tempera
62. Over Current Trip Level Off 50 800 FLA or 03 Undr Cur Lvl Under Current Trip Level Off 5 100 off 93 04 Undr Cur Time Under Current Trip Delay Time Off 0 1 90 0 Seconds 01 94 05 Cur Imbl Lvl Current Imbalance Trip Level Off 5 40 p is 06 nr Cur Imbl Time Current Imbalance Trip Time 0 1 90 Seconds 10 95 PFN 07 Resid GF Lvl Residual Ground Fault Trip Level Off 5 100 FLA KOA 09 09 _ Gnd Fit Time Ground Fault Trip Time Fault Ground Fault Trip Time Time 01 900 1 01 900 90 0 Seconds 10 Over Vlt Lvl Over Voltage Trip Level Off 1 40 Epp 11 Undr Vit Lvl Under Voltage Trip Level off 1 40 1 off 1 40 40 Cre ol aren Heme n PFN 13 Ph Loss Time Phase Loss Trip Time 0 1 5 0 Seconds 02 100 PFN 14 Over Over Frequency Trip 24 72 ea rea 15 Undr Lvl Under Frequency Trip 23 71 M PEN 16 PENI6 _ Trip Time Frequency Trip Time 01 900 1 01 900 90 0 Off 0 80 lag to 17 o een PF Lvl PF PF Lead Trip Levl PF Lead Trip Levl Level 0 01 lead m Ra re pn TineBevemsins ______ omiso Mme om 02 p emt PEN 23 23 Auto Reset Reset Auto Auto Fault Reset Time Reset Time off 1 900 1 900 Seconds 102
63. PA 15116 United States of America The before mentioned products comply with the following EU directives and Standards Safety UL 508 Standard for Industrial Control Equipment covering devices for starting stopping regulating controlling or protecting electric motors with ratings of 1500 volts or less Electromagnetic Compatibility EN 50081 2 Emissions Radiated Conducted EN 55011 05 98 A1 1999 EN 50082 2 Immunity Susceptibility which includes EN 61000 4 2 Electrostatic Discharge EN 61000 4 3 Radiated RF EN 61000 4 4 Electrical Fast Transient Burst EN 61000 4 6 Injected Currents 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 products conform to the requirements of the Directive and applicable standards Glenshaw PA USA 1 October 2003 Neil Abrams Quality Control Manager 208 APPENDIX MODBUS REGISTER 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 11 Relay 5
64. 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 61 4 KEYPAD OPERATION A 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 FUN 22 Miscellaneous Commands 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 Below is a list of the minimum parameters that will need to be set again FUN 05 Rated RMS Voltage FUN 03 CT Ratio I O 01 08 Digital Inputs I O 10 15 Relay Outputs 3 NOTE You must consult the wiring schematic for digital inputs and relay output configuration 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 buttons together This sets the motor overload content to 0 LED Display A 10 LED Display The card mounted LED display can be used to access most of the parameters when the standard remote mounted display
65. RTD module 24VDC power supply Verify that the RTD module s are set to the same address as the MX module address parameters RTD01 and RTDO2 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 Keypad Communication Fault 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 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 FUNI8 defined time Modbus Timeout Fault Verify communication parameter settings FUN16 FUN19 Check wiring between the remote network and the MX control card Examine remote system for cause of communication loss 193 8 TROUBLESHOOTING amp MAINTENANCE Fault Code Detailed Description of Fault Possible Solutions Communication between the two MX cards has been lost E Verify that both cards are mounted together and that the mounting hardware is not to I O Card Communication loose Fault Interboard fault Verify that no foreign matter is located between the two boards Consult factory if fault persists Typically occurs when attempting to ru
66. Run Motor Overloads 1 Enabled r 0 Disabled 30104 40104 Motor Overload Running Enable 1 Enabled 30084 40084 RTDs with Shorted Leads 211 APPENDIX MODBUS REGISTER Absolute Register Address 0 Disabled 30106 40106 Motor Overload Starting Enable 1 Enabled 30108 40108 Motor Overload Hot Cold Ratio 0 99 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 FLA 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 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 0 212 APPENDI
67. Stack In Benshaw Only Unfused 120 VAC Out Stack Control Control Power m 120 VAC scR1 Auxiliary Relays 10 12 SCR4 SCR 2 Digital Inputs 1 3 SCR 5 Modbus Communications Port FUN 16 19 Keypad Port scr VO 26 Analog Input ac r VO 16 20 7 Analog Output 21 23 M xx E ue coe ja E CT Inputs S I FUN 03 Analog Voltage Current Lcd LED Display Selector Switch SW1 84 E Part Serial 1 2 3 4 5 6 41 3 INSTALLATION 3 9 Card Layout Figure 17 Card Layout J1 Remote RTD Module s RJ45 Socket A Li FC 5 r 3 E Relay Outputs R4toR6 3 Fe t J6 Digital Inputs A 014 to 018 y L e J7 MOT PTC Motor Ta D Thermistor Part Serial 42 15 Zero Sequence Ground Fault CT 3 10 Terminal Block Layout RTD Module s RJ45 Socket J3 Relay Outputs R4 to R6 J6 Digital Inputs DIA to DI8 J7 MOT PTC Motor Thermistor TB1 120VAC Control Power Input TB2 Relay Outputs R1 to R3 TB3 Digital Inputs DI1 to DI3 TB4 Modbus Slave RS485 J2 Remote Keypad RJ45 Socket TB5 Analog I O 3 INSTALLATION Figure 18 Terminal Block Layout J4 Auxiliary Power J5 Phase Connector J6 to J11 SCR Connectors Phase CTs
68. 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 Ifa 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 Stop Mode parameter CFN15 on page 85 DC Brake Level parameter CFN20 on page 88 DC Brake Time parameter CFN21 on page 89 Theory of Operation section 7 5 9 DC Injection Braking Control on page 164 Preset Slow Speed 23 LCD Display Range Description See Also Off 1 0 40 0 Default Off 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 Energizing the Slow Speed Input when the starter is idle will initiate slow speed operation 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 not set to Off during slow speed operation it is recommended t
69. 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 71 204 Low Line L1 L2 Low Line L2 L3 Instantaneous over current 1 0 C Phase Rotation Error not ABC F00 F01 F02 F03 F04 F05 F06 F07 F08 F10 F12 F13 F14 F15 F21 F22 F23 F24 F25 F26 F27 F28 F29 F30 F34 F35 F36 7 F38 F39 F40 F41 F46 F47 F48 F49 F50 F53 F54 F55 F56 F60 F61 F62 F63 APPENDIX C FAULT CODES Fault Codes Controlled Fault Stop Shunt Trip Fault Auto Reset Allowed 205 APPENDIX C FAULT CODES Fault Code hend oled Fault Shunt Trip Fault Auto Reset Allowed N 206 APPENDIX D SPARE PARTS Options and Accessories 1 LCD Display small KPMX3SLCD H 63mm 2 48 W 101mm 4 LCD Display large KPMX3LLCD H 77mm 3 03 W 127mm 5 pied 9
70. crimp on wire connectors manufactured by Penn Union Corp for copper wire Table 14 Single Hole Compression Lugs LU LU BLU Boum Table 15 Two Compression Lugs 3 6 6 3 INSTALLATION Torque Requirements for Power Wiring Terminations Table 16 Slotted Screws and Hex Bolts Tightening torque pound inches N m Wire size installed in conductor H head ext l dri ket iid Slot width 0 047 inch Slot width over 0 047 2 1 2mm or less inch 1 2mm or slot AWG kcmil mm slot length inch length over inch Split bolt connectors Other connectors 6 4mm or less 6 4mm or less 18 10 09 59 29 ss ao so om 75 es 8 84 25 o G9 s G3 1 e 5 25 Gro 1 ae 0 20 635 64 sss 635 19 Qo 30 40 650 172 so soo Ge 250 250 350 07 1 5 6 ma 35 Gen ew s G9 s 032 35 Gen e s gs o2 22 600 750 304 380 66 0o 35 22 300 100 406 59 so no 0243 so Ge 150 200 5 100 no 69 36 NOTE For a value of slot width or length not corresponding to those specified above the lar
71. current for 30 seconds 115 Continuous HORSEPOWER RATING 230 240V 380 400V 440 480V 575 600V MODEL NUMBER NOMINAL AMPS 200 208V 36 NOTE Do not exceed Class 10 overload setting E 4 N 15 2 TECHNICAL SPECIFICATIONS 2 3 2 Heavy Duty 500 current for 30 sec Ratings Table 6 Heavy Duty Horsepower Ratings Heavy Duty 500 current for 30 seconds 125 Continuous NOMINAL HORSEPOWER RATING suma m 5 2 Less Tessas as 20 Tresore 0 Desas e 20 0 3 NOTE Do not exceed Class 20 overload setting 16 2 33 2 TECHNICAL SPECIFICATIONS Severe Duty 600 current for 30 sec Ratings Table 7 Severe Duty Horsepower Ratings Severe Duty 600 current for 30 seconds 125 Continuous ONU HORSEPOWER RATING A L5 L7 L7 a4 a a m A a oo RB3 1 S 838A 20C 36 NOTE Do not exceed Class 30 overload setting 17 2 TECHNICAL SPECIFICATIONS 2 3 4 Inside Delta Connected Standard Duty 350 for 30 sec Ratings Table 8 Inside Delta Standard Duty Horsepower Ratings INSIDE DELTA Std Duty 350 start for 30 seconds 115 Continuous NOMINAL HORSEPOWER RATING MODEL NUMBER 200 208V 220 240V 3
72. 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 parameter setting See Also Start Mode CFNO1 on page 78 Ramp Time 1 QSTOS 2 on page 78 Maximum Current 1 QSTO7 CFN04 on page 79 Kick Level 1 CFN11 on page 84 Kick Time CFN12 on page 84 Theory of Operation section 7 3 1 Current Ramp Settings Ramps and Times on page 148 75 6 PARAMETER DESCRIPTION Maximum Current 1 OST 07 LCD Display Range 100 800 of FLA Default 600 Description The Maximum Current parameter is set as a percentage of the Motor FLA QSTO1 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
73. 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 1 Fault Description 2 Status when the fault occurred Run Stopped Accel ete i O 3 P Thellcumenatthetimeofthefaul ____ 4 P Thel2cumentatthetimeofthefaut 5 f Thel3cumentatthetimeofthefaut y U Ts 9 Wameumesemdk __ 4 4 6 Fault Screen When a Fault occurs the main screen is replaced 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 36 NOTE For a list of the Faults refer to Appendix Fault Codes on page 205 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
74. dropping below 175 FLA indicating Reduce load on motor during starting that the motor has not come up to speed DISBIGRHONS Accelor Motor FLA QSTO01 or CT ratio Verify that Motor FLA and CT ratio FUNO3 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 FLA or CT incorrect Verify FLA and CTs settings 8 3 3 Starter not accelerating as desired Kick start current CFN11 too high Decrease or turn off Kick current Motor accelerates too quickly ot Motor FLA QSTO01 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 Maximum Motor Current setting 8 Review acceleration ramp settings set too low FUNO3 parameter set incorrectly parameters are set correctly 184 8 TROUBLESHOOTING amp MAINTENANCE 8 3 4 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 CFN17 set improperly End levels Decel time seems correct but motor surges oscillates at beginning of deceleration 1 Begin Level 16 set too high
75. 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 Stop Mode parameter CFN15 on page 85 Decel Begin Level parameter CFN16 on page 86 Decel Time parameter CFN18 on page 87 Controlled Fault Stop Enable parameter PFN25 on page 103 Theory of Operation section 7 4 Deceleration Control on page 157 Decel Time 18 LCD Display Range 1 180 seconds Default 15 87 6 PARAMETER DESCRIPTION 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 When 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 decel 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 When 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 If the motor stops rotating before the
76. eu CUR ES 178 715 6 Shielding aed SEO a Bade Ode ed the eee 178 Tilo WIBIBE s 2 3 9 eos E RU E dd ROR ee RES a dors 179 8 TROUBLESHOOTING amp MAINTENANCE 182 81 Safety Precautions oko or 182 8 2 Preventative Maintenances 24 EE SS GO RSS 182 8 2 1 General Information 33 Gee EO e ep Gu REGE SOS ed 182 8 22 Preventative Maintenance end ded us dede eh d Rd x werd d db da 182 8 3 General Troubleshooting Charts e 183 8 3 1 Motor does not start outputto motor 2 183 8 3 2 During starting motor rotates but does not reach full speed 184 8 3 3 Starter not accelerating 5 ngora taki pa ais dex Wi Adee dex aw HRT DOS 184 8 3 4 Starter not decelerating as 185 8 3 5 Motor stops unexpectedly whilerunning eee eee 185 8 3 6 M termg incOrFfeCE sos s RR om OR BUR 186 837 ee 187 8 E Fault Code Table s s Ve ak ke Sete ato
77. 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 comes 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 40 TruTorque Ramp Motor Torque Max Torque Motor Running a ee ee c UTE Torque Start command Optional Kick Current Initial Torque 1 Time Kick Time Ramp Time gt Up To 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 149 7 THEORY OF OPERATION Initial Torque Maximum Torque Ramp Time 150 This parameter CFNO8 sets the initial torqu
78. 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 Analog Input Trip Level parameter 1 017 on page 114 Analog Input Trip Time Level parameter 1 018 on page 114 Analog Input Span parameter 1 019 on page 115 Analog Input Offset parameter 1 O20 on page 116 Starter Type parameter FUNO7 on page 128 Theory of Operation section 7 11 Phase Control on page 173 Theory of Operation section 7 12 Current Follower on page 175 113 6 PARAMETER DESCRIPTION Analog Input Trip Level I O 17 LCD Display Range 0 10095 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 1 016 parameter to Low and setting the Analog Input Trip Level I O17 parameter to a value less than 20 3 NOTE The analog input trip lev
79. installed with all the White dots towards the input line side CT1 L1 CT2 L2 CT3 L3 a GF Metering not 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 186 8 3 7 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 p ek Reduce starting load and or review Acceleration time too long d celeration ramp aching Incorrect motor OL settings Review and correct motor OL settings R ling air obstructions Check Motor cooling obstructed damaged e i
80. is not connected The LED parameter numbers Pxx are shown in the parameter table See chapter 5 62 Parameter Groups 5 GROUPS Introduction 5 1 52 52 1 Introduction 3 The MX 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 changed 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 REN ns 01 EI MotorFLA Mo
81. 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 4 KEYPAD OPERATION 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 3 NOTE After pressing ENTER you can shift through all the different starter states times and dates by using the UP and DOWN arrows 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 The communications loss is displayed when the starter loses communication with the remote RTD modules The open lockout is displayed when the RTD module senses an open RTD 60 4 KEYPAD OPERATION The short lockout is displayed when the RTD module senses shorted RTD 3 NOTE XX XX is the time remaining until the lockout releases 4 4 9 Alarm Screen 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
82. 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 202 Appendix C Fault Codes on page 205 135 6 PARAMETER DESCRIPTION LCD Display The first screen displayed in the event recorder gives the starter state on the second line of the screen See below 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 See Also Appendix A Event Codes on Page 202 136 Theory of Operation 7 THEORY OF OPERATION Motor Overload 7 1 7 1 1 Solid State Motor Overload Protection Overview The MX contains an advanced rt electronic motor overload OL protection function For optimal motor protection the MX has forty standard NEMA style overload 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 a
83. motor wraps at 10 000 Phase Rotation Line Frequency Analog Input 96 Analog Output Running time in days wraps at 2 730 days Running time in Hours and Minutes wraps at 24 00 Number of Starts wraps at 65 536 TruTorque Power Peak starting current Last starting duration Zero sequence ground fault Highest Stator temperature Highest Bearing temperature Highest Other temperature Highest of all temperatures Parameters FUN 01 and FUN 02 configure which meters are displayed on the two lines of the main display 125 6 PARAMETER DESCRIPTION CT Ratio FUN 03 LCD Display Range 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 Description 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 Only Benshaw supplied CTs can be used on the starter The CTs are custom 0 2 amp secondary CTs specifically designed for use on the starter The CT ratio is then normalized to a 1A secondary value The supplied CT ratio can be confirmed by reading the part number on the CT label The part number is of the form BICTxxx1M where xxx is the CT primary and the 1 indicates the normalized 1 amp 3 NOTE It is very important that the CT ratio is set correctly Otherwise many starter functions will
84. of PTC chain 1500 Ohms Zero Sequence Ground Fault CT input Zero Sequence Ground Fault CT input CT Type 50 0 025 2000 1 ratio Measurement range 0 1A 25 0 Amps Accuracy 3 Burden at 25Amps 0 0089 VA Display Door Mounted Display Connector J6to J11 1 ee SCR gate Connections E RN Cathode Phase C T Phase CT Connector Wire Gauge The terminals can support 1 14 AWG wire or 2 16 AWG wires or smaller 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 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 Layouts starting on page 41 2 TECHNICAL SPECIFICATIONS 2 2 2 Measurements and Accuracies Table 2 Measurements and Accuracies Conversion True RMS Sampling 1 562kHz Finns Range 1 6400A Conversion True RMS Sampling 1 562kHz Ling Voltages Inputs Range 100VAC to 1000VAC 23 to 72 Hz Metering Current 0 40 000 Amps 3 Voltage 0 1250 Volts 3 Watts 0 9 999 MW 5 Volts Amps 0 9 999 MVA 5 Watt Hours 0 10 000 MWh 5 PF 0 01 to 0 01 Lag amp Lead 5 Line Frequency 23 72 Hz 0 1 Hz
85. sav 8 cou i 2 3 5 HABA stoe 7 sos a Don RESET PARAM DOWN UP ENTER zu Do 5i uncos 8 ow e Do 42 BIPC 400100 01 82 CARD ASSEMBLY Pee os mm 28 Oo 8 2 EE gus e Dos Lom DDO Be 168 7 THEORY OF OPERATION The utilizes an intelligent Wye to Delta transition algorithm During starting if the measured motor current drops below 85 of FLA and more than 25 of the Up To Speed timer setting has elapsed then a Wye to Delta transition occurs The intelligent transition algorithm prevents unnecessarily long motor starts which reduces motor heating If a Wye to Delta transition has not already occurred a transition always occurs when the complete Up To Speed Time expires The MX can operate two configurations of Wye Delta starters open transition and closed transition An open transition starter momentarily disconnects the motor from the input line during the transition from Wye to Delta operating mode A closed transition starter uses resistors that are inserted during the transition so that the motor is never completely disconnected from the input line The presence of the resistors in a closed transition starter smooths the transition A typical closed transition Wye Delta starter schematic is shown in Figure 51 on page 168 The closed transition resistors generally are sized to be
86. slave starter s Adjust analog output jumper JP1 to provide either a voltage or a current output Set the slave MX Starter Type parameter to Phase Control and verify that the Analog Input Offset and Analog Input Span parameters are set to accept the master signal 3 The slave MX needs to be provided with a start command from the master MX ARUN programmed relay from the master MX can be used to provide the start command to the slaves The slave s Control Source parameters Local Source and Remote Source settings need to be set appropriately 4 The slave MX analog input s needs to be configured for the appropriate voltage or current input signal type Set the analog input jumper SWI 1 to the desired input type For additional master slave application information consult the factory 174 Current Follower 7 12 7 THEORY OF OPERATION Current Follower When the Starter Type parameter FUN 07 is set to Current Follower the MX is configured to operate as a Closed Loop current follower Current Follower mode can be used to control the current applied to motors resistive heaters etc The Current Follower mode uses the analog input to receive the desired current command and controls the SCRs to output the commanded current The MX reference command can be generated from any 0 10V 0 20mA or 4 20mA source such as a potentiometer another or an external controller such as a PLC Figure 56 Current Follower Mode
87. that when the fault is reset the starter will start in Current control mode 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 QST04 on page 74 Remote Source parameter 05705 on page 74 Communication Baud Rate parameter FUN17 on page 131 Communication Timeout parameter FUN18 on page 132 Communication Byte Framing parameter FUN19 on page 132 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 131 6 PARAMETER DESCRIPTION See Also Local Source parameter QST04 on page 74 Remote Source parameter QST05 on page 74
88. to ABC only Phase Rotation Error notrABC Verify correct phase rotation of input power Correct wiring if necessary Verify correct setting of Input Phase Sensitivity parameter FUN04 Input phase rotation is not CBA and Input Phase Sensitivity parameter FUN04 is set to CBA only High Line Frequency Line frequency above Over Freq Trip PFN14 Line power quality problem excessive line distortion Verify input line frequency 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 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 Input power not three phase gt Verify that the SCR gate wires are properly connected to the MX control card Verify that the Rated Voltage parameter FUNOS 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 was detected for longer than the Over Under Voltage Trip delay time PFN12 Verify that the actual input voltage level is correct Low Line L2 L3 i Verify that the Rated Voltage parameter FUNOS is set correctly Che
89. 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 THEORY OF OPERATION 7 3 8 Acceleration Ramp Selection 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
90. with a 5V input For a 4 20mA input a 80 Analog Input Span setting and a 20 Analog Input Offset setting results 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 96 100 gt 12096 Ain Ain Span 80 Offset 2V 1 10V 20mA Input Signal See Also Analog Input Trip Level parameter 1 017 on page 114 Analog Input Trip Time parameter 1 018 on page 114 Analog Input Offset parameter 1 O20 on page 116 Starter Type parameter FUNO7 on page 128 Theory of Operation section 7 11 Phase Control on page 173 Theory of Operation section 7 12 Current Follower on page 175 115 6 PARAMETER DESCRIPTION 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 gt 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 85 NOTE For a 4 20mA input set the Analog Input Span to 80 and the Analog Input Offset to 20 3 NOTE The measured input reading is clamped at 0 minimum See Also Analog Input Trip Level parameter I O17 on page 114 Analog Input Trip Time parameter 1 O18 on page 114 Analog Input
91. 03 CARD 1 1 1 NEUTRAL S l 1 1 CPU L iDQuve El 1 1 a 1 1 LIVE on BIPC 500034 02 1 1 x MX3 CARD 2 1 ael zw 7 37 1 i 19 Q sv PWR BE 6 8 1 1 1 1 j 2 NEM rot i PROGRAMMABLE 55 1 1 RCD evar R1 en an 2 1 i4 ed Ee an 1 1 gs i com 1B2 602 pS ov 5 PROGRAMMABLE R2 si cu 1 1 H i K Ze suco 9 1 2 js 1 i 5o 1 1 ee zg H B PROGRAMMABLE 9 RELAY R3 T SERIAL COMMUNICATION 85 g Zo A ESV MAX 1 1 i 1 1 1 1 1 1 1 89 1 QVERTEMP SWITCH ON HEATSINK 1 1 1 i 5 i 1 m n 7 1 4 1 1 i i EED procraumasre 5 1 1 RELAY R6 Bet 68 0 EI 6 H J 1 i a XD start 5 5 W W W W Wi H on RESET PARAM DOWN UP ENTER 1 H O o2 28 LEDS IN CONNECTOR 52 i D ois Oo 8 5 1 E uo 4 8 RX TX 1 gg 1 Je 1 0 Zs BIPC 400100 01 S85 CARD ASSEMBLY 05 i CONSISTS OF BIPC 300055 03 BIPC 300034 02 BOTTOM pos ns 228 1 7 8 g omo ow g 2 came 1 t 9
92. 05704 Local Source and QSTO5 Remote Source 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 74 6 PARAMETER DESCRIPTION Figure 33 Local Remote Source Local Source e Keypad e Terminal Serial 8 e Start Source Remote Source e Keypad e Terminal Local Remote Input 018 configured by Parameter I O 01 1 0 08 Serial oe Modbus Starter Control Register Local Remote Bit See Also Local Source parameter QST04 on page 74 Digital Input Configuration parameters I O 01 08 page 111 Keypad Stop Disable parameter 1 026 on page 119 Communication Address parameter FUNI16 page 131 Communication Baud Rate parameter FUN17 on page 131 Communication Timeout parameter FUN18 on page 132 Initial Current 1 OST 06 LCD Display Range 50 600 of FLA Default 100 Description The Initial Current 1 parameter is set as a percentage of the Motor FLA QSTO1 parameter setting The Initial Current 1 parameter sets the current that is initially supplied to the motor when a start is commanded The initial
93. 1 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 LCD Description Range 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 parameter are retrieved from non volatile memory Factory Rst 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 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 does 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 volat
94. 1 1 Q gt gt Qm Q Q Qe a ete 1200 1200 M 179 7 THEORY OF OPERATION NOTES 180 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 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 power 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 of the motor windings Voltages used for insulation resistance testing can cause failure of SCR s Do not make any measurements on the controller with an IR tester megger Preventative Maintenance 8 2 82 1 Preventative Maintenance General Information Pr
95. 1 Solid State Motor Overload Protection on page 138 109 6 PARAMETER DESCRIPTION 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 3696 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 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 start 3 NOTE The OL does not have to reach 100 for the lockout to occur See Also Motor OL Lockout Level PFN34 on page 109 Theory of Operation 7 1 Solid State Motor Overload Protection on page 138 Jump to Parameter I
96. 100 FLA The motor overload content exponentially rises to a new steady state value of 80 80 H C Ratio x 100 FLA 80 142 7 1 7 7 THEORY OF OPERATION RTD Overload Biasing The RTD biasing calculates 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 RTD Bias Min Level RTD27 BiasOL 0 RTD Bias Min Level 7027 lt Max measured stator RTD temp lt RTD Bias Mid Point Level 1028 RTD max MinBiasTemp MidBiasTemp MinBiasTemp BiasOL xHot Cold Ratio RTD Bias Mid Point Level RTD28 Max measured stator RTD temp RTD Bias Max Level RTD29 RTD max MidBiasTemp MaxBiasTemp MidBiasTemp BiasOL 99 9 hot cold _ rato 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 37 RTD Bias Curve RTD Bias Curve
97. 22 2A Dimensions xcu eu e de Gee decem eae qu US UE RUE Rr S 23 2 4 1 Chassis with Integral Bypass eee 23 242 RC3 Chassis With nio BY Pass i BBs ae BORE ees ae 24 25 Environmental Conditions s fese sss RR SEE 25 2 6 Altitude D tating s v shed ox RUP d ed bd ded Ge Bedok Ra 26 27 Real Time Clock 5s ata Betas oe SES los BUS dox dod tene 26 2 0 induere de Und apre ved 26 29 Gertificate oF Compliance soleo RN RE SUR du a 26 3 INSTALLATION 4s mo euo Ro CES SUP E Ro Ue OS s 28 31 Before You Start ec ke pm dm y EEG REE RE dec e s E OE Y Ox pO E 28 3 1 1 Installation Precautions 5 kk ARR eR Rb mS AXES E EE Re 28 31 2 Safety Precautions re sb ee o dr edes RP REOR OG JG Ke eed de RP e 28 3 2 Installation Considerations 2 29 3 21 Site Preparations d ei oe eth Be AP ech He tS Be Rw ach o ERE A BAe 29 3 22 EMC Installation Guidelines oye a WES aed e ee om ek 29 3 2 3 Use of Power Factor Capacitors 2 Re ENE eee CE 29 3 2 4 Use of Electro Mechanical BraKes oraa darm ee e yo
98. 29 3 2 5 Reversing Contactor s s HO GR Roe pU RGR ROCA EUR 29 3 3 Mounting Considerations i somt egte e EE Rh Re 30 331 Bypassed Starters a sep ean exe e Km RR RU CR Ro CR D ERG 30 3 32 Non Bypassed Starters e vy er ER SERGE EA ERE E EE xs 30 3 4 Wiring Considerations x x sme ed Bu EU QUEE oH Desi oe ce bas vi 31 WirnngPraetces s x tardier ba et ed ee a esee ESSE 31 3 4 2 Considerations for Control and Power Wiring 2 31 3 4 3 Considerations for Signal Wiring 2 31 JAA a ccna sata s eae dou aed uy ew EUR deu ende dug eae Res 31 9S5 ElghPot Testi aes d Reo eu HERRERA Ee BUR at AC eg SUA pH dk 31 3 5 Power and Control drawings for Bypassed and Non Bypassed PowerStacks 32 TABLE OF CONTENTS 3 6 Power WINS e e 6b n Row d acere eese go b OH v RS eee 35 3 6 1 Recommended Incoming Line Protection eA 35 3 62 Recommended Wire Gauges ass de we deen HL do ae E e 35 9 6 9 Power Wire Connections a Sse 4 Se 9 Gow af x doen du den ER Res gode REO ES 35 3 64 Motor Lead Length s xy sea 9344 93 EERE REE YAT 35 3 6 5 Compression DUZS se pce voe nd it Reo cle Bek end ee de doe OR c
99. 30158 40158 Over Voltage Trip Enable 1 Enabled 30159 40159 Over Voltage Trip Level 0 Disabled 30160 40160 Under Voltage Trip Enable l Enabled EM 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 0 1 22 0 1 Disabled 30175 40175 Analog Input Trip Enable Enabled Disabled Enabled Disabled Enabled Fault High Fault Low Fault Reset Disconnect Inline Feedback 249 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 S
100. 4 Kick Time 1 CFN12 on page 84 Theory of Operation section 7 3 1 Current Ramp Settings Ramps and Times on page 148 Maximum Current 1 CEN 04 LCD Display Range 100 800 of FLA Default 600 79 6 PARAMETER DESCRIPTION Description See Also The Maximum Current parameter is set as a percentage of the Motor FLA QSTO1 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 Up To Speed Time 05709 on page 77 Start Mode CFNO1 on page 78 Ramp Time 1 QST08 CFN02 on page 78 Initial Current 1 QST06 on page 79 Kick Level 1 on page 84 Kick Time CFN12 on page 84 Theory of Operation section 7 3 1 Current Ramp Settings Ramps and Times on page 148 Ramp Time 2 05 LCD Display Range Description See Also 0 300 seconds Default 15 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 curre
101. 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 72 1 4 16 4 wraps 288 1 96 1 144 1 3900 1 5760 1 14400 1 CT CT combination 28800 1 CT CT combination For the following CT Ratios consult factory 12 2 TECHNICAL SPECIFICATIONS 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 Model Number SPR 100P RTD Type 1000 Platinum 3 lead TCR 0 00385 Q O C DIN 43760 Maximum Lead Resistance 250 per lead Recommended Lead Resistance Less than 160 per lead Shorted Lead Detection 600 Open Lead Detection gt 2600 RTD Sensing Current 10 mA DC RTD Sensing Voltage 10V DC maximum Range 0 to 200 C 32 to 392 F Resolution
102. 80 415V 440 480V 575 600V RB3 1 S 156A 14C 250 RB3 1 S 180A 14C RB3 1 S 180A 15C RB3 1 S 240A 15C 361 RB3 1 S 302A 15C 414 150 RB3 1 S 414A 17C 590 200 250 350 500 L weasssenc wo om sw wo 0 ine so so wo woo 85 NOTE Do not exceed Class 10 overload setting 18 2 TECHNICAL SPECIFICATIONS RB3 Power Stack Ratings and Protection Requirements 2 3 5 j nsuoo 80 DTV 194814 104 c PrepueiS vIASN Aq peuop se pede 1 woyed YWAIN sng p BOY sng 01 9ZIS YOOTY JOMO SApH c ZIS YOOTY uoneor dd eoq oprsu 10 unes v ANELA SIH ames PIS p ssed g dug Y quoram 55 10 Sunew suyey 9216 y I9poJA 55071 wI 9 qE MO TV PULISYA putjsuprA 611 8 d L uonoouuo xun xun 19 j nsuoo 8 jy 19481 104 100 YWAN Aq peugop se pede soy YWAIN sng 9104 1 qe sng 01 9215 JOOJ C 1 9215 IM YOOTY 1
103. ATION 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 ramp 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 43 Effect of UTS Timer on Voltage Ramp Voltage Full Voltage 4 Optional Kick Current Initial Voltage Time SS Ramp Kick Time gt lt Time gt k UTS Time 7 3 6 Tachometer Ramp Selection Description The Tachometer control ramp profile provides a method to linearly ramp the speed of the system When this Tachometer Requirements 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 c
104. ATION Inside Delta Connected Starter 7 7 771 Inside Delta Connected Starter There are differences between a line connected soft starter as shown in Figure 49 and the inside delta connected soft starter as shown in Figure 50 that need to be considered By observation of Figure 50 access to all six stator winding terminals is required for an inside delta application For a 12 lead motor all 12 stator terminals must be accessible In the line connected soft starter of Figure 49 access to only three leads of the stator windings of the motor is required One failed SCR on any phase of the inside delta soft starter results in a single phase condition A shunt trip circuit breaker is recommended to protect the motor in this case A programmable relay can be configured as a shunt trip relay and can be used to trip the breaker When certain faults occur the shunt trip relay energizes The SCR control for an inside delta application is different than the SCR control for a standard soft starter The Starter Type parameter needs to be properly set so that the SCRs are gated correctly If a circuit breaker is the only means to disconnect the soft starter and motor from the line then one leg of the motor leads in the inside delta soft starter is always electrically live when the circuit breaker is closed This requires caution to ensure these leads of the motor are not exposed to personnel Line Connected Soft Starter In Figure 49 the power po
105. Also Auto Reset parameter PFN23 on page 102 Controlled Fault Stop Enable 25 LCD Display Range Off 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 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 CFN15 on page 85 Appendix C Fault Codes on page 205 103 6 PARAMETER DESCRIPTION Speed Switch Trip Time 26 LCD Display Range Off 1 250 seconds Default Off Description When using the Speed Switch Trip Time 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 is removed The zero speed input requires a high Speed Sw NC or low Sp
106. C and 23 to 72Hz 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 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 9 Fault Log Real Time Clock Zero Sequence Ground Fault Backspin Timer Starts per Hour Time between Starts PORT P
107. C 3A at 30VDC 1250VA 750VA Normally Open Contact Relay Output SPST NO form A Normally Open Contact Resistive 5A at 250VAC 5A at 125VAC 5A at 30VDC 1250VA Relay 4 R4 Relay 5 R5 Relay 6 R6 Normally Open Contact Relay Output SPST NO form A Normally Open Contact Resistive 5A at 250VAC 5A at 125VAC 5A at 30VDC 1250VA Normally Open Contact Relay Output SPST NO form A Normally Open Contact Resistive 5A at 250VAC 5A at 125VAC 5A at 30VDC 1250VA Relay 3 R3 NO3 Normally Open Contact 10A at 250VAC RC3 Common Contact 10A at 125VAC NC3 Normally Closed Contact 10A at 30VDC 2500VA 2 TECHNICAL SPECIFICATIONS Table 1 Terminals Function tua Terminal Number Description Block Start 120VAC digital input DII 2500V optical isolation DD2 4mA current draw DB Off 0 35VAC Common On 60 120VAC Digital Inputs Digital Inputs DIA 120VAC digital input DIS 2500V optical isolation 016 4mA current draw DI7 Off 0 35VAC DIS On 60 120VAC Common Modbus RTU serial communication port RS 485 interface 19 2k baud maximum 2500V Isolation PTC Thermistor Input Motor PTC Positive Temperature Coefficient Thermistor Motor PTC 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
108. CR yo gt Siov Lad e c 3 DVD 2 50 o 1 BPS ay T BPO TO DVDT 1 VET 1 o FOR 2 PHASE 1 as Ji 2 Ja f 5 6 OT SWICH p AAAAA A 92 m2 Jt bb cB gt BP2 D P T 2 8 14 DvDT 2 FOR 2 PHASE 2 BB 5 Is OT p ARAAA A 3 2 2 5 4 5 6 oro E e BP3 T SERIAL COMMUNICATION D He 3 65485 5V G te DVDT 3 1 FOR 2 PHASE 3 L RAE ENG RES sO DISPLAY iQ wO DISPLAY CABLE 2 5 m 66 SCR3 MX CARD SCRE SCR2 MX CARD SCR5 SCRI MX CARD SCR4 33 3 INSTALLATION Figure 11 Power Schematic for RC3 100 600 3e50 60Mz e a Lo CUSTOMER SUPPLIED lo hs hs h7 20 p m75m 055 2 e 17 FSCRI rs i i i 1 1 IKA p 8 5 oa i z BIPC 300055 03 Bop tee SOR 1 NEUTRAL MX3 CARD 1 8 i Ei E H sors 1 NEUTRAL B KS E m L Diuve E sh 2 ORS 1 1 LIVE adr IE BIPC 300034 02 KE i MX3 CARD 2 i 20
109. Communication Address parameter FUNI16 on page 131 Communication Timeout parameter FUN18 on page 132 Communication Byte Framing parameter FUN19 on page 132 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 QST04 on page 74 Remote Source parameter QST05 on page 74 Stop Mode parameter CFN15 on page 85 Controlled Fault Stop Enable parameter PFN25 on page 103 Communication Address parameter FUN16 on page 131 Communication Baud Rate parameter FUN17 on page 131 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 FUN16 on page 131 Communication Baud Rate parameter FUN17 on page 131 Communication Timeout parameter FUN18 on page 132 Software Version 1 FUN 20 LCD Display Description This parameter shows the software version 1 The software version is also displayed on power up 132 6 PARAMETER DESCRIPTION Software Version 2 FUN 2
110. Controlled Fault Stop Enable parameter PFN25 on page 103 Digital Input parameters I O 01 08 on page 111 Theory of Operation section 7 1 Solid State Motor Overload Protection on page 138 Theory of Operation section 7 5 1 DC Injection Braking Control on page 160 DC Brake Time CEN 21 LCD Display Range Description See Also 1 180 Seconds Default 5 When the Stop Mode CFN15 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 Motor Running Overload Class parameter QST03 on page 73 Stop Mode parameter CFN15 on page 85 DC Brake Level parameter CFN20 on page 88 DC Brake Delay parameter CFN22 on page 89 Controlled Fault Stop Enable parameter PFN25 on page 103 Theory of Operation section 7 5 9 DC Injection Braking Control on page 164 DC Brake Delay CEN 22 LCD Display Range 0 1 3 0 Seconds Default 0 2 89 6 PARAMETER DESCRIPTION Description See Also When the Stop Mode 15 is set to DC brake the DC Brake Delay time is the time delay between when
111. DC Brake Function Programming Steps 1 The DC Brake function may be enabled by setting the stop mode CFN15 to DC Brake 88 See Also 6 PARAMETER DESCRIPTION 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 inertia s less than 6 x motor inertia 3 NOTE Heavy duty braking For NEMA MGI parts 12 and 20 maximum load inertia s 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 heating 3 NOTE Consult motor manufacturer for high inertia applications 36 NOTE Not to be used as an emergency stop When motor braking is required even during a power outage an electro mechanical brake must be used Stop Mode parameter CFN15 on page 85 DC Brake Time parameter CFN21 on page 89 DC Brake Delay parameter CFN22 on page 89
112. DC Injection Braking Standard Duty The MX Standard Duty Braking allows up to approximately 25096 FLA current to be applied to the motor The MX Standard Duty consists of an extra braking contactor that shorts motor terminals 2 and 3 together while braking as DC current is applied by the starter to provide moderate braking torque CAUTION Contactor MUST NOT short phase T1 and phase T3 85 NOTE Contactor sizing requires contactor rating Motor FLA 1 6 The three contacts must be paralleled 7 5 2 DC Injection Braking Heavy Duty The MX Heavy Duty Braking allows up to 400 FLA current to be applied to the motor for maximum braking 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 In combination with the applied DC current from the 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 3 NOTE Semi Conductor Fuse and 7th SCR supplied by Benshaw 7 5 3 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 112 for more information The output of a Braking relay is needed to control the contactor and or 7 SCR gating control card use
113. 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 PFN07 on page 96 Zero Sequence Ground Fault Trip Level PFNOS on page 97 Over Voltage Trip Level 10 LCD Display Range Off 1 40 Default Off Description If the MX 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 FUN05 must be set correctly 3 NOTE The voltage level is only checked when the starter is running See Also Under Voltage Level parameter PFN11 on page 99 Voltage Trip Time parameter PFN12 on page 99 Auto Reset parameter PFN23 on page 102 Controlled Fault Stop Enable parameter PFN25 on page 103 Rated Voltage parameter FUNO05 on page 126 98 6 PARAMETER DESCRIPTION Under Voltage Trip Level 11 LCD Display Range Off 1 40 Default Off Description If the MX detects a one cycle input phase voltage that is below the under 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 3 NOTE For the under voltage protection to operate correctly the Rated Voltage parameter FUN05
114. ELAY R3 45 a td he G SERIAL COMMUNICATION 1 go M RS485 5V 1 1 gt BL 3 1 i 1 1 1 1 1 1 PROGRAMMABLE OVERTEMP SWITCH i 0 RELAY R4 ON HEATSINK 1 919 3 1 1 2 PROGRAMMABLE 1 1 1 RELAY R5 1 4 1 45 1 0 4 1 1 1 PROGRAMMABLE 535 1 31 Two WIRE CONTROL RELAY R6 E 8 iri EN 4 SPA STOP mE uza L 6 4 4 1 pole i START 3 3 5 5 TONER NND SW2 SWS SW4 SW5 SW6 THREE WIRE CONTROL RESET PARAM DOWN UP ENTER R3 28 LEDS IN CONNECTOR o 58 1 Bo RX By 5 g es pS ed zS 1 i ES zs BIPC 400100 01 CARD ASSEMBLY CONSISTS OF BIPC 300055 03 TOP 1 amp BIPC 300034 02 BOTTOM DISPLAY 1 1 1 2 DISPLAY de 1 1 5 32 L1 100 600 12 3e50 60Hz e i L3 je CUSTOMER SUPPLIED 120 VAC 1 Figure 10 Power Schematic for RB3 High HP 17 18 2 13 j4 15 16 n 12 3 14 5 16 17 18 m 2 2 m 4 4 2 l J 412 J15 i FUNO3 GND FLT 7
115. 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 72 6 PARAMETER DESCRIPTION Motor Service Factor OST 02 LCD Display Range 1 00 1 99 Default 1 15 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 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 147 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 run
116. FN21 on page 89 DC Brake Delay CFN22 on page 89 Controlled Fault Stop Enable PFN25 on page 103 Digital Input Configuration I O 01 08 on page 111 Relay Output Configuration I O 10 15 on page 112 Theory of Operation section 7 4 Deceleration Control on page 157 Theory of Operation section 7 5 Braking Controls on page 159 Decel Begin Level CFN 16 LCD Display Range 1 100 of phase angle firing Default 40 Description Stop Mode 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 when a stop is commanded decrease this parameter value If there is a sudden drop in motor speed when a 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 3 NOTE It is important that the FUN06 Rated Power Factor parameter is set properly so that the
117. IC A AAD Ness BS Hee Aes 156 7 4 Deceleration Control 2 157 7 4 1 Voltage Control 229 RUE e DELE 157 7 42 Tru Torque Deceleration s siirre d p qos M does E ROO ad ORO 158 7 5 Braking Controls ss ss eR xs RR RR RUE ROS voi boh o EUR RUE 159 751 DC Injection Braking Standard ER EORR Rs 160 75 2 DC Injection Braking Heavy Duty 22222232494 99 bx ed Xd E en ve eda 160 7 0 3 Braking Output Relay nie be Bioeng e e ee e de tie e M nee 160 7 5 4 Stand Alone Overload Relay for emergency ATL Across The Line 160 7 5 5 DC Injection Brake Wiring Example i seco teque d e 161 796 DC Brake Timing 2 525 5 52 59 d oo p Da ede e ER A oe 162 7 5 7 DC Injection Brake Enable and Disable Digital Inputs 162 7 5 8 Use of Optional Hall Effect CurrentS ensor ra 163 7959 DC Injection Braking Parameters sg uua ue m VOR X WE RUP ds E 164 TABLE OF CONTENTS 7 6 Slow Speed Cyclo Converter se ra de ideo son oe mum Fuge ks vex deem eue Gre eed 164 761 Operations soe ha ee She Roe Re Ux 164 7 6 2 Slow Speed Cyclo Co
118. O PLC OUTPUT CONTACT STOP START Xs 51 uli eS 120VAC LIVE 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 176 7 THEORY OF OPERATION Simplified I O Schematics 7 14 Simplified I O Schematics Figure 58 Digital Input Simplified Schematic 15 0 5 02 CN NANA COM 15 0 Figure 59 Analog Input Simplified Schematic 100 100 C e e 505 75 Q _ 100 AIN 5 1 1 ON 0 20mA 100 KO 100 AN 2 e e xm
119. O 0 O3 OIIVLCO 0 OM d L uoro ouuo wun euruoN 21 2 TECHNICAL SPECIFICATIONS 2 3 8 Starter Control Power Requirements Table 9 RB3 Starter CPT VA Requirements Poner Recommended Power Recommended Model Number Required Min TX size Model Number Required Min TX size RB3 1 S 027A 11C RB3 1 S 240A 15C RB3 1 S 040A 11C RB3 1 S 302A 15C RB3 1 S 052A 12C RB3 1 S 361A 16C 4 4 4 i 4 RB3 1 S 156A 14C RB3 1 S 720A 19C RB3 1 S 180A 14C RB3 1 S 838A 20C 243 RB3 1 S 065A 12C RB3 1 S 414A 17C RB3 1 S 077A 13C RB3 1 S 477A 17C aa RB3 1 S 096A 13C RB3 1 S 515A 17C 243 243 243 41 41 41 41 41 243 2 3 9 Starter Control Power Requirements Table 10 RC3 Starter CPT VA Requirements Puser Recommended Powe Recommended Model Number Required ei TX size Model Number Required apud p VA VA Dwrsomenc c asf ist as s fonsas 3 s Dersane frenss fs 75 75 75 75 75 75 150 150 150 22 2 4 Dimensions 2 4 1 RB3 Chassis with Integral Bypass Figure 4 RB3 96A 830A 2 TECHNICAL SPECIFICATIONS Mechanical Drawings B D Figure 5 RB3 125 361A l So 1
120. ON EID eS Resets to 0 each time the running time hours increments at 35 999 Refer to page 202 Refer to address 30611 30619 2 registers 32 bit unsigned integer event seconds since Jan 1 1972 12am lt 3 0 lt 3 microseconds 10 counts sec APPENDIX MODBUS REGISTER Starter Control Register Bit 0 Run Stop j 0 No action Bit 1 Fault Reset Fault Reset 0 No action Bit 2 Emergency Overload Reset Emergency Overload Reset 1 1 1 Bit 3 Local Remote 0 Local 1 Remote 0 b i Heater Enabled Bit 4 Heat Disabled Heater Disabled 0 Rampl Bit 5 Ramp Select Ramp 2 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 1 027 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 OFF 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 Starter Status Register 0 I
121. 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 3 1 Connect a tachometer with appropriate DC output voltage and correct polarity to the MX power card input TB5 2 input TB5 3 input 2 The start mode CFN01 is to be selected as Tach Ramp Program Tachometer Full Speed Voltage FUN13 Program Tachometer Loss Time FUNI14 Program Tachometer Loss Action FUNI5 Set the Initial Current Level to the desired current limit Set the Maximum Current Level 4 to the desired maximum current limit MO gt See Al
122. Range Description 100 90 80 70 60 50 40 30 RTD Bias Value 96 20 See Also Off On Default Off 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 I t thermal model of the 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 I t based calculation then the RTD biasing value will be used Ifthe I t value is higher then the I t value will be used RTD Bias Curve 50 RTD BiasMax Setpoints RTD27 Bias Minimum Level Setpoint RTD28 Bias Midpoint Level Setpoint RTD29 Bias Maximum Level Setpoint RTD BiasMid Sa SS t Hot Cold Ratio 1 1 1 1 50 100 150 200 250 Maximum Temperature C RTD Biasing OL group in section 7 1 7 on page 143 123 6 PARAMETER DESCRIPTION RTD Bias Minimum Level RTD 27 LCD Display Range 0 198 Default 40 Description Typically set to ambient conditions 40 C See Also RTD Biasing OL group in section 7 1 7 on page 143 RTD Bias Midpoint Level RTD 28 LCD Display Range 1 199 C Default 130 Description Typically set at the rated motor running temperature 3 NOTE Consult motor manufacturer for information See Also RTD Biasing
123. Rd eed end a oe 36 3 6 6 Torque Requirements for Power Wiring 5 37 9 7 Current Transformers a 6465 eS Rom y EE ee oy Ee 38 34 5 CI Mounting zx ku E UR OE AURA OW B X RUBRA ERU EUR 38 94 2 CM Polarity 25 38 3 7 3 Zero Sequence Ground Fault Current 2 39 3 8 Control Layout is cca oe ot ERR OE ERR GRE EGRE 41 3 9 I O Card Layout e este ca Beene m o RE ro RON SD GS eds a E y v CX p es 42 3 10 Terminal Block Layout 35 4524 e005 Pom eee Y yee eG ORO Rh 43 S H Control Wiring ps pue duces 44 SAT T Control POWE ya pata Sd be Sd eque be det 44 3112 Output Relaysi o bx Eug owed P vede Pu ped ue pase due Pee eee 44 3 11 3 Digital Input se s eaea a Bh UR AC UR m Rx ROSA Um 45 Analog e son e soe ed we eu UR a ale en 46 3 11 5 Analog eue ERU ded BR Cue Eqs dd 46 93 6 5WILDIP 2 aye tice he i bog bp 47 9317 Motor PIG 04368 Ses ahead EN 4 oS ers dee PR CAE red RC ed 47 3 11 8 RTD Module Connector ue eas qon e Rege OR eque gh le KORR Be 47 3 12 Remote LCD Keypad Displays D
124. Span parameter 019 on page 115 Starter Type parameter FUNO07 on page 128 Theory of Operation section 7 11 Phase Control on page 173 Theory of Operation section 7 12 Current Follower on page 175 Analog Output Function I O 21 LCD Display LCD Description Range Off Off Disabled Default 0 200 Curr Based on per cycle RMS values 0 800 Curr Based on per cycle RMS values 0 150 Volt Based on per cycle RMS values 0 150 OL Motor Thermal Overload 0 10 kW 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 Ain 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 O22 on page 116 Analog Output Offset parameter 1 023 on page 118 Theory of Operation section 7 11 Phase Control on page 173 Theory of Operation section 7 12 Current Follower on page 175 116 6 PARAMETER DESCRIPTION Analog Output Span I O 22 LCD Display Range 1 125 Default 100 Description The analog output signal c
125. T3 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 Verify that the load is actually steady Load is notsteady 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 FUNOS set incorrectly CT ratio parameter FUNO3 set Verify that the CT ratio parameter is set incorrectly 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 CT ratio parameter is set incorrectly correctly Verify correct CT wiring and verify that not reading correctly CTs installed ired i the CTs are
126. TO7 CFN04 on page 79 Kick Level 1 CFN11 on page 84 Kick Time CFN12 on page 84 Theory of Operation section 7 3 1 Current Ramp Settings Ramps and Times on page 148 Initial Current 1 03 LCD Display Range Description See Also 50 600 of FLA Default 100 The Initial Current 1 parameter is set as a percentage of the Motor FLA QSTO1 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 by 2096 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 parameter setting Start Mode CFNO01 on page 78 Ramp Time 1 8 CFNO02 on page 78 Maximum Current 1 QSTO7 4 on page 79 Kick Level 1 CFN11 on page 8
127. 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 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 47 Stack Overload Alarm This occurs when the stack thermal r
128. X MODBUS REGISTER Absolute Register Address 30136 40136 Slow Speed Quee d eU da o 30137 40137 Slow Speed Current Level 10 400 FLA Disabled 30138 40138 Slow Speed Time Limit Enable Enabled NEN 30139 40139 Slow Speed Time Limit 1 900 0 Disabled 30140 40140 Slow Speed Kick Enable 1 Enabled mE 30141 40141 Slow Speed Kick Level 100 800 FLA 30142 40142 Slow Speed Kick Time 1 100 100 mSec 213 APPENDIX MODBUS REGISTER Absolute Register Address 00 SON 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 1 Enabled 30149 40149 Overcurrent Delay Time 1 900 100 mSec 0 Disabled 30150 40150 Undercurrent Trip Enable 1 Enabled 30151 40151 Undercurrent Trip Level 5 100 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 214 APPENDIX MODBUS REGISTER Absolute Register Address 0 Disabled Residual Ground Fault Trip Enable 1 Enabled EE 30157 40157 Residual Ground Fault Trip Level 5 100 FLA 0 Disabled
129. X 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 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 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 146 7 THEORY OF OPERATION Motor Service Factor 7 2 General Motor Service Factor The Motor Service Factor QST02 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 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
130. X C FAULT CODES cede Rave B e x X RR ee RUE 205 APPENDIX D SPARE PARTS 2 xemhe Pe Ree dU RC UR 207 APPENDIX E EU DECLARATION OFCONFORMITY 208 APPENDIX F MODBUS REGISTER 209 APPENDIX PARAMETER TABLES 222 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 are 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 low 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 befo
131. actual deceleration torque levels are the levels desired 86 See Also 6 PARAMETER DESCRIPTION Stop Mode parameter CFN15 on page 85 Decel End Level parameter CFN17 on page 87 Decel Time parameter CFN18 on page 87 Controlled Fault Stop Enable parameter PFN25 on page 103 Rated Power Factor parameter FUN06 on page 127 Theory of Operation section 7 4 Deceleration Control on page 157 Decel End Level 17 LCD Display Range Description See Also 1 99 of phase angle firing Default 20 Stop Mode CFNI5 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 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 No 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 CFNI5 set to TruTorque Deceleration The decel end level parameter sets the
132. ake 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 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 If the 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 Slow Speed Cyclo Converter The MX Soft Starter implements a patented Slow Speed algorithm that can be used to rotate a three phase AC motor with control of
133. ame as the Phase Order FUN04 parameter a phase order fault will occur 197 8 TROUBLESHOOTING amp MAINTENANCE Step 4 SCR Replacement 8 7 SCR Replacement This section is to help with SCR replacements on stack assemblies Please read prior to installation 8 7 1 Typical Stack Assembly APPLY TWO 2 1 LONG BEADS OF SILICONE TO SECURE O T WIRES BETWEEN HEATSINK FINS 8 7 2 SCR Removal To remove the SCR from the heatsink loosen the two bolts 3 on the loader bar side of the clamp Do not turn on the nuts 5 The nuts have a locking ridge that sink into the aluminum heatsink Do turns until the SCR comes loose Remove the SCRs from the heatsink 3 NOTE Do not loosen nut on indicator washer 6 This will change the clamping pressure of the clamp and the clamp will be defective 8 7 3 SCR Installation Coat the faces of the SCRs to be installed with a thin layer of Electrical Joint Compound Place the SCRs onto the dowel pins The top SCR will have the cathode to the left and the bottom SCR will have the cathode to the right The SCR symbol has a triangle that points to the cathode Finger tighten nuts on the bolts 198 8 TROUBLESHOOTING amp MAINTENANCE 8 7 4 SCR Clamp Below is an exploded view of a typical SCR clamp Refer to the Clamp Parts List on page 199 for names of the parts being used SCR CLAMP PARTS 5 2 Serrated nut larger style clamp has 1 suppo
134. ameters I O 10 15 on page 112 Current Imbalance Trip Level PEN 05 LCD Display Range 94 Off 5 40 Default 15 Description See Also 6 PARAMETER DESCRIPTION The Current Imbalance Trip 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 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 Jave 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 lave Imax imbalance x 100 lave Ifthe highest calculated current imbalance is greater than the current imbalance level for the Current Imbalance Delay Trip Time PFN06 the starter shuts down the motor and declares a Fault 37 Current Imbalance Alarm Fault Condition Trip Imbalance i 1 I 1 Current Imbl Lvl PFN 05 77777 Ti
135. an 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 10096 output 36 NOTE For 4 20mA output set the Analog Output Span to 80 and the Analog Output Offset to 20 36 NOTE The output does not exceed 100 10V or 20mA Example 0 output gt 4mA 100 output gt 20ma Analog Output 10 ____________________ 20mA Aout Span 8096 7 Aout Offset 0V OmA 72078 Selected Output Selected Output value 0 value 100 See Also Analog Output Offset parameter 1 023 on page 118 117 6 PARAMETER DESCRIPTION Analog Output Offset I O 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 10096 output the span should be reduced to 100 minus offset so that a 10096 output request causes a 10096 output voltage 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 I O22 on page 117 Inline Configuration I O 24 LCD Display Range Off 0 10 0 seconds Default 3 0
136. and 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 Besure 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 Riskof 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 installation is in place Apply only the voltage that i
137. ard 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 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 1 parts 12 and 20 It is recommended a thermistor or RTD be installed to protect the motor from overheating Speed RPM Inertia Ib ft2 a s 2 35 59 __ us o m m 3 x m 9 ox s 75 me 3 9 x x4 359 99 9 3w un x ee um ow o 3m 7 e 35 1506 4 1 1 a 35 me 9 3 me 39 4 34s zw e w 3 o rd o 3e 39 1 159 7 THEORY OF OPERATION 7 5 1
138. 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 5 130 6 PARAMETER DESCRIPTION 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 LCD Description Range Fault The starter will shutdown and indicate a tachometer loss fault Current Acceleration If the tachometer signal is lost the starter will fault However the start mode parameter will be set to Current control acceleration so
139. ate 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 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 PFN15 on page 100 Frequency Trip Time PFN16 on page 101 Under Frequency Trip Level 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 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 unnecessar
140. ation on page 164 6 PARAMETER DESCRIPTION Slow Speed Time Limit 25 LCD Display Range Description See Also Off 1 900 Seconds Default 10 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 if kick is enabled 3 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 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 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 Motor Running Overload Class parameter QST03 on page 73 Slow Speed Current Level parameter CFN24 on page 90 Motor Trip Time 27 on page 104 Theory of Operation section 7 6 Slow Speed Operation on page 164 Slow Speed Kick Level 26
141. aver Mode Heating Slow Speed Slow Speed Forward Slow Speed Reverse DC Braking Cooling Fan PORT Tach Loss 215 APPENDIX MODBUS REGISTER 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 30178 40178 Analog Input Trip Delay Time 1 900 100 mSec 0 0 0 0 0 30179 40179 Analog Input Span 1 100 Jo 30180 40180 Analog Input Offset 0 99 gt gt f Ps ____ Off no output 0 200 Current 0 800 Current 0 150 Voltage 0 150 Overload O 10kW 30181 40181 Analog Output Function 0 100kW 0 1MW 0O 10MW 1 100 Analog Input 0 100 Firing 11 Calibration full output A _____ SO 30182 40182 Analog Output Span 1 125 30183 40183 Analog Output Offset SA 0 Disabled 30184 40184 Inline Enable 1 Enabled 30185 40185 Inline Delay Time 10 100 100 mSec 30186 40186 Bypass Feedback Time 100 mSec POA AUR DUO Em 30187 40187 Keypad Stop dico 30188 40188 Modbus Timeout Enable me p 1 Enabled 30189 40189 Modbus Timeout 1 120 Disabled Start after power applied 30191 40191 Auto Start Start after fault reset Starter after power applied and after fault reset Disabled 30192 40192 Energy Saver Enable 1 Enabled 1 30194 40194 Heater Anti Windmill Level FLA Normal
142. cal closed transition Wye Delta starting current profile is shown in Figure 52 Figure 52 Wye Delta Profile Wye Delta Closed Transition Current Profile 600 500 E Full 400 Load Motor N Current 300 N 20096 1008 70 Xj 0 speed Transition from Wye to Delta mode A digital input can be programmed as a 2M contactor feedback input This input provides verification that the 2M contactor has fully closed preventing operation when the transition resistors are still connected in the motor circuit The use of this feedback is recommended to prevent the overheating of the transition resistors if the 2M contactor does not close properly The 2M confirmation trip time can be adjusted by modifying the Bypass Feedback Time parameter 38 NOTE When in Wye Delta mode the acceleration ramp kick and deceleration settings have no effect on motor operation 3 NOTE When in Wye Delta mode the SCR gate outputs are disabled 170 7 THEORY OF OPERATION Across The Line Starter 7 9 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 an output relay that is programmed to RUN Therefore when a start command is given the RUN programmed re
143. capability of the starter 30 Wiring Considerations 3 4 3 4 1 3 4 2 3 4 3 3 44 3 4 5 3 INSTALLATION Wiring Considerations 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 degrees angle Different wire groups should be run in separate conduits Witha 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 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 200VAC 600VAC respectively Select po
144. ccelerate 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 05709 on page 77 Start Mode CFN01 on page 78 Initial Current 1 QST06 CFN03 on page 79 Maximum Current 1 QSTO7 CFN04 on page 79 Kick Level 1 CFN11 on page 84 Kick Time 1 12 on page 84 Theory of Operation section 7 3 1 Current Ramp Settings Ramps and Times on page 148 76 6 PARAMETER DESCRIPTION Up To Speed Time OST 09 LCD Display Range Description See Also 1 300 seconds Default 20 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 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
145. ching the direction of the reversing contactor The reversing contactor must never be switched while the soft starter is operating 29 3 INSTALLATION Mounting Considerations 3 3 3 3 1 Mounting Considerations Bypassed Starters Provisions should be made to ensure that the average temperature inside the enclosure never rises above 50 C If the temperature inside the enclosure is too high the starter can be damaged or the operational life can be reduced Non Bypassed Starters Provisions should be made to ensure that the temperature inside the enclosure never rises above 50 C Ifthe temperature inside the enclosure is too high the starter can be damaged or the operational life can be reduced As a general rule of thumb the following ventilation guidelines can be followed Table 13 Ventilation Requirements 401 to 600 amps 2 x 4 fan 230 cfm 2 x 6 grills 28 sq in 601 to 700 amps 2 x 6 fan 470 cfm 2 x 6 grills 28 sq in gt 700 amps Consult factory Consult Factory The starter produces 4 watts of heat per amp of current and 26 square inches of enclosure surface is required per watt of heat generation Contact Benshaw and ask for the enclosure sizing technical note for more information concerning starters in sealed enclosures Benshaw supplies starters under 124 amps non bypassed with the heat sink protruding from the back of the enclosure This allows a small enclosure size while still maintaining the cooling
146. ck input supply for open fuses or open connections On medium voltage systems verify wiring of the voltage feedback measurement circuit On medium voltage systems verify wiring of the voltage feedback measurement circuit Low voltage below the Under voltage Trip Level parameter setting was detected for longer than the Over Under Voltage Trip delay time PFN12 Verify that the actual input voltage level is correct Low Line L1 L2 Three phase power has been detected when the starter is expecting single phase power 14 189 8 TROUBLESHOOTING amp MAINTENANCE Verify that the Rated Voltage parameter FUNOS is set correctly Fault Code Detailed Description of Fault Possible Solutions Check input supply for open fuses or open connections Low voltage below the Under voltage Trip Level parameter setting PFN11 was detected for longer than the Over Under Voltage Trip delay time PFN12 Verify that the actual input voltage level is correct Low Line L3 L1 On medium voltage systems verify wiring of the voltage feedback measurement circuit Verify that the actual input voltage level is correct Verify that the Rated Voltage parameter FUNOS is set correctly High voltage above the Over voltage Trip Level parameter setting PFN10 was detected for longer than the Over Under Voltage Trip delay time PFN12 High Line L1 L2 Line power quality problems excessive line distortions Verify that the actual input voltage
147. ck motor wiring for short circuits or ground faults 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 QSTO01 and CT ratio FUNO3 settings are correct Verify that the SCR gate wires are properly connected to the MX control card 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 F27 Phase Loss Check motor wiring for open or intermittent connections On medium voltage systems verify wiring of the voltage feedback measurement circuit 190 8 TROUBLESHOOTING amp MAINTENANCE Motor current exceeded the Over Current Trip Level setting PFNO1 for longer Over current than the Over Current Trip Delay Time setting PFN02 Check motor for a jammed or an overload condition Motor current dropped under the Under Current Trip Level setting for Undercurrent longer than the Under Current Trip Delay time setting PFN04 The motor power factor went above the PF leading trip level Power Factor Leading Verify loading of motor On synchronous motors verify field supply current Power Factor Lagging Verify loading of motor A current imbalance larger than the Current Imbalance Trip L
148. 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 2 input 3 input 4 common 7 shield Figure 22 Analog Input Wiring Examples 4 9 TBS za 5K 10Kohm g Q AO A 4 20 SOURCE e Lig 9 RRN B 3 POTENTIOMETER 4 20mA See Also Analog Input I O 16 20 on page 113 Starter Type parameter FUNO07 on page 128 Theory of Operation section 7 11 Phase Control on page 173 Theory of Operation section 7 12 Current Follower on page 175 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 on it is a Voltage loop output The control is shipped with the Switch on 3 NOTE The analog output is a low voltage output maximum of 15VDC The output will be damaged if control power 115VAC or line power is applied to the analog output The terminals are as follows 5 analog output 6 common
149. d 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 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 3 NOTE Consult motor manufacturer data to determine the correct motor OL settings See Also Independent Starting Running Overload parameter PFN28 on page 105 Motor Running Overload Class parameter PFN30 on page 106 Motor Overload Hot Cold Ratio parameter PFN31 on page 107 Motor Overload Cooling Time parameter PFN32 on page 108 Relay Output Configuration parameters I O 10 15 on page 112 Theory of Operation section 7 1 Solid State Motor Overload Protection on page 138 Motor Running Overload Class 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 If separate starting versus running overload classes are desired set the parameter to On 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 100 with 0 representing a
150. d during braking th 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 7 5 4 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 160 7 5 5 DC Injection Brake Wiring Example 4 100 600 3050 60Hz 7 4 CUSTOMER SUPPLIED 120 VAC Figure 47 DC Injection Brake Wiring Example Il LU m m crouno 1 1 1 1 ji deeem NEUTRAL 1 NEUTRAL 1 120 VAC POWER INPUT DIGITAL INPUTS NO 01 1 0 08 m2 3 4 1 MX3 CARD 1 1 1 6 1 Pwr cu Rx TX BIPC 400100 01 MX3 CARD ASSEMBLY CONSISTS OF BIPC 300055 03 TOP amp BIPC 300034 02 BOTTOM BIPC 300034 02 I MX3 CARD 2 1 9 I i ge E i ze 8i zo Re 5 o o E z ED J BARA Bum RESET PARAM DOWN UP ENTER LEOS IN CONNECTOR ne cb cay cs En uq 7 THEORY OPERATION AN Power aint 2 3 4 aout 3 5 5 10 7 7 2 SERIAL COMMUNICATION RS485
151. d 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 178 7 THEORY OF OPERATION 7 15 7 Wiring Figure 62 shows the wiring of TB4 to a Modbus 485 Network If the starter is the end device in the network a 120O 1 4W terminating resistor may be required Please refer to Figure 61 for wire and termination practices Figure 62 TB4 Connector a CH L AL B O A COM CJ Figure 61 Modbus Network Wiring Example MX 1 MX 2 MODBUS SLAVE MODBUS SLAVE
152. d 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 drawings are produced in AutoCADO format The drawings are available on standard CD DVD or via e mail by contacting Benshaw RediStart MX 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 01 01 This manual pertains to the card hardware assembly version number BIPC 400100 01 03 See page 229 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 INTRODUCTION Contacting Benshaw Contacting Benshaw
153. decel time expires decrease the decel time parameter If the motor is still rotating when the decel time expires increase the decel time 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 See Also Stop Mode parameter 15 on page 85 Decel Begin Level parameter CFN16 on page 86 Decel End Level parameter CFN17 on page 87 Controlled Fault Stop parameter PFN25 on page 103 Theory of Operation section 7 4 Deceleration Control on page 157 Decel Ramp Profile 19 LCD Display Range Linear Default Squared S Curve Description See Accel Prof CFN10 for details on page 83 See Also Stop Mode CFN15 on page 85 DC Brake Level 20 LCD Display Range 10 100 of available brake torque Default 25 Description When the Stop Mode 15 is set to DC brake the DC Brake Level 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 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 inertia s It is required that a PTC Thermistor or RTD MUST be installed to protect the motor
154. deno pom Ie Ro 188 5 5 SCR Testing aux s REO ROS X OX eg Roc LEA aa SRR ES or Eos RO X CRX 195 8 5 1 Resistance x c Ro Be UR RUNG EUR Rose us 195 8 552 Voltage Loue db queque rq dee Aa ed ke eS fa eG e e quee ks 195 8 5 9 Integral Bypass RBS ace i wb RO nce WU SH d SR Ree pe bBo eS 195 8 6 Built In Self Test Functions s s REOR RR RR E 195 8 6 1 Standard BIST Tests oeg ocu d Re Per eee ea ede ESS oes 195 8 6 2 Powered BIST Tests Boe eek OER Re RERS 197 87 SCRReplacem nt os cr ok Rb x Y Ep 198 87 1 TypicalStack Assembly kg RR RR n RR Et EU UA RE S RUE 198 8 72 SCR Removal 32 9 he tela yw rei ae eet ue oko Ue we ee Rr 198 SCR Installation asus ies queo 6 pw iE qu adag dq E ques x d 198 Clap os 645 848 G4 NAAR 199 Clamp sy dem pr rede Frayed as Ba RiGee Sw Heal aaah ef 199 8 7 6 Testing SCR pee nk ROM ORO Om EOP Ee CR ded e 199 TABLE OF CONTENTS APPENDIX A EVENT CODES 4 eee IG Ux coe Rx XE EG RR 202 APPENDIXB ALARM CODES 203 APPENDI
155. djustable exponential motor cooling CAUTION Ifthe MX 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 chapter 6 of this manual for additional parameter information 1l Motor FLA QSTOI Motor Service Factor 05702 Motor Running Overload Class PFN30 Motor Starting Overload Class PFN29 Independent Starting Running Overload PFN28 Motor Overload Hot Cold Ratio PFN31 Motor Overload Cooling Time PFN32 Un dee 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 is 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 mot
156. ds 7 1 6 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 content 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 OL H C Ratio 1 Max Hot Locked Rotor Time x 10094 Max Cold Locked Rotor Time If no 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 Obs Raton 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 harmonics and or RTD Biasing Ifthe existing motor overload content is less than the calculated running OL content the
157. e 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 3 13 3 Power Connections The 24VDC power source is connected to the following terminals 24VDC Negative connection to 24VDC power supply e 24VDC Positive connection to 24VDC power supply Chassis ground connection 50 3 13 4 3 13 5 3 INSTALLATION 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 pin4 B RS 485 positive communications connection pin 8 Com RS 485 common connection RTD Connections Each Remote RTD Module has connections for up to 8 RTDs The terminals for the RTD wires are as follows R 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 30 Remote RTD Module Wiring RTD RTD2 RTD3 RTD4 D D i GO Q8 GHD 0009 PINS BLU WHT EN MODULES CARIE REMOTE RTO MODULE PINB BRN ON STARTER EN S Or
158. e Derate Factor The rise or fall time for the overload to reach this steady state is defined by the Motor Overload Cooling Time PFN32 parameter The default value of 60 for Motor Overload Hot Cold Ratio parameter is typical for most motors A 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 100 36 NOTE Consult motor manufacturer data to determine the correct motor overload settings See Also Independent Starting Running Overload parameter PFN28 on page 105 Motor Running Overload Class parameter PFN30 on page 106 Motor Starting Overload Class parameter PFN29 on page 106 Motor Overload Cooling Time parameter PFN32 on page 108 Relay Output Configuration parameters I O 10 15 on page 112 Theory of Operation section 7 1 6 Hot Cold Motor Overload Compensation on page 141 107 6 PARAMETER DESCRIPTION Motor Overload Cooling Time 32 LCD Display Range 1 0 999 9 minutes Default 30 0 Description The Motor Overload Cooling Time parameter is the time to cool from 100 to less than lt 1 When the motor is stopped the overload content reduces exponentially based on Motor Overload Cooling Time parameter Refer to the following equation 5 OL Content OL Content when Stopped So motor with a
159. e Hom Grup a ie Peiper SU IE Mink roo Bc a ee Lieu SERA Beside ar 65 52 3 Protection GrOUD s E om UE OAK UN BUR NOR UR EURO 66 Group s a Kanes chaos puma sx aaa es GP PS NEA Ee CoS E PS 67 Dub RID GOUD e a edo e as NU RA AED e dU GP ake ah aed Genie iie dog Ge 68 5 2 6 B ticttOr Groupa si ra ga uod d d ese qe iue Budd s 69 52 7 Fault Log Group ELT FL9 ecc teg e ho eem hex ope Rm ee qun Ger ed det aeos 70 5 2 8 Event Loe Group EOL E99 s a s s shoe ee REOR Re m Rem e BR a TR ow n 70 6 PARAMETER DESCRIPTION 72 6 1 Parameter Descriptions 0 2 72 7 THEORY OFOPERATION 45949599939 eese 198 7 1 Solid State Motor Overload 138 Zale OVeEVIeW 55 cs i tee D ate te esse Ed v on RU ne ti Bea hee eigen arat E atra 138 74 2 Setting Up The MX Motor 4 138 7 1 3 Motor Overload Operation ps y ep bao deer Shoe Soe TER XS dede d 140 7 1 4 Current Imbalance Negative Sequence Current 140 7 1 5 Harmonie Compensation 2 3 4 4 4 Aue eu Cur ede ded e RO AE M gebe xe 14 7 1 6 Hot Cold Motor Overload Compensation
160. e Screen Section B Display Desripion Starter is stopped and no Faults UTS Wye UTS StarterisUpToSpeed _______ Starter is decelerating the load Wye ______ InWyedelta control indicates motor is accelerating in Wye mode DC Injection Braking Table 22 Operate Screen Section S p Keypad Control Terminal Block Wiring Control Serial Communication Connection Control 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 CFN 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 57 4 KEYPAD OPERATION 444 Meter Pages Although any meter may be 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 58 4 KEYPAD OPERATION 4 4 5 Fault Log Screen Information regarding each fault is available through the remote MX LCD
161. e 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 14 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 wiring schematic for grounding provision location Wiring Refer to Wiring Practices on page 31 Filtering To comply with Conducted Emission Limits CE requirement a high voltage 1000V or greater 0 1 uF capacitor should be connected from each inpu
162. e 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 motor torque 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 This parameter 9 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 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 torq
163. ed This timer does not prevent the 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 reduce the Slow Speed Kick Level and or reduce the Slow Speed Kick Time 165 7 THEORY OF OPER
164. ee bbe eee SS TE E RE 48 3121 Remote Display ade dle e ly e Die a Re 48 912 2 Installing Displays ic ag Ss atten ek 48 9 12 9 Display Cutouts 3 35912 26358 642 By a Bead RP ad Gp edad aa P NEUE 49 3 13 RTD Module Installation 0 22 24 eo on RR a 50 aloe LOCION gt 50 3 13 2 Modbus Address ose Boe ee a xr mene we RO RD bee ae 50 3 13 3 Power Connections so xu ea a OUR ea EU E RR 50 9 13 4 RS 485 COMMUNICA ton a oP gt eal ela pae tee i Ga de 51 93 5 RTD CODFIECHORS a4 tos ird 51 9 13 6 RID Temperature vs Resistance deum Xo 9 VOR LAUR OS dusk BAS a a 52 4 KEYPAD OPERATION 54 4 T Introductions REE REE RYO OR e SESS HUGS 54 4 2 Description of the LEDs on the Keypad 54 4 3 Description of the Keys on the Remote LCD 55 44 Alphanumeric Display oed e ex b ded e E RE decem Rode RR ER E E 56 ZA T PowerUp s 9 dues a ONCE dosis SR E SU E Sas GET NDA 56 AAD Operate Screens E E ae
165. eed Sw NO signal to indicate the zero speed condition to a digital input I O 01 I O 08 Fault Code 04 Speed Switch Timer will be displayed when a stalled motor condition is detected See Also Digital Inputs 01 08 on page 111 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 36 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 38 NOTE Open terminals will give a F05 fault immediately if this parameter is not set to Off The input is designed for DIN44081 and DIN44082 standard thermistors 104 6 PARAMETER DESCRIPTION Independent Starting Running Overload 28 LCD Display Range Description See Also Off On Default Off If Off When this parameter is Off the overload defined by the Motor Running Overload Class parameter QST03 is active 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 PFN29 is used during motor acceleration and acceleration kick The
166. el is NOT affected by the Analog Input Offset or Analog Input Span parameter settings Therefore if the trip level is set to 10 and the Analog Input Trip Type parameter is set to Low a fault occurs when the analog input signal level is less than or 2mA regardless of what the Analog Input and Analog Input Span parameters values are set to See Also Analog Input Trip Type parameter 1 016 on page 113 Analog Input Span parameter 019 on page 115 Analog Input Offset parameter 1 020 on page 116 Analog Input Trip Delay Time I O 18 LCD Display Range 0 1 90 0 seconds Default 0 1 Description The Analog Input Trip Delay Time parameter sets the length of time the analog input trip level must be exceeded before a trip occurs See Also Analog Input Trip Type parameter I O16 on page 113 Analog Input Trip Level parameter I O17 on page 114 Analog Input Span parameter I O19 on page 115 Analog Input Offset parameter 1 020 on page 116 114 6 PARAMETER DESCRIPTION Analog Input Span I O 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 0 input reading with a 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
167. ere can be significant negative sequence currents present in the motor when a current imbalance is present These negative sequence currents have a 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 in section 7 1 6 The MX derating factor is based on NEMA MG 1 14 35 specifications and is shown in Figure 35 Figure 35 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 96 140 7 THEORY OF OPERATION 7 1 5 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 loa
168. eter FUNO1 FUN02 on page 125 Motor Rated Power Factor FUN 06 LCD Display Range Description See Also 0 01 lag 1 00 unity Default 0 92 The Motor Rated Power Factor parameter sets the motor power factor value that is used by the MX 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 can be entered into the Rated Power Factor parameter Meter parameters FUNO1 FUN02 on page 125 Theory of Operation section 7 3 3 TruTorque Acceleration Control Settings and Times on page 149 Theory of Operation section 7 3 4 Power Control Acceleration Settings and Times on page 151 127 6 PARAMETER DESCRIPTION Starter Type FUN 07 LCD Display LCD Description Range Normal Normal Reduced Voltage Soft Starter RVSS Default Inside Del
169. evel parameter setting PFN05 was present for longer than the curr imbal trip time Fault Code Detailed Description of Fault Possible Solutions Check motor wiring for cause of imbalance Verify dual voltage and 6 lead Current Imbalance 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 PFN07 8 has been detected for longer than the delay time PFN09 setting F38 Check motor wiring for ground faults Check motor for ground faults Ground Fault Megger motor and cabling disconnect from starter before testing Verify that the motor FLA QSTO01 and CT ratio FUNO3 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 10 of FLA while the starter was running Check system for cause of under current condition The motor power factor went below the PF lagging trip level On synchronous motors verify field supply current Verify Motor Connections Verify the CT wiring to the MX control card No Current at Run Check if load is still con
170. eventative 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 This includes factory wired equipment Inspect the cooling fans 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 Inspect the cooling fans every three months to ensure proper operation Cleanor replace any air vent filters on the starter every three months 9 NOTE If mechanical vibrations are present at the installation site inspect the electrical connections more frequently 182 8 TROUBLESHOOTING amp MAINTENANCE General Troubleshooting Charts 8 3 General Troubleshooting Charts The following troubleshooting charts can be used to help solve many of the more common problems that may occur 8 3 1 Motor does no
171. fault Coast to Stop Volt Decel Open Loop Voltage Deceleration TT Decel TruTorque Deceleration DC Brake D C Braking 85 6 PARAMETER DESCRIPTION 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 Decel End Level and Decel Time TruTorque Decel In this mode the starter linearly reduces the motor torque based on the Decel End Level and Decel Time DC Brake In this mode the starter provides D C injection for frictionless braking of a three phase motor 3 NOTE The MX stops the motor when any fault occurs Depending on the application it may be desirable for the motor to be 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 parameter CFN16 on page 86 Decel End Level parameter CFN17 on page 87 Decel Time parameter CFN18 on page 87 Deceleration Ramp Profile CFN19 on page 88 DC Brake Level CFN20 on page 88 DC Brake Time C
172. gest 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 DANGER HAZARD OF ELECTRIC SHOCK EXPLOSION OR ARC FLASH Only qualified personnel familiar with low 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 37 3 INSTALLATION Table 17 Tightening Torque for Inside Hex Screws 043 E 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 Current Transformers 3 7 371 3 72 38 Current Transformers CT Mounting For star
173. h dd mm yy 24h Time Present FUN 25 Date Date Emm mee mew Fault Group Fault Starter Enn Fault D ipti k Event Group N 228 Publication History 12 15 06 Initial Release ADVANCED CONTROLS amp DRIVES BENSHAW 615 Alpha Drive Pittsburgh PA 15238 Phone 412 968 0100 Fax 412 968 5415 BENSHAW Canada 550 Bright Street Listowel Ontario NAW 3W3 Phone 519 291 5112 Fax 519 291 2595
174. h mode Tach Loss Energized when the starter has faulted on a Tachometer Loss of Signal Fault 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 112 See Also 6 PARAMETER DESCRIPTION Up To Speed Time parameter QST09 on page 78 Over Current Level parameter PFNO1 on page 92 Under Current Level parameter on page 93 Residual Ground Fault Level parameter PFNO07 on page 96 Inline Configuration parameter 1 024 on page 118 Heater Level parameter FUNO08 on page 128 Energy Saver parameter 0 09 on page 129 Theory of Operation section 7 1 Motor Overload Operation on page 138 Theory of Operation section 7 8 Wye Delta Operation on page 168 Theory of Operation section 7 9 Across The Line Full Voltage Starter on page 171 Appendix C Fault Codes on page 205 Analog Input Trip Type I O 16 LCD Display Range Description See Also 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 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 comparator based on the analog
175. hat the motor temperature be monitored when slow speed is used for long periods of time Slow Speed Current Level parameter CFN24 on page 90 Slow Speed Time Limit parameter CFN25 on page 94 Motor PTC Trip Time PFN27 on page 104 Digital Input Configuration parameters I O 01 08 on page 111 Relay Output Configuration parameter I O 10 15 on page 112 Theory of Operation section 7 6 Slow Speed Operation on page 164 Preset Slow Speed Current Level 24 LCD Display Range Description See Also 90 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 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 Motor Running Overload Class parameter QST03 on page 73 Slow Speed Time Limit parameter CFN25 on page 94 Motor PTC Trip Time PFN27 on page 104 Theory of Operation section 7 6 Slow Speed Oper
176. hes 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 A06 Stator RTD Alarm This occurs when a RTD assigned to the Stator group reaches its alarm level 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 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 start 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 frequency 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 MX is st
177. ial torque level is the value desired Start Mode 1 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 3 NOTE It is important that the FUN06 Rated Power Factor parameter is set properly so that the actual initial power level is the value desired Start Mode CFNO01 on page 78 Ramp Time 1 CFN02 on page 78 Initial Current 1 CFN03 QST06 on page 79 Maximum Torque Power CFN09 on page 81 Rated Power Factor FUNO6 on page 127 Theory of Operation section 7 3 Acceleration Control on page 148 Maximum Torque Power CEN 09 LCD Display Range 10 325 of Torque Power Default 10594 81 6 PARAMETER DESCRIPTION Description See Also 82 Start Mode CFNO1 set to Open Loop Voltage Acceleration Not used when the Start Mode 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 CFNO1 set to Current Control Acceleration Not used when the Start Mode
178. id 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 N 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 insulating pad and make it a habit to use only one h
179. ile 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 6 1 on page 195 The powered BIST command will put the starter into a powered BIST test See section 8 6 2 on page 197 133 6 PARAMETER DESCRIPTION Time and Date Format FUN 23 LCD Display LCD Range mm dd yy 12h mm dd yy 24h yy mm dd 12h yy mm dd 24h dd mm yy 12h dd mm yy 24h 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 Date FUN 25 LCD Display Description Sets the present date See Also Time and Date parameter FUN 23 134 6 PARAMETER DESCRIPTION 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 i
180. ilt In Self Test Functions The MX has two built in self test BIST modes The first test is the standard self test and is used to test many of the basic functions of the starter without line voltage being applied The second test is a line powered test that is used to verify the current transformer s locations and connections and to test for shorted SCRs power poles open or non firing SCRs power poles and ground fault conditions 8 6 1 Standard BIST Tests FUN 22 Std BIST The standard BIST tests are designed to be run with no line voltage applied to the starter In selected low voltage systems where 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 FUN22 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 MX control card and contactors so that self testing can occur safely In low voltage applications 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 CAUTION In low voltage systems with an inline isolation contactor Before the inline test is performed verify that no line voltage is applied to the line side of the inline contactor
181. ily large fluctuations in the speed of the motor The frequency must be below the under frequency setting for the Frequency Trip Time PFN16 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 PFN14 on page 100 Frequency Trip Time PFN16 on page 101 100 6 PARAMETER DESCRIPTION Frequency Trip Time PFN 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 PFN14 or below the Under Frequency Trip Level PFN15 parameter before a high or low frequency fault will occur See Also Over Frequency Level PEN14 on page 100 Under Frequency Level PFN15 on page 100 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 19 Fault 35 will occur See Also Power Factor Lag Trip Level PFN18 on page 101 Power Factor Trip Time 19 on page 101 PF Lag Trip Level PFN 18 LCD Display Range Off 0 01 lag to 0 80 lead Default Off Description The amount of power factor lag before the specified PF Trip Time PFN19 Fault 36 will occur See Also Power Factor Lead Trip Level PFN17 on page 101 Power
182. in the circuit for a short period of time To protect the resistors from over heating one input should be programmed as a Bypass 2M contact feedback input and the Bypass 2M confirm parameter must be set For the Wye Delta starter mode to operate properly one output relay needs to be programmed to the RUN output function and another output relay needs to be programmed to the UTS output function Refer to the Relay Output Configuration parameters on page 112 for more information Based on the typical closed transition schematic shown in Figure 51 when a start command is given the starter enters the Wye starting mode by energizing the relay programmed as RUN The transition to Wye Starting mode occurs as follows 1 Start command is given to the starter 2 The RUN relay is energized which energizes the 1S contactor 3 When the 1S contactor pulls in the 1M contactor is energized The MX starter remains in the Wye mode until either 1 The start command is removed 2 The Up To Speed Time expires 3 The measured motor current is less than 85 of FLA and more than 25 of the Up To Speed Timer setting has elapsed 4 A fault occurs When the Up To Speed Time expires the starter changes from Wye starting mode to the Delta or normal running mode by energizing the relay programmed as UTS In Delta mode the RUN and UTS relays are both energized and the motor is connected in the normal running Delta configuration The transition to Delta R
183. ing is correct Verify that disconnect is not faulty The MX electronic power stack OL protection has detected an overload condition Check motor for jammed or overloaded condition Verify that the CT ratio FUNO3 is correct Motor load exceeds power stack rating Consult 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 O25 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 the UTS function 1 010 1 015 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 when there may be significant line voltage drop one or more of the current sensor inputs Verify that no actual current is flowing through any of the starter s CTs when the starter is not running Increase Initial Current to make sure motor starts turning immediately after the start command is given 8 TROUBLESHOOTING amp MAINTENANCE During powered BIST testing the disconnect was opened during testing During powered BIST testing line voltage was lost du
184. is 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 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 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 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 152 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
185. ises 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 fault 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
186. ition 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 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 119 6 PARAMETER DESCRIPTION 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 the 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 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 addres
187. l 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 run command needs to be held active during the power outage otherwise the MX will perform a normal stop 129 6 PARAMETER DESCRIPTION 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 P O R T Recovery Method FUN 12 LCD Display LCD Description Range 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 Select digital input Tach Ramp Speed controlled acceleration ramp Ramp starts at motor speed measured at start of recovery and accelerates motor
188. lay 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 53 A Typical ATL Starter Schematic with the MX NN 12 yan 100 600 VAC 3050 60Hz 2 un 4M T3 e CUSTOMER SUPPLIED 120 MAC um 5 m 4 5 1 In n Funds ond FLT PENOS Es m b GROUND 5 pue 7 p BIPC 300055 03 NEUTRAL MX3 fos muat mg o Ple ma Dine 8 7 J E 8 MO BIPC 300034 02 ril 1 CARD2 2 n o Be LX Ele 3 m 5 w 3 Power PROGRAMMABL ED Rt se eG C 52 m PI oq Oai 5 8 mur 31 906 is sHieLo 7 m2 A ER E ER e RA ht ze 587 ge B s E 5 co 3 L PROGRAMMABLE 2 oltm s ED onec 5 HAHAH Sis ms LI SA ggg go 592 505 SWA SWS We on RESET PARAM DOWN UP ENTER it Doz 55 uos n conector ES Es Bg 38 53 RK TX 8 2s g
189. le parameter values to be corrupted Typically occurs when the is re flashed with new software CPU Error Parameter EEPROM Checksum 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 F84 F85 F86 F87 F88 F89 F90 F91 F94 F95 F96 F97 F98 The non volatile program memory has been corrupted CPU Error Program EPROM 5 F99 Checksum Fault Consult factory Control software must be reloaded in to the control card before normal operation can resume 194 8 TROUBLESHOOTING amp MAINTENANCE SCR Testing 8 5 SCR Testing 8 5 1 Resistance The SCRs in the starter can be checked with a standard ohmmeter to determine their condition Remove power from the starter before performing these checks Check from L to T on each phase The resistance should be over 50k ohms Check between the gate leads for each SCR red and white twisted pair The resistance should be from 8 to 50 ohms 36 NOTE The resistance measurements may not be within these values and the SCR may still be good The checks are to determine if an SCR is shorted
190. les of the soft starter are connected in series with the line The starter current equals the line current Figure 49 Typical Motor Connection T1 L1 714 N N gt T2 2 Y 4 e pel 24 T3 p L3 MW 1 166 7 THEORY OF OPERATION 772 Inside Delta Connected Starter An inside delta connected soft starter is shown in Figure 50 where the power poles are connected in series with the stator windings of a delta connected motor Figure 50 Typical Inside Delta Motor Connection CONES L2 L3 Na i i i i i i i cn I T L1 4 W 3 C 1 14 me T2 2 B 4 MW 1 4 P i gt T3 L3 1C g 2 2 2 2 2222 22 2 22 2 22 NOTE Current Transformers MUST be installed to measure the full line current and never installed so they measure the current inside the delta connection For an inside delta connected motor the starter current is less than the line current by a factor of 1 55 FLA 1 55 By comparison of Figure 49 and Figure 50 the most obvious advantage of the inside delta starter is the reduction of current seen by the soft starter The soft starter can be downsized by a factor of 1 55 providing significant savings in cost and size of the starter An inside delta soft star
191. level is correct Verify that the Rated Voltage parameter FUNOS is set correctly High voltage above the Over voltage Trip Level parameter setting PFN10 was detected for longer than the Over Under Voltage Trip delay time PFN12 High Line L2 L3 Line power quality problems excessive line distortions Verify that the actual input voltage level is correct Verify that the Rated Voltage parameter FUNOS is set correctly Line power quality problems excessive line distortions High voltage above the Over voltage Trip Level parameter setting PFN10 was detected for longer than the Over Under Voltage Trip delay time PFN12 High Line L3 L1 Check Gate and Cathode connections to MX card No input voltage was detected for longer than the Inline Configuration time delay parameter setting 1 024 when a start command was given to the starter If an inline contactor is being used verify that the setting of the Inline Configuration time delay parameter 1 024 allows enough time for the inline contactor to completely close No Li E Check input supply for open disconnects open fuses open circuit breakers or disconnected wiring 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 FUN10 if possible During operation the detected a very high level of current in one or more phases Che
192. low 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 PFN26 on page 104 Speed Sw NC Speed Switch Normally Closed 120V applied See PFN26 on page 104 I O parameters 1 3 configure which features are performed by the DI 1 to DI 3 terminals I O parameters 4 8 configure which features are performed by the DI 4 to DI 8 terminals Local Source parameter QST04 on page 74 Remote Source parameter QSTO05 on page 74 Digital Fault Input Trip Time 1 009 on page 112 Bypass Feedback Time parameter 1 025 on page 118 Heater Level parameter FUNOS on page 128 Theory of Operation section 7 1 12 Emergency Motor Overload Reset on page 146 Theory of Operation section 7 3 7 Dual Acceleration Ramp Control on page 154 Theory of Operation section 7 8 Wye Delta Operation on page 168 Theory of Operation section 7 13 Start Stop Control with a Hand Off Auto Selector Switch on page 176 111 6 PARAMETER DESCRIPTION Digital Fault Input Trip Time I O 09 LCD Display Range 0 1 90 0 Seconds Default 0 1 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 Digital Input Configuration parameter on page 111 Relay Output Configu
193. mber where the caller can be contacted Fax number 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 MX Series Model Numbers RB3 1 S 052A 12C C Open Chassis Frame Size Amp Rating 0 999A Fault Level S Standard H High Type of Bypass 0 None only available with RC 1 Integrated 2 Separate Definite Purpose Only with 1000V Starter 3 Separate ATL IEC AC3 Rated 4 Separate ATL NEMA Rated AC4 Type of Control 2 MX 3 MX Family of RediStart Starter B Bypass C Continuous 1 INTRODUCTION General Overview of a Reduced Voltage Starter General Overview The RediStart MX motor starter is a microprocessor controlled starter for single or 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 line voltage and frequency values of 100VAC to 600VAC optional 1000V A
194. me Current Imbalance Trip Time 06 Current Imbalance Trip Time PFN06 on page 95 Auto Reset parameter PFN23 on page 102 Controlled Fault Stop Enable parameter PFN25 on page 103 Current Imbalance Trip Time PEN 06 LCD Display Range Description See Also 0 1 90 0 seconds Default 10 0 The Current Imbalance Trip Time parameter sets the time that the current imbalance must be greater than the percent imbalance parameter 5 before a trip Fault 37 will occur Current Imbalance Trip Level 5 on page 94 95 6 DESCRIPTION Residual Ground Fault Trip Level 07 LCD Display Range Description See Also 96 Residual Gnd Fault Level PEN 07 Off 5 100 FLA Default Off The Residual Ground Fault Trip Level 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 MX 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 9 Once the starter recognizes a ground fault condition it shuts down the motor and declares a Fault 38 Ground Fault Alarm Fault Condition Trip FLA Time
195. motor overload exponentially increases the overload content until the appropriate running overload content level is achieved If the existing motor 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 PFN32 parameter 141 7 THEORY OF OPERATION The following diagram illustrates how the current and the Motor Overload Hot Cold Ratio PFN31 parameter determine the steady state overload content It assumes there is no current imbalance Figure 36 Motor Overload H C Ratio Example 100 FLA Motor D Current 0 80 OL H C Ratio 30 0 96 80 96 Motor Overload 40 Content 30 15 0 At time TO the motor current is 100 FLA and the OL 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 HO 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
196. must be set correctly 36 NOTE The voltage level is only checked when the starter is running See Also Over Voltage Level parameter PFN10 on page 98 Voltage Trip Time parameter PFN12 on page 99 Auto Reset parameter PFN23 on page 102 Controlled Fault Stop Enable parameter PFN25 on page 103 Rated Voltage parameter FUNO5 on page 126 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 PFN10 on page 98 Under Voltage Level parameter PFN11 on page 99 Auto Reset parameter PFN23 on page 102 Controlled Fault Stop Enable parameter PFN25 on page 103 99 6 PARAMETER DESCRIPTION Phase Loss Trip Time PFN 13 LCD Display Range 0 1 5 0 seconds Default 0 2 Description The Phase Loss Trip Time 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 current at run faults Over Frequency Trip Level PEN 14 LCD Display Range 24 72 Hz Default 72 Description The Over Frequency Trip Level parameter sets the highest line frequency that the starter will oper
197. n a version of application software that is I O Card SW version Fault 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 I O Card Current Offset Error ZS GF Lvl PFNOS is turned Off Verify that no current is flowing through the zero sequence ground fault CT Consult factory is fault persists I O card has detected a problem with the Real Time Clock operation Consult factory I O Card Error I O card has detected an internal CPU problem Consult factory T O Card SW Watchdog I O card has detected an internal software problem Consult factory T O Card Error I O Card Error I O card has detected an internal CPU problem Consult factory I O Card Program EPROM Checksum card has detected an internal CPU problem Consult factory 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 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 volati
198. n the fault has occurred L1 Currents The current that the load is drawing from Line 1 when the fault has occurred 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 L1 L2 Voltages The line voltage that is present between lines 1 and 2 when a fault occurs L2 L3 Voltages The line voltage that is present between lines 2 and 3 when a fault occurs L1 Voltages The line voltage that is present between lines 3 and 1 when a fault occurs Kilowatts The power that the load is drawing when a fault occurs Line Periods The line period 1 frequency that is present when a fault occurs Run Time Hours The value of the running time meter when a fault occurs Run Time Counts The value of the running time meter when a fault occurs The running counts provides more resolution than the running time hours Event Codes Bit 15 indicates whether a record is an event or fault A 1 indicates fault and a 0 indicates an event The remaining 15 bits contain the code The system state when the event or fault occurred may be read Time and Date Stamp Refer to page 205 Initializing Locked Out Faulted Stopped Heating Kicking Ramping Slow Speed Not UTS UTS up to speed Phase Control Current Follower Decelerating Braking Wye PORT BIST Shorted SCR Test Open SCR Test 00 V
199. nected to starter 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 Shorted Open SCR Verify that the Input Phase Sensitivity parameter setting FUN04 is correct Verify that the Starter Type parameter setting FUNOT is correct Verify the motor wiring Verify dual voltage motors for correct wiring configuration Verify that the motor FLA QST01 and CT ratio FUNO3 settings are correct 191 8 TROUBLESHOOTING amp MAINTENANCE Current at Stop Disconnect Open Stack Protection Fault stack thermal overload Bypass 2M Contactor Fault Inline Contactor Fault Control Power Low Current Sensor Offset Error Tachometer Signal Loss 192 Detailed Description of Fault Possible Solutions 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 QSTO01 and CT ratio FUNO3 settings are correct A signal on the disconnect digital input 1 001 1 008 was not present when a start was commanded Verify that disconnect feedback wir
200. ng Time PFN32 parameter 60 minutes Motor Cooling Time minutes Starts per hour 3 NOTE The Motor Overload Cooling Time PFN32 parameter is 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 PFN32 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 PFN32 parameter and the Motor Overload Hot Cold Ratio PFN31 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 Cooling Time Running Cooling Time Stopped Motor FLA Current Imbalance Derate Factor 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 air is being applied to the motor Emergency Motor Overload Reset The M
201. ng will take place and the starter will return to the idle state 7 5 8 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 e O 4 N 4 24VDC 30W TO POWER SUPPLY TZOVAC S82K 03024 CD eet co on 24VDC 30W POWER SUPPLY GND S82K 03024 CJ 2 785 gt POWER ant 7 2 RESISTOR Z AN 3 i LI Z 6 7 4 5 aout 5 E 1 SIVIC 5 6 e S 1 gt le t mo 9 a e f NO r 2 T3 e 36 NOTE Hall effect current sensor must be used when load inertia exceeds motor manufactures recommended specifications 163 7 THEORY OF OPERATION 7 5 9 DC Injection Braking Parameters Brake Level The DC Brake Level parameter sets the level of DC current applied to the motor during braking The desired br
202. ngs and Times Power control is a closed loop power based acceleration control The primary purpose of Power controlled acceleration is to control and limit 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 41 Power Ramp Motor Input Power Max Power MolorRunning lt 2 225222 oe 090 2n Ani lati T Ue S Power Level Start command Optional Kick Current Initial Power _ Time Kick Time gt lt Ramp Time Up To Speed Timer 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 Initial Power This parameter CFNOS sets the initial power level that the motor draws at the beginning of the starting ramp profile A typical value is usually 10 to 3096 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
203. ning if the Independent Starting Running Overload parameter is set to Off If separate starting versus running overload classes are desired set the Independent S R OL PFN28 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 PFN28 on page 105 Motor Starting Overload Class PFN29 on page 106 Motor Overload Hot Cold Ratio PFN31 on page 107 Motor Overload Cooling Time PFN32 on page 108 Motor OL Alarm Level PFN33 on page 108 Motor OL Lockout Level PFN34 on page 109 Motor OL Auto Lockout Level PFN35 on page 110 Relay Output Configuration I O 10 15 on page 112 Theory of Operation section 7 1 Solid State Motor Overload Protection on page 138 73 6 PARAMETER DESCRIPTION Local Source T 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 Defaul
204. nitializing or Faulted and Decelerating or Faulted and Braking Bit 0 R dy Faulted and Stopped or Lockout 1 Otherwise Bit 1 Running id a 0 Not UTS Bit 2 UTS 1 UTS 3 Alarm 0 No alarm conditions 1 or more alarm conditions 0 No Fault Condition Pincha 1 Fault Condition 0 Start or Fault Reset not locked out 1 Start or Fault Reset locked out Possible causes Overload Lockout State Bit 5 Lockout 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 221 APPENDIX 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 Fw peer wewma i9 f osa TT RN NN RON GR cue spere se osro m sMoerCuemi soo
205. not operate correctly Input Phase Sensitivity FUN 04 LCD Display LCD Description Range 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 Description 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 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 voltage that is used when the starter performs Over and Under line voltage calculations This value is the supply voltage NOT the motor utilization voltage 36 NOTE Settings above 1140V are for medium voltage applications 38 NOTE The rated RMS voltage must be set properly in order for the starter to operate properly 126 See Also 6 PARAMETER DESCRIPTION Over Voltage Level parameter PFN10 on page 98 Under Voltage Level parameter PFN11 on page 99 Voltage Trip Time parameter PFN12 on page 99 Meter param
206. 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 motor overload 144 7 THEORY OF OPERATION 7 1 10 Motor Cooling While Stopped The Motor Overload Cooling Time PFN32 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 nenne When the motor is stopped the motor overload cools as shown in the following Figure 38 Figure 38 Motor Cooling While Stopped Curves MX Motor OL Cooling Motor Stopped 100 90 4 80 4 70 60 50 40 Remaining OL Content 20 0 T 0 200 400 600 800 1000 1200 1400 1600 1800 2000 Time sec 145 7 THEORY OF OPERATION 7 1 11 7 1 12 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 189 30 min oe 60 min 190 90 400 440 120 500 180 min Larger frames Consult 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 Cooli
207. nt when the second ramp is active Refer to the Ramp Time 1 QST08 2 for description of operation Ramp Time 1 QST08 2 on page 78 Digital Input Configuration I O 01 08 on page 111 Theory of Operation section 7 3 1 Current Ramp Settings Ramp and Times on page 148 Theory of Operation section 7 3 7 Dual Acceleration Ramp Control on page 154 Initial Current 2 06 LCD Display Range Description See Also 50 600 of FLA Default 100 The Initial Current 2 parameter is set as a percentage of the Motor FLA QSTO1 parameter setting when the second ramp is active Refer to the Initial Current 1 for description of operation Initial Current 1 on page 79 Digital Input Configuration I O 01 08 on page 111 Theory of Operation section 7 3 1 Current Ramp Settings Ramps and Times on page 148 Theory of Operation section 7 3 7 Dual Acceleration Ramp Control on page 154 Maximum Current 2 CEN 07 LCD Display Range 80 100 800 of FLA Default 600 Description See Also 6 PARAMETER DESCRIPTION The Maximum Current 2 parameter is set as a percentage of the Motor FLA QSTO1 parameter setting when the second ramp is active Refer to the Maximum Current 1 04 for description of operation Maximum Current 1 CFN04 on page 79 Digital Input Configuration I O 01 08 on page 111 Theory of Operation section 7 3 1 Current Ramp Settings
208. nverter Parameters 165 7 7 Inside Delta Connected Starter os eiai bomo a Rte Roe mm A RE EUR eU 166 7721 Line Connected Soft Starter s noe Ue RUE Reo Ge tee 166 7 2 Maside Delta Connected Starter s xa 303 RR GORGE SURE Poe GE Oe S 167 7 8 Wye Delta Starter css chos REOR ROG eG EORR RR RO 168 7 9 Across The Line Full VoltageStarter ee 171 7 10 Single Phase Soft Starter te RR E eR RE Ree 172 AIT Phase Conto 4 uis ede ain 173 7 AT PhaseControllet 3 sce era per eer du AE eee RS RARI ES quet 174 7 11 2 Master Slave Starter Configuration see ee eth hh ehh 174 7 12 Current FolloWe s4 cbs ook t ORE DEER ERO ee a 175 7 13 Start Stop Control with a Hand Off Auto Selector Switch 176 7 14 Simplified I O Schem ties s a 239 ev uo aD E OE RE 177 7 15 Remote Modbus Communications en 178 75 1 Supported Commands 4 6400 OE 178 7 5 2 Modbus Register Addresses o sh oe OR RO S 178 7 15 3 Cable Specifications ea sor e uma hor m DA ec Boe eR E ES 178 7 15 4 Terminating ResistOrS Lu wie A VUE Sb e V ee a do obo See wee 178 7 15 5 Grounding
209. o 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 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 1 025 parameter a Bypass 2M Fault will occur 3 NOTE If the dedicated bypass relay is set to fan and if no digital input are assigned as a Bypass Confirm input this test will always pass Step 4 Sequential SCR gate firing L1 L1 L2 L2 L3 L3 In this test the SCR gate outputs are sequentially fired starting with the L1 device s and ending with the L3 device s This test can be used to verify that the SCR gate leads are connected properly The gate voltage can be verified using a DC voltage meter or oscilloscope The voltage on each red and white wire pair should be between 0 5 VDC and 2 0VDC This test will check all 6 gates separately The order the BIST will check the gates is as follows Gate 6 Gate 3 Gate 5 Gate 2 Gate 4 Gate 1 The question mark in the display below refers to which gate is being fired up Step 5 Simultaneous SCR gate firing 196 In this test the SCR gate outputs are simultaneously fired all gates on This test can be used to verify that the SCR gate leads are connected properly The gate voltage can be verified using a DC vol
210. o pages 19 21 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 5C 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 T2 and T3 terminals Use lugs crimps or terminals Lugs and Crimps are to be provided by the user Attach the power source cables Usethe 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 2000 feet of properly sized cable between the T leads of the starter and that of the motor For wire runs greater than 2000 feet contact Benshaw Inc for application assistance If shielded cable is used consult factory for recommended length 35 3 INSTALLATION 3 6 5 36 Compression Lugs The following is a list of the recommended
211. oad 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 164 7 THEORY OF OPERATION 7 6 2 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 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 NOTE The Slow Speed Time Limit resets when the motor is stopp
212. 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 SHAW Fax 519 291 2595 Benshaw West 14715 North 78th Way Suite 600 Scottsdale AZ 85260 Phone 480 905 0601 Fax 480 905 0757 Information about Benshaw products and services is available by contacting Benshaw at one of the following 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 MX 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 contacting Benshaw Name of Company Telephone nu
213. ol Card set is UL cUL Recognized Certificate of Compliance 2 9 Certificate of Compliance CE Mark See Appendix E on page 208 Installation 3 INSTALLATION Before You Start 3 1 3 1 1 3 1 2 28 Before You Start Installation Precautions Inspection Before storing or installing the RediStart MX 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 The numbering system for a chassis is shown below General Information Installation of some models may require halting production during installation If applicable ensure that 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 The starter is the correct current rating and voltage ra
214. ondition Verify that the combined kick time CFN12 and acceleration ramp time QST08 is shorter than the UTS timer QST09 setting UTS Time Limit Expired 5 P 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 05709 Check motor for mechanical failure jammed overloaded condition Verify the motor thermal overload parameter settings QST03 and PFN28 to PFN35 and motor service factor setting 05102 Verify that the motor FLA QST01 and CT ratio FUNO3 settings are correct F02 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 PFN34 Slow Speed Timer Increase Slow Speed Timer CFN25 Increase Speed Switch Time PFN 26 Speed Switch Time Limit Expired Accelerate motor faster F07 Bearing RTD Overtemperature 188 8 TROUBLESHOOTING amp MAINTENANCE Fault Code Detailed Description of Fault Possible Solutions Input phase rotation is not ABC and Input Phase Sensitivity parameter FUN04 is set
215. one 2 Stop Bit Software Part Number 2 Display Only ECS Reset RT Reset kWh Reflash Mode Misc Command Miscellaneous Commands Store Parameters None Load Parameters Factory Reset Std BIST Powered BIST mm dd yy 12h mm dd yy 24h T D Format Time and Date Format d m n dd yy 134 dd mm yy 12h dd mm yy 24h FUN mm SY rms be e LL Draw mee dos 5 2 7 Fault Log Group FL9 Page Group Fault Fault eee ag n 13 v2 kw mz E 135 Number Description State Time 228 5 2 8 Event Log Group E01 E99 Event DE ui LS Description 70 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 displayed 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 the group Motor FLA OST 01 LCD Display Range 1 6400 Amps RMS Default 10A Description The Motor
216. opped 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 If a start is commanded a Fault 15 occurs This alarm exists while the MX is stopped and low line voltage is detected Ifa start is commanded a Fault 21 may occur This alarm exists while the MX is stopped and low line voltage is detected Ifa start is commanded a Fault 22 may occur This alarm exists while the MX is stopped and low line voltage is detected Ifa start is commanded a Fault 23 may occur This alarm exists while the MX is stopped and high line voltage is detected Ifa start is commanded a Fault 24 may occur This alarm exists while the MX is stopped and high line voltage is detected Ifa start is commanded a Fault 25 may occur This alarm exists while the MX is stopped and high line voltage is detected Ifa 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 Tine This alarm exists while the MX needs to be synchronized or is trying to sync to the line and no line is detected 203 APPENDIX B ALARM CODES Alarm Sis This alarm exists while the MX is in Power Outage Ride P O R T
217. or is operating at 600 rated current a Class 20 overload trips in 20 seconds when the motor is operating at 600 rated current The equation for the MX standard overload curves after the pick up point has been reached is 35seconds Class 1 Current Imbal Derate Factor 1 Time to Trip seconds Measured Current 138 Seconds to Trip 7 THEORY OF OPERATION Figure 34 Commonly Used Overload Curves 10000 zm 1000 17 100 M 7 pe E 10 1 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 Current FLA Class 40 Class 35 Class 30 Class 25 Class 20 Class 15 Class 10 Class 5 3 NOTE In some cases the power stack rating may determine what motor overload settings are available Each power stack is designed to support specific motor overload classes The RB3 power stack is designed for class 10 duty without derating Refer to the RB3 horsepower rating tables in chapter 2 for the specific RB3 overload capabilities Also in certain heavy duty DC braking applications the overload settings may be limited to protect the motor from potential damage during braking Visit the web at www benshaw com for an automated overload calculator 139 7 THEORY OF OPERATION 7 1 3
218. 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 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 operation needs to be monitored to ensure that the 128 6 PARAMETER DESCRIPTION motor is not overheated The current level should be set as low as possible and then slowly increased over a
219. ory as part of the package Install short circuit protection 1 circuit breaker or fuses if not previously installed by the factory as part of the package Consult Power Ratings for the fault rating on pages 19 21 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 3 INSTALLATION Installation Considerations 3 2 32 1 3 2 2 3 2 3 3 2 4 3 2 5 Installation Considerations Site Preparation General Information Before the starter can be installed the installation site 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 th
220. ould 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 and or reduce the Slow Speed Kick Time See Also Preset Slow Speed CFN23 on page 90 Slow Speed Kick Level parameter 26 on page 91 Motor PTC Trip Time PFN27 on page 104 Theory of Operations section 7 6 Slow Speed Operation on page 164 Jump to Parameter 00 LCD Display Description By changing the value of this parameter and pressing ENTER you can jump directly to any parameter within the group Over Current Trip Level 01 LCD Display Range Off 50 800 of FLA Default Off 92 Description See Also Over Cur Level 6 PARAMETER 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 starter 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 Fault Current Condition 1 01 QST 01 Time
221. oup RTD 3 Group RTD 4 Group RTD 5 Group RTD 6 Group RTD 7 Group RTD 8 Group RTD 9 Group RTD 10 Group RTD 11 Group RTD 12 Group RTD 13 Group 30287 40287 RTD 14 Group 30288 40288 RTD 15 Group MODBUS REGISTER MAP 0 Disabled 1 Enabled 1 250 S 0 Disabled Enabled 0 Disabled Enabled 900 100 mSec 1 100 7 0 Disabled Enabled 0 Disabled 1 Enabled 0 198 1 199 105 200 0 0 0 0 0 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 16 23 0 Disabled Enabled 16 23 Off Stator Bearing Other ec ec 0 0 C C C C 219 APPENDIX MODBUS REGISTER Absolute Register Address 0 Disabled RTD Voting Enable 1 Enabled 220 30296 40296 30601 40601 to 30609 40609 30611 40611 to 30619 40619 30621 40621 to 30629 40629 30631 40631 to 30639 40639 30641 40649 to 30649 40649 30651 40651 to 30659 40659 30661 40661 to 30669 40669 30671 40671 to 30679 40679 30681 40681 to 30689 40689 30691 40691 to 30699 40699 30701 40701 to 30709 40709 30711 40711 to 30719 40719 30801 40801 newest to 30899 40899 oldest 30901 40901 newest to 30999 40999 oldest 31001 41001 to 31198 41198 Fault Code newest fault to Fault Code oldest fault System States The state that the starter was in whe
222. ower Outage Ride Through 16 RTDs with Biasing D C Injection Braking Light or Heavy duty 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 3 MX control card set RB Power Stacks with Bypass Integral and Separate RC Power Stacks Continuous operation NO bypass Electrical Ratings 2 2 Electrical Ratings 2 2 1 Terminal Points and Functions Table 1 Terminals Function Terminal Terminal Number Description Block Control Power ground 96 144 VAC input 50 60 Hz 120VAC neutral 45VA required for control card N 120VAC neutral Relay 1 R1 Relay 2 R2 L 120VAC line L 120VAC line NO1 Normally Open Contact Relay Output SPDT form C RC1 Common NO Contact resistive NC Contact resistive Normally Closed Contact 5 at 250VAC 3A at 250VAC 5A at 125VAC at 125VAC 5A at 30VDC 3A at 30VDC 1250VA 750VA NO2 Normally Open Contact Relay Output SPDT form C RC2 Common Contact NO Contact resistive NC Contact resistive NC2 Normally Closed Contact 5A at 250VAC at 250 5A at 125VAC 3A at 125VAC 5A at 30VD
223. pad Stop Disable Enabled Disabled EE Enabled mus T 27 Auto Start Power On Start Selection Disabled Power Fault Disabled 119 Power and Fault RTD Group RTD Module 2 Address 225 Off Stator Bearing Other APPENDIX PARAMETER TABLES RTD 21 Other Alrm Other Alarm Level RTD 22 Stator Trip Level RTD 23 Bearing Trip Bearing Trip Level RTD20 Bearing Alrm Bearing Alarm Level 1 200 RTD24 Other Trip Other Trip Level Other Trip Level Level RTD25 RTD Voting RTD Voting i en ms Disabled riam RTD26 Biasing RTD Motor RTD Motor OL Biasing RTD Motor OL Biasing omon RTD 28 RTD Bis Mid RTD Bas Mid Point Level ET SaaS RTD 29 RTD Bias RTD Bias Maximum Level 105 200 iss ef Function Group FUNG ramp Code _ Ampwpemer 19m _ __ 226 L1 Current L2 Current L3 Current Curr Imbal Ground Fault Ave Volts Ave L1 L2 Volts Current L2 L3 Volts L3 L1 Volts Overload Power Factor Phase Order Line Freq Analog Input Analog Output Run Days Run Hours Starts TruTorque Power Pk Accel Cur Last Start T Zero Seq GF Stator Temp Bearing Temp Other Temp Temp 72 1 96 1 144 1 288 1 864 1 1320 1 2640 1 2880 1 3900 1 5760 1 8000 1 14400 1 28800 1 50 5 150 5 250 5 800 5 2000 5 5000 5 APPENDIX PARAMETER TABLES Insensitive eae ABC FUN 04 P77 Phase Orde
224. parameter is set to current control acceleration mode Refer to the Maximum Current 1 parameter 4 to set the maximum current level Start Mode CFNO01 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 10096 or greater Ifthe 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 36 NOTE It is important that the FUN06 Rated Power Factor parameter is set properly so that the desired maximum torque level is achieved Start Mode CFNO1 set to Power Control Acceleration This parameter sets the final or maximum power KW consumption level that will be achieved at the end 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 36 NOTE It is important that the FUN06 Rated Power Factor parameter is set properly so that the actual maximum power level is achieved Start Mode CFNO1 on page 78 Ramp Time 1 2 QST08 on page 78
225. pd Fwd 14 R5 Config Relay Output 5 Configuration Ready Slow Spd Rev 5 Off Locked Out Braking Overcurrent Cool Fan Ctl I O 15 R6 Config Relay Output 6 Configuration Undercurrent PORT Off OL Alarm Tach Loss Shunt FS I O 08 I O 16 5 Analog Input Trip Type ee Level Off 113 High Level 1 5 PS 5 5 5 Off 0 200 Curr 0 800 Curr 0 150 Volt 0 150 OL 21 Aout Fctn Analog Output Function 4 E Tone 0 1 MW 0 10 MW 0 100 Ain 0 100 Firing Calibration Disabled Power I O 27 Auto Start Power On Start Selection Fault Disabled 119 Power and Fault 5 GROUPS 5 2 5 RTD Group n RTD 19 Stator Alarm Level RTD 20 Bearing Alrm Bearing Alarm Level RTD 21 Other Alrm Other Alarm Level 120 sme RTD Mow Lag 1 or ror RID Bis Min RTD Bies Minimum Leret 0 198 o ros RTD Bis Mid RTD Bias Mid Poin eva 139 ded xr RTD Bias Max RTD Bias 105 20 123 124 68 5 2 6 5 GROUPS Function Group FONW _ dem fp Ave Current L1 Current L2 Current L3 Current Curr Imbal Ground Fault FUN 01 P71 Meter 1 Meter 1 Ave Volts Ave Current L1 L2 Volts L2 L3 Volts L3 L1 Volts Overload Power Factor Watts VA vars kW hours MW hours Phase Order Line Freq Analog Input Analog Output Run Days Meter 2 Meter 2 Ave Volts TruTorque
226. peed 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 The 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 Ramp Time 7 THEORY OF OPERATION 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 3 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 curren
227. pes of control methods that require extra smooth starts S Curve See Also Start Mode CFNO01 on page 78 83 6 PARAMETER DESCRIPTION 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 rotating increase the kick current by 100 and re adjust the kick time See Also Start Mode parameter on CFNO1 on page 78 Kick Time 1 parameter on CFN12 on page 84 Theory of Operation section 7 3 2 Programming A Kick Current on page 149 Kick Time 1 12 LCD Display Range 0 1 10 0 seconds Default 1 0 Description The Kick Time 1 parameter sets the length of time that the kick current level CFN11 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
228. play Range 1 200 Default 200 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 3 NOTE Consult motor manufacturer 121 6 PARAMETER DESCRIPTION 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 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 36 NOTE Consult motor manufacturer Other Trip Level RTD 24 LCD Display Range 1 200 C Default 200 Description This parameter sets the other trip temperature when a trip will occur Fault delay time is 1 second 122 6 PARAMETER DESCRIPTION RTD Voting RTD 25 LCD Display Range Description Disabled Enabled Default Disabled 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 3 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
229. r Off or the desired overload class settings The Motor Starting Overload Class PFN29 parameter value is used for the motor overload calculations when the starter is starting the motor kick 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 PFN30 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 38 NOTE When the Independent Starting Running Overload PFN28 parameter is set to Off the running OL is used at all times 3 NOTE The Hot Cold motor compensation is still active when either the starting or running overload is disabled Therefore the motor overload content may still slowly increase or decrease depending on the measured motor current However if the motor overload is disabled the motor overload content is limited 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 0 and the starter does
230. r Input Phase Sensitivity CBA Insens 126 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 a ee 480 126 4600 4800 6000 6600 6900 10000 11000 11500 12000 12470 13200 13800 Normal Inside Delta Wye Delta Starter Type Starter Type Phase Ctl Normal 128 Curr Follow ATL nergy Saver Energy Saver Off On ORT FltTim P O R T Fault Time Off 0 1 90 0 Off ime Voltage Ramp Fast Recover P O R T Recovery Current Ramp Fast PORT Method Curr Ramp 2 Recover Ramp Select Tach Ramp FUN 07 oo ns el ins 2 FUN 12 dE FS Lvl Tachometer Full Speed 1 00 10 00 Volts Voltage FUNI4 Tach Los Tim Tachometer Loss Time 0 1 90 0 Fault FUN 15 Tach Los Act Tachometer Loss Action Fault oo Com B 5 Communication Even 1 Stop Bit Communications Byte Odd 1 Stop Bit Even 1 EUER Com Framing None 1 Stop Bit Stop 193 None 2 Stop None Reset RT Reset kWh Miscellaneous Reisa Miodle FUN22 P67 Misc Command C Store Parameters None ommands ib oad Parameters Factory Reset Std BIST Powered BIST 227 APPENDIX G PARAMETER TABLES mm dd yy 12h mm dd yy 24h yy mm dd 12h mm dd yy FUN 23 T D Format Time and Date Format yy mm dd 24h 12h 134 dd mm yy 12
231. r 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 MX 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 118 6 PARAMETER DESCRIPTION See Also Digital Input Configuration parameters I O 01 08 on page 111 Theory of Operation section 7 8 Wye Delta Operation on page 168 Keypad Stop Disable I O 26 LCD Display LCD Description Range 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 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 QST04 on page 74 Remote Source parameter QSTO05 on page 74 Auto Start Selection 27 LCD Display LCD Description Range Disabled When Disabled the Start input must always trans
232. ration YO 10 15 LCD Display LCD Description Range 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 PORT Energized when the starter is in the Power Outage Ride Throug
233. re 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 Oncsite 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 MX Information about start up services and fees are available by contacting Benshaw Benshaw technical field support personnel are available to conduct on site training on RediStart MX operations an
234. rent 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 MX 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 9 Once the starter recognizes a ground fault condition it will shut down the motor and display a fault F38 Ground Fault Alarm Fault Condition Trip Amps Zero Sequence Gnd Fault Level PFN 08 Time lt lt Ground Fault Trip Time PFN 09 If a programmable relay 10 15 is set to GROUND FAULT the starter energizes the relay when the condition exists NOTE The MX 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 located on the I O card See Control Card layout starting on page 41 See Also Ground Fault Trip Time PFN09 on page 98 Auto Reset parameter PFN23 on page 102 Controlled Fault Stop PFN25 on page 103 Relay Outputs I O 10 15 on page 112 97 6 PARAMETER DESCRIPTION Ground Fault Trip Time 09 LCD Display Range 0 1 90 0 seconds Default 3 0
235. ring 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 External Fault on DI 1 Input External Fault on DIZ2 Input External Fault on DI 3 input External Fault on DIZ4 input 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 5 input External Fault on DI 6 input External Fault on DI 7 input External Fault on DIZ8 input Increase Digital Fault Input Trip Time I O09 Based on the Analog Input parameter settings the analog input level has either exceeded or dropped below the Analog Input Trip Level setting 1 017 for longer than the Analog Input Trip Delay time 1 018 Measure value of analog input to verify correct reading F71 Analog Input Level Fault Trip Verify settings of all Analog Input parameters 1 016 1 020 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 RTD Module Communications Fault Verify
236. rolled Fault Stop Off On Speed Sw Time Speed Switch Trip Time Off 1 250 Off M PTC Time Motor PTC Trip Time Off 1 5 Off 4 Indep 8 OL Independent Starting Running Off On Off Overload 10 10 Starting OL Motor Overload Class Starting Off 1 Undr Vit Lvl Under Voltage Trip Level Off 1 40 0 15 Off 5 GROUPS 5 2 4 I O 01 DI 1 Config Digital Input 1 Configuration Off Slow Spd Fwd o so m 5 Stop Slow Spd Rev I O 02 DI 2 Config Digital Input 2 Configuration Fault High Brake Disable Off I O 03 DI 3 Config Digital Input 43 Configuration Fault Low Brake Enable Off 7004 DI4Config Digital Input 4 Configuration FaultReset 5 Sw NO Off Disconnect Speed Sw NC I O 05 DI 5 Config Digital Input 45 Configuration Inline Cnfrm Off voos D16 Config Digital Input 46 Configuration al Cnfrm Off E OL Reset 07 DI 7 Config Digital Input 7 Configuration Local Remote o Heat Disable DI 8 Config Digital Input 8 Configuration Heat Enable Off Ramp Select I O 09 Dig Trp Time Digital Fault Input Trip Time 0 1 to 90 0 10 Ps2 Ri Config Relay Output 1 Configuration Off Shunt NFS FaulFS Fault FS Ground Fault 11 R2 Config Relay Output 2 Configuration Fault NFS EE EE Off VO 12 R3 Config Relay Output 3 Configuration Running Heating 13 R4 Config Relay Output 4 Configuration UTS Slow Spd Off Alarm Slow S
237. rt bar Indicator Washer Quantity dependant lor2 on style of clamp 8 7 5 Tightening Clamp Finger tighten the clamp Ensure both bolts are tightened an equal amount so that the loader bar item 1 is square in the heatsink Tighten the bolts equally in 1 8 turn increments until the indicator washer s item 6 which are under the nut s in the center of the loader bar becomes loose indicating the clamp is tight On the loader bars with two indicator washers it may be necessary to tighten or loosen one side of the clamp to get both indicator washers free 8 7 6 Testing SCR After the SCRs have been replaced conduct the resistance test as defined in Section 8 5 199 8 TROUBLESHOOTING amp MAINTENANCE NOTES 200 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 LLL omite sse emere LLL 1 202 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 Motor Overload Alarm Motor PTC Alarm This occurs when the motor thermal content reaches the Motor OL Alarm Level PFN33 The MX trips when it reac
238. s a standard RJ 45 The wires connect as follows 4 B 5 8 common 47 3 INSTALLATION Remote LCD Keypad Display 3 12 3 12 1 3 12 2 48 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 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 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 for the display screen is 0 7 NM 6 195 in lbs Plug the cable into the display connector on the MX card See figure 16 control card layout on page 41 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 31 Plug the other end of the cable into the LCD display Figure 26 Mounting Remote Keypads CLIP CLIP ENCLOSURE DOOR MX DISPLAY CABLE MX DISPLAY 3 INSTALLATION 3 12 3 Display Cutout Figure 27 Small Display Keypad Mounting Dimensions Part KPMX3SLCD
239. s fully active During braking the Running Motor overload setting is used The 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 162 7 THEORY OF OPERATION Once DC Braking is stopped due to a digital input state change no further DC braki
240. s 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 36 NOTE To re establish password protection after it has been cleared the password must be entered again Fault Log FL1 9 LCD Display Range FL1 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 205 Event Recorder 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
241. s of the second 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 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 LCD Description Range Off RTD channel not read Stator RTD included in Stator metering group Bearing RTD included in Bearing metering group Other RTD acts independently 120 6 PARAMETER DESCRIPTION Description Each of the 16 available RTD input channels has a parameter to assign that RTD channel to a grouping 3 NOTE RTD 1 8 is on module 1 RTD 9 16 is on module 2 Stator Alarm Level RTD 19 LCD Display Range 1 200 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 3 NOTE Consult motor manufacturer Bearing Alarm Level RTD 20 LCD Display Range 1 200 C Default 200 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 36 NOTE Consult motor manufacturer Other Alarm Level RTD 21 LCD Dis
242. s 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 e Ifparts are missing or soft starter is damaged do not operate the RediStart MX 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 MX 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 1 INTRODUCTION OPW 309 9 Ro UR VON RES RO CE 2 2 TECHNICAL SPECIFICATIONS 8 21 General Information 2 xen ee
243. seconds after a start is commanded increase this parameter If this value is set too low a No Current at Run fault may occur Maximum Power This parameter CFNO9 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 set 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 KW 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 3 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 151 7 THEORY OF OPERATION Ramp Time 3 NOTE Depending on loading the motor may achieve full speed at any time during the Power ramp Th
244. 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 See Also Independent Starting Running Overload parameter PFN28 on page 105 Motor Running Overload Class parameter PFN30 on page 106 Motor Starting Overload Class parameter PFN29 on page 106 Motor Overload Hot Cold Ratio parameter PFN31 on page 107 Theory of Operation section 7 1 10 Motor Cooling While Stopped on page 145 Theory of Operation section 7 1 11 Motor Cooling While Running on page 146 Motor OL Alarm Level 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 112 Theory of Operation 7 1 Solid State Overload Protection on page 138 108 6 PARAMETER DESCRIPTION Motor OL Lockout Level PEN 34 LCD Display Range 1 99 Default 15 Description After 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 7
245. so Initial Voltage Torque Power CFNO8 on page 81 Maximum Torque Power 9 on page 81 Acceleration Ramp Profile CFN10 on page 83 Theory of Operation section 7 3 Acceleration Control on page 148 Ramp Time 1 02 LCD Display Range 0 300 seconds Default 15 78 Description See Also 6 PARAMETER 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 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 3 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 9 on page 77 Start Mode CFNO1 on page 78 Initial Current 1 QST06 CFN03 on page 79 Maximum Current 1 QS
246. t Serial The start stop Fault High control is from the network Description The MX can have three sources of start and stop control Terminal Keypad and Serial Two parameters 05704 Local Source and 05705 Remote Source select the source 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 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 1 026 parameter on page 119 See Also Remote Source QST05 on page 74 Digital Input Configuration I O 01 08 on page 111 Keypad Stop Disable 1 O26 on page 119 Communication Address FUNI16 on page 131 Communication Baud Rate FUN17 on page 131 Communication Timeout FUN18 on page 132 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 MX can have three sources of start and stop control Terminal Keypad and Serial Two parameters
247. t 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 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 157 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 46 TruTorque Deceleration
248. t line to ground at the point where the line enters the cabinet 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 correction 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 3 NOTE If the motor manufacturer supplies surge capacitors they must be removed before starting 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 swit
249. t start no output to motor Contr l volt bsent Check for proper control voltage input Display Blank CPU Heartbeat LED on voltage absent Verify fuses and wiring Consult factory O MX control board problem Consult factory Fault Displayed 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 TNCS properly connected to the MX control NOL or No Line is displayed and a start No line voltage has been detected by the board command is given it will fault in F28 MX when a start command is given On medium voltage systems verify wiring of the voltage feedback measurement circuit See fault code troubleshooting table for more details 183 8 TROUBLESHOOTING amp MAINTENANCE 8 3 2 During starting motor rotates but does not reach full speed Fault Displayed Fault Occurred See fault code troubleshooting table for more details I M Motor Review acceleration ramp settings 05707 set too low p 55 Motor loading too high and or current
250. t to reach full speed Alternatively the motor and load may take longer than the set ramp time to achieve full speed 7 3 2 Programming A Kick Current General Kick Level Kick Time The kick 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 7 3 3 TruTorque Acceleration Control Settings and Times General 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
251. ta Inside Delta RVSS Wye Delta Wye Delta Phase Ctl Open Loop Phase control using external analog input reference Curr Follow Closed Loop Current follower using external analog input reference ATL Across the line Full Voltage Description 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 is providing the motor protection and the necessary control for these applications 3 NOTE For single phase operation select Normal for the Starter Type parameter and Single Phase for the phase order parameter FUN04 See Also Input Phase Sensitivity parameter FUN04 on page 126 3 Theory of Operation section 7 7 2 Inside Delta Connected Starter using the MX on page 167 Theory of Operation section 7 8 Wye Delta Operation on page 168 Theory of Operation section 7 11 Phase Control on page 173 Theory of Operation section 7 12 Current Follower on page 175 Heater Level FUN 08 LCD Display Range Off 1 40 FLA Default Off Description The Heater Level parameter sets the level of D C current that reaches the 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
252. tage meter or oscilloscope The voltage on each red and white wire pair should be between 0 5 VDC and 2 0VDC Pressing ENTER on the keypad at any time will abort the current test in progress and proceed to the next BIST test During the standard BIST tests if line voltage or phase current is detected the MX will immediately exit BIST mode and declare a BIST Abnormal Exit fault 8 6 2 8 TROUBLESHOOTING amp MAINTENANCE Step 6 Powered BIST Tests FUN 22 Powered BIST The powered BIST tests are designed to be run with normal line voltage applied to the starter and a motor connected Powered BIST verifies that the power poles are good no ground faults exist CTs are connected and positioned correctly and that the motor is connected Powered BIST mode can be entered by entering the appropriate value into the Miscellaneous Command FUN22 user parameter 3 NOTE The powered BIST test is only for use with SCR based reduced voltage soft starters Powered BIST can not be used with wye delta or ATL types of starters 3 NOTE The motor wiring MUST be fully connected before starting the powered BIST tests Also the motor must be at rest stopped Otherwise the powered BIST tests will not function correctly 3 NOTE Before using the powered BIST test function the following MX user parameters MUST be set for correct operation of the powered BIST test Motor FLA QSTO01 CT Ratio FUNO3 Phase Order FUN04 Rated Voltage
253. tarts a delay time Ifthe 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 Current Condition Trip 1 Motor FLA QST 01 Under Cur Level 03 i Time lt lt Under Current Trip Delay Time PFN 04 Under Current Time parameter PFN04 on page 94 Auto Reset parameter PFN23 on page 102 Controlled Fault Stop Enable parameter PFN25 on page 103 Relay Output Configuration parameters I O 10 15 on page 112 Under Current Trip Delay Time PEN 04 LCD Display Range Description See Also Off 0 1 90 0 seconds Default 0 1 The Under Current Trip Delay Time parameter sets the period of time that the motor current must be less than the Under Current Level parameter before an under current fault and trip occurs If Off is selected the under current timer does not operate and the starter does not trip It energizes any relay set to Under Current until the current rises Under Current Level parameter on page 93 Auto Reset parameter PFN23 on page 102 Controlled Fault Stop Enable parameter PFN25 on page 103 Relay Output Configuration par
254. ter can also be considered for motors with more than 6 leads including 12 lead dual voltage motors NEMA and IEC use different nomenclature for motor terminal markings for 3 and 6 leaded motors NEMA labels motors leads 1 2 3 4 5 6 IEC labels motor leads U1 V1 W1 U2 V2 W2 167 7 THEORY OF OPERATION Wye Delta Starter 7 8 Wye Delta Starter When the Starter Type parameter is set to Wye Delta the MX is configured to operate an electro mechanical Wye Delta Star Delta starter When in Wye Delta mode all motor and starter protective functions except bad SCR detection and power stack overload are available to provide full motor and starter protection A typical closed transition Wye Delta starter schematic is shown in the figure below Figure 51 Wye Delta Motor Connection to the MX 1 100 600 12 3 3e50 60Hz d CUSTOMER SUPPLIED T 120 VAC 2 3 4 5 0 6 fe jn K anc so0055 05 E uma 1 CARD NEUTRAL H p le m c ine m 8 E 06 m BIPC 300034 02 ks 1 CARD 2 N rq UE 1 ott 28 POWER S ane ie m E EL aout 5 Bled suero 7 p gS e E nu gu A E sies
255. ters larger than 124 amps the CTs are shipped loose from the power stack and need to be mounted on the power wiring Thread the motor or incoming lead through the CT with the polarity mark 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 at least three inches from the power wire lugs using two tie wraps Figure 12 Typical CT Mounting CUSTOMER MUST FASTEN CT TO POWER WIRE WITH TWO 1 4 NYLON WRAPS TO PREVENT MOVEMENT DURING RUNNING MUST BE A 3 MIN 4 SPACE BETWEEN CT AND TOP OF LUG Dot or X y White Wire 2 FRONT VIEW SIDE VIEW DETAIL 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 CT1 must be on Line L1 CT2 must be on Line L2 CT3 must be on Line L3 3 INSTALLATION 3 7 3 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 13 BICT 2000 1 6 Mechanical Dimensions
256. 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 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 111 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 112 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 State Motor Overload Protection is fully active During slow speed operation the Running Motor overl
257. 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 To Speed Time 05709 on page 77 Start Mode CFNO1 on page 78 Ramp Time 1 QST08 CFN02 on page 78 Initial Current 1 QST06 on page 79 Kick Level 1 on page 84 Kick Time CFN12 on page 84 Theory of Operation section 7 3 1 Current Ramp Settings Ramps and Times on page 148 Ramp Time 1 OST 08 LCD Display Range 0 300 seconds Default 15 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 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 3 NOTE Setting the ramp time to a specific value does not necessarily mean that the motor will take this time to a
258. ting 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 Ensure that the installation site meets all of the required environmental conditions Refer to Site Preparation page 29 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 fact
259. tion Alarm Slow Spd Fwd Relay Output 4 Ready Slow Spd Rev Configuration Locked Out Braking Off Overcurrent Cool Fan Ctl Relay Output 5 Undercurrent PORT Off Configuration OL Alarm Tach Loss Relay Output 46 Shunt FS 3 Off Configuration Off 16 55 Ain Trp Type Analog Input Trip Type Low Level Off High Level T O 1 P56 AinTrpLvl Analog Input Trip Level 0 to 100 5 Analog Input Trip Delay 0 1 to 90 0 Second 0 Time j 0 sil Analog Input Span 1 to 100 10 11 Digital Input 3 IO 0 Configuration J P50 DI3 Config T O 0 J 14 Config T O 0 15 Config T00 DI 6 Config IO 0 J I7 Config 1 0 0 J I 8 Config IO 0 P51 ig Trp Time T O 1 52 1 Config 1 53 R2Config Configuration T O 1 N P54 R3 Config 1 Config 1 5 Config IO 1 R6 Config T O 1 57 Ain Trp Tim T O 19 58 Ain Span 20 59 Ain Offset 1017 1019 1020 224 APPENDIX PARAMETER TABLES ia off Analog Output Function 0 200 Curr 0 800 Curr 0 15096 Volt 0 150 OL 0 10 kW 0 100 0 1 MW 0 10 MW 0 100 Ain 0 10095 Firing Calibration E rer rou Span Ang Cupar rers 139 3 EST ERE ET 1024 24 Inline Confg Inline Configuration Of 1 0t0100 1 0 Of 1 0t0100 10 0 E 26 Stop Key
260. tor FLA Zero Sequence Ground Fault Detection Off 0 1 25Amps ANSI 66 Starts Hour amp Time Between Starts Restart Block Backspin Timer e ANSI 74 Alarm relay output available e ANSI 81 Over Under Frequency ANSI 86 Overload lockout Single Phase Protection Shorted SCR detection Mechanical Jam gt gt gt gt gt gt 10 2 2 4 2 TECHNICAL SPECIFICATIONS Solid State Motor Overload The MX control has an advanced I t electronic motor overload OL protection function For optimal motor protection the MX control has forty standard NEMA style overload curves available for use Separate overloads can be programmed one for acceleration and another for normal running operation The overloads can be individual the same or completely disabled if necessary The MX 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 4 NN 2 8 RSs 100 N 1 Class 40 ee ee 35 m Class 30 A eee e Class 25 Class 20 10 Class 15 Class 10 Class 5 14 100 150 200 250 300 350 400 450 500
261. tor FLA 1 to 6400 e Amps QST 03 Running OL Motor Overload Class Running Off 1 to 40 Jo 74 Terminal EN Terminal estos W sCuemi owo wA 1 75 Pastor Pr Maxcuri __ MeimumCummi 100080 ow Fem romping ee mei ow eweenme utem pem mS n 64 5 2 2 5 GROUPS Control Function Group Voltage Ramp Current Ramp Current 01 Start Mode Start Mode TT Ramp Ramp 78 Power Ramp Tach Ramp m Tam ime 03e Sew amp is 7 cmo sono 100 79 er Max Cort Maximum Moor Caren 10010800 rts ooo 7 Lcmos RanpTine RampTine sents is 9 em cw iat Moor Carena 19 35 Max Cor Maximum moror Cunem2 10010800 vera _ Linear 10 Accel Prof Acceleration Ramp Profile Squared Linear 83 S Curve Coast Volt Decel CFN 15 P15 Stop Mode Stop Mode TT Decel Coast 85 DC Brake CFN 16 Decel Begin Decel Begin Level 100 to 1 4 86 Linear CFN 19 Decel Prof Decel Ramp Profile Squared Linear S Curve CFN 20 Brake Level DC Brake Level 10 to 100 22 Brake Delay DC Brake Delay 0 1 to 3 0 Seconds 02 89 23 SSpd Speed Slow Speed Off 1 40 of 24 SSpd Curr Slow Speed Current Level 10 to 400 FLA 100 90
262. ts 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 the 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 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
263. ture Hottest RTD Temperature 217 APPENDIX MODBUS REGISTER Absolute Register Address Units None Reset Run Time Reset kWh Enter Reflash Mode Store Parameters Load Parameters Factory Reset Standard BIST Powered BIST Linear 30221 40221 Acceleration Profile Squared 30222 40222 Deceleration Profile S Curve Disabled 30223 40223 PORT Bypass Enable 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 10 mV 30227 40227 Tachometer Loss Delay Time 100 mSec 0 Fault Closed Loop Current Ramp TruTorque Ramp Power Ramp MM DD YY 12 Hour 1 2 3 0 1 MM DD YY 24 Hour 2 YY MM DD 12 Hour 3 4 5 1 30199 40199 Misc Commands Eee rs Le Ee 30225 40225 PORT Recovery Method Unger 30228 40228 Tachometer Loss Action 30229 40229 Time Date Format YY MM DD 24 Hour DD MM YY 12 Hour DD MM YY 24 Hour 30230 40230 Current Imbalance Delay Time 900 100 mSec 0 Disabled 30231 40231 Zero Sequence Ground Fault Trip Enable 1 Enabled 1 0 1 0 30237 40237 Over Under Frequency Delay Time 100 mSec Disabled 2 30238 40238 Power Factor Leading Trip Enable Enabled 80 99 0 80 to 0 99 lag 30239 40239 Power Factor Leading Trip Level 100 120 1 00 to 0 80 lead 0 Disabled 30240 40240 Power
264. ue 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 level 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 9 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 7 3 4 General 7 THEORY OF OPERATION Power Control Acceleration Setti
265. un mode occurs as follows The UTS relay is energized which energizes the 25 contactor 2 When the 2S contactor pulls in resistors are inserted in the circuit and the 1S contactor is de energized 3 When the 1S contactor drops out the 2M contactor is energized 4 When the 2M contactor is pulled in feedback can be sent to the MX control card to confirm that the transition sequence to Delta is complete The starter remains in the Delta or running mode until the start command is removed or a fault occurs 169 7 THEORY OF OPERATION Usually the MX intelligent Wye to Delta transition algorithm provides an optimal transition point that minimizes the transient current and torque surges that can occur However the Wye to Delta transition will occur when the Up To Speed Time parameter has expired In order to reduce the current surge during the transition from Wye to Delta mode the Up To Speed Time parameter should be adjusted so that the transition occurs as close to full speed as possible within the constraints of the load If the Up To Speed Time is set too short the starter will transition too soon and a large current and torque surge will occur If the Up To Speed Time is set too long the motor may not have sufficient torque to continue accelerating when in Wye mode and may stop accelerating at a low speed until the transition to Delta mode occurs If this occurs the start is unnecessarily prolonged and motor heating is increased A typi
266. 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 36 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 parameter QST09 on page 77 Start Mode parameter on page 78 Kick Level 1 on page 84 Theory of Operation section 7 3 2 Programming A Kick Current on page 149 84 6 PARAMETER DESCRIPTION Kick Level 2 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 parameter on page 84 for description of operation Kick Time 2 14 LCD Display Range 0 1 10 0 seconds Default 1 0 Description The Kick Time 2 parameter sets the length of time that the kick current level CFN11 is applied to the motor when the second ramp is active Refer to the Kick Time 1 parameter on page 84 for description of operation See Also Kick Level 1 parameter CFN11 on page 84 Digital Input Configuration I O 01 08 parameters on page 111 Theory of Operation section 7 3 2 Programming A Kick Current on page 149 Theory of Operation section 7 3 7 Dual Acceleration Ramp Control on page 154 Stop Mode CEN 15 LCD Display Range LCD Description Coast De
267. urrent 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 MX 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 TB5 3 negative 2 The tachometer feedback Start Mode CFNO1 is selectable as Tach Ramp from the Starter Modes menu 3 Program the appropriate variables in the Tachometer Setup menu FUNI3 Tachometer Full Speed Voltage on page 130 FUN14 Tachometer Loss Time on page 130 FUNI5 Tachometer Loss Action on page 131 4 Set the Initial Current QST06 CFN03 level to the desired starting current 5 Set the Maximum Current QST07 CFN04 level to the desired maximum current limit 153 7 THEORY OF OPERATION 7 3 7 General Dual Acceleration Ramp Control 154 Two independent current ramps and kick currents may be programmed The use of two different starting profiles can be very
268. 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 recommended Figure 42 Voltage Ramp Voltage Full Voltage 7 Optional Kick Current Initial Voltage Time Kick Time la 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 7 THEORY OF OPER
269. wer wiring as follows Useonly UL or CSA recognized wire e Wire voltage rating must be a minimum of 300V for 2307 AC systems and 600V Class 1 wire for 460VAC and 600VAC systems 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 Wire must be made of copper and rated 60 75 C for units 124 Amps and below Larger amp units may use copper or aluminum wire Refer to NEC table 310 16 or local codes for proper wire selection 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 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 High Pot Testing If the starter needs to be high pot tested perform a DC high pot test The maximum high point voltage must not e
270. 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 36 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 102 6 PARAMETER DESCRIPTION Description The Auto Fault Reset Time 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 B Fault Codes 36 NOTE A start command needs to be initiated once the timer resets the fault See Also Appendix C Fault Codes on page 205 Auto Reset Limit parameter PFN23 on page 103 Auto Fault Reset Count Limit PFN 24 LCD Display Range Off 1 10 Default Off Description The Auto Reset Count 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 the 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
271. 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 a PLC The 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 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 is programmed as a Stop input Figure 57 Example of Start Stop with a Hand Off Auto Selector Switch OFF HAND 4 AUT
272. x motor cooling fan Fan power supply lost Verify fan power supply check fuses Fan wiring problem Check fan wiring Voltage Current output switch SW 1 2 Saye wid io aive correct On fru not set correctly 5 put Wiring problem Verify output wiring Analog Output Function parameter Verify that the Analog Output Function 1 021 set incorrectly parameter is set correctly Analog Output Offset and or Span parameters 023 and 022 set incorrectly Verify load on analog output meets the Load on 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 parameter is On mares Revel RUNDE parameter to Keypad cable not plugged in properly or cable is damaged 187 8 TROUBLESHOOTING amp MAINTENANCE Fault Code Table 8 4 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 05709 expired Check motor for jammed or overloaded c
273. xceed 2 0 times rated RMS voltage 1000VAC 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 high point voltage is 2 0 rated RMS voltage 1000 0 75 31 3 INSTALLATION Power and Control Drawings for Bypassed and Non Bypassed Power Stacks 3 5 Power and Control drawings for Bypassed and Non Bypassed Power Stacks Figure 9 Power Schematic for RB3 Low HP L1 SCRE 1 AT gt NS L __ ch za Se f CUSTOMER SUPPLIED 120 VAC E AL J2 1 F NO3 GND FLT a 1 i G GROUND 5 62 amp BIPC 500055 05 91 NEUTRAL MX3 CARD 1 c5 1 1 m 39 NEUTRAL K5 1 1 PWR 63 fo Oque 5 1 1 1 1 5 6 i LIVE Jn BIPC 300034 02 ks 1 1 MX3 CARD 2 1 1 a g i i me m 819 1 1 1 1 1 1 1 1 i 1 TB5 i 5 row POWER 1 PROGRAMMABLE 2 RELAY RI m ant 1 1 1 4 an 3 1 gs i coq 1 1 1 ES aout 5 1 1 PROGRAMMABLE RELAY R2 g O 1 1 55 7 1 1 i g ge Tes i 5 1 bai B 1 PROGRAMMABLE 25 9 t R

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