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BENSHAW RediStart RB2 User Manual

Solid state starter mx2 control
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890034-01-02
August 2008
Software Version:
810023-01-08
Hardware Version:
300055-01-05
©
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
Control
RB2, RC2, RX2E Models
User Manual
TM

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Summary of Contents for BENSHAW RediStart RB2

  • Page 1 August 2008 Software Version: 810023-01-08 Hardware Version: 300055-01-05 © 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 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.
  • Page 3 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. •...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Table of Contents 1 INTRODUCTION ..........2 1.1 Additional MX Product Features.
  • Page 5 TABLE OF CONTENTS 3.6 Power Wiring ..........35 3.6.1 Recommended Incoming Line Protection .
  • Page 6 TABLE OF CONTENTS 5 PARAMETER GROUPS ......... 60 5.1 Introduction .
  • Page 7 TABLE OF CONTENTS 7.8 Wye Delta Starter ..........160 7.9 Across The Line (Full Voltage Starter) .
  • Page 8 TABLE OF CONTENTS APPENDIX A ALARM CODES ........194 APPENDIX B FAULT CODES .
  • Page 9 Introduction...

  • Page 10: 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 11 See page 213. Warranty 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.
  • Page 12 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 13: Additional Mx 3 Product Features

    If you require additional features, please review the expanded feature set of the MX Solid State Starter below. For the additional information on the MX Solid State Starter contact Benshaw. Product Features 5 Additional Digital Inputs...
  • Page 14 1 - INTRODUCTION Interpreting Model Numbers Figure 1: RediStart MX Series Model Numbers RB2-1-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...
  • Page 15 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: •...
  • Page 16 1 - INTRODUCTION NOTES:...
  • Page 17 2 Technical Specifications...

  • Page 18: 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 19: Measurements And Accuracies

    2 - TECHNICAL SPECIFICATIONS Table 1: Terminals Terminal Function Terminal Number Description Block J6 to J11 1: Gate SCR gate Connections 2: Cathode Phase C.T. 1: CT1 See CT Connector 2: CT1 3: CT2 4: CT2 5: CT3 6: CT3 Wire Gauge: The terminals can support 1- 14 AWG wire or 2-16 AWG wire or smaller.

  • Page 20: Solid State Motor Overload

    The motor overload trip time will be reduced when there is a current imbalance present. NOTE: Refer to Theory of Operation, section 7.1 on page 132 for more motor overload details and a larger graph. Refer to http://www.benshaw.com/olcurves.html for an automated overload calculator.

  • Page 21: Ct Ratios

    2 - TECHNICAL SPECIFICATIONS 2.2.5 CT Ratios Table 3: CT Ratios Minimum FLA Maximum FLA CT Ratio (A rms) (A rms) 72:1 (4 wraps 288:1) 96:1 (3 wraps 288:1) 144:1 (2 wraps 288:1) 288:1 864:1 2640:1 3900:1 5760:1 1285 8000:1 1800 14400:1 3200...

  • Page 22: Standard Duty (350% For 30 Sec) Ratings

    2 - TECHNICAL SPECIFICATIONS 2.3.1 Standard Duty (350% for 30 sec) Ratings Table 4: Standard Duty Horsepower Ratings Standard Duty (350% current for 30 seconds, 115% Continuous) HORSEPOWER RATING NOMINAL MODEL NUMBER AMPS 200-208V 230-240V 380-400V 440-480V 575-600V RB2-1-S-027A-11C RB2-1-S-040A-11C RB2-1-S-052A-12C RB2-1-S-065A-12C RB2-1-S-077A-13C...

  • Page 23: Heavy Duty (500% Current For 30 Sec) Ratings

    2 - TECHNICAL SPECIFICATIONS 2.3.2 Heavy Duty (500% current for 30 sec) Ratings Table 5: Heavy Duty Horsepower Ratings Heavy Duty (500% current for 30 seconds, 125% Continuous) HORSEPOWER RATING NOMINAL MODEL NUMBER AMPS 200-208V 230-240V 380-400V 440-480V 575-600V RB2-1-S-027A-11C RB2-1-S-040A-11C RB2-1-S-052A-12C RB2-1-S-065A-12C...

  • Page 24: Severe Duty (600% Current For 30 Sec) Ratings

    2 - TECHNICAL SPECIFICATIONS 2.3.3 Severe Duty (600% current for 30 sec) Ratings Table 6: Severe Duty Horsepower Ratings Severe Duty (600% current for 30 seconds 125% Continuous) HORSEPOWER RATING NOMINAL MODEL NUMBER AMPS 200-208V 230-240V 380-400V 440-480V 575-600V RB2-1-S-027A-11C RB2-1-S-040A-11C RB2-1-S-052A-12C RB2-1-S-065A-12C...

  • Page 25: Inside Delta Connected Standard Duty (350% For 30 Sec) Ratings

    2 - TECHNICAL SPECIFICATIONS 2.3.4 Inside Delta Connected Standard Duty (350% for 30 sec) Ratings Table 7: Inside Delta Standard Duty Horsepower Ratings INSIDE DELTA Std Duty (350% start for 30 seconds 115% Continuous) HORSEPOWER RATING NOMINAL MODEL NUMBER AMPS 200-208V 220-240V 380-415V...

  • Page 26: Rb2 Power Stack Ratings And Protection Requirements

    2 - TECHNICAL SPECIFICATIONS 2.3.5 RB2 Power Stack Ratings and Protection Requirements...

  • Page 27: Power Stack Input Ratings With Protection Requirements For Separate Bypass

    2 - TECHNICAL SPECIFICATIONS 2.3.6 Power Stack Input Ratings with Protection Requirements for Separate Bypass...

  • Page 28: Power Stack Input Ratings With Protection Requirements For Rc No Bypass

    2 - TECHNICAL SPECIFICATIONS 2.3.7 Power Stack Input Ratings with Protection Requirements for RC No Bypass...

  • Page 29: Rb2 Starter Control Power Requirements

    2 - TECHNICAL SPECIFICATIONS 2.3.8 RB2 Starter Control Power Requirements Table 8: RB2 Starter CPT VA Requirements Power Power Recommended Recommended Model Number Required Model Number Required Min. TX size Min. TX size (VA) (VA) RB2-1-S-027A-11C RB2-1-S-240A-15C RB2-1-S-040A-11C RB2-1-S-302A-15C RB2-1-S-052A-12C RB2-1-S-361A-16C RB2-1-S-065A-12C RB2-1-S-414A-17C...

  • Page 30: Dimensions

    2 - TECHNICAL SPECIFICATIONS Mechanical Drawings Dimensions 2.4.1 RB2 Chassis with Integral Bypass Figure 3: RB2 - 27A - 96A Model RB2 27-65A 12.5 8.43 0.84 0.31 13.5 8.43 0.84 0.31 RB2 77-96A Figure 4: RB2 125 - 361A Model 19.5 12.27 13.25 0.31 RB2 125A...
  • Page 31 2 - TECHNICAL SPECIFICATIONS Figure 5: RB2 414 - 838A Model 27.66 18.5 26.25 0.31 RB2 414-590A 29.38 18.5 0.31 RB2 720A RB2 838A 27.75 26.6 23.5 0.31...

  • Page 32: Rc2 Chassis With No Bypass

    2 - TECHNICAL SPECIFICATIONS 2.4.2 RC2 Chassis with no Bypass Figure 6: RC2 0 - 124A Model RC2 27-52A 9.875 3.375 4.69 8-32 TAP 4.375 4.75 ¼-20 TAP RC2 65-77A 5.313 4.75 ¼-20 TAP RC2 96-124A Figure 7: RC2 156 - 590A Model 13.5 RC2 156-180A...

  • Page 33: 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 11 provides the derating percentage to be considered when using a starter above 3,300 feet (1000 meters).

  • Page 34: Approvals

    2 - TECHNICAL SPECIFICATIONS Approvals Approvals Control Card is UL, cUL Recognized Certificate of Compliance Certificate of Compliance CE Mark, See Appendix D on page 198.
  • Page 35 Installation...

  • Page 36: Installation

    3 - INSTALLATION Before You Start Before You Start 3.1.1 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.

  • Page 37: 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 38: Mounting Considerations

    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.

  • Page 39: 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: • 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;...

  • Page 40: Power And Control Drawings For Bypassed And Non Bypassed Power Stacks

    3 - INSTALLATION Power and Control Drawings for Bypassed and Non Bypassed Power Stacks Power and Control drawings for Bypassed and Non Bypassed Power Stacks Figure 8: Power Schematic for RB2 Low HP...
  • Page 41 3 - INSTALLATION Figure 9: Power Schematic for RB2 High HP...
  • Page 42 3 - INSTALLATION Figure 10: Power Schematic for RC2...

  • Page 43: Power Wiring

    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...

  • Page 44: Compression Lugs

    3 - INSTALLATION 3.6.5 Compression Lugs The following is a list of the recommended crimp-on wire connectors manufactured by Penn-Union Corp. for copper wire. Table 13: Single Hole Compression Lugs Wire Size Part # Wire Size Part # BLU-1/0S20 500 MCM BLU-050S2 BLU-2/0S4 600 MCM...

  • Page 45: Torque Requirements For Power Wiring Terminations

    3 - INSTALLATION 3.6.6 Torque Requirements for Power Wiring Terminations Table 15: 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 46: Current Transformers

    3 - INSTALLATION Table 16: Tightening Torque for Inside Hex Screws Socket size across flats Tightening torque inches (mm) Pound-inches (N-m) (3.2) (5.1) 5/32 (4.0) (11.3) 3/16 (4.8) (13.6) 7/32 (5.6) (16.9) ¼ (6.4) (22.6) 5/16 (7.9) (31.1) (9.5) (42.4) ½...

  • Page 47: Control Card Layout

    Figure 12: Control Card Layout 120 VAC 120 VAC 120 VAC 120 VAC 120 VAC Stack In Stack In Stack In Stack In Stack In (Benshaw Only) (Benshaw Only) (Benshaw Only) (Benshaw Only) (Benshaw Only) Unfused Unfused Unfused Unfused Unfused 120 VAC Out...

  • Page 48: Control Wiring

    3 - INSTALLATION Control Wiring Control Wiring 3.9.1 Control Power The 120VAC control power is supplied to TB1. The connections are as follows: 1 - Ground 2 - Neutral 3 - Neutral 4 - Line (120VAC) 5 - Line (120VAC) Figure 13: Control Power Wiring Example 120VAC NEUTRAL 120VAC LIVE...

  • Page 49: Digital Input Wiring Options

    3 - INSTALLATION 3.9.3 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 15: Digital Input Wiring Examples...

  • Page 50: Analog Input

    3 - INSTALLATION 3.9.4 Analog Input The analog input can be configured for voltage or current loop. The input is shipped in the voltage loop configuration unless specified in a custom configuration. Below TB5 is SW1-1. When the switch is in the on position, the input is current loop. When off, it is a voltage input.

  • Page 51: Sw1 Dip Switch

    3 - INSTALLATION 3.9.6 SW1 DIP Switch The 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. Switching to the up or top position is ON and switching towards card or down is OFF. Figure 18: DIP Switch Settings ANALOG INPUT ANALOG OUTPUT...

  • Page 52: Display Cutout

    3 - INSTALLATION 3.10.2 Display Cutout Figure 19: Small Display Keypad Mounting Dimensions Part # : KPMX3SLCD 101.00 [3.98"] 50.50 50.50 [1.99"] [1.99"] Figure 20: Large Display Keypad Mounting Dimensions Part # : KPMX3LLCD 127.00 [5.00"] 63.50 63.50 [2.50"] [2.50"]...

  • Page 53: Installing Display

    3 - INSTALLATION 3.10.3 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 54 3 - INSTALLATION NOTES:...
  • Page 55 Keypad Operation...

  • Page 56: Keypad Operation

    4 - KEYPAD OPERATION Introduction Introduction The MX provides a comprehensive set of parameters to allow the use of the reduced voltage solid state starter in nearly any industrial application. While the starter 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 57: 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 58: Running

    4 - KEYPAD OPERATION 4.5.3 Running When running, the display shows the selected meter function. The following meters can be selected using the Meter display parameter (P79). Avg. Voltage (RMS) Line Frequency TruTorque % Avg. RMS current L1-L2 Voltage (RMS) Analog Input % Power % Phase 1 RMS current...

  • Page 59: Restoring Factory Parameter Settings

    4 - KEYPAD OPERATION 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. The display blinks “dFLt”. Parameters unique to the motor starter applications need to be set again to appropriate values before motor operation.

  • Page 60: 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 [START], [STOP], and a [LEFT] arrow for moving the cursor around in the LCD display.

  • Page 61: 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 62: Jump Code

    4 - KEYPAD OPERATION Jump Code 4.12 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. Alphanumeric Display 4.13 Alphanumeric Display...

  • Page 63: Parameter Group Screens

    4 - KEYPAD OPERATION Table 20: Operate Screen Section B Display Description Stopped Starter is stopped and no Faults Fault Starter tripped on a Fault Heater Starter is on and heating motor Kick Starter is applying kick current to the motor Accel Starter is accelerating the load Kick 2...

  • Page 64: Meter Pages

    4 - KEYPAD OPERATION 4.13.2 Meter Pages Although any meter may be viewed by changing the two Meter parameters (FUN 01 & FUN 02), there are 13 “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 65: 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 starter was in when the fault occurred. Enter Step Fault Description.

  • Page 66: Procedure For Setting Data

    4 - KEYPAD OPERATION Procedure for Setting Data 4.14 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: T Ready Ia= 0.0A Stopped Va= 480 V Press [MENU] key and the display shows QST: (Quick Start) screen.
  • Page 67 Parameter Groups...

  • Page 68: Parameter Groups

    5 - PARAMETER GROUPS Introduction Introduction 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 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 69: Led And Lcd Display Parameters Cross Reference

    5 - PARAMETER GROUPS LED & LCD Display Parameters Cross Reference LED and LCD Display Parameters Cross Reference Parameter Parameter Group Parameter Name Page # Group Parameter Name Page # Number Number QST 01 Motor FLA PFN 11 Auto Reset Limit QST 02 Motor Service Factor PFN 12 Controlled Fault Stop Enable QST 03...

  • Page 70: Led Display Parameters

    5 - PARAMETER GROUPS LED Display Parameters LED Display Parameters Number Parameter Setting Range Units Default Page Motor FLA 1 – 6400 RMS Amps Motor Service Factor 1.00 – 1.99 1.15 Motor Running Overload Class Off, 1 – 40 Local Source PAd: Keypad tEr: Terminal...
  • Page 71 5 - PARAMETER GROUPS Number Parameter Setting Range Units Default Page Auto Fault Reset Time Off, 1 – 900 Seconds Auto Reset Limit Off, 1 – 10 Controlled Fault Stop Enable Off, On Independent Starting/Running Off, On Overload Motor Starting Overload Class Off, 1 –...
  • Page 72 5 - PARAMETER GROUPS Number Parameter Setting Range Units Default Page 0: Off (no output) 1: 0 – 100% Curr 2: 0 – 200% Curr 3: 0 – 800% Curr 4: 0 – 150% Volt 5: 0 – 150% OL 0: Off Analog Output Function 6: 0 –...
  • Page 73 5 - PARAMETER GROUPS Number Parameter Setting Range Units Default Page 72:1, 96:1, 144:1, 288:1, 864:1, 2640:1, 3900:1, CT Ratio 5760:1, 8000:1, 14400:1, 28800:1 0: Status 1: Ave Current 2: L1 Current 3: L2 Current 4: L3 Current 5: Curr Imbal 6: Ground Fault 7: Ave Volts 8: L1-L2 Volts...

  • Page 74: 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 75: Control Function Group

    5 - PARAMETER GROUPS 5.4.2 Control Function Group Number Display Parameter Setting Range Units Default Page CFN 00 Jump Code Jump to Parameter 1 to 25 Voltage Ramp Current Ramp CFN 01 Start Mode Start Mode Current Ramp TT Ramp Power Ramp CFN 02 Ramp Time 1...

  • Page 76: Protection Group

    5 - PARAMETER GROUPS 5.4.3 Protection Group Number Display Parameter Setting Range Units Default Page PFN 00 Jump Code Jump to Parameter 1 to 17 PFN 01 Over Cur Lvl Over Current Trip Level Off, 50 to 800 %FLA PFN 02 Over Cur Tim Over Current Trip Delay Time Off, 0.1 to 90.0...
  • Page 77 5 - PARAMETER GROUPS Number Display Parameter Setting Range Units Default Page I/O 05 R1 Config R1 Configuration (Relay #1) Fault FS Fault FS (Fail Safe) I/O 06 R2 Config R2 Configuration (Relay #2) Fault NFS (Non Fail Safe) Running Alarm Ready Locked Out...

  • Page 78: Function Group

    5 - PARAMETER GROUPS 5.4.5 Function Group Number Display Parameter Setting Range Units Default Page FUN 00 Jump Code Jump to parameter 1 to 16 FUN 01 Meter 1 Meter 1 Ave Current Ave Current L1 Current L2 Current L3 Current Curr Imbal Ground Fault Ave Volts...

  • Page 79: Lcd Fault Group

    5 - PARAMETER GROUPS Number Display Parameter Setting Range Units Default Page Even, 1 Stop Bit Odd, 1 Stop Bit FUN 13 Com Parity Communications Byte Framing Even, 1 Stop None, 1 Stop Bit None, 2 Stop Bit FUN 14 Software 1 Software 1 Part Number Display Only...
  • Page 80 5 - PARAMETER GROUPS NOTES:...
  • Page 81 Parameter Description...

  • Page 82: 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 62 can be used to find the page number of the parameter in this chapter.
  • Page 83 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. Motor FLA QST 01 LED Display LCD Display: QST: Motor FLA 10 Amp Range Model Dependent, 1 –...
  • Page 84 6 - PARAMETER DESCRIPTION Motor Overload Class Running QST 03, PFN 15 LED Display LCD Display QST: Running OL PFN: Running OL Range Off, 1– 40 (Default 10) Description The Motor Running Overload Class parameter sets the class of the electronic overload for starting and running.
  • Page 85 6 - PARAMETER DESCRIPTION Local Source QST 04 LED Display LCD Display QST: Local Src 04 Terminal Range 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;...
  • Page 86 Communication Timeout (P68 / FUN 12) parameter on page 121. Communication Baud Rate (P69 / FUN 11) parameter on page 121. Communication Address (P70 / FUN 10) parameter on page 121. Modbus Register Map, refer to www.benshaw.com. Figure 24: Local Remote Source Local Source...
  • Page 87 6 - PARAMETER DESCRIPTION Initial Motor Current 1 QST 06, CFN 03 LED Display LCD Display QST: Init Cur 1 100 % CFN: Init Cur 1 100 % Range 50 – 600 % of FLA (Default 100%) Description The Initial Motor Current 1 parameter is set as a percentage of the Motor FLA (P1 / QST 01) parameter setting.
  • Page 88 6 - PARAMETER DESCRIPTION Maximum Motor Current 1 QST 07, CFN 04 LED Display LCD Display QST: Max Cur 1 600 % CFN: Max Cur 1 600 % Range 100 – 800 % of FLA (Default 600%) Description The Maximum Motor Current 1 parameter is set as a percentage of the Motor FLA (P1 / QST 01) parameter setting.
  • Page 89 6 - PARAMETER DESCRIPTION Ramp Time 1 QST 08, CFN 02 LED Display LCD Display QST: Ramp Time 1 15 sec CFN: Ramp Time 1 15 sec 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.
  • Page 90 6 - PARAMETER DESCRIPTION Up To Speed Time QST 09 LED Display LCD Display QST: UTS Time 20 sec Range 1– 900 Seconds (Default 20) Description The Up To Speed Time parameter sets the maximum time the motor can take to accelerate to full speed. A stalled motor condition is detected if the motor does not get up-to-speed before the up-to-speed timer expires.
  • Page 91 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. Start Mode CFN 01 LED Display LCD Display CFN: Start Mode 01 Current Ramp Range Description...
  • Page 92 6 - PARAMETER DESCRIPTION Initial Voltage/Torque/Power CFN08 LED Display LCD Display CFN: Init V/T/P 25 % Range 1 – 100 % of Voltage/Torque/Power (Default 25%) Description Start Mode (P10/CFN01) 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.
  • Page 93 6 - PARAMETER DESCRIPTION Maximum Torque/Power CFN 09 LED Display LCD Display CFN: Max T/P 105 % Range 10 – 325 % of Torque/Power (Default 105%) Description Start Mode (P10/CFN01) 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.
  • Page 94 6 - PARAMETER DESCRIPTION Kick Level 1 CFN 10 LED Display LCD Display CFN: Kick Lvl 1 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.
  • Page 95 6 - PARAMETER DESCRIPTION Stop Mode CFN 14 LED Display LCD Display CFN: Stop Mode 14 Coast Range Description Coast Coast to stop. (Default) SdcL Volt Decel Open loop voltage deceleration. tdcL TT Decel TruTorque deceleration. DC Brake DC Braking. Description Coast: A coast to stop should be used when no special stopping requirements are necessary;...
  • Page 96 6 - PARAMETER DESCRIPTION Decel Begin Level CFN 15 LED Display LCD Display CFN: Decel Begin 40 % Range 1 % – 100% of phase angle firing (Default 40%) Description Stop Mode (P15/CFN14) 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.
  • Page 97 6 - PARAMETER DESCRIPTION Decel End Level CFN 16 LED Display LCD Display CFN: Decel End 20 % Range 1 – 99 % of phase angle firing (Default 20%) Description Stop Mode (P15/CFN14) 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.
  • Page 98 6 - PARAMETER DESCRIPTION Decel Time CFN 17 LED Display LCD Display CFN: Decel Time 15 sec Range 1 – 180 seconds (Default 15) 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.
  • Page 99 6 - PARAMETER DESCRIPTION DC Brake Level CFN 18 LED Display LCD Display CFN: Brake Level 25 % Range 10 – 100 % of available brake torque (Default 25%) Description When the Stop Mode (P15 / CFN 14) is set to DC brake, the DC Brake Level parameter sets the level of DC current applied to the motor during braking.
  • Page 100 6 - PARAMETER DESCRIPTION DC Brake Time CFN 19 LED Display LCD Display CFN: Brake Time 5 sec Range 1 – 180 Seconds (Default 5) Description When the Stop Mode (P15 / CFN 14) is set to "DC brake", the DC Brake Time parameter sets the time that DC current is applied to the motor.
  • Page 101 6 - PARAMETER DESCRIPTION DC Brake Delay CFN 20 LED Display LCD Display CFN: Brake Delay 0.2 sec Range 0.1 – 3.0 Seconds (Default 0.2) Description When the Stop Mode (P15, CFN 14) is set to "DC brake", the DC Brake Delay time is the time delay between when a stop is commanded and the DC braking current is applied to the motor.
  • Page 102 6 - PARAMETER DESCRIPTION Ramp Time 2 CFN 05 LED Display LCD Display CFN: Ramp Time 2 15 sec Range 0 – 300 seconds (Default 15) Description The Ramp Time 2 parameter sets the time it takes for the starter to allow the current to go from the initial current to the maximum current when the second ramp is active.
  • Page 103 6 - PARAMETER DESCRIPTION Preset Slow Speed CFN 21 LED Display LCD Display CFN: SSpd Speed Range Off, 7.1%, 14.3 % (Default Off) Description The Preset Slow Speed parameter sets the speed of motor operation. When set to "Off", slow speed operation is disabled.
  • Page 104 6 - PARAMETER DESCRIPTION Slow Speed Time Limit CFN 23 LED Display LCD Display CFN: SSpd Timer 10 sec Range Off, 1 – 900 Seconds (Default 10) Description The Slow Speed Time Limit parameter sets the amount of time that continuous operation of slow speed may take place.
  • Page 105 6 - PARAMETER DESCRIPTION Slow Speed Kick Time CFN 25 LED Display LCD Display CFN: SSpd Kick T 1.0 sec 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 (P30, CFN 24) is applied to the motor at the beginning of slow speed operation.
  • Page 106 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. Over Current Trip Level PFN 01 LED Display LCD Display PFN: Over Cur Lvl Range Off, 50 –...
  • Page 107 6 - PARAMETER DESCRIPTION Over Current Trip Delay Time PFN 02 LED Display LCD Display PFN: Over Cur Tim 0.1 sec Range Off, 0.1 – 90.0 seconds (Default 0.1) Description The Over Current Trip Delay Time parameter sets the period of time that the motor current must be greater than the Over Current Level (P32 / PFN 01) parameter before an over current fault and trip occurs.
  • Page 108 6 - PARAMETER DESCRIPTION Under Current Trip Level PFN 03 LED Display LCD Display PFN: Undr Cur Lvl Range Off, 5 – 100 % of FLA (Default Off) Description If the MX detects a one cycle, average current that is less than the level defined, an under current alarm condition exists and any relays programmed as alarm will energize.
  • Page 109 6 - PARAMETER DESCRIPTION Current Imbalance Trip Level PFN 05 LED Display LCD Display PFN: Cur Imbl Lvl 15 % Range Off, 5 – 40 % (Default 15%) Description The Current Imbalance Trip Level parameter sets the imbalance that is allowed before the starter shuts down. The current imbalance must exist for 10 seconds before a fault occurs.
  • Page 110 6 - PARAMETER DESCRIPTION Residual Ground Fault Trip Level PFN 06 LED Display LCD Display PFN: Resid GF Lvl Range Off, 5 – 100 % FLA (Default Off) Description 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.
  • Page 111 6 - PARAMETER DESCRIPTION Over Voltage Trip Level PFN 07 LED Display LCD Display PFN: Over Vlt Lvl Range Off, 1 – 40 % (Default Off) Description If the MX detects a one cycle input phase voltage that is above the Over Voltage Trip Level, the over/under voltage alarm is shown and the voltage trip timer begins counting.
  • Page 112 6 - PARAMETER DESCRIPTION Over/Under Voltage Trip Delay Time PFN 09 LED Display LCD Display PFN: Vlt Trip Tim 0.1 sec Range 0.1 – 90.0 seconds (Default 0.1) Description The Voltage Trip Delay Time parameter sets the period of time that either an over voltage (P38 / PFN 07) or under voltage (P39 / PFN 08) condition must exist before a fault occurs.
  • Page 113 6 - PARAMETER DESCRIPTION Controlled Fault Stop Enable PFN 12 LED Display LCD Display PFN: Ctrl Flt En Range Off – On (Default On) Description A Controlled Fault Stop Enable can occur if this parameter is "On". The controlled stop will occur before the starter trips.
  • Page 114 6 - PARAMETER DESCRIPTION Independent Starting/Running Overload PFN 13 LED Display LCD Display PFN: Indep S/R OL Range Off – On (Default Off) Description If “Off” When this parameter is “Off” the overload defined by the Motor Running Overload Class (P3 / QST 03/PFN 15) parameter is active in all states.
  • Page 115 6 - PARAMETER DESCRIPTION Motor Overload Class Starting PFN 14 LED Display LCD Display PFN: Starting OL Range Off, 1 – 40 (Default class 10) Description The Motor Overload Class Starting 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”...
  • Page 116 6 - PARAMETER DESCRIPTION Motor Overload Hot/Cold Ratio PFN 16 LED Display LCD Display PFN: OL H/C Ratio 60 % 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).
  • Page 117 6 - PARAMETER DESCRIPTION Motor Overload Cooling Time PFN 17 LED Display LCD Display PFN: OL Cool Tim 30.0 min 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 (<) 1%. When the motor is stopped, the overload content reduces exponentially based on Motor Overload Cooling Time parameter.
  • Page 118 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. P48,49,50 Digital Input Configuration I/O 01,02,03 LED Display LCD Display I/O: DI 1 Config 01 Stop I/O: DI 2 Config I/O: DI 3 Config...
  • Page 119 6 - PARAMETER DESCRIPTION Digital Fault Input Trip Time I/O 04 LED Display LCD Display I/O: Din Trp Time 0 .1 sec Range 0.1-90.0 Seconds (Default 0.1 Sec) Description: The Digital Fault Input Trip Time parameter sets the length of time the Digital input must be high or low before a trip occurs.
  • Page 120 6 - PARAMETER DESCRIPTION P52, 53, 54 Relay Output Configuration I/O 05, 06, 07 LED Display LCD Display I/O: R1 Config 05 Fault FS I/O: R2 Config 06 Off I/O: R3 Config 07 Off Description Range Off, Not Assigned. May be controlled over Modbus (Default R2 & R3) FLFS Fault FS Faulted –...
  • Page 121 6 - PARAMETER DESCRIPTION Analog Input Trip Type I/O 08 LED Display LCD Display I/O: Ain Trp Type Range Description Off, Disabled. (Default) Low Level Low, Fault if input signal below preset trip level. High Level High, Fault if input signal above preset trip level. Description The analog input is the reference input for a starter configured as a Phase Controller or Current Follower.
  • Page 122 6 - PARAMETER DESCRIPTION Analog Input Trip Level I/O 09 LED Display LCD Display I/O: Ain Trp Lvl 50 % Range 0 – 100% (Default 50%) Description The Analog Input Trip Level parameter sets the analog input trip or fault level. This feature can be used to detect an open 4-20mA loop by setting the parameter to "Low"...
  • Page 123 6 - PARAMETER DESCRIPTION Analog Input Span I/O 11 LED Display LCD Display I/O: Ain Span 100 % 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 0V input and a 100% input reading with a 10V input.
  • Page 124 6 - PARAMETER DESCRIPTION Analog Input Offset I/O 12 LED Display LCD Display I/O: Ain Offset 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) =>...
  • Page 125 6 - PARAMETER DESCRIPTION Analog Output Span I/O 14 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 126 6 - PARAMETER DESCRIPTION Inline Configuration I/O 16 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 127 6 - PARAMETER DESCRIPTION Keypad Stop Disable I/O 18 LED Display LCD Display I/O: Keypad Stop 18 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] key will not stop the starter.
  • Page 128 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. Miscellaneous Commands FUN 15 LED Display LCD Display FUN: Misc Command 15 None Range Description...
  • Page 129 6 - PARAMETER DESCRIPTION Communication Timeout FUN 12 LED Display LCD Display FUN: Com Timeout 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.
  • Page 130 If the load on the motor increases, the starter immediately returns the output of the starter to full voltage. NOTE: This function does not operate if a bypass contactor is used. NOTE: In general, Energy Saver can save approximately 1000 watts per 100 HP. Consult Benshaw for further detail.
  • Page 131 6 - PARAMETER DESCRIPTION Heater Level FUN 08 LED Display LCD Display FUN: Heater Level Range Off, 1 – 25% 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.
  • Page 132 6 - PARAMETER DESCRIPTION Starter Type FUN 07 LED Display LCD Display FUN: Starter Type 07 Normal Range Description Normal Normal Reduced Voltage Soft Starter RVSS. (Default) Inside Delta Inside Delta, RVSS. Wye-Delta Wye Delta. Phase Ctl Open Loop Phase control using external analog input PctL reference.
  • Page 133 6 - PARAMETER DESCRIPTION Motor Rated Power Factor FUN 06 LED Display LCD Display FUN: Motor PF -0.92 Range -0.01 – 1.00 (Default –0.92) Description The 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.
  • Page 134 The CT ratio 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 MX starter.
  • Page 135 6 - PARAMETER DESCRIPTION Meter 1 ,Meter 2 FUN 01, 02 LED Display LCD Display FUN: Meter 1 01 Ave Current FUN: Meter 2 02 Ave Volts Range Description Status Running State. (LED meter only, Default LED meter) Ave Current Average current.
  • Page 136 The Software Part Number parameter displays the MX software version, for hardware BIPC-300055-01-04. 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 137 6 - PARAMETER DESCRIPTION Passcode FUN 16 LED Display LCD Display FUN: Passcode 16 Off Description The MX supports a 4-digit passcode. When the passcode is set, parameters may not be changed. The MX provides a means of locking parameter values so that they may not be changed. Once locked, the parameters values may be viewed on the display, but any attempt to change their values by pressing the [UP] or [DOWN] keys is ignored.
  • Page 138 6 - PARAMETER DESCRIPTION Fault Log LED Display LCD Display FL1: Last Fault # Fault Name 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.
  • Page 139 Theory of Operation...

  • Page 140: Theory Of Operation

    7 - THEORY OF OPERATION Motor Overload Solid State Motor Overload Protection 7.1.1 Overview The MX contains an advanced I t electronic motor overload (OL) protection function. For optimal motor protection, the MX has forty standard NEMA style 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.
  • Page 141 RB2 for the specific RB2 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.

  • Page 142: Motor Overload Operation

    7 - THEORY OF OPERATION 7.1.3 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.

  • Page 143: Harmonic Compensation

    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 loads.

  • Page 144: Separate Starting And Running Motor Overload Settings

    7 - THEORY OF OPERATION The following diagram illustrates how the current and the Motor Overload Hot/Cold Ratio parameter determines the steady state overload content. It assumes there is no current imbalance. Figure 27: Motor Overload H© Ratio Example 100%FLA Motor 50%FLA Current...

  • Page 145: Motor Cooling While Stopped

    7 - THEORY OF OPERATION 7.1.8 Motor Cooling While Stopped The Motor Overload Cooling Time 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. CoolingTim Content Content wh...

  • Page 146: Motor Cooling While Running

    7 - THEORY OF OPERATION If the motor manufacturer does not specify the motor cooling time, the following approximations for standard TEFC cast iron motors based on frame size can be used: Frame Size Cooling Time 30 min 60 min 90 min 400/440 120 min...

  • Page 147: Motor Service Factor

    7 - THEORY OF OPERATION Motor Service Factor Motor Service Factor General The Motor Service Factor 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.

  • Page 148: Acceleration Control

    7 - THEORY OF OPERATION Acceleration Control 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 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.

  • Page 149: Programming A Kick Current

    7 - THEORY OF OPERATION Ramp Time 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.
  • Page 150 7 - THEORY OF OPERATION 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.

  • Page 151: Power Control Acceleration Settings And Times

    7 - THEORY OF OPERATION 7.3.4 Power Control Acceleration Settings and Times General 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.
  • Page 152 7 - THEORY OF OPERATION NOTE: Depending on loading, the motor may achieve full speed at any time during the Power ramp. This means that the Maximum Power level may not be reached. Therefore, the maximum power level is the maximum power level that is permitted.

  • Page 153: Open Loop Voltage Ramps And Times

    7 - THEORY OF OPERATION 7.3.5 Open Loop Voltage Ramps and Times General The open loop voltage ramp provides soft starting of a motor by increasing the voltage applied to motor from the Initial Voltage setting to full (100%) line voltage. The ramp time sets the speed at which the voltage is increased.
  • Page 154 7 - THEORY OF OPERATION UTS Timer When the start mode is set to open-loop voltage ramp acceleration, the UTS Timer acts as an acceleration kick. When the UTS timer expires, full voltage is applied to the motor. This feature can be used to reduce motor surging that may occur near the end of an open loop voltage ramp start.

  • Page 155: Dual Acceleration Ramp Control

    7 - THEORY OF OPERATION 7.3.6 Dual Acceleration Ramp Control General Two independent current ramps and kick currents may be programmed. The use of two different starting profiles can be very useful with applications that have varying starting loads such as conveyors that can start either loaded or unloaded.
  • Page 156 7 - THEORY OF OPERATION Changing Ramp Profiles The selected ramp profile may be changed during starting by changing the Ramp Select input. When the Ramp Select input changes during ramping, control switches to the other profile as if it were already in progress. It does not switch to the beginning of the other profile.

  • Page 157: Deceleration Control

    7 - THEORY OF OPERATION Deceleration Control 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 decelerate the motor. The curve shows the motor voltage versus the decel setting. Figure 35: Motor Voltage Versus Decel Level Beginning Level This sets the starting voltage of the deceleration ramp.

  • Page 158: Trutorque Deceleration

    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.

  • Page 159: Braking Controls

    (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.

  • Page 160: Dc Injection Braking, Standard Duty

    When Braking, the stop must be counted as another motor start when looking at the motor starts per hour limit. 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.

  • Page 161: Dc Injection Brake Wiring Example

    7 - THEORY OF OPERATION 7.5.5 DC Injection Brake Wiring Example Figure 37: DC Injection Brake Wiring Example...

  • Page 162: Dc Brake Timing

    7 - THEORY OF OPERATION 7.5.6 DC Brake Timing The MX DC injection brake timing is shown below: Figure 38: DC Injection Brake Timing DC Brake Delay Time DC Brake Delay after Time DC Brake Brake Relay On Braking Relay Energized Brake Relay Off DC Injection On Starter SCRs On, DC Current Applied...

  • Page 163: Dc Injection Brake Enable And Disable Digital Inputs

    7 - THEORY OF OPERATION 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.

  • Page 164: Dc Injection Braking Parameters

    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 brake level is determined by the combination of the system inertia, system friction, and the desired braking time.

  • Page 165: Slow Speed Cyclo Converter Parameters

    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 Off, slow speed operation is disabled. Slow Speed Current Level: The Slow Speed Current Level parameter selects the level of current applied to the motor during slow speed operation.

  • Page 166: Inside Delta Connected Starter

    7 - THEORY OF OPERATION Inside Delta Connected Starter Inside Delta Connected Starter There are differences between a line connected soft starter as shown in Figure 39 and the inside delta connected soft starter as shown in Figure 40 that need to be considered. By observation of Figure 40, access to all six stator-winding terminals is required for an inside delta application.

  • Page 167: Inside Delta Connected Starter

    7 - THEORY OF OPERATION 7.7.2 Inside Delta Connected Starter An inside delta connected soft starter is shown in Figure 40, where the power poles are connected in series with the stator windings of a delta connected motor. Figure 40: Typical Inside Delta Motor 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).
  • Page 168 7 - THEORY OF OPERATION Wye Delta Starter 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 MX motor and starter protective functions except bad SCR detection and power stack overload, are available to provide full motor and starter protection.
  • Page 169 7 - THEORY OF OPERATION The MX 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.
  • Page 170 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.
  • Page 171 7 - THEORY OF OPERATION Across The Line Starter 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.
  • Page 172 7 - THEORY OF OPERATION Single Phase Soft Starter 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.
  • Page 173 7 - THEORY OF OPERATION Phase Control 7.11 Phase Control When the Starter Type parameter 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.
  • Page 174 7 - THEORY OF OPERATION 7.11.1 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.
  • Page 175 7 - THEORY OF OPERATION Current Follower 7.12 Current Follower When the Starter Type parameter 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.
  • Page 176 7 - THEORY OF OPERATION Start/Stop Control with a Hand/Off/Auto Selector Switch 7.13 Start/Stop Control Logic Often times, a switch is desired to select between local or “Hand” mode and remote or “Auto” mode. In most cases, local control is performed as 3-wire logic with a normally open, momentary contact Start pushbutton and a normally closed, momentary contact Stop pushbutton, while remote control is performed as 2-wire logic with a “Run Command”...
  • Page 177 7 - THEORY OF OPERATION 7.14 Hand/Off/Auto Selector Switch The MX2 has the capability to use a selector switch to change the source of control. A popular use is to switch between using the door mounted display for Hand operation and using contact input for Auto operation. The following drawing shows how to wire the unit to allow this operation.
  • Page 178 7 - THEORY OF OPERATION Simplified I/O Schematics 7.15 Simplified I/O Schematics Figure 48: Digital Input Simplified Schematic Figure 49: Analog Input Simplified Schematic Figure 50: Analog Output Simplified Schematic...
  • Page 179 7 - THEORY OF OPERATION Remote Modbus Communications Figure 49: TB4 Connector 7.16 Remote Modbus Communications The MX 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 180 7 - THEORY OF OPERATION 7.16.4 Figure 50: Modbus Network Wiring Example IMPORTANT DO NOT CREATE STUBS - CABLE MUST GO TO EACH STARTER. Right Wrong...
  • Page 181 Troubleshooting & Maintenance...
  • Page 182 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 183 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 184 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. Display shows Accel or Run. Maximum Motor Current setting Review acceleration ramp settings.
  • Page 185 8 - TROUBLESHOOTING & MAINTENANCE 8.3.4 Starter not decelerating as desired Cause Solution Condition Motor stops too quickly. Decel Time (P18/CFN17) set too short. Increase Decel Time. Decel Begin and End Levels (P16/CFN15 Increase Decel Begin and/or Decel and P17/CFN16) set improperly. End levels.
  • Page 186 8 - TROUBLESHOOTING & MAINTENANCE 8.3.6 Metering incorrect Condition Cause Solution Power Metering not reading correctly. CTs installed or wired incorrectly. 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 (P78/FUN03) set Verify that the CT ratio parameter is set...
  • Page 187 8 - TROUBLESHOOTING & MAINTENANCE 8.3.7 Other Situations Condition Cause Solution Motor Rotates in Wrong Direction. Phasing incorrect. If input phasing correct, exchange any two output wires. If input phasing incorrect, exchange any two input wires. Erratic Operation. Loose connections. Shut off all power and check all connections.
  • Page 188 8 - TROUBLESHOOTING & MAINTENANCE Fault Code Table Fault Code Table The following is a list of possible faults that can be generated by the MX starter control. Fault Code Description Detailed Description of Fault / Possible Solutions UTS Time Limit Expired Motor did not achieve full speed before the UTS timer (P9/QST09) expired.
  • Page 189 8 - TROUBLESHOOTING & MAINTENANCE Fault Code Description Detailed Description of Fault / Possible Solutions High Line Frequency Line frequency above 72 Hz was detected. Verify input line frequency. If operating on a generator, check generator speed governor for malfunctions. Line power quality problem / excessive line distortion.
  • Page 190 8 - TROUBLESHOOTING & MAINTENANCE Fault Code Description Detailed Description of Fault / Possible Solutions High Line L1-L2 High voltage above the Over voltage Trip Level parameter setting (P35/PFN07) was detected for longer than the Over/Under Voltage Trip delay time (P40/PFN09). Verify that the actual input voltage level is correct.
  • Page 191 8 - TROUBLESHOOTING & MAINTENANCE Fault Code Description Detailed Description of Fault / Possible Solutions I.O.C. During operation, the MX detected a very high level of current in one or more phases. (Instantaneous Over current) Check motor wiring for short circuits or ground faults. Check motor for short circuits or ground faults.
  • Page 192 8 - TROUBLESHOOTING & MAINTENANCE Fault Code Description Detailed Description of Fault / Possible Solutions Shorted / Open SCR 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.
  • Page 193 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 motor FLA (P1/QST01), CT ratio (P78/FUN03) and burden switch settings are correct.
  • Page 194 8 - TROUBLESHOOTING & MAINTENANCE Modbus Timeout Fault 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 (FUN12) defined time. Verify communication parameter settings (FUN 10 - FUN13). Check wiring between the remote network and the MX control card.
  • Page 195 8 - TROUBLESHOOTING & MAINTENANCE SCR Testing 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).
  • Page 196 “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.
  • Page 197 8 - TROUBLESHOOTING & MAINTENANCE NOTE: If one dedicated bypass is set to "fan" and if no digital input are assigned as a Bypass Confirm input, this test will always pass. LCD Display (BIST Mode) LED Display b bc (bypass closed) Bypass Closed b bo (bypass open) Bypass Open...
  • Page 198 8 - TROUBLESHOOTING & MAINTENANCE 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. 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 (P1 / QST 01), CT Ratio (P78 / FUN 03), Phase Order (P77 / FUN 04), Rated Voltage (P76 / FUN 05), and Starter Type (P74 / FUN 07).
  • Page 199 8 - TROUBLESHOOTING & MAINTENANCE SCR Replacement SCR Replacement This section is to help with SCR replacements on stack assemblies. Please read prior to installation. 8.7.1 Typical Stack Assembly 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.
  • Page 200 8 - TROUBLESHOOTING & MAINTENANCE 8.7.4 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 201 Appendices...
  • Page 202 APPENDIX A - 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 Description Notes...
  • Page 203 APPENDIX A - ALARM CODES Alarm Description Notes Code This alarm exists while the MX is running and a ground current above the defined threshold is detected, but the Ground Fault delay for the fault has not yet expired. When the delay expires, a Fault 38 occurs.
  • Page 204 APPENDIX B - FAULT CODES Fault Codes Fault Code Description Controlled Fault Stop Shunt Trip Fault Auto-Reset Allowed No fault UTS Time Limit Expired Motor Thermal Overload Trip Slow Speed Time Limit Expired Phase Rotation Error, not ABC Phase Rotation Error, not CBA Low Line Frequency High Line Frequency Input power not single phase...
  • Page 205 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 206 RC2-1-S-720A-19C RC2-1-S-180A-14C RC2-1-S-414A-17C RC2-1-S-838A-20C RC2-1-S-180A-15C RC2-1-S-477A-17C 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 207 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 208 APPENDIX E - MODBUS REGISTER MAP Absolute Register Address Description Range Units Bit 0: “L OL” – Motor overload Bit 1: – Reserved - (Motor PTC) Bit 2: – Reserved - (RTD Stator) Bit 3: – Reserved - (RTD Bearing) Bit 4: –...
  • Page 209 APPENDIX E - MODBUS REGISTER MAP Absolute Register Address Description Range Units Disabled 30104/40104 Motor Overload Running Enable Enabled 30105/40105 Motor Overload Running Class 1 – 40 Disabled 30106/40106 Motor Overload Starting Enable Enabled 30107/40107 Motor Overload Starting Class 1 – 40 30108/40108 Motor Overload Hot/Cold Ratio 0 –...
  • Page 210 APPENDIX E - MODBUS REGISTER MAP Absolute Register Address Description Range Units 10: 400 11: 415 30143/40143 Rated RMS Voltage Vrms 12: 440 13: 460 14: 480 15: 500 16: 525 17: 575 18: 600 19: 660 20: 690 21: 800 22: 1000 23: 1140 30144/40144...
  • Page 211 APPENDIX E - MODBUS REGISTER MAP Absolute Register Address Description Range Units Disabled 30168/40168 Controlled Fault Stop Enabled 30169/40169 DI 1 Configuration Stop 30170/40170 DI 2 Configuration Fault High Fault Low Fault Reset Disconnect Inline Feedback (F49) Bypass / 2M Feedback (F48) Emergency Motor OL Reset Local / Remote Control Source...
  • Page 212 APPENDIX E - MODBUS REGISTER MAP Absolute Register Address Description Range Units Disabled 30184/40184 Inline Enable Enabled 30185/40185 Inline Delay Time 10 – 100 100 mSec 30186/40186 Bypass Feedback Time 1 – 50 100 mSec Disabled 30187/40187 Keypad Stop Enabled Disabled 30188/40188 Modbus Timeout Enable...
  • Page 213 APPENDIX E - MODBUS REGISTER MAP Absolute Register Address Description Range Units Ave Current L1 Current L2 Current L3 Current Current Imbalance % Residual Ground Current Ave. Volts 30197/40197 LCD Display Meter 1 L1-L2 Volts L2-L3 Volts 10: L3-L1 Volts 11: Overload 12: Power Factor 13: Watts...
  • Page 214 APPENDIX E - MODBUS REGISTER MAP Absolute Register Address Description Range Units 30641/40641 (most recent) L3 Currents: The current that the load is drawing from Line 3 when the fault has Arms 30649/40649 (oldest) occurred. 30651/40651 (most recent) L1-L2 Voltages: The line voltage that is present between lines 1 and 2 when a fault Vrms 30659/40659 (oldest)
  • Page 215 APPENDIX E - MODBUS REGISTER MAP 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 AutoStart parameter (P66 – I/O19). The fault reset bit must transition from 0 to 1 for a fault to be reset.
  • Page 216 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 Parameter Setting Range Units Default Page Setting QST 01 Motor FLA...
  • Page 217 APPENDIX F - PARAMETER TABLES Protection Function Group Parameter Setting Range Units Default Page Setting PFN 01 Over Current Level Off, 50 – 800 % FLA PFN 02 Over Current Trip Delay Time Off, 0.1 – 90.0 Seconds PFN 03 Under Current Trip Level Off, 5 –...
  • Page 218 APPENDIX F - PARAMETER TABLES Parameter Setting Range Units Default Page Setting OFF: FLFS: Fault (fail safe) FLnF: Fault (non fail Fault FS I/O 05 R1 Configuration safe) run: Running utS: Alarm rdyr: Ready I/O 06 R2 Configuration LOC: Locked Out Over Current Under Current OLA:...
  • Page 219 APPENDIX F - PARAMETER TABLES Function Group Parameter Setting Range Units Default Page Setting Status Ave Current L1 Current L2 Current L3 Current Curr Imbal Residual Ground Fault FUN 01 Meter 1 Ave Current Ave Volts L1-L2 Volts L2-L3 Volts L3-L1 Volts Overload Power Factor...
  • Page 220 APPENDIX F - PARAMETER TABLES Parameter Setting Range Units Default Page Setting 0: Even Parity, 1 Stop bit Even Parity, 1: Odd Parity, 1 Stop bit FUN 13 Communication Byte Framing 2: No Parity, 1 Stop bit 1 Stop bit 3: No Parity, 2 Stop bits FUN 14 Software Version 1 Display Only...
  • Page 221 Publication History; Revision Date ECO# 12/15/06 Initial Release 09/10/07 Revisions based on 08/21/08 shared review...
  • Page 222 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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