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BENSHAW RediStart MX2 SEP User Manual

Synchronous control
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890040-01-00
Software Version:
810027-01-00
Hardware Version:
300063-01
©
2008 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.
RediStart
Solid State Starter
2
SEP
Synchronous Control
MX SEP Models
User Manual
TM

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  • Page 1 890040-01-00 Software Version: 810027-01-00 Hardware Version: 300063-01 © 2008 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.
  • Page 2 SEP Series Controllers. 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.
  • Page 3 SAFETY PRECAUTIONS Safety Precautions Electric Shock Prevention • While power is on or controller is running, do not open the front cover. You may get an electrical shock. • This controller contains high voltage which can cause electric shock resulting in personal injury or loss of life. •...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Table of Contents 1 INTRODUCTION ..........2 2 TECHNICAL SPECIFICATIONS .
  • Page 5 TABLE OF CONTENTS 4 KEYPAD OPERATION ......... 28 4.1 Introduction .
  • Page 6 TABLE OF CONTENTS 7.3 Simplified I/O Schematics........90 7.4 Remote Modbus Communications .
  • Page 7 Introduction...

  • Page 8: Introduction

    1 - INTRODUCTION Using this Manual Layout This manual is divided into 10 sections. Each section contains topics related to the section. The sections are as follows: • Introduction • Technical Information • Installation • Keypad Operation • Parameters • Parameter Description •...
  • Page 9 See page 127. Warranty Benshaw provides a 1 year standard warranty with its controllers. 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 controllers and will be quoted specifically to each customers needs.
  • Page 10 1 - INTRODUCTION Contacting Benshaw Contacting Benshaw Information about Benshaw products and services is available by contacting Benshaw at one of the following offices: Benshaw Inc. Corporate Headquarters Benshaw High Point 1659 E. Sutter Road EPC Division Glenshaw, PA 15116...
  • Page 11 1 - INTRODUCTION Interpreting Model Numbers Figure 1: RediStart MX2 SEP Series Model Numbers MX2SEP-125VDC-50A-3-S-C C = Open Chassis S = Solid State M = Mechanical (contactors) 1 = Single phase bridge 3 = Three phase bridge Current Rating of Bridge Voltage rating of field (125 or 250 VDC) MX2 Control Example of Model Number: MX2SEP-125VDC-50A-3-S-C...
  • Page 12 1 - INTRODUCTION General Overview of a Synchronous Field Controller General Overview The RediStart MX SEP synchronous field controller is a microprocessor based controller for single or three-phase field supply. The sync controller can be custom designed for specific applications. A few of the features are: •...
  • Page 13 2 Technical Specifications...

  • Page 14: Technical Specifications

    2 - TECHNICAL SPECIFICATIONS Technical Specifications 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: •...

  • Page 15: Measurements And Accuracies

    2 - TECHNICAL SPECIFICATIONS Table 1: Terminals Terminal Terminal Number Description Function Block J6 to J11 1: Gate SCR gate Connections 2: Cathode Wire Gauge: The terminals can support 1- 14 AWG wire or 2-16 AWG wire or smaller. Torque Rating: The terminals on the control card have a torque rating of 5.0-inch lb. or 0.56Nm. This MUST be followed or damage will occur to the terminals. Refer to the Control Card Layout on page 21.

  • Page 16: Environmental Conditions

    Altitude Derating Altitude Derating Benshaw's starters are capable of operating at altitudes up to 3,300 feet (1000 meters) without requiring altitude derating. Table 3 provides the derating percentage to be considered when using a starter above 3,300 feet (1000 meters).
  • Page 17 Installation...

  • Page 18: Installation

    3 - INSTALLATION Before You Start Before You Start 3.1.1 Inspection Before storing or installing the RediStart MX SEP Series sync controller, thoroughly inspect the device for possible shipping damage. Upon receipt: • Remove the controller from its package and inspect exterior for shipping damage. If damage is apparent, notify the shipping agent and your sales representative.

  • Page 19: Installation Considerations

    3.2.2 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.

  • Page 20: Mounting Considerations

    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 capability of the starter.

  • Page 21: Wiring Considerations

    3 - INSTALLATION Wiring Considerations Wiring Considerations 3.4.1 Wiring Practices When making power and control signal connections, the following should be observed: • Power wiring to the motor must have the maximum possible separation from all other wiring. Do not run control wiring in the same conduit;...

  • Page 22: Power And Control Drawings

    3 - INSTALLATION Power and Control Drawings Power and Control Drawings 3.5.1 MX2 ATL Synchronous Brushtype (Field Control) Solid State Figure 2: Power Schematic for RB2 Low HP...

  • Page 23: Mx2 Atl Synchronous Brushtype With Contactors

    3 - INSTALLATION 3.5.2 MX2 ATL Synchronous Brushtype with contactors Figure 3: MX2 ATL Synchronous Brushtype with contactors...

  • Page 24: Mx2 Atl Synchronous Brushless

    3 - INSTALLATION 3.5.3 MX2 ATL Synchronous Brushless Figure 4: MX2 ATL Synchronous Brushless...

  • Page 25: Power Wiring

    3 - INSTALLATION Power Wiring Power Wiring 3.6.1 Recommended Incoming Line Protection A semi-conductor fuse is needed. The fuse shall be 150% of the DC Field Amps from motor. A HCJ fuse is recommended. Input Line Requirements The input line source needs to be an adequate source, generally 2 times the rating of the motor rotor FLA. (This may not apply in some cases such as being connected to a generator).

  • Page 26: Torque Requirements For Power Wiring Terminations

    3 - INSTALLATION 3.6.5 Torque Requirements for Power Wiring Terminations Table 9: Slotted Screws and Hex Bolts Tightening torque, pound-inches (N-m) Wire size installed in conductor Hexagonal head-external drive socket Slotted head NO. 10 and larger wrench Slot width-0.047 inch Slot width-over 0.047 (1.2mm) or less and inch (1.2mm) or slot...

  • Page 27: Control Card Layout

    3 - INSTALLATION Control Card Layout Control Card Layout Figure 5: Control Card Layout Jumper Jumper Jumper Jumper Jumper Jumper 120 VAC Stack In (Benshaw Only) Unfused 120 VAC Out Stack Control Control Power 120 VAC SCR 1 Auxiliary Relays SCR 4...

  • Page 28: Control Wiring

    3 - INSTALLATION Control Wiring Control Wiring 3.8.1 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 6: Control Power Wiring Example 120VAC NEUTRAL 120VAC LIVE...

  • Page 29: Digital Input Wiring Options

    3 - INSTALLATION 3.8.3 Digital Input Wiring Options TB3 is for the digital inputs. The digital inputs use 120VAC. The digital inputs are as follows: 1 - Start: Start Input 2 - DI1: Digital Input 1 3 - DI2: Digital Input 2 4 - DI3: Digital Input 3 5 - Com: 120VAC neutral Figure 8: Digital Input Wiring Examples...

  • Page 30: Analog Output

    3 - INSTALLATION 3.8.4 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 TB5 is SW1-2. When the switch is in the off position, the output is current. When on, it is a Voltage loop output.

  • Page 31: Remote Lcd Keypad/Display

    3 - INSTALLATION Remote LCD Keypad/Display Remote LCD Keypad/Display The display has a NEMA 13/IP65 service rating. The display is available in 2 versions, a small display as P/N KPMX3SLCD and large display as P/N KPMX3LLCD. 3.9.1 Remote Display The MX SEP control has one of two types of keypads, either a LED display or a LCD display.

  • Page 32: Installing Display

    3 - INSTALLATION 3.9.3 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. •...
  • Page 33 Keypad Operation...

  • Page 34: Keypad Operation

    4 - KEYPAD OPERATION Introduction Introduction The MX SEP provides a comprehensive set of parameters. While the controller can meet the requirements of many applications right out of the box, customization of parameter values to better suit your particular application is easily accomplished with the standard, on-board, 4-digit, 7-segment LED display/keypad.

  • Page 35: Changing Parameter Values

    4 - KEYPAD OPERATION Changing Parameter Values Changing Parameter Values Parameter change mode can be entered by: At the default meter display, press the [PARAM] key to enter parameter mode. Use the [UP] and [DOWN] keys to scroll through the available parameters. The value of the parameter can be viewed by pressing the [ENTER] key.

  • Page 36: Messages Displayed

    4 - KEYPAD OPERATION Messages Displayed Messages Displayed In addition to being able to view and change parameters, various special messages may be displayed during different conditions. Here is a summary of the possible special messages. The following sections provide more detail for some of the conditions that cause special messages to be displayed. LED Display No line voltage Ready...

  • Page 37: Power Up

    4 - KEYPAD OPERATION LCD Display Stopped Controller Stopped Fault Controller tripped on a Fault Lockout Controller is locked out due to a unusual condition being present Controller is monitoring start and waiting for command and/or timer to expire before applying field Wait current.

  • Page 38: Lockout Condition

    4 - KEYPAD OPERATION 4.5.5 Lockout Condition When a lockout condition exists, the display shows the lockout code. The lockout code is displayed as “L XX”: where XX is the lockout code. Following are the defined lockout conditions and their codes: •...

  • Page 39: Jump Code

    4 - KEYPAD OPERATION Jump Code 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 Restoring Factory Parameter Settings To restore ALL parameters to the factory default settings, press and hold the [PARAM] and [ENTER] pushbutton switch on power up.

  • Page 40: 2X16 Remote Lcd Keypad

    4 - KEYPAD OPERATION Remote LCD Keypad and Display 2x16 Remote LCD Keypad Like the standard keypad, the remote LCD keypad has the same basic functions with enhancements that allow using plain text instead of codes and a menu structure instead of a straight line of parameters. Additional keys have been added, such as [MENU], [STOP], and a [LEFT] arrow for moving the cursor around in the LCD display.

  • Page 41: Description Of The Keys On The Remote Lcd Keypad

    4 - KEYPAD OPERATION Description of the Keys on the Remote LCD Keypad 4.11 Description of the Keys on the Remote LCD Keypad The [UP] arrow, [DOWN] arrow, [ENTER] and [MENU] keys on the LCD keypad perform the same functions as the [UP], [DOWN], [ENTER] and [PARAM] keys on the standard keypad.

  • Page 42: Alphanumeric Display

    4 - KEYPAD OPERATION Alphanumeric Display 4.12 Alphanumeric Display The remote LCD keypad and display uses a 32-character alphanumeric LCD display. All controller functions can be accessed by the keypad. The keypad allows easy access to starter programming with parameter descriptions on the LCD display. Power UP Screen On power up, the software part number is displayed for five seconds.

  • Page 43: Parameter Group Screens

    4 - KEYPAD OPERATION Table 13: Operate Screen Section B Display Description Stopped Starter is stopped and no Faults Fault Starter tripped on a Fault Lockout Controller is locked out due to a unusual condition being present Syncing Controller is attempting to apply field and synchronize motor Synced Motor running synchronized Sync FF...

  • Page 44: Meter

    4 - KEYPAD OPERATION 4.12.2 Meter Pages Although any meter may be viewed by changing the two Meter parameters (FUN 01 & FUN 02), there are 6 “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.

  • Page 45: Fault Screen

    4 - KEYPAD OPERATION Press [MENU] until you get to the FL1 parameter. Pressing the [UP] and [DOWN] keys navigates through older and newer faults in the log. Repeatedly pressing the [ENTER] key rotates through the conditions the controller was in when the fault occurred. Enter Step Fault Number and Description.

  • Page 46: Procedure For Setting Data

    4 - KEYPAD OPERATION Procedure for Setting Data 4.13 Procedure for Setting Data Select a parameter that is to be changed. To change the Current Setpoint from 10 Amps to 30 Amps: From the main screen: T Ready Ia= 0.0A Stopped Va= 480 V Press [MENU] key and the display shows QST: (Quick Start) screen.
  • Page 47 4 - KEYPAD OPERATION...
  • Page 48 4 - KEYPAD OPERATION NOTES:...
  • Page 49 Parameter Groups...

  • Page 50: Parameter Groups

    5 - PARAMETER GROUPS Introduction Introduction The MX SEP incorporates a number of parameters that allow you to configure the controller to meet the special requirements of your particular application. The parameters are organized two ways, depending on the display being used. When the standard, on-board LED display is used, the parameters are in a single group and numbered P1, P2, P3…...

  • Page 51: Led And Lcd Display Parameters Cross Reference & Control Mode Reference

    5 - PARAMETER GROUPS LED & LCD Display Parameters Cross Reference LED and LCD Display Parameters Cross Reference & Control Mode Reference Parameter Control Page Parameter Control Page Group Parameter Name Group Parameter Name Number Mode Number Mode QST 01 B, BL, CF Current Setpoint B, BL, CF DI 1 Function I/O 01...

  • Page 52: Led Display Parameters

    5 - PARAMETER GROUPS LED Display Parameters LED Display Parameters Adjust Number Parameter Setting Range Step Size Units Default During Page Current Setpoint 1–1000 Arms Slip Percentage 0.5–10.0 Field Application Delay OFF, 0.1–10.0 Field Forcing Level 50–125 Field Forcing Time OFF, 0.1–90.0 Incomplete Sequence Time 1–200...
  • Page 53 5 - PARAMETER GROUPS Adjust Number Parameter Setting Range Step Size Units Default During Page Auto Fault Reset Delay Time OFF, 1–900 Auto Fault Reset Cnt OFF, 1–10 – Controlled Fault Stop Enable On, Off Input Phase Sensitivity AbC, Cba, InS, SPH –...
  • Page 54 5 - PARAMETER GROUPS Adjust Number Parameter Setting Range Step Size Units Default During Page 0: OFF (no output) 1: Ave. Current (0–200%) RFA) 2: Ave. Voltage (0–150% Rated) Analog Output Function 3: Motor Slip % (0–100%) – 4: Analog Input (0–100%) 5: Output Voltage (firing angle) 6: Calibrate (full 100% output) Analog Output Span...

  • Page 55: Lcd Display Parameters

    5 - PARAMETER GROUPS LCD Display Parameters LCD Display Parameters The 2x16 display has the same parameters available as the LED display, with the exception of two meter parameters instead of one since two meters may be displayed on the main screen. The parameters are subdivided into five groups. The groups are QST (Quick Start), CFN (Control Functions), I/O (Input/Output Functions), PFN (Protection Functions) and FUN (Function).

  • Page 56: Control Function Group

    5 - PARAMETER GROUPS 5.4.2 Control Function Group Adjust Number Display Parameter Setting Range Units Default During Page CFN 00 Jump Code Jump to Parameter 1 to 11 CFN 01 Slip Percent Slip Percentage 0.5 – 10.0 CFN 02 F Apply Dly Field Application Delay Time OFF, 0.1 –...

  • Page 57: I/O Group

    5 - PARAMETER GROUPS 5.4.4 I/O Group Adjust Number Display Parameter Setting Range Units Default During Page I/O 00 Jump Code Jump to parameter 1 to 19 I/O 01 DI 1 Config DI 1 Configuration OFF: Off StOP: Stop I/O 02 DI 2 Config DI 2 Configuration inch: Inching...

  • Page 58: Function Group

    5 - PARAMETER GROUPS 5.4.5 Function Group Adjust Number Display Parameter Setting Range Units Default During Page FUN 00 Jump to Parameter 1 to 16 Ave Current FUN 01 Meter 1 LCD Meter 1 Ave Volts Current L1-L2 Volts L2-L3 Volts L3-L1 Volts Slip Percent Phase Order...

  • Page 59: Lcd Fault Group

    5 - PARAMETER GROUPS 5.4.6 LCD Fault Group Fault Controller Group Fault Description Time Number State 5.4.7 LED Fault Group Fault Fault Group Fault Description Fault Description Number Number...
  • Page 60 5 - PARAMETER GROUPS NOTES...
  • Page 61 Parameter Description...

  • Page 62: Parameter Description

    6 - PARAMETER DESCRIPTION Parameter Descriptions Parameter Descriptions The detailed parameter descriptions in this chapter are organized in the same order as they appear on the LED display. If the remote LCD display is being used, the table in chapter 5 beginning on page 49 can be used to find the page number of the parameter in this chapter.
  • Page 63 6 - PARAMETER DESCRIPTION Jump to Parameter QST 00 By changing the value of this parameter and pressing [ ENTER ], you can jump directly to any parameter within that group. Current Setpoint QST 01 LED Display LCD Display: QST: Cur Setpoint 10 Amp Range 1 –...
  • Page 64 6 - PARAMETER DESCRIPTION Inc Seq Time QST 03 LED Display LCD Display QST: Inc Seq Time 30 sec Range 1– 200 (Default 30) Description The Incomplete sequence timer sets how long the motor has to reach synchronization before the controller trips on an incomplete sequence fault.
  • Page 65 Local Source (P37 / QST 04) parameter on page 58. Digital Input Configuration (P40-P42 / I/O 01-03) parameters on page 72. Keypad Stop Disable (P58 / I/O 14) parameter on page 77. Modbus Register Map, refer to www.benshaw.com. Figure 16: Local Remote Source Local Source “Local/Remote”...
  • Page 66 6 - PARAMETER DESCRIPTION Jump to Parameter CFN 00 By changing the value of this parameter and pressing [ENTER], you can jump directly to any parameter within that group. Slip Percent CFN 01 LED Display LCD Display CFN: Slip Percent 5.0 % Range 0.5 –...
  • Page 67 6 - PARAMETER DESCRIPTION Field Force Lvl CFN 03 LED Display LCD Display CFN: F Force Lvl 120 % Range 50 – 125 % (Default 120%) Description The Field Force Level allows a user to over drive the field at synchronization for a programmed time. This is most commonly used where the load takes more time to stabilize or the application requires a higher magnitude of torque to synchronize.
  • Page 68 6 - PARAMETER DESCRIPTION See Also Dynamic Brake Level (P11 / CFN 06) on page 62. Dynamic Brake Time (P12 / CFN 07) on page 62. Dynamic Brake Delay (P13 / CFN 08) on page 62. Dynamic Brake Level CFN 06 LED Display LCD Display CFN: Brake Level...
  • Page 69 6 - PARAMETER DESCRIPTION Inch Field Level CFN 09 LED Display LCD Display CFN: Inch Field 100 % Range 75 – 125 % (Default 100 %) Description The inching field level parameter sets the field current level that will be applied when the controller is in inching mode.
  • Page 70 6 - PARAMETER DESCRIPTION Jump to Parameter PFN 00 By changing the value of this parameter and pressing [ENTER], you can jump directly to any parameter within that group. Open Field Trip Time PFN 01 LED Display LCD Display PFN: Open Field T 1.0 sec Range Off, 0.1 –...
  • Page 71 6 - PARAMETER DESCRIPTION Over Current Time PFN 03 LED Display LCD Display PFN: Over Cur Tim 1.0 sec Range Off, 0.1 – 90.0 seconds(Default 1.0 s) Description The Over Current Trip Time parameter sets the period of time that the motor field current must be greater than the Over Current Level (PFN 02) parameter before an over current fault and trip occurs.
  • Page 72 6 - PARAMETER DESCRIPTION Under Current Time PFN 05 LED Display LCD Display PFN: Undr Cur Tim 1.0 sec Range Off, 0.1 – 90.0 seconds (Default 1.0 s) Description The Under Current Trip Time parameter sets the period of time that the motor field current must be less than the Under Current Level (PFN 04) parameter before an under current fault and trip occurs.
  • Page 73 6 - PARAMETER DESCRIPTION Voltage Trip Time PFN 08 LED Display LCD Display PFN: Vlt Trip Tim 0.1 sec 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 (PFN 06) or Under Voltage (PFN 07) condition must exist before a fault occurs.
  • Page 74 6 - PARAMETER DESCRIPTION Under Freq Level PFN 11 LED Display LCD Display PFN: Undr Frq Lvl 23 Hz Range 23 – 71 Hz (Default 23 Hz) Description The Under Frequency Level parameter sets the lowest line frequency that the controller will operate on. When operating on line power, the default setting will usually suffice.
  • Page 75 6 - PARAMETER DESCRIPTION Auto Reset Limit PFN 14 LED Display LCD Display PFN: Auto Rst Lim Range Off, 1 – 10 (Default Off) Description The Auto Reset Limit parameter sets the number of times that an auto reset may occur. Once the Auto Reset Limit is reached, faults will no longer be automatically reset.
  • Page 76 6 - PARAMETER DESCRIPTION Pullout Mode PFN 16 LED Display LCD Display PFN: Pullout Mode 16 Fault Immed Range Fault Immed, Retry, Ride Thru (Default Fault Immed) Description The pullout mode selects the controllers response to a slipped pole. The controller can be set to either trip immediately, try a number of resynchronization attempts, or attempt to ride through the situation.
  • Page 77 6 - PARAMETER DESCRIPTION Resync Tries PFN 18 LED Display LCD Display PFN: Resync Tries Range 1 – 10 (Default 1) Description When Pullout Mode (P7 / PFN 16) is set as "Retry" the controller will try to resync the motor the number of times this parameter is set to.
  • Page 78 6 - PARAMETER DESCRIPTION Jump to Parameter I/O 00 By changing the value of this parameter and pressing [ENTER], you can jump directly to any parameter within that group. P40,41,42 Digital Input Configuration I/O 01,02,03 LED Display LCD Display I/O: DI 1 Config I/O: DI 2 Config I/O: DI 3 Config Range...
  • Page 79 6 - PARAMETER DESCRIPTION P44,45,46 Relay Output Configuration I/O 05, 06, 07 LED Display LCD Display I/O: R1 Config 05 Interlock FS I/O: R2 Config 06 FS1 I/O: R3 Config 07 Running Range Description Off, Not Assigned. May be controlled over Modbus FLFS Fault FS Faulted –...
  • Page 80 6 - PARAMETER DESCRIPTION FCA Delay Timer I/O 08 LED Display LCD Display I/O: FCA Delay Range Off, 0.1 – 90.0 seconds (Default Off) Description The FCA delay timer controls the "Fld Cont Aux" relay. Once the controller has synchronized the motor, it will count down this timer and then energize any relay programmed as "Fld Cont Aux"...
  • Page 81 6 - PARAMETER DESCRIPTION Analog Output Span I/O 10 LED Display LCD Display I/O: Aout Span 100 % Range 1 – 125% (Default 100%) Description The analog output signal can be scaled using the Analog Output Span parameter. For a 0-10V output or 0-20mA output, a 100% scaling outputs the maximum voltage (10V) or current (20mA) when the selected output function requests 100% output.
  • Page 82 6 - PARAMETER DESCRIPTION Inline Configuration I/O 12 LED Display LCD Display I/O: Inline Confg 3.0 sec Range Off, 0 – 10.0 seconds (Default 3.0) Description The Inline Configuration parameter controls the behavior of the No Line warning, No Line fault, and the Ready relay function.
  • Page 83 6 - PARAMETER DESCRIPTION Keypad Stop Disable I/O 14 LED Display LCD Display I/O: Keypad Stop 14 Enabled Range Description Disabled Keypad Stop does not stop the starter Enabled Keypad Stop does stop the starter (Default) Description If “Disabled” When this parameter is set to "Disabled", the keypad [STOP] button is de-activated. This should be done with caution, as the [STOP] button will not stop the starter.
  • Page 84 6 - PARAMETER DESCRIPTION Jump to Parameter FUN 00 By changing the value of this parameter and pressing [ENTER], you can jump directly to any parameter within that group. Meter 1 ,Meter 2 FUN 01, 02 LED Display LCD Display FUN: Meter 1 01 Ave Current FUN: Meter 2...
  • Page 85 6 - PARAMETER DESCRIPTION Hall Effect Ratio FUN 03 LED Display LCD Display FUN: HE Ratio 2000:1 Range 1000:1, 2000:1, 5000:1 (Default 2000:1) Description The Hall Effect (LEM) ratio parameter selects Hall Effect Ratio Number of Turns Burden Resistance (Ohms) Current Low Current High (P36/FUN04)
  • Page 86 6 - PARAMETER DESCRIPTION Input Phase Sensitivity FUN 05 LED Display LCD Display FUN: Phase Order 05 Insensitive Range Description Insensitive Runs with any three phase sequence. (Default) Only runs with ABC phase sequence. Only runs with CBA phase sequence. Single Phase Single Phase.
  • Page 87 6 - PARAMETER DESCRIPTION Reserved FUN 08 LED Display LCD Display FUN: Reserved Range Description Control Type FUN 09 LED Display LCD Display FUN: Control Type 09 Field Ctl Range Description Fct 1 Field Ctl Brush type motor field controller. See Brushtype control in section 7.1.1 on page 86.
  • Page 88 6 - PARAMETER DESCRIPTION Communication Baudrate FUN 11 LED Display LCD Display FUN: Com Baudrate 11 19200 Range 1200, 2400, 4800, 9600, 19200 bps (Default 19200) Description The Communication Baud Rate parameter sets the baud rate for Modbus communications. See Also Local Source (QST 04) parameter on page 58.
  • Page 89 The Software Part Number parameter displays the MX SEP software version, for hardware BIPC-300063-01. When calling Benshaw for service, this number should be recorded so it can be provided to the service technician. In addition to viewing the software version with this parameter, the software version is also displayed on power up.
  • Page 90 6 - PARAMETER DESCRIPTION Passcode FUN 16 LCD Display FUN: Passcode 16 Off Description The MX SEP supports a 4-digit passcode. When the passcode is set, parameters may not be changed. The MX SEP 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] key is ignored.
  • Page 91 Theory of Operation...

  • Page 92: Theory Of Operation

    7 - THEORY OF OPERATION Control Modes of Synchronous Motor Operation Control Modes of Synchronous Motor Operation 7.1.1 Brush Type (Field Control) Synchronous Motor Operation Description: The brush type (field control) synchronous motor will start as an induction motor. The field winding will generate an AC voltage during starting and a resistor must be connected to the winding to control the voltage levels generated.

  • Page 93: Brushless Type Synchronous Motor Operation

    7 - THEORY OF OPERATION 7.1.2 Brushless Type Synchronous Motor Operation Description: The brushless type synchronous motor will start as an induction motor. The brushless motor has an auxiliary generator installed on the motor shaft that provides the field current. All of the field controls are installed on the rotor of the motor. The external motor controller just has to provide the DC field current for the auxiliary generator at the appropriate time.

  • Page 94: Use Hall Effect Current Sensor

    7 - THEORY OF OPERATION Hall Effect Current Sensor Use Hall Effect Current Sensor The Hall Effect Current sensor is connected to the analog input of the MX SEP 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.
  • Page 95 7 - THEORY OF OPERATION Hall Effect Connections (0 – 200 DC Amps) GO TO LEM + M - White Black COMMON BURDEN RESISTOR (SEE P.35/FUN03) 300063-01-xx (MX² CARD) 300044-02-01 (SYNC CARD)

  • Page 96: Simplified I/O Schematics

    7 - THEORY OF OPERATION Simplified I/O Schematics Simplified I/O Schematics Figure 19: Digital Input Simplified Schematic Figure 20: Analog Input Simplified Schematic Figure 21: Analog Output Simplified Schematic...

  • Page 97: Remote Modbus Communications

    7 - THEORY OF OPERATION Remote Modbus Communications Remote Modbus Communications The MX2 SEP starter provides a 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).

  • Page 98: Wiring

    7 - THEORY OF OPERATION 7.4.7 Wiring Figure 22 shows the wiring of TB4 to a Modbus-485 Network. If the starter is the end device in the network, a 120 , 1/4W terminating resistor may be required. Please refer to Figure 23 for wire and termination. Figure 22: TB4 Connector...
  • Page 99 7 - THEORY OF OPERATION Figure 23: Modbus Network Wiring Example IMPORTANT DO NOT CREATE STUBS - CABLE MUST GO TO EACH STARTER. Right Wrong...

  • Page 100: Dynamic Braking

    7 - THEORY OF OPERATION Dynamic Braking Dynamic Braking The dynamic braking can be used to quickly stop the motor. The motor is used as a generator and the energy from the motor is dissipated into resistors. Dynamic Braking only works on Brush type motors. Braking operation sequence Figure 24: MX2 ATL Synchronous Brushtype with DB Braking Resistor The dynamic braking resistor is sized to 3X the motor FLA at rated motor voltage.
  • Page 101 Troubleshooting & Maintenance...

  • Page 102: Troubleshooting & Maintenance

    8 - TROUBLESHOOTING & MAINTENANCE Safety Precautions Safety Precautions For safety of maintenance personal as well as others who might be exposed to electrical hazards associated with maintenance activities, the safety related work practices of NFPA 70E, Part II, should always be followed when working on electrical equipment. Maintenance personnel must be trained in the safety practices, procedures, and requirements that pertain to their respective job assignments.

  • Page 103: General Troubleshooting Charts

    8 - TROUBLESHOOTING & MAINTENANCE General Troubleshooting Charts 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 not start, no output to motor Condition Cause Solution Display Blank, CPU Heartbeat LED on...

  • Page 104: During Starting, Motor Rotates But Does Not Reach Full Speed

    8 - TROUBLESHOOTING & MAINTENANCE 8.3.2 During starting, motor rotates but does not reach full speed Condition Cause Solution Fault Displayed. Fault Occurred. See fault code troubleshooting table for more details. 8.3.3 Motor stops unexpectedly while running Condition Cause Solution Fault Displayed.

  • Page 105: Metering Incorrect (Hall Effect)

    8 - TROUBLESHOOTING & MAINTENANCE 8.3.4 Metering incorrect (Hall Effect) Condition Cause Solution Current or Voltage meters fluctuating Loose connections. Shut off all power and check all connections. with steady load SCR fault. Verify that the SCRs gate leads are connected properly and the SCRs are Load actually is not steady.

  • Page 106: Other Situations

    8 - TROUBLESHOOTING & MAINTENANCE 8.3.5 Other Situations Condition Cause Solution Erratic Operation Loose connections Shut off all power and check all connections Controller cooling fans do not operate Fan power supply lost Verify fan power supply, check fuses. (When Present) Fan wiring problem Check fan wiring.

  • Page 107: Fault Code Table

    8 - TROUBLESHOOTING & MAINTENANCE Fault Code Table Fault Code Table The following is a list of possible faults that can be generated by the MX2 SEP starter control. Fault Code Description Detailed Description of Fault / Possible Solutions Slip percentage (P2 / CFN 01) is set too low. Incomplete Sequence Incomplete Sequence Time (P6 / QST 03) is set too low.
  • Page 108 8 - TROUBLESHOOTING & MAINTENANCE Fault Code Description Detailed Description of Fault / Possible Solutions Low Line L2-L3 Low voltage below the Under voltage Trip Level parameter setting (P25/PFN07) was detected for longer than the Over/Under Voltage Trip delay time (P26/PFN08). Verify that the actual input voltage level is correct.
  • Page 109 8 - TROUBLESHOOTING & MAINTENANCE Fault Code Description Detailed Description of Fault / Possible Solutions No Line No input voltage was detected for longer than the Inline Configuration time delay parameter setting (P49/ I/O12) 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 (P49/ I/O12) allows enough time for the inline contactor to completely close.
  • Page 110 8 - TROUBLESHOOTING & MAINTENANCE Fault Code Description Detailed Description of Fault / Possible Solutions Current Sensor Offset Error Indicates that the MX control card self-diagnostics have detected a problem with one or more of the current sensor inputs. Verify that the Current Setpoint (P1/QST01) and HE Sensor Turns (P36/FUN04) and burden switch settings are correct.
  • Page 111 8 - TROUBLESHOOTING & MAINTENANCE Fault Code Description Detailed Description of Fault / Possible Solutions CPU Error – Parameter EEPROM The MX SEP found the non-volatile parameter values to be corrupted. Checksum Fault Typically occurs when the MX SEP is re-flashed with new software. Perform a Factory Parameter reset and then properly set all parameters before resuming normal operation.

  • Page 112: Scr Testing

    8 - TROUBLESHOOTING & MAINTENANCE SCR Testing SCR Testing 8.5.1 Resistance The SCRs in the controller can be checked with a standard ohmmeter to determine their condition. Remove power from the controller before performing these checks. Check L to F+ for each phase. The resistance should be over 50k ohms. Check L to F- for each phase.

  • Page 113: Built In Self Test Functions

    8 - TROUBLESHOOTING & MAINTENANCE Built-In Self Test Functions Built In Self Test Functions The MX SEP has 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. 8.7.1 Powered BIST Tests: The powered BIST tests are designed to be run with normal line voltage applied to the starter and a motor connected.

  • Page 114: Scr Replacement

    8 - TROUBLESHOOTING & MAINTENANCE Step 4 LED Display LCD Display b-- (tests completed) Tests completed. BIST Mode Tests completed The controller will reset back to normal operation once the BIST is complete. Pressing [ENTER] on the keypad at any time will abort the BIST test.. NOTE: The powered BIST tests will verify that the input phase order is correct.

  • Page 115: Scr Clamp

    8 - TROUBLESHOOTING & MAINTENANCE 8.8.4 SCR Clamp Below is an exploded view of a typical SCR clamp. Refer to the Clamp Parts List below for names of the parts being used. SCR CLAMP PARTS Item # Quantity Description Loader Bar Insulator cup Bolt Washer...
  • Page 116 8 - TROUBLESHOOTING & MAINTENANCE NOTES...
  • Page 117 Appendices...

  • Page 118: Appendix A Alarm Codes

    APPENDIX A - ALARM CODES Alarm Codes The following is a list of all MX2 SEP 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 Description Notes...
  • Page 119 APPENDIX A - ALARM CODES Alarm Description Notes Code This alarm exists while the MX2 SEP SEP is running and a current imbalance above the defined threshold is detected, Current Imbalance but the delay for the fault has not yet expired. When the delay expires, a Fault 37 occurs.

  • Page 120: Appendix B Fault Codes

    APPENDIX B - FAULT CODES Fault Codes Fault Code Description Controlled Fault Stop Shunt Trip Fault Auto-Reset Allowed No fault Incomplete Sequence Loss of Synchronization Low Line Frequency High Line Frequency Input power not single phase Input power not three phase Low Line L1-L2 Low Line L2-L3 Low Line L3-L1...

  • Page 121: Appendix C Spare Parts

    APPENDIX C - SPARE PARTS Options and Accessories Description Part Number Size LCD Display (small) KPMX3SLCD H=63mm (2.48"), W=101mm (4") LCD Display (large) KPMX3LLCD H=77mm (3.03"), W=127mm (5") RI-100008-00 3' or 1 meter LCD display cable RI-100009-00 6' or 2 meter Communication Modules -consult factory Spare Parts...

  • Page 122: Appendix D Eu Declaration Of Conformity

    MX2SEP-250VDC-025A-1-S-C MX2SEP-250VDC-050A-1-S-C MX2SEP-250VDC-100A-1-S-C MX2SEP-250VDC-200A-1-S-C MX2SEP-250VDC-400A-1-S-C MX2SEP-250VDC-600A-1-S-C Manufacturer's Name: Benshaw, Inc. Manufacturer's Address: 1659 East Sutter Road Glenshaw, 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.

  • Page 123: Appendix E Modbus Register Map

    APPENDIX E - MODBUS REGISTER MAP Modbus Register Map Following is the Modbus Register Map. Note that all information may be accessed either through the Input registers (30000 addresses) or through the Holding registers (40000 addresses). Absolute Register Address Description Range Units Bit Mask:...
  • Page 124 APPENDIX E - MODBUS REGISTER MAP Absolute Register Address Description R/W Range Units 30100/40100 Running Field Amps R/W 1 – 1000 Arms 30101/40101 etc... Fault Code – Most Recent Fault 30601/40601 Log Entry Fault Code – 2nd Most Recent 30602/40602 Fault Log Entry Fault Code –...
  • Page 125 APPENDIX E - MODBUS REGISTER MAP Absolute Register Address Description R/W Range Units Voltage L1 – 2nd Most Recent 30632/40632 Vrms Fault Log Entry Voltage L1 – 3rd Most Recent 30633/40633 Vrms Fault Log Entry Voltage L1 – 4th Most Recent 30634/40634 Vrms Fault Log Entry...
  • Page 126 APPENDIX E - MODBUS REGISTER MAP Absolute Register Address Description Range Units Line Period – 5th Most Recent 30665/40661 micro-seconds Fault Log Entry Line Period – 6th Most Recent 30666/40661 micro-seconds Fault Log Entry Line Period – 7th Most Recent 30667/40661 micro-seconds Fault Log Entry...
  • Page 127 APPENDIX E - MODBUS REGISTER MAP Controller Control Register 0 to 0: Stop 0 to 1: Start Bit 0 – Run/Stop 1 to 1: No action 1 to 0: Stop 0 to 0: No action 0 to 1: Fault Reset Bit 1 –...

  • Page 128: Appendix F Parameter Tables

    APPENDIX F - 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 Adjust User Number Display Parameter Setting Range Units Default During...
  • Page 129 APPENDIX F - PARAMETER TABLES Protection Function Group Adjust Number Display Parameter Setting Range Units Default During Page User Settings PFN 00 Jump to Parameter 1 to 18 PFN 01 Open Field T Open Field Trip Time OFF, 0.1 – 90.0 PFN 02 Over Cur Lvl Over Current Level...
  • Page 130 APPENDIX F - PARAMETER TABLES I/O Group Adjust User Number Display Parameter Setting Range Units Default During Page Settings I/O 00 Jump Code Jump to parameter 1 to 19 I/O 01 DI 1 Config DI 1 Configuration OFF: Off StOP: Stop I/O 02 DI 2 Config DI 2 Configuration...
  • Page 131 APPENDIX E - MODBUS REGISTER MAP Function Group Adjust User Number Display Parameter Setting Range Units Default During Page Settings FUN 00 Jump to Parameter 1 to 16 FUN 01 Meter 1 LCD Meter 1 Ave Current Ave Current Ave Volts L1-L2 Volts L2-L3 Volts L3-L1 Volts...
  • Page 132 APPENDIX F - PARAMETER TABLES LCD Fault Group Fault Controller Group Fault Description Time Number State LED Fault Group Fault Fault Group Fault Description Fault Description Number Number...
  • Page 133 Publication History; Revision Date ECO# 02/07/08 E1970...
  • Page 134 BENSHAW 615 Alpha Drive Pittsburgh, PA 15238 Phone: (412) 968-0100 Fax: (412) 968-5415 BENSHAW Canada 550 Bright Street Listowel, Ontario N4W 3W3 Phone: (519) 291-5112 Fax: (519) 291-2595...

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