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BENSHAW RediStart EXEXMVRMX3 Series User Manual

Solid state starter mx3 control, 10kv to 13.8kvac
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890034-06-00
Motor Starter Card Set:
Software Version 1:
Software Version 2:
Gate Driver Card:
Gate Power Distributor Card: BIPC-300007-02
©
2006 Benshaw Inc.
Benshaw retains the right to change specifications and illustrations in text without prior notification. The contents of this document may
not be copied without the explicit permission of Benshaw.
BIPC-450100-02-01
810023-02-01
810024-01-01
BIPC-300003-01
RediStart
Solid State Starter
Control
MVRMX36 Models
10KV to 13.8KVAC
User Manual
TM

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Summary of Contents for BENSHAW RediStart EXEXMVRMX3 Series

  • Page 1 Gate Driver Card: BIPC-300003-01 Gate Power Distributor Card: BIPC-300007-02 © 2006 Benshaw Inc. Benshaw retains the right to change specifications and illustrations in text without prior notification. The contents of this document may not be copied without the explicit permission of Benshaw.
  • Page 3 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 4 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 5: Table Of Contents

    TABLE OF CONTENTS Table of Contents 1 INTRODUCTION ........2 2 TECHNICAL SPECIFICATIONS .
  • Page 6 TABLE OF CONTENTS 3.6 Power Wiring ......... 24 3.6.1 Recommended Wire Gauges .
  • Page 7 TABLE OF CONTENTS 4.6 Jump Code ......... . . 48 4.7 Restoring Factory Parameter Settings .
  • Page 8 TABLE OF CONTENTS 7.5 Braking Controls ........133 7.5.1 DC Injection Braking, Standard Duty .
  • Page 9 TABLE OF CONTENTS 8.7 Ohm Meter Testing ........166 8.7.1 Fuse Tests .

  • Page 11: Introduction

    Introduction...
  • Page 12 1 - INTRODUCTION Using This Manual Layout This manual is divided into 9 sections. Each section contains topics related to the section. The sections are as follows: • Introduction • Technical Information • Installation • Keypad Operation • Parameters • Parameter Descriptions •...
  • Page 13 Publication History See page 211. Benshaw provides a 1 year standard warranty with its starters. An extension to the 3 year warranty is provided Warranty 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.
  • Page 14 1 - INTRODUCTION Contacting Benshaw Information about Benshaw products and services is available by contacting Benshaw at one of the following Contacting Benshaw offices: Benshaw Inc. Corporate Headquarters Benshaw High Point 1659 E. Sutter Road EPC Division Glenshaw, PA 15116...
  • Page 15 1 - INTRODUCTION Interpreting Model Numbers Figure 1: RediStart EXEXMVRMX Series Model Numbers CFMVRMX36-3500-13.8K-1 - Nema 1 3R - Nema 3R 12 - Nema 12 Voltage 36 - 10KV - 11KV - 11.5KV - 12KV - 12.47KV - 13.2KV - 13.8KV MV MX Control Combination Fusable Example of Model Number: CFMVRMX36-3500-13.8KV-1...
  • Page 16 1 - INTRODUCTION General Overview Of A Reduced Voltage Starter The RediStart EXMVRMX motor starter is a microprocessor-controlled starter for three-phase motors. The General Overview starter can be custom designed for specific applications. A few of the features are: • Solid state design •...

  • Page 17: Technical Specifications

    2 Technical Specifications...

  • Page 18: General Information

    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 2 - TECHNICAL SPECIFICATIONS Terminal Terminal Number Description Function Block Serial Comm 1: B+ Modbus RTU serial communication port. 2: A- RS-485 interface 3: COM 19.2k baud maximum 2500V Isolation Analog I/O 1: Ain Power Input: 2: Ain + Voltage or Current 3: Ain - Voltage: 0-10VDC, 67KW impedance 4: Common...

  • Page 20: Measurements And Accuracies

    2 - TECHNICAL SPECIFICATIONS 2.2.2 Measurements and Accuracies Table 2: Measurements and Accuracies Internal Measurements Conversion: True RMS, Sampling @ 1.562kHz CT Inputs Range: 1-6400A Conversion: True RMS, Sampling @ 1.562kHz Line Voltage Inputs Range: 10,000 - 13,800VAC, 23 to 72 Hz Metering Current 0 –...

  • Page 21: Solid State Motor Overload

    The motor overload trip time will be reduced when there is a current imbalance present. z NOTE: Refer to Theory of Operation, Chapter 7 in section 7.1 for more motor overload details and a larger graph. Refer to http://www.benshaw.com/olcurves.html for an automated overload calculator.

  • Page 22: Ct Ratios

    1800 5000:5 1100 4500 2.2.6 Optional RTD Module Specifications The starter has the option of operating with up to two Benshaw SPR-100P remote RTD modules. Table 4: Remote RTD Module Specifications SPR-100P Model Number RTD Type 100W Platinum, 3 lead 0.00385 W/W/°C...

  • Page 23: Optional Zero Sequence Ground Fault Ct

    2 - TECHNICAL SPECIFICATIONS 2.2.7 Optional Zero Sequence Ground Fault CT The Benshaw BICT 2000/1-6 CT has the following excitation curve. Figure 3: BICT2000/1-6 Excitation Curve...

  • Page 24: Sample Redistart Exmvrmx Unit

    2 - TECHNICAL SPECIFICATIONS Sample RediStart EXMVRMX Unit Sample RediStart EXMVRMX Unit z NOTE: This is only a sample diagram drawing for component identification purposes. Component locations may change to meet end users specifications.

  • Page 25: 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 6 provides the derating percentage to be considered when using a starter above 3,300 feet (1000 meters).
  • Page 26 2 - TECHNICAL SPECIFICATIONS NOTES: z NOTE: This is only a sample diagram drawing for component identification purposes. Component locations may change to meet end users specifications.

  • Page 27: Installation

    Installation...

  • Page 28: Before You Start

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

  • Page 29: Installation Considerations

    The installation site must adhere to the applicable starter NEMA/CEMA rating. For optimal performance, the installation site must meet the appropriate environmental and altitude requirements. 3.2.2 EMC Installation Guidelines In order to help our customers comply with European electromagnetic compatibility standards, Benshaw Inc. has General developed the following guidelines. Attention This product has been designed for Class A equipment.

  • Page 30: Use Of Power Factor Capacitors

    3 - INSTALLATION 3.2.5 Use of Power Factor Capacitors Power factor correction capacitors and surge capacitors CAN NOT be connected between the starter and the motor. These devices can damage the SCRs during ramping. These devices appear like a short circuit to the SCR when it turns on, which causes a di/dt level greater than the SCR can handle.

  • Page 31: Mounting Considerations

    3 - INSTALLATION Mounting Considerations Mounting Considerations 3.3.1 Bypassed Starters Provisions should be made to ensure that the temperature inside the enclosure never rises above 50°C. If the temperature inside the enclosure is too high, the starter can be damaged or the operational life can be reduced. Wiring Considerations Wiring Considerations 3.4.1...

  • Page 32: Typical Wiring Schematics

    3 - INSTALLATION Typical Wiring Schematics Typical Wiring Schematics 3.5.1 EXMVRMX Power Wiring Schematic Figure 6: EXMVRMX Power Wiring Schematic...

  • Page 33: Power Wiring

    The standard starter can operate a motor with a maximum of 600 feet of properly sized cable between the “T” leads of the starter and that of the motor. For wire runs greater than 600 feet contact Benshaw Inc. for application assistance. If shielded cable is used, consult factory for recommended length.

  • Page 34: Torque Requirements For Power Wiring Terminations

    3 - INSTALLATION 3.6.5 Torque Requirements for Power Wiring Terminations Table 10: Slotted Screws and Hex Bolts Tightening torque, pound-inches (N-m) Wire size installed in conductor 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 35: Current Transformers

    3 - INSTALLATION Current Transformers Current Transformers 3.7.1 CT Mounting If the CTs are shipped loose they need to be mounted on the power wiring. Thread the power wire through the CT and supplied sleeving, ensuring the polarity mark is towards the line side. (The polarity marks may be a white or yellow dot, an “X” on the side of the CT, or the white wire.) Each phase has its own CT.
  • Page 36 3 - INSTALLATION The correct installation of the current transformer on the motor leads is important. The shield ground wire should also be passed through the CT window if the motor conductors use shielded cable. Otherwise, capacitive coupling of the phase current into the cable shield may be measured as ground fault current.

  • Page 37: Exmvrmx Control Card Layout

    3 - INSTALLATION EXMVRMX Control Card Layout EXMVRMX Control Card Layout Figure 10: EXMVRMX Control Card Layout 120 VAC Stack In (Benshaw Only) Unfused 120 VAC Out Stack Control Control Power 120 VAC Auxiliary Relays P52-54 I/O 5-7 Digital Power LED...

  • Page 38: Exmvrmx I/O Card Layout

    3 - INSTALLATION EXMVRMX I/O Card Layout EXMVRMX I/O Card Layout Figure 11: EXMVRMX I/O Card Layout...

  • Page 39: Terminal Block Layout

    3 - INSTALLATION EXMVRMX Terminal Block Layout 3.10 EXMVRMX Terminal Block Layout Figure 12: EXMVRMX Terminal Block Layout Auxiliary Power Remote RTD Module(s) RJ45 Socket Phase Connector STAT FBK SCR 1A to 1F Phase 1 Relay Fiber Optic Outputs 120VAC R4 to R6 Control Power...

  • Page 40: Control Wiring

    3 - INSTALLATION Control Wiring 3.11 Control Wiring 3.11.1 Control Power The 120VAC control power is supplied to TB1. The connections are as follows: 1 - Ground 2 - Neutral 3 - Neutral 4 - Line (120VAC) 5 - Line (120VAC) Figure 13: Control Power Wiring Example 120VAC NEUTRAL 120VAC LIVE...

  • Page 41: Digital Input

    3 - INSTALLATION 3.11.3 Digital Input TB3 is for digital inputs Start, DI1, DI2 and DI3. These digital inputs use 120VAC. These digital inputs connect 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 Terminal block J6 is for digital inputs DI4 to DI8.

  • Page 42: Analog Input

    3 - INSTALLATION 3.11.4 Analog Input The analog input can be configured for voltage or current loop. The input is shipped in the voltage loop configuration unless specified in a custom configuration. Below 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 43: Motor Ptc

    RTD Module Connector Connector J1 is for the connection of Benshaw Remote RTD Modules. These modules can be mounted at the motor to reduce the length of the RTD leads. The connector is a standard RJ-45. The wires connect as follows;...

  • Page 44: Remote Lcd Keypad/Display

    3 - INSTALLATION Remote LCD Keypad/Display 3.12 Remote LCD Keypad/Display The display has a NEMA 13 / IP65 service rating. The display is available in 2 versions, a small display as P/N KPMX3SLCD and large display as P/N KPMX3LLCD. 3.12.1 Remote Display The LCD keypad is mounted remotely from the MX Control via a straight through display cable which connects between the MX...

  • Page 45: Display Cutout

    3 - INSTALLATION 3.12.2 Display Cutout Figure 21: Large Display Keypad Mounting Dimensions Part # : KPMX3LLCD 127.00 [5.00"] 63.50 63.50 [2.50"] [2.50"] 3.12.3 Installing Display The remote display is installed as follows: • Install the gasket onto the display. •...

  • Page 46: Rtd Module Installation

    This eliminates long RTD wire lengths which save time and money on installation and wiring. The Benshaw Remote RTD Module is designed to mount on industry standard 35mm wide by 7.5mm deep DIN rail.

  • Page 47: Rtd Connections

    3 - INSTALLATION 3.13.5 RTD Connections Each Remote RTD Module has connections for up to 8 RTDs. The terminals for the RTD wires are as follows: • R- RTD return wire • C- RTD compensation wire • H- RTD hot wire Each RTD is connected to the three terminals with the common number.

  • Page 49: Keypad Operation

    Keypad Operation...

  • Page 50: Introduction

    4 - KEYPAD OPERATION Introduction Introduction The MX has a 2x16 character, back-lit LCD display/keypad that is mounted remotely from the MX control card. The remote keypad is NEMA 13 / IP65 when mounted directly on the door of an enclosure with the correct gasket. Figure 24 - Remote LCD Keypad Description of the LEDs on the Keypad Description of the LEDs on the Keypad...

  • Page 51: Description Of The Keys On The Remote Lcd Keypad

    4 - KEYPAD OPERATION Description of the Keys on the Remote LCD Keypad Description of the Keys on the Remote LCD Keypad Table 13: Function of the Keys on the LCD Keypad Function • This key causes the starter to begin the start sequence. The direction is dependent on wiring and phase selection.

  • Page 52: Alphanumeric Display

    4 - KEYPAD OPERATION Alphanumeric Display Alphanumeric Display The remote LCD keypad and display uses a 32-character alphanumeric LCD display. All starter functions can be accessed by the keypad. The keypad allows easy access to starter programming with parameter descriptions on the LCD display. 4.4.1 Power Up Screen On power up, the software part numbers are displayed for a few seconds.

  • Page 53: Parameter Group Screens

    4 - KEYPAD OPERATION Table 15: 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 54: Meter

    4 - KEYPAD OPERATION 4.4.4 Meter Pages Although any meter may be viewed by changing the two meter parameters (FUN 01, FUN 02), there are 19 “Meter Pages” that are easily accessed to view all of the meter information. These meter pages are scrolled through by pressing the [UP] or [DOWN] down arrows from the operate screen.

  • Page 55: Fault Log Screen

    4 - KEYPAD OPERATION 4.4.5 Fault Log Screen Information regarding each fault is available through the remote MX LCD display. FL#: Fault ## NNNNNNNNNNNNN FL#: = Fault Log Number. FL1 is the most recent fault and FL9 is the oldest fault. Fault ## = Fault Code NNN…...

  • Page 56: Lockout Screen

    4 - KEYPAD OPERATION 4.4.8 Lockout Screen When a lockout is present, one of the following screens will be displayed. The main status screen is not shown until the lockout is cleared. The overload lockout displays the overload content and the time until reset if an overload occurs. Overload Lockout xx.xx The stack over temperature lockout will be displayed if a stack over temperature is detected.

  • Page 57: Alarm Screen

    4 - KEYPAD OPERATION 4.4.9 Alarm Screen When an alarm is present, the word “Alarm” is displayed on the operate screen. Pressing the [ENTER] key displays more information about the alarm. Alarm ## Alarm Name Procedure for Setting Data Procedure for Setting Data Select a parameter that is to be changed.

  • Page 58: 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 Go to the FUN group by pressing [MENU].

  • Page 59: Parameter Groups

    Parameter Groups...

  • Page 60: Introduction

    5 - PARAMETER GROUPS Introduction Introduction The EXMVRMX incorporates a number of parameters that allow you to configure the starter to meet the special requirements of your particular application. The parameters are divided into groups of related functionality, and within the groups the parameters are identified by a short, descriptive name.

  • Page 61: Control Function Group

    5 - PARAMETER GROUPS 5.2.2 Control Function Group Group Display Parameter Setting Range Units Default Page CFN 00 Jump Code Jump to Parameter 1 to 27 Voltage Ramp Current Ramp Current CFN 01 Start Mode Start Mode TT Ramp Ramp Power Ramp Tach Ramp CFN 02...

  • Page 62: Protection Group

    5 - PARAMETER GROUPS 5.2.3 Protection Group Group Display Parameter Setting Range Units Default Page PFN 00 Jump Code Jump to Parameter 1 - 35 PFN 01 Over Cur Lvl Over Current Trip Level Off, 50 - 800 %FLA PFN 02 Over Cur Time Over Current Trip Delay Time Off, 0.1 - 90.0...

  • Page 63: I/O Group

    5 - PARAMETER GROUPS 5.2.4 I/O Group Number Display Parameter Setting Range Units Default Page I/O 00 Jump Code Jump to Parameter 1 to 27 I/O 01 DI 1 Config Digital Input #1 Configuration Off Slow Spd Fwd Stop Stop Slow Spd Rev I/O 02 DI 2 Config...

  • Page 64: Rtd Group

    5 - PARAMETER GROUPS 5.2.5 RTD Group Group Display Description Setting Range Units Default Page # RTD 00 Jump Code Jump to Parameter 1 - 29 RTDMod1 RTD 01 RTD Module #1 Address Addr Off, 16 - 23 RTDMod2 RTD 02 RTD Module #2 Address Addr RTD 03...

  • Page 65: Function Group

    5 - PARAMETER GROUPS 5.2.6 Function Group Number Display Parameter Setting Range Units Default Page FUN 00 Jump Code Jump to Parameter 1 to 24 Ave Current L1 Current L2 Current L3 Current Curr Imbal Ground Fault FUN 01 Meter 1 Meter 1 Ave Current Ave Volts...

  • Page 66: Fault Group

    5 - PARAMETER GROUPS Number Display Parameter Setting Range Units Default Page FUN 08 Heater Level Heater Level Off, 1 to 40 %FLA FUN 09 Energy Saver Energy Saver Off, On Seconds FUN 10 PORT Flt Tim P.O.R.T. Fault Time Off, 0.1 - 90.0 Seconds FUN 11...

  • Page 67: Parameter Description

    Parameter Description...

  • Page 68: Parameter Descriptions

    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 LCD display. Each parameter has a detailed description that is displayed with the following format. Parameter Name MMM__ LCD Display...
  • Page 69 6 - PARAMETER DESCRIPTION The Motor Service Factor parameter should be set to the service factor of the motor. The service factor is Description used for the overload calculations. If the service factor of the motor is not known, then the service factor should be set to 1.00.
  • Page 70 6 - PARAMETER DESCRIPTION programmed as Local / Remote, then the local/remote bit in the starter control Modbus register selects the control source. The default value of the bit is Local (0). z NOTE: By default, the [STOP] key is always enabled, regardless of selected control source. It may be disabled though using the Keypad Stop Disable (I/O 26) parameter.
  • Page 71 6 - PARAMETER DESCRIPTION Initial Current 1 QST 06 LCD Display QST: Init Cur 1 100 % Range 50 – 600 % of FLA (Default: 100%) The Initial Current 1 parameter is set as a percentage of the Motor FLA (QST 01) parameter setting. This Description parameter sets the current that is initially supplied to the motor when a start is commanded.
  • Page 72 6 - PARAMETER DESCRIPTION Ramp Time 1 QST 08 LCD Display QST: Ramp Time 1 15 sec Range 0 – 300 seconds (Default: 15 seconds) The Ramp Time 1 parameter is the time it takes for the starter to allow the current, voltage, torque or power Description (depending on the start mode) to go from its initial to the maximum value.
  • Page 73 6 - PARAMETER DESCRIPTION Starter Type (FUN 07) on page 103. Application section 7.6.2, Wye-Delta on page 139. Theory of Operation section 7.3, Acceleration Control on page 123. Jump to Parameter CFN 00 LCD Display CFN: Jump Code Description: By changing the value of this parameter and pressing [ENTER], you can jump directly to any parameter within that group.
  • Page 74 6 - PARAMETER DESCRIPTION Ramp Time 1 CFN 02 LCD Display CFN: Ramp Time 1 15 sec Range 0 – 300 seconds (Default: 15 seconds) The Ramp Time 1 parameter is the time it takes for the starter to allow the current, voltage, torque or power Description (depending on the start mode) to go from its initial to the maximum value.
  • Page 75 6 - PARAMETER DESCRIPTION Maximum Current 1 CFN 04 LCD Display CFN: Max Cur 1 600 % Range 100 – 800 % of FLA (Default: 600%) The Maximum Current 1 parameter is set as a percentage of the Motor FLA (QST 01) parameter setting and Description performs two functions.
  • Page 76 6 - PARAMETER DESCRIPTION Maximum Current 2 CFN 07 LCD Display CFN: Max Cur 2 600 % Range 100 – 800 % of FLA (Default: 600%) The Maximum Current 2 parameter is set as a percentage of the Motor FLA (QST 01) parameter setting, when Description the second ramp is active.
  • Page 77 6 - PARAMETER DESCRIPTION Maximum Torque/Power CFN 09 LCD Display CFN: Max T/P 105 % Range 10 – 325 % of Torque/Power (Default: 105%) Start Mode (CFN 01) set to Open Loop Voltage Acceleration: Description Not used when the Start Mode (CFN 01) parameter is set to open-loop voltage acceleration. When in open loop voltage acceleration mode, the final voltage ramp value is always 100% or full voltage.
  • Page 78 6 - PARAMETER DESCRIPTION Squared – The squared profile increases the control reference (voltage, current, torque, power, speed) in a squared manner. A squared acceleration profile can be useful when using TruTorque control on a load with a squared torque characteristic (such as pumps, and fans). A squared torque profile can provide a more linear speed profile during acceleration and deceleration.
  • Page 79 6 - PARAMETER DESCRIPTION Kick Time 1 CFN 12 LCD Display CFN: Kick Time 1 1.0 sec Range 0.1 – 10.0 seconds (Default: 1.0 sec) The Kick Time 1 parameter sets the length of time that the kick current level is applied to the motor. Description The kick time adjustment should begin at 0.5 seconds and be adjusted by 0.1 or 0.2 second intervals until the motor begins rotating.
  • Page 80 6 - PARAMETER DESCRIPTION Stop Mode CFN 15 LCD Display CFN: Stop Mode 15 Coast Range Description Coast Coast to stop. (Default) Volt Decel Open loop voltage deceleration TT Decel TruTorque deceleration DC Brake DC Braking Description Coast: A coast to stop should be used when no special stopping requirements are necessary; example: crushers, balls mills, centrifuges, belts, conveyor.
  • Page 81 6 - PARAMETER DESCRIPTION z NOTE: It is important that the Rated Power Factor (FUN 06) parameter is set properly so that the actual deceleration torque levels are the levels desired. See Also Stop Mode (CFN 15) on page 70. Decel End Level (CFN 17) on page 71.
  • Page 82 6 - PARAMETER DESCRIPTION If the motor stops rotating before the decel time expires, decrease the Decel Time (CFN 18) parameter. If the motor is still rotating when the decel time expires, increase the Decel Time (CFN 18) parameter. A typical decel time is 20 to 40 seconds. z NOTE: Depending on the motor load and the Decel parameter settings, the motor may or may not be fully stopped at the end of the deceleration time.
  • Page 83 6 - PARAMETER DESCRIPTION z NOTE: Not to be used as an emergency stop. When motor braking is required even during a power outage an electromechanical brake must be used. See Also Stop Mode parameter (CFN 15) on page 70. DC Brake Time parameter (CFN 21) on page 73.
  • Page 84 6 - PARAMETER DESCRIPTION The Preset Slow Speed parameter sets the speed of motor operation. When set to "Off", slow speed operation Description is disabled. Slow speed operation is commanded by programming one of the digital inputs to either "Slow Speed Forward"...
  • Page 85 6 - PARAMETER DESCRIPTION Although the Motor OL is active (if not set to "Off") during slow speed operation it is recommended that the motor temperature be monitored if slow speed is used for long periods of time. See Also Motor Running Overload Class (QST 03) parameter on page 59.
  • Page 86 6 - PARAMETER DESCRIPTION Jump to Parameter PFN 00 LCD Display PFN: Jump Code By changing the value of this parameter and pressing [ENTER], you can jump directly to any parameter Description within that group. Over Current Trip Level PFN 01 LCD Display PFN: Over Cur Lvl Off, 50 –...
  • Page 87 6 - PARAMETER DESCRIPTION set to Over current until the current drops or the starter trips on an overload. A shear pin function can be implemented by setting the delay to its minimum value. See Also Over Current Level parameter (PFN 01) on page 76. Auto Reset parameter (PFN 23) on page 84.
  • Page 88 6 - PARAMETER DESCRIPTION Current Imbalance Trip Level PFN 05 LCD Display PFN: Cur Imbl Lvl 15 % Range Off, 5 – 40 % (Default: 15 %) The Current Imbalance Level parameter sets the imbalance that is allowed before the starter shuts down. The Description current imbalance must exist for the Current Imbalance Delay Trip Time (PFN 06) before a fault occurs.
  • Page 89 6 - PARAMETER DESCRIPTION The Imbalance Delay parameter sets the time that the current imbalance must be greater than the Percent Description Imbalance (PFN 05) parameter before a trip will occur. See Also Current Imbalance Trip Level (PFN 05) on page 78. Residual Ground Fault Trip Level PFN 07 LCD Display...
  • Page 90 6 - PARAMETER DESCRIPTION Zero Sequence Ground Fault Trip Level PFN 08 LCD Display PFN: ZS GF Lvl Range Off, 1.0 – 25.0 amps (Default: Off) Description The Zero Sequence Ground Fault parameter sets a ground fault current trip or alarm level that can be used to protect the system from a ground fault condition.
  • Page 91 6 - PARAMETER DESCRIPTION Over Voltage Trip Level PFN 10 LCD Display PFN: Over Vlt Lvl Range Off, 1 – 40 % (Default: Off) If the EXMVRMX detects a one cycle input phase voltage that is above the over voltage level, the over/under Description voltage alarm is shown and the voltage trip timer begins counting.
  • Page 92 6 - PARAMETER DESCRIPTION Phase Loss Trip Time PFN 13 LCD Display PFN: Ph Loss Time 0.2 sec Range 0.1 – 5.0 seconds (Default: 0.2) The Phase Detect Delay parameter sets the delay time on Fault #27: "Phase Loss." This fault detects a loss of Description proper phase timing even when the phasing remains valid;...
  • Page 93 6 - PARAMETER DESCRIPTION Frequency Trip Time PFN 16 LCD Display PFN: Frq Trip Tim 0.1 sec Range 0.1 – 90.0 seconds (Default: 0.1) The Frequency Trip Time parameter sets the time that the line frequency must go above the Over Frequency Description Trip Level (PFN 14) or below the Under Frequency Trip Level (PFN 15) parameter before a high or low frequency fault will occur.
  • Page 94 6 - PARAMETER DESCRIPTION Backspin Timer PFN 20 LCD Display PFN: Backspin Tim Range Off, 1 – 180 minutes (Default: Off) The Backspin Timer parameter sets the minimum time between a stop and the next allowed start. If the starter Description is stopped and a time has been set, the starter will display a backspin lockout and the time until the next allowed start in the bottom right of the display.
  • Page 95 6 - PARAMETER DESCRIPTION Appendix C - Fault Codes on page 181. See Also Auto Fault Reset Count Limit parameter (PFN 24) on page 85. Auto Fault Reset Count Limit PFN 24 LCD Display PFN: Auto Rst Lim Range Off, 1 – 10 (Default: Off) The Auto Reset Limit parameter sets the number of times that an auto fault reset may be performed.

  • Page 96: Motor Overload

    6 - PARAMETER DESCRIPTION Digital Inputs (I/O 01 - 08) on page 90. See Also Motor PTC Trip Time PFN 27 LCD Display PFN: M PTC Time Range Off, 1 – 5 seconds (Default: Off) Description The soft starter has the capability to monitor a PTC (Positive Temperature Coefficient) thermistor signal from the motor.
  • Page 97 6 - PARAMETER DESCRIPTION Motor Starting Overload Class PFN 29 LCD Display PFN: Starting OL Range Off, 1 – 40 (Default: 10) The Motor Starting Overload Class parameter sets the class of the electronic overload when starting. The Description starter stores the thermal overload value as a percentage value between 0 and 100%, with 0% representing a “cold”...
  • Page 98 6 - PARAMETER DESCRIPTION Motor Overload Hot/Cold Ratio PFN 31 LCD Display PFN: OL H/C Ratio 60 % Range 0 – 99 % (Default: 60) The Motor Overload Hot/Cold Ratio parameter defines the steady state overload content (OL ) that is reached Description when the motor is running with a current less than full load current (FLA) * Service Factor (SF).
  • Page 99 6 - PARAMETER DESCRIPTION Independent Starting/Running Overload parameter (PFN 28) on page 86. See Also Motor Running Overload Class parameter (PFN 30) on page 87. Motor Starting Overload Class parameter (PFN 29) on page 87. Motor Overload Hot/Cold Ratio parameter (PFN 31) on page 88. Theory of Operation section 7.1.10, Motor Cooling While Stopped on page 120.
  • Page 100 6 - PARAMETER DESCRIPTION during a start shall only be added to the list if the motor start fully completes the start (i.e. the starter reaches up to speed). z NOTE: This feature should not be used on systems where the starting load varies greatly from start to start.
  • Page 101 6 - PARAMETER DESCRIPTION Local Source parameter (QST 04) on page 59. See Also Remote Source parameter (QST 05) on page 60. Bypass Feedback Time parameter (I/O 25) on page 96. Heater Level parameter (FUN 08) on page 104. Theory of Operation section 7.1.12, Emergency Motor Overload Reset on page 121. Theory of Operation section 7.3.6, Dual Acceleration Ramp Control on page 128.
  • Page 102 6 - PARAMETER DESCRIPTION Parameters I/O 10-12 configure which functions are performed by the R1 to R3 relays located on MX card. Description Parameters I/O 13-15 configure which functions are performed by the R4 to R6 relays located on I/O card. See Also Up To Speed Time parameter (QST 09) on page 62.
  • Page 103 6 - PARAMETER DESCRIPTION Analog Input Trip Type parameter (I/O 16) on page 92. See Also Analog Input Span parameter (I/O 19) on page 93. Analog Input Offset parameter (I/O 20) on page 94. Analog Input Trip Delay Time I/O 18 LCD Display I/O: Ain Trp Tim 0.1 sec...
  • Page 104 6 - PARAMETER DESCRIPTION Analog Input Offset parameter (I/O 20) on page 94. Starter Type parameter (FUN 07) on page 103. Analog Input Offset I/O 20 LCD Display I/O: Ain Offset 0 – 99 % (Default: 0) Range 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 105 6 - PARAMETER DESCRIPTION Analog Output Span I/O 22 LCD Display I/O: Aout Span 100 % Range 1 – 125 % (Default: 100) The analog output signal can be scaled using the Analog Output Span parameter. For a 0-10V output or Description 0-20mA output, a 100% scaling outputs the maximum voltage (10V) or current (20mA) when the selected output function requests 100% output.
  • Page 106 6 - PARAMETER DESCRIPTION Inline Configuration I/O 24 LCD Display I/O: Inline Confg 3.0 sec Range Off, 0 – 10.0 seconds (Default: 3.0) The Inline Configuration parameter controls the behavior of the No Line warning, No Line fault, and the Description Ready relay function.
  • Page 107 6 - PARAMETER DESCRIPTION If the keypad is selected as local or remote control sources, the [STOP] key cannot be disabled. If “Enabled” When this parameter is set to "Enabled", the keypad stop button is enabled and stops the starter regardless of the selected control source (keypad, terminal or serial).
  • Page 108 6 - PARAMETER DESCRIPTION RTD Module #2 Address RTD 02 LCD Display RTD: RTDMod2 Addr Range Off, 16 to 23 (Default Off) The module #2 address parameter has to be set to the Modbus address of the second RTD module attached to Description the soft-starter.
  • Page 109 6 - PARAMETER DESCRIPTION The Bearing Alarm Level parameter selects its Alarm temperature level. When an RTD in this group reaches Description Alarm level an alarm condition will be declared. This parameter sets the alarm level for any RTD set to "Bearing".
  • Page 110 6 - PARAMETER DESCRIPTION RTD Voting RTD 25 LCD Display RTD: RTD Voting 25 Disabled Range Disabled, Enabled (Default: Disabled) RTD Trip voting can be enabled for extra reliability in the event of a RTD malfunction. When RTD voting is Description enabled, two (2) RTDs in one assigned group will need to exceed their trip temperature before a fault is declared.
  • Page 111 6 - PARAMETER DESCRIPTION Typically set to ambient conditions (40°C) Description See Also RTD Biasing OL group in section 7.1.7 on page 118. RTD Bias Midpoint Level RTD 28 LCD Display RTD: RTD Bias Mid 130 C Range 1 – 199°C (Default: 130 Description Typically set at the rated motor running temperature.
  • Page 112 6 - PARAMETER DESCRIPTION L2-L3 Volts Voltage in, L2 to L3 RMS. L3-L1 Volts Voltage in, L3 to L1 RMS. Overload Thermal overload in %. Power Factor Motor power factor. Watts Motor real power consumed. Motor apparent power consumed. vars Motor reactive power consumed.
  • Page 113 6 - PARAMETER DESCRIPTION Rated RMS Voltage FUN 05 LCD Display FUN: Rated Volts 2200 Range 100, 110, 120, 200, 208, 220, 230, 240, 350, 380, 400, 415, 440, 460, 480, 500, 525, 575, 600, 660, 690, 800, 1000, 1140, 2200, 2300, 2400, 3300, 4160, 4600, 4800, 6000, 6600, 6900, 10.00K, 11.00K, 11.50K, 12.00K, 12.47K, 13.20K, 13.80K (Default: 480) Description The Rated Voltage parameter sets the line voltage that is used when the starter performs Over and Under line...
  • Page 114 6 - PARAMETER DESCRIPTION Curr Follow Closed Loop Current follower using external analog input reference. - Consult Factory Across the line (Full Voltage). Description The MX has been designed to be the controller for many control applications; Solid State Starter, both Normal (outside Delta) and Inside Delta, and electro mechanical starters, Wye Delta, Across the line full voltage starter, Phase Control/Voltage Follower, Current Follower.
  • Page 115 If the load on the motor increases, the starter immediately returns the output of the starter to full voltage. z NOTE: This function does not operate if a bypass contactor is used. z NOTE: In general, Energy Saver can save approximately 1000 watts per 100 HP. Consult Benshaw for further detail. P.O.R.T. Fault Time...
  • Page 116 6 - PARAMETER DESCRIPTION P.O.R.T. Recovery Method FUN 12 LCD Display FUN: PORT Recover 12 Fast Recover Range Description Fast Recover Current acceleration ramp from 100% FLA -> 800% FLA with a ramp time of 1 second. (Default) Current Ramp Current acceleration ramp using the Ramp#1 user parameter settings.
  • Page 117 6 - PARAMETER DESCRIPTION TruTorque Accel If the tachometer signal is lost the starter will fault. However the start mode parameter will be set to TruTorque control acceleration so that when the fault is reset the starter will start in Current control mode. KW (Power) If the tachometer signal is lost the starter will fault.
  • Page 118 6 - PARAMETER DESCRIPTION Communication Byte Framing FUN 19 LCD Display FUN: Com Parity 19 Even, 1 Stop Range Even, 1 Stop (Default) Odd, 1 Stop None, 1 Stop None, 2 Stop Description The Communication Byte Framing parameter sets both the parity and number of stop bits. Communication Address parameter (FUN 16) on page 107.
  • Page 119 6 - PARAMETER DESCRIPTION The Miscellaneous Commands parameter is used to issue various commands to the MX starter. Description The Reset Run Time command resets the user run time meters back to zero (0). The Reset kWh command resets the accumulated kilowatt-hour and megawatt-hour meters back to zero (0). The Reflash Mode command puts the MX into a reflash program memory mode.
  • Page 120 6 - PARAMETER DESCRIPTION Passcode FUN 26 LCD Display FUN: Passcode Description The MX provides a means of locking parameter values so that they may not be changed. Once locked, the parameters values may be viewed on the display, but any attempt to change their values by pressing the [UP] or [DOWN] keys is ignored.
  • Page 121 6 - PARAMETER DESCRIPTION Pressing [ENTER] will now display the starter state at the time of the event on the bottom line of the screen. See below; E01: Event #?? Fault Pressing [ENTER] for a 2nd time will display the time of the event on the bottom line of the screen. See below;...
  • Page 122 6 - PARAMETER DESCRIPTION NOTES:...
  • Page 123 Theory of Operation...

  • Page 124: Solid State Motor Overload Protection

    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 125: Motor Overload Operation

    Class 15 Class 10 Class 5 Current % (FLA) Visit the web at www.benshaw.com for an automated overload calculator. 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.

  • Page 126: Harmonic Compensation

    7 - THEORY OF OPERATION 7.1.4 Current Imbalance / Negative Sequence Current Compensation The MX motor overload calculations automatically compensate for the additional motor heating which results from the presence of unbalanced phase currents. There can be significant negative sequence currents present in the motor when a current imbalance is present,.
  • Page 127 7 - THEORY OF OPERATION If no motor information is available, a Hot/Cold ratio value of 60% is usually a good starting point. The MX adjusts the actual motor overload content based on the programmed Hot/Cold Ratio set point and the present running current of the motor so that the accumulated motor overload content accurately tracks the thermal condition of the motor.

  • Page 128: Rtd Overload Biasing

    7 - THEORY OF OPERATION 7.1.7 RTD Overload Biasing The RTD biasing calculates a motor thermal value based on the highest stator RTD measurement. The motor thermal overload content is set to this calculated value, if this calculated value is higher than the motor thermal overload content. The RTD biasing is calculated as follows: Max measured stator RTD temp <...

  • Page 129: Overload Auto Lockout

    7 - THEORY OF OPERATION 7.1.8 Overload Auto Lockout This feature prevents an overload trip during the motor start due to insufficient thermal capacity. It will automatically calculate the overload content required to start the motor. It will lockout the starter if there is not enough overload content available. The release value calculated is based on OL content used for the past four (4) successful motor starts.

  • Page 130: Motor Cooling While Stopped

    7 - THEORY OF OPERATION 7.1.10 Motor Cooling While Stopped The Motor Overload Cooling Time (PFN 32) parameter is used to adjust the cooling rate of the motor overload. When the motor is stopped and cooling, the accumulated motor overload content is reduced in an exponential manner. CoolingTim Content Content wh...

  • Page 131: 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 132: Motor Service Factor

    7 - THEORY OF OPERATION Motor Service Factor Motor Service Factor The Motor Service Factor (QST 02) parameter should be set to the service factor of the motor. The service General 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 133: Acceleration Control

    7 - THEORY OF OPERATION Acceleration Control Acceleration Control 7.3.1 Current Ramp Settings, Ramps and Times The current ramp sets how the motor accelerates. The current ramp is a linear increase in current from the General 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 134: Programming A Kick Current

    7 - THEORY OF OPERATION The ramp time is the time it takes for the current to go from the initial current to the maximum current. To Ramp Time make the motor accelerate faster, decrease the ramp time. To make the motor accelerate slower, increase the ramp time.
  • Page 135 7 - THEORY OF OPERATION This parameter (CFN 08) sets the initial torque level that the motor produces at the beginning of the starting Initial Torque ramp profile. A typical value is 10% to 20%. If the motor starts too quickly or the initial motor torque is too high, reduce this parameter.

  • Page 136: 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 137: Open Loop Voltage Ramps And Times

    7 - THEORY OF OPERATION z 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 138: Dual Acceleration Ramp Control

    7 - THEORY OF OPERATION When the start mode is set to open-loop voltage ramp acceleration, the UTS Timer acts as an acceleration UTS Timer 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 139 7 - THEORY OF OPERATION Current Ramp 2 and Kick Current 2 starting profiles are selected by programming a digital input to the Ramp Acceleration Ramp Selection Select function and then energizing that input by applying 120 Volts to it. When a digital input is programmed to Ramp Select, but de-energized, Current Ramp 1 and Kick Current 1 are selected.
  • Page 140 7 - THEORY OF OPERATION The selected ramp profile may be changed during starting by changing the Ramp Select input. When the Changing Ramp Profiles Ramp Select input changes during ramping, control switches to the other profile as if it were already in progress.

  • Page 141: Deceleration Control

    7 - THEORY OF OPERATION Deceleration Control Deceleration Control 7.4.1 Voltage Control Deceleration The deceleration control on the MX uses an open loop voltage ramp. The MX ramps the voltage down to Overview decelerate the motor. The curve shows the motor voltage versus the decel setting. Figure 38: Motor Voltage Versus Decel Level This sets the starting voltage of the deceleration ramp.

  • Page 142: 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 143: 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 144: 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. z 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 145: Dc Injection Brake Wiring Example

    7 - THEORY OF OPERATION 7.5.5 DC Injection Brake Wiring Example Figure 40: DC Injection Brake Wiring Example SCRs HEAVY DUTY BRAKE 5A CT PHASE 1 SCR STACK 5A CT 3Ø50/60Hz. 3Ø50/60Hz. PHASE 2 SCR STACK 2200-6900 VAC 2200-6900 VAC 5A CT PHASE 3 SCR STACK GROUND BUS...

  • Page 146: Dc Brake Timing

    7 - THEORY OF OPERATION 7.5.6 DC Brake Timing The MX DC injection brake timing is shown below: Figure 41: DC Injection Brake Timing DC Brake Delay Time DC Brake Delay after Time DC Brake Brake Relay On Braking Relay Energized Brake Relay Off DC Injection On Starter SCRs On, DC Current Applied...

  • Page 147: Use Of Optional Hall Effect Current Sensor

    7 - THEORY OF OPERATION Once DC Braking is stopped due to a digital input state change, no further DC braking will take place and the starter will return to the idle state. 7.5.8 Use of Optional Hall Effect Current Sensor The Hall Effect Current Sensor should be located on Phase 1 of the motor output wiring.

  • Page 148: 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 149 7 - THEORY OF OPERATION operator from stopping and re-starting the motor which can result in the slow speed operation time of the motor being exceeded. Slow Speed Kick Level: The Slow Speed Kick Level sets the short-term current level that is applied to the motor to accelerate the motor for slow speed operation.

  • Page 150: Across The Line (Full Voltage Starter)

    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 a digital output relay that is programmed for the RUN function.

  • Page 151: Start/Stop Control With A Hand/Off/Auto Selector Switch

    7 - THEORY OF OPERATION Start/Stop Control with a Hand/Off/Auto Selector Switch Start/Stop Control with a Hand/Off/Auto Selector Switch Often times, a switch is desired to select between local or “Hand” mode and remote or “Auto” mode. In most cases, local control is performed as 3-wire logic with a normally open, momentary contact Start pushbutton and a normally closed, momentary contact Stop pushbutton, while remote control is performed as 2-wire logic with a “Run Command”...

  • Page 152: Simplified I/O Schematics

    7 - THEORY OF OPERATION Simplified I/O Schematics Simplified I/O Schematics Figure 44: Digital Input Simplified Schematic Figure 45: Analog Input Simplified Schematic Figure 46: Analog Output Simplified Schematic...

  • Page 153: Remote Modbus Communications

    7 - THEORY OF OPERATION Remote Modbus Communications 7.10 Remote Modbus Communications The MX starter provides Modbus RTU to support remote communication. The communication interface is RS-485, and allows up to 247 slaves to be connected to one master (with repeaters when the number of drops exceeds 31).

  • Page 154: Wiring

    7 - THEORY OF OPERATION 7.10.7 Wiring Figure 47 shows the wiring of TB4 to a Modbus-485 Network. If the starter is the end device in the network, a 120W, 1/4W terminating resistor may be required. Please refer to Figure 48 for wire and termination practices. Figure 47: TB4 Connector Figure 48: Modbus Network Wiring Example...
  • Page 155 7 - THEORY OF OPERATION NOTES:...
  • Page 156 7 - THEORY OF OPERATION...

  • Page 157: Troubleshooting & Maintenance

    Troubleshooting & Maintenance...

  • Page 158: Safety Precautions

    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 159: Led Diagnostics

    8 - TROUBLESHOOTING & MAINTENANCE LED Diagnostics LED Diagnostics There are several LEDs located on the EXMVRMX circuit cards. These LEDs can be used to help troubleshoot problems with the starter. Refer to the circuit card layouts for LED locations. CARD LED # Description...
  • Page 160 8 - TROUBLESHOOTING & MAINTENANCE RediStart EXMVRMX Gate Driver Card ATTENTION: The Fiber Optic cables can be damaged if struck or bent sharply. The edge of the printed circuit board should be held to prevent damage.

  • Page 161: 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 common issues that may occur. 8.4.1 Stack Overtemp Lockout Stack Overtemp Lockout Condition Cause Solution Check wiring to the OTR from the Gate OTP overtemperature relay is not energized.

  • Page 162: During Starting, Motor Rotates But Does Not Reach Full Speed

    8 - TROUBLESHOOTING & MAINTENANCE 8.4.3 During starting, motor rotates but does not reach full speed Condition Cause Solution See fault code troubleshooting table for Fault Displayed. Fault Occurred. more details. Maximum Motor Current setting Review acceleration ramp settings. (QST07) set too low. Motor loading too high and/or current not dropping below 175% FLA indicating Reduce load on motor during starting.

  • Page 163: Starter Not Decelerating As Desired

    8 - TROUBLESHOOTING & MAINTENANCE 8.4.5 Starter not decelerating as desired Condition Cause Solution Decel Time (CFN18) set too short. Increase Decel Time. Motor stops too quickly. Decel Begin and End Levels (CFN16 and Increase Decel Begin and/or Decel CFN17) set improperly. End levels.

  • Page 164: Metering Incorrect

    8 - TROUBLESHOOTING & MAINTENANCE 8.4.7 Metering incorrect Condition Cause Solution Verify correct CT wiring and verify that the CTs are installed with all the White CTs installed or wired incorrectly. dots towards the input line side. Power Metering not reading correctly. CT1=L1 CT2=L2 CT3=L3 CT ratio parameter (FUN03) set Verify that the CT ratio parameter is set...

  • Page 165: Other Situations

    8 - TROUBLESHOOTING & MAINTENANCE 8.4.8 Other Situations Condition Cause Solution If input phasing correct, exchange any two output wires. Motor Rotates in Wrong Direction. Phasing incorrect. If input phasing incorrect, exchange any two input wires. Shut off all power and check all Erratic Operation.

  • Page 166: 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 MX starter control. Fault Code Description Detailed Description of Fault / Possible Solutions Motor did not achieve full speed before the UTS timer (QST 09) expired. Check motor for jammed or overloaded condition.
  • Page 167 8 - TROUBLESHOOTING & MAINTENANCE Fault Code Description Detailed Description of Fault / Possible Solutions Input phase rotation is not ABC and Input Phase Sensitivity parameter (FUN 04) is set to ABC only. Phase Rotation Error, not ABC Verify correct phase rotation of input power. Correct wiring if necessary. Verify correct setting of Input Phase Sensitivity parameter (FUN 04).
  • Page 168 8 - TROUBLESHOOTING & MAINTENANCE Fault Code Description Detailed Description of Fault / Possible Solutions High voltage above the Over voltage Trip Level parameter setting (PFN 10) was detected for longer than the Over/Under Voltage Trip delay time (PFN 12). Verify that the actual input voltage level is correct.
  • Page 169 8 - TROUBLESHOOTING & MAINTENANCE Fault Code Description Detailed Description of Fault / Possible Solutions The motor power factor went above the PF leading trip level. Power Factor Leading Verify loading of motor. On synchronous motors, verify field supply current. The motor power factor went below the PF lagging trip level.
  • Page 170 8 - TROUBLESHOOTING & MAINTENANCE Fault Code Description Detailed Description of Fault / Possible Solutions The MX electronic power stack OL protection has detected an overload condition. Stack Protection Fault (stack Check motor for jammed or overloaded condition. thermal overload) Verify that the CT ratio (FUN 03) is correct.
  • Page 171 8 - TROUBLESHOOTING & MAINTENANCE Fault Code Description Detailed Description of Fault / Possible Solutions External Fault on DI#1 Input External Fault on DI#2 Input External Fault on DI#3 input DI # 01 - 08 (I/O 01 - 08) has been programmed as a fault type digital input and External Fault on DI#4 input the input indicates a fault condition is present.
  • Page 172 8 - TROUBLESHOOTING & MAINTENANCE Fault Code Description Detailed Description of Fault / Possible Solutions I/O card has detected a problem with the Real Time Clock operation. Consult I/O Card Error factory. I/O Card Error I/O card has detected an internal CPU problem. Consult factory. I/O Card SW Watchdog I/O card has detected an internal software problem.

  • Page 173: Minimum Safety Practices

    8 - TROUBLESHOOTING & MAINTENANCE Minimum Safety Practices Minimum Safety Practices Before performing any tests on electrical equipment make certain all PPE (Personal Protective Equipment) is worn. Check with your Health and Safety co-ordinator or for more information see (www.NFPA.ORG) Electrical Safety in the workplace. Open the disconnect switch and perform lockout and tag procedures.

  • Page 174: Ohm Meter Testing

    If all values are greater than 50K ohms, proceed to the SCR Gate to Cathode Test. If an SCR measures less than 50K ohms but not 0 ohms, the SCR still may be good. Contact Benshaw for further assistance. If any of the recorded values are 0 ohms then one or more of the SCRs in that phase has failed.

  • Page 175: Scr Gate To Cathode Test

    8 - TROUBLESHOOTING & MAINTENANCE 8.7.3 SCR Gate to Cathode Test To perform the gate to cathode test, attach the ohmmeter to SCRs like in the picture shown below to measure the resistance between the red and white SCR gate leads. Figure 50: SCR Gate Test Table 18: Ohmmeter Position for SCR Gate Test Test...

  • Page 176: Scr Replacement

    8 - TROUBLESHOOTING & MAINTENANCE SCR Replacement SCR Replacement 8.8.1 Card Removal Before the SCRs can be removed, the PC boards and Lexanä or glastic must first be removed. If unsure of any wiring connections to the card, write down location of wires on drawings. 8.8.2 SCR Clamp The SCR clamp pictured below is typical of the clamp used on all SCRs.

  • Page 177: Scr Removal

    SCR Installation To install an SCR, use Benshaw approved SCR's. Note that the SCR grade must match the grades of the rest of the SCRs in that phase. Coat the faces of the SCR's to be installed with a thin layer of electrical joint compound (EJC). Place the SCR's onto the dowel pins (refer to Figure 52 for proper SCR position).

  • Page 178: Built-In Self Test (Bist)

    “Run/Test” isolation switches, test power plugs, and wiring diagrams are available from Benshaw. CAUTION: Verify that line voltage is not applied to the line side of the inline contactor before the test is performed. Otherwise the inline test will apply line voltage to the starter and a BIST test fault will occur.
  • Page 179 8 - TROUBLESHOOTING & MAINTENANCE z NOTE: If the gate power LED does not light up, check and verify the 24 VAC Transformer T3. If the transformer is functional then the gate power distributor card has failed. Figure 54: Fiber Optic Driver Card Location (BIPC-300003-xx)

  • Page 180: Conducting A Bist

    8 - TROUBLESHOOTING & MAINTENANCE 8.9.4 Conducting a BIST To conduct a BIST Test, follow these steps: • Press the [MENU] button six times to scroll to th FUN group. • Press the [DOWN] button five times to get to FUN 22. •...

  • Page 181: Sequential Scr Gate Firing

    Press [ENTER] pushbutton to move to the next BIST step. z NOTE: If the SCR gate indicators do not light in the proper sequence during this test then consult Benshaw. Do not attempt to operate the starter as SCR damage will occur.

  • Page 182: Resetting System

    All gates on Press [ENTER] pushbutton to complete BIST procedure. z NOTE: If the LED gate indicators do not all light during this test then consult Benshaw. Do not attempt to operate the starter as SCR damage will occur. 8.9.10...

  • Page 183: Rtd Module Troubleshooting

    Periodical Inspection: Benshaw controls require only periodical inspections. These inspections can be visual for physical traces of dust, dirt or visible damage. Circuit boards should be physically tested to ensure that all the cables are connected properly. Remember cleaning solvents should not come in contact with circuit or PC boards.
  • Page 184 Replacement of the contactor is the reverse of the removal. Test the contactor before installing to ensure proper operation. A contactor manual is provided with each starter and should be referred to when disassembling and reassembling the contactor. If required contact Benshaw for a manual. Vacuum Bottles: The contacts in a vacuum bottle can not be seen or examined directly.
  • Page 185 8 - TROUBLESHOOTING & MAINTENANCE NOTES:...
  • Page 187 Appendices...

  • Page 188: Appendix A Event Codes

    APPENDIX A - EVENT CODES Event Codes ** Event Number 1 through 99 - See starter fault listing for description of faults. The event log will only indicate that a fault of a given fault code occurred and a time stamp when it occurred. Event Number Event Event Number...

  • Page 189: Appendix B Alarm Codes

    APPENDIX B - ALARM CODES Alarm Codes The following is a list of all MX alarm codes. The alarm codes correspond to associate fault codes. In general, an alarm indicates a condition that if continued, will result in the associated fault. Alarm Description Notes...
  • Page 190 APPENDIX B - ALARM CODES Alarm Description Notes Code This alarm exists while the MX is in Power Outage Ride P.O.R.T. Timeout Through mode and it is waiting for line power to return. When the PORT fault delay expires a Fault 29 shall occur. This alarm exists while the MX is running and the average current is above the defined threshold, but the delay for the...

  • Page 191: Appendix C Fault Codes

    APPENDIX C - 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 Speed Switch Time Limit Expired Motor PTC Overtemperature Stator RTD Overtemperature Bearing RTD Overtemperature Other RTD Overtemperature...
  • Page 192 APPENDIX C - FAULT CODES Controlled Fault Fault Code Description Shunt Trip Fault Auto-Reset Allowed Stop External Fault on DI 5 Input External Fault on DI 6 Input External Fault on DI 7 Input External Fault on DI 8 Input Analog Input #1 Level Fault Trip RTD Module Communication Fault Keypad Communication Fault...

  • Page 193: Appendix D Spare Parts

    APPENDIX D - SPARE PARTS Options and Accessories Description Part Number Size LCD Display (large) KPMX3LLCD H=77mm(3.03"), W=127mm(5") LCD display cable RI-100009-00 6' or 2 meter Remote RTD Module SPR-100P Zero Sequence Ground Fault CT CT-2000/1-6 (CT100001-01) Communication Modules consult factory Spare Parts Description Part Number...

  • Page 194: Appendix E Eu Declaration Of Conformity

    - 13,800 Volts MV MX Control Combination Fusable Example of Model Number: CFMVRMX36-3500-13200-1 A Combination Fusable RediStart starter with MX control, 13,200 Volts, 3500 Horsepower, NEMA 1 Enclosure. Benshaw, Inc. Manufacturer's Name: Manufacturer's Address: 659 East Sutter Road Glenshaw, PA 15116...

  • Page 195: Appendix F Modbus Register Map

    APPENDIX F - MODBUS REGISTER MAP Modbus Register Map Following is the Modbus Register Map. Note that all information may be accessed either through the Input registers (30000 addresses) or through the Holding registers (40000 addresses). Absolute Register Address Description Range Units Bit Mask:...
  • Page 196 APPENDIX F - MODBUS REGISTER MAP Absolute Register Address Description Range Units Bit 0: “A 64” – DI 5 Bit 1: “A 65” – DI 6 – 30025/40025 Alarm Status 3 Bit 2: “A 66” – DI 7 Bit 3: “A 67” – DI 8 Bit 4: “A 71”...
  • Page 197 APPENDIX F - MODBUS REGISTER MAP Absolute Register Address Description Range Units 30058/40058 Peak Starting Current 30059/40059 Last Starting Duration 0.1 Sec °C 30060/40060 Hottest Stator RTD Temperature 0 - 200 °C 30061/40061 Hottest Bearing RTD Temperature 0 - 200 °C 30062/40062 Hottest Other RTD Temperature...
  • Page 198 APPENDIX F - MODBUS REGISTER MAP Absolute Register Address Description Range Units – 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 199 APPENDIX F - MODBUS REGISTER MAP Absolute Register Address Description Range Units 10: 3.1 11: 3.3 12: 3.5 13: 3.8 14: 4.2 15: 4.5 30136/40136 Slow Speed 16: 5.0 17: 5.5 18: 6.2 19: 7.1 20: 8.3 21: 9.1 22: 10.0 23: 11.1 24: 12.5 25: 14.3...
  • Page 200 APPENDIX F - MODBUS REGISTER MAP Absolute Register Address Description Range Units 10: 400 11: 415 12: 440 13: 460 14: 480 15: 500 16: 525 17: 575 18: 600 19: 660 30143/40143 Rated RMS Voltage 20: 690 Vrms 21: 800 22: 1000 23: 1140 24: 2200...
  • Page 201 APPENDIX F - MODBUS REGISTER MAP Absolute Register Address Description Range Units Disabled – 30156/40156 Residual Ground Fault Trip Enable Enabled 30157/40157 Residual Ground Fault Trip Level 5 – 100 % FLA Disabled – 30158/40158 Over Voltage Trip Enable Enabled 30159/40159 Over Voltage Trip Level 1 –...
  • Page 202 APPENDIX F - MODBUS REGISTER MAP Absolute Register Address Description Range Units Low – Fault below preset level – 30176/40176 Analog Input Trip Type High – Fault above preset level 30177/40177 Analog Input Trip Level 0 – 100 30178/40178 Analog Input Trip Delay Time 1 –...
  • Page 203 APPENDIX F - MODBUS REGISTER MAP Absolute Register Address Description Range Units Status Ave Current L1 Current L2 Current L3 Current Current Imbalance % Residual Ground Fault Ave. Volts L1-L2 Volts L2-L3 Volts 10: L3-L1 Volts 11: Overload 12: Power Factor 13: Watts 14: VA 15: vars...
  • Page 204 APPENDIX F - MODBUS REGISTER MAP Absolute Register Address Description Range Units None Reset Run Time Reset kWh Enter Reflash Mode – 30199/40199 Store Parameters Misc. Commands Load Parameters Factory Reset Standard BIST Powered BIST Linear – 30221/40221 Acceleration Profile Squared –...
  • Page 205 APPENDIX F - MODBUS REGISTER MAP Absolute Register Address Description Range Units 30250/40250 Speed Switch Delay Time 1 – 250 Disabled – 30251/40251 Motor PTC Enable Enabled 30252/40252 Motor PTC Delay Time 1 – 5 Disabled – 30253/40253 PORT Trip Enable Enabled 30254/40254 PORT Trip Delay Time...
  • Page 206 APPENDIX F - MODBUS REGISTER MAP Absolute Register Address Description Range Units 30601/40601 Fault Code (newest fault) – Refer to page 181 30609/40609 Fault Code (oldest fault) Initializing Locked Out Faulted Stopped Heating Kicking Ramping Slow Speed 30611/40611 System States: The state that the starter Not UTS –...
  • Page 207 APPENDIX F - MODBUS REGISTER MAP Starter Control Register: Stop Bit 0 – Run/Stop Start No action Bit 1 – Fault Reset Fault Reset No action Bit 2 –Emergency Overload Reset Emergency Overload Reset Local Bit 3 –Local/Remote Remote Heater Enabled Bit 4 –Heat Disabled Heater Disabled Ramp 1...
  • Page 208 APPENDIX F - MODBUS REGISTER MAP Starter Status Register: Initializing or Faulted and decelerating or Faulted and Braking or Bit 0 – Ready Faulted and Stopped or Lockout Otherwise Not Running Bit 1 – Running Running Not UTS Bit 2 –UTS No alarm conditions Bit 3 –Alarm 1 or more alarm conditions...

  • Page 209: Appendix G Application Glossary

    APPENDIX G - APPLICATION GLOSSARY Glossary Alternating Current Ambient Temperature Is the temperature of the air, water or a surrounding medium where equipment is operated or stored. American Wire Gauge A standard system used for designing the size of electrical conductors. Gauge numbers have an inverse relationship to size;...
  • Page 210 APPENDIX G - APPLICATION GLOSSARY Interface Board This circuit board take line-side and load-side voltage feedback signals from the voltage feedback board and passes them via pin cables to the processor. Jogging Is a means of accomplishing momentary motor movement by repetitive closure of a circuit using a single push button or contact element.
  • Page 211 APPENDIX G - APPLICATION GLOSSARY Remote I/O I/O connected to a processor across a serial link. With a serial link, remote I/O can be located long distances from the processor. RS-232-C An EIA standard that specifies electrical, mechanical and functional characteristics for serial binary communication circuits in a point-to-point link.

  • Page 212: Appendix H 3-Year Warranty

    3-Year Warranty Benshaw's standard warranty is one (1) year from date of shipment. Benshaw will extend this warranty to three (3) years from date of shipment when done by a supervised start up by a Benshaw Technician. See attached Warranty Statement and Terms of Conditions.
  • Page 213 APPENDIX H - 3-YEAR WARRANTY...
  • Page 214 APPENDIX I - PARAMETER TABLES Parameter Table Following is the parameter table for both the LED and LCD Display. The last column is a convenient place to write down parameter settings. Quick Start Group Display Parameter Setting Range Units Default Page Setting QST 01...
  • Page 215 APPENDIX I - PARAMETER TABLES Group Display Parameter Setting Range Units Default Page Setting CFN 22 Brake Delay DC Brake Delay 0.1 to 3.0 Seconds CFN 23 SSpd Speed Slow Speed Off, 1 – 40 CFN 24 SSpd Curr Slow Speed Current Level 10 to 400 % FLA CFN 25...

  • Page 216: Appendix I Parameter Tables

    APPENDIX I - PARAMETER TABLES Group Display Parameter Setting Range Units Default Page Setting PFN 31 OL H/C Ratio Motor Overload Hot/Cold Ratio 0 - 99 PFN 32 OL Cool Time Motor Overload Cooling Time 1.0 - 999.9 Minutes PFN 33 OL Alarm Lvl Motor OL Alarm Level 1 - 100...
  • Page 217 APPENDIX I - PARAMETER TABLES Display Parameter Setting Range Units Default Page Setting Group 0 – 200% Curr 0 – 800% Curr 0 – 150% Volt 0 – 150% OL Analog Output 0 – 10 kW I/O 21 Aout Fctn Function 0 –...
  • Page 218 APPENDIX I - PARAMETER TABLES RTD 19 Stator Alrm Stator Alarm Level RTD 20 Bearing Alrm Bearing Alarm Level RTD 21 Other Alrm Other Alarm Level 1 - 200 RTD 22 Stator Trip Stator Trip Level RTD 23 Bearing Trip Bearing Trip Level RTD 24 Other Trip...
  • Page 219 APPENDIX I - PARAMETER TABLES Number Display Parameter Setting Range Units Default Page Setting Insensitive FUN 04 Phase Order Input Phase Sensitivity Insens. Single Phase 100, 110, 120, 200, 208, 220, 230, 240, 350, 380, 400, 415, 440, 460, 480, 500, 525, 575, 600, 660, 690, 1000, 1140, 2200, FUN 05...
  • Page 220 APPENDIX I - PARAMETER TABLES Number Display Parameter Setting Range Units Default Page Setting mm/dd/yy 12h mm/dd/yy 24h yy/mm/dd 12h mm/dd/yy FUN 23 T/D Format Time and Date Format yy/mm/dd 24h dd/mm/yy 12h dd/mm/yy 24h Present FUN 24 Time Time Time Present FUN 25...
  • Page 221 Publication History; Revision Date ECO# 12/15/06 Initial Release...
  • 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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