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MX2 Control (RB2, RC2, RX2E Models) (Publication # 890034-23

1. 120 1 1 1 12 1 R Tel 11202 ji cRouND Ji2 I 5 P68 FUNO3 amp NEUTRAL 374 1 NEUTRAL 4 8 49 LME BIPC 300055 01 MX2 CARD i 1 III e 200 on i Jf HE i m 2 185 I L AN POwER i 182 E B a an 2 J PROGRAM REY RI AA 8 an 3 ZL 1 5 aout 5 T82 g 5 6 5 5 RELAY R2 r3 SHIELD 7 a Rx ORE 68 1 TB4 182 MM z 2 a SERIAL COMMUNICATION I Procrwmase 8 RS485 5V MAX E RH RELAY R3 S CM6 TWO WIRE CONTROL qM H A uw 1 al CPU STOP START pog mj OVERTEMP SWITCH epe I MTD ON HEATSINK 1 1 022 gt cae mae 09 e gt 1 BP1 1 Doz 33 m 8 5 ois gt __ _ 5 861 6 gt 20 RJA5 DISPLAY pue L dececeene 9 fo Gee en a 7 DISPLAY o 1 53 2 1 CID CAD fu t Utd CI CT MN L OPTIONAL DOOR MOUNT DISPLAY 6 THEORY OF OPERATION Phase Control 6 11 6 11 1 Phase Control When the Starter Type parameter is set to Phase Control the MX is configured to operate a
2. COMPUTER 1200 DO NOT CREATE STUBS CABLE MUST GO TO EACH STARTER Right 118 Troubleshooting amp Maintenance 7 TROUBLESHOOTING amp MAINTENANCE Safety Precautions 7 1 Safety Precautions For safety of maintenance personal as well as others who might be exposed to electrical hazards associated with maintenance activities the safety related work practices of NFPA 70E Part II should always be followed when working on electrical equipment Maintenance personnel must be trained in the safety practices procedures and requirements that pertain to their respective job assignments WARNING To avoid shock hazard disconnect main power before working on controller starter motor or control devices such as start stop pushbuttons Procedures which require parts of the equipment to be energized during troubleshooting testing etc must be performed by properly qualified personnel using appropriate work practices and precautionary measures as specified in NFPA70 Part CAUTION Disconnect the controller starter from the motor before measuring insulation resistance IR of the motor windings Voltages used for insulation resistance testing can cause failure of SCR s Do not make any measurements on the controller with an IR tester megger Preventative Maintenance 7 2 7 2 1 Preventative Maintenance General Information Pre
3. Time Kick Time lt Ramp gt Time UTS Tim 92 6 THEORY OF OPERATION 6 3 6 Dual Acceleration Ramp Control General Acceleration Ramp Selection Two independent current ramps and kick currents may be programmed The use of two different starting profiles can be very useful with applications that have varying starting loads such as conveyors that can start either loaded or unloaded The Current Ramp 1 profile is programmed using the parameters Initial Current 1 Maximum Current 1 and Ramp Time 1 The Current Ramp 2 is programmed using the parameters Initial Current 2 Maximum Current 2 and Ramp Time 2 Kick Current 1 profile is programmed using the parameters Kick Level 1 and Kick Time 1 Kick Current 2 profile is programmed using the parameters Kick Level 2 and Kick Time 2 Current Ramp 2 and Kick Current 2 starting profiles are selected by programming a digital input to the Ramp Select function and then energizing that input by applying 120 Volts to it When a digital input is programmed to Ramp Select but de energized Current Ramp 1 and Kick Current 1 are selected When no digital inputs are programmed to the Ramp Select function the Ramp 1 profile is used The Ramp Select input only affects the starting profile when using a current ramp profile and during a kick The Ramp Select input does not affect the TruTorque ramp Power ramp or the Voltage ramp profile unless kicking is enabled at the begi
4. __ _ _ __ 3 3 _ 2 _ Time Kick Time Ramp Time gt Up To Speed Timer gt The initial current should be set to the level that allows the motor to begin rotating within a couple of seconds of receiving a start command To adjust the initial current setting give the starter a run command Observe the motor to see how long it takes before it begins rotating and then stop the unit For every second that the motor doesn t rotate increase the initial current by 20 Typical loads require an initial current in the range of 50 to 175 For most applications the maximum current can be left at 600 This ensures that enough current is applied to the motor to accelerate it to full speed The maximum current can also be set to a lower current limit This is usually done to limit the voltage drop on the power system or to limit the torque the motor produces to help prevent damage to the driven load 3 NOTE The motor may achieve full speed at any time during the current ramp This means that the maximum current setting may not be reached Therefore the maximum current setting is the most current that could ever reach the motor and not necessarily the maximum current that reaches the motor 3 NOTE When setting a current limit the motor must be monitored to ensure that the current is high enough to allow the motor to reach full speed under worst case load conditions Ramp Time 6 THEORY OF
5. 6 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 If a Wye to Delta transition has not already occurred a transition always occurs when the complete Up To Speed Time expires The MX can operate two configurations of Wye Delta starters open transition and closed transition An open transition starter momentarily disconnects the motor from the input line during the transition from Wye to Delta operating mode A closed transition starter uses resistors that are inserted during the transition so that the motor is never completely disconnected from the input line The presence of the resistors in a closed transition starter smooths the transition A typical closed transition Wye Delta starter schematic is shown in Figure 28 on page 106 The closed transition resistors generally are sized to be in the circuit for a short period of time To protect the resistors from over heating one input should be programmed as a Bypass 2M contact feedback input and the Bypass 2M confirm parameter must be set For the Wye Delta starter mode to operate properly one output relay needs to be programmed to the RUN output function and another out
6. d OR P xe Kg ds 3 7 2 112 RC2 Cliassiswithino Bypass a2 oem rd 6 9 deed diag e A we 9 3 1 Power and Control drawings for Bypassed and Non Bypassed Power Stacks 12 3 2 Current Transformers 9 ua RR Rx Ee ee RR RA 15 Dod CUMOUDnBIPS ders fant arte cS ot RR 15 3 12 CF Polarity ig eoe a e Ub ADAC Rh 5 doe ec uere eodem e Ee 15 3 3 Control Card Layout e mos de W W W R E Y E Y x 16 4 PARAMETER GROUPS sek a qua oh 9 9 9 4 w X y RR 18 Introductions ss vs rn Rr ob 98 Y WE Sea Kr Eg 18 4 2 LED and LCD Display Parameters Cross Reference 19 43 LED Display Parameters w w e s 20 44 LCD Display Parameters suede dedu Dale p OS 5 4 24 441 Quick Start Group gt gt see be eR ee SOROR ee 24 442 Control Function Group uu xe quu xeu rA ESTA qud e Wed 25 4 49 IProtectio eo e Ia ded Da Sra o RC ded EC Re gl S NIN QU 26 44A T O CrOUp MED 26 4 45 Function Group e Ecce ore ee ife Ses aL Nes sarin iul ees 28 446 HCD Fault Group e s
7. 84 6 110 Emergency Motor Overload Reset w s eu hua edra Gw hu eu a w Gua k 6 8 k G N 84 6 2 Motor Service Eactor beh eh 85 TABLE OF CONTENTS 6 3 Acceleration Control i n sacre s Seve Soda wee Ge W Sk PA oats ASS 86 6 3 1 Current Ramp Settings Ramps 86 6 32 Programming A Kick Current asa o pA R R4 E A da p eA 87 6 3 3 TruTorque Acceleration Control Settings and 87 6 3 4 Power Control Acceleration Settings and 89 6 3 5 Open Loop Voltage Ramps and Times gt gt slca e kG 91 6 3 6 Dual Acceleration Ramp Control 2 2 93 6 4 Deceleration iue vee wx pus erae ATE 95 641 Voltage Control Deceleration i ek oe UG 84 OSG RAT wD 95 6 4 2 Tr Torque Deceleration potus RE EXT ERE TEES LEER E Se 95 65 Braking Controls s osos s w RESO og kiku Rr E Xe Roy Ron ooo e omo 97 6 9 1 DC Injection Braking Standard Duty y 244 5 6645 p e 8 89 98 65 2 DC Injection Braking Heavy Duty Quo rer Bel ORG S E Eoo 98 655 3 Braking Output Relay 4 6d Ro o eU RR OS Re
8. Ore d 98 6 5 4 Stand Alone Overload Relay for emergency ATL Across The Line operation 98 65 5 DC Injection Brake Wiring Example cu s Romo hoe m 99 6 5 6 DC Brake Timing de sa e ud Ga BA Ge s A 100 6 5 7 DC Injection Brake Enable and Disable Digital Inputs 100 6 5 8 Use of Optional Hall Effect CurrentSensor sa sa s w s w s s n s ss s W s s w a w 8 101 6 5 9 DC Injection Braking Parameters eX qu 102 6 6 Slow Speed Cyclo Converter ea ss ws kx RR So e Re 102 6 61 Operatioris 2 5 eu a dte k a o euet rt EGE dde ue Sede dnte e ICs oe D ae 6266 102 6 6 2 Slow Speed Cyclo Converter Parameters us s a oh 103 6 7 Inside Delta Connected Starter 2 ee 104 6 7 1 Line Connected Soft Starter iu scere Re eS OO ee UP Rom rege e eve 104 6 7 2 Inside Delta Connected Starter pos scr s stala e eti hb oh A 105 6 6 Wee Delta 4 22 dodo Getrag euh Pom he Bolen etel AR Qe dr edu erecta 106 6 9 Across The Line Full Voltage 109 6 10 S
9. was tine Confguaion sens 39 Le 301664016 Bypass Feedback Time seems 20 Cres sao Keypad Siop Disable Enables Dira 7 0 Disabled 1 Start after power applied onl 30191 40191 Power On Start Selection 2 after fault reset only 67 Start after power applied and after fault reset None Reset Run Time Reset KWh MWh Enter Reflash mode 30199 40199 Miscellaneous Commands Store Parameters Load Parameters Factory Reset Std BIST _ BIST Communication Baud Rate 19200 19200 Communication Address 1 27 _ 1 27 ______ 0 Even Parity 1 Stop Bit Communication Byte Framing 3 No Parity 2 Stop Bits Normal Inside Delta Wye Delta Other P74 30195 40195 Starter Type Electro mechanical nor 72 Phase Control Current Follow Full Voltage ATL 100 110 120 200 208 220 230 240 350 380 400 415 P76 30143 40143 Rated Voltage 440 460 480 500 525 575 RMS Voltage 480 73 600 660 690 800 1000 1140 InS Insensitive AbC ABC 30144 40144 Phase Order CbA CBA InS 73 SPH Single Phase 22 U 09 Q gt F2 CD 4 PARAMETER GROUPS M db 72 1 96 1 144 1 288 1 864 1 2640 1 3900 1 5760 1 8000 1 14400 1 28800 1 Status Ave Current L1 Current L2 Current L3 Current Curr Imbal Ground Fault Av
10. L Pe 1 MX2 CARD 03 1 10 1 1 r 10 3 MX I OT SWITCH A 1 cpp 10 MM 2 ee nh MI 1 61 22 i eki Kep iA M TO SCR2 1 E gt G I TB5 2 gt c2 e I do POWER gt K2 E j 1 Qo AN 2 8516 TO MX CARD gt loo 1 PROGRAMMABLE X 65 Ee MI m p T B 1 1 L CMC 2 ess 1 1 FOR TO 5005 1 aout GJ PHASE 2 KB E 9 1 8 gt f g 2 OT SWITCH tA i ED emunt 5 sero 0 61 x eie IC By TO SCRI 1 12 g ki 6 8 G Teal BPs Oci 1 MODBUS r 8 1 182 SLAVE 8 0 1 5 RY r 403 d cas SERIAL COMMUNICATION kK 516 TO MX CARD 1 s RS485 5V MAX o 1 6 3 PROGRAMMABLE H RELAY K3 BPS e L p gt a K ODES 6 PHASE 3 1 TO SCR4 L 9 1 D a 1 1 D Dit g 022 5 1 1 9 o Doz ri 505 5 5M4 3 RESET PARAMETER DOWN ENTER J5 ois 4 1 5 8 com RJ45 P k OPTIONAL DOOR MOUN INSTALLATION Figure 8 Power Schematic for RC2
11. Poo Poi ro Analog Output Offset inline Configuration vox Ps voi Keypad Stop Disable Cros 1019 Power On Stat Selection 67 por FUNIS Miscellaneous Commands Pe Communication Baud Rte FONT Conmmnicaion Adres FUN 13 Communication Bye Framing m rune Energy sever _ unos tener Level ws Rated Power Factor we Fonos Rated voine EUN 04 Phase Order rono _ _ FUN 14 Sofware Veson _ _ P4 P4 P4 P4 P4 P4 P4 P4 P5 P5 P P5 P5 P5 P5 P5 P P6 P6 P6 P6 P6 P6 P6 P6 P7 P P7 P P7 P P7 P7 P7 P7 P 5 5 5 5 5 5 5 5 S 6 6 6 6 6 6 6 6 6 6 7 7 7 7 7 7 7 7 5 5 8 9 9 9 2 2 3 4 5 5 7 70 0 7 p 72 B 3 3 4 4 75 5 2 3 4 5 6 7 8 9 0 p 53 4 5 6 T 8 59 1 2 3 4 5 7 8 9 0 71 p 73 4 75 6 7 8 9 80 82 76 4 PARAMETER GROUPS LED Display Parameters 4 3 LED Display Parameters BIS sooo ET amsa munasa Dr M gt Dima X a 3010540105 Moor Running vetoed cas s J _ oons 50 000 oa xr sonawona 37 _
12. Current Imbalance A current imbalance larger than the Current Imbalance Trip Level parameter setting P36 PFNOS5 was present for longer than ten 10 seconds F37 Check motor wiring for cause of imbalance Verify dual voltage and 6 lead motors for correct wiring configuration Check for large input voltage imbalances that can result in large current imbalances Check motor for internal problems F38 Ground Fault Ground current above the Ground Fault Trip level setting P37 PFN06 has been detected for longer than 3 seconds Check motor wiring for ground faults Check motor for ground faults Megger motor and cabling disconnect from starter before testing Verify that the motor FLA P1 QST01 and CT ratio P78 FUN03 settings are correct Verify that the CTs are installed with all the White dots towards the input line In Single phase applications verify that only two CTs are being used that they are installed with all the White dots or Xs in the correct direction and that the CTs are connected to the L1 and L3 CT inputs on the MX control card No Current at Run Motor current went below 1096 of FLA while the starter was running Verify Motor Connections Verify the CT wiring to the MX control card Verify that the motor FLA P1 QST01 and CT ratio P78 FUNO03 settings are correct Check if load is still connected to starter Check if motor may have been driven by the load a regeneration condition Check Gat
13. co norae O on T L9 PFN 09 VIt Trip Tim o Under Voltage Tup Delay 0 1 to 90 0 PFN 10 Auto Fault Reset Time Off 1 to 900 PFN 12 Ctrl Flt En Controlled Fault Stop Enable Off On PFN 13 Indep S OL Independent Starting Running Off On Overload rus Ruming OL Oed e ww o 4 4 4 Group I O 01 DI 1 Config DI 1 Configuration Off P Stop 59 52 53 53 54 54 55 55 55 56 3 I 5 Stop 02 DI 2 Config DI 2 Configuration Fault High Fault Low Fault Reset Disconnect Inline Cnfrm Bypass Cnfrm E OL Reset 03 DI 3 Config DI 3 Configuration Local Remote Off Heat Disable Heat Enable Ramp Select Slow Spd Fwd Slow Spd Rev Brake Disabl Brake Enable I 0 04 Dig Trp Time Digital Fault Input Trip Time 0 1 to 90 0 Seconds 01 60 26 4 PARAMETER GROUPS I O 05 R1 Config Configuration Relay 1 Off Fault FS 5 Fault FS Fail Safe ws 10 06 R2 Config R2 Configuration Relay 2 Fal NES Non Fal CL or Safe Running UTS Alarm Ready Locked Out Overcurrent Undercurrent OL Alarm I O 07 R3 Config R3 Configuration Relay 3 Shunt Trip FS Shunt Trip NFS Ground Fault Energy Saver Heating Slow Spd Slow Spd Fwd Slow SPd Rev Braking Cool Fan Ctl Off I O 08 Ain Trp Type Analog Input Trip Type Low Level Off 61 High Lev
14. Description The Analog Input Trip Delay Time parameter sets the length of time the analog input trip level P56 I O 09 must be exceeded before a trip occurs See Also Analog Input Trip Type P55 I O 08 parameter on page 61 Analog Input Trip Level P56 I 0 09 parameter on page 61 Analog Input Span P58 I O 11 parameter on page 62 Analog Input Offset 059 I O 12 parameter on page 63 Theory of Operations http www benshaw com literature manuals 890034 1 1 xx pdf P58 Analog Input Span I O 11 LED Display LCD Display Range 1 100 Default 100 Description The analog input can be scaled using the Analog Input Span parameter Examples For a 0 10V input or 0 20mA input a 100 Analog Input Span setting results in a 0 input reading with a OV input and a 100 input reading with a 10V input For a 0 5V input a 50 Analog Input Span setting results in a 0 input reading with a OV input and a 100 input reading with a 5V input For a 4 20mA input a 80 Analog Input Span setting and a 20 Analog Input Offset setting results in a 0 input reading at 4mA and a 100 input reading at 20mA 3 NOTE Input signal readings are clamped at a 100 maximum Example 0 input 20ma 100 input 62 S PARAMETER DESCRIPTION Analog Input Reading 100 0 20 Aini Ain Span 80 Offset 2V 1 4 20mA Input Signal See Also Analog Input Trip Level P56 I O 09 parameter
15. Run Command contact provided by a PLC The MX can perform both 2 wire start stop logic and 3 wire start stop logic With 2 wire logic the starter starts when a run command is applied to the Start input It continues to run until the run command is removed from the Start input With 3 wire logic the starter starts when a start command is momentarily applied to the Start input and continues to run until an input programmed as a Stop input goes low The MX automatically determines whether to use 2 wire logic or 3 wire logic by the presence of a high level on a Stop input If there is an input programmed as a Stop input and that input is high when the Start input goes high then 3 wire start stop logic is used Otherwise 2 wire start stop logic is used This feature eliminates the need for external logic relays often used to seal in the momentary Start and Stop pushbuttons creating a 2 wire logic signal The key is to have the Stop input be high when the Hand Off Auto switch is in the Hand position but be low when the switch is in the Auto position The following wiring diagram illustrates a possible implementation In this example DI 1 on the MX is programmed as a Stop input Figure 34 Example of Start Stop with a Hand Off Auto Selector Switch OFF HAND 4 AUTO PLC 120VAC LIVE OUTPUT CONTACT START UG TB2 X olo SELECTOR S
16. SCR6 L1 cn P Soy n e epa E E N L2 12 SCR pS T2 100 600 VAC CT2 Siov e 3050 60Hz e a e SCR2 C L3 13 14 es SCR4 T3 90V E o gt 4 5 he sm CUSTOMER SUPPLIED 120 VAC L di at m N 2 H 1 12 13 14 15 16 i I m fo 2 C m l J Je scri GROUND J12 5 P68 FUNO3 9 NEurRAL E 7 se 1 1 amp 1 1 19 NeuTRAL 5 3 40 8 J9 EscRs i C uve BIPC 300055 01 1 1 m MX2 CARD Jio scr3 FT 20 I m SCRE 1 1 1 1 J4 I 2 TB5 3 power 182 1 E ao AIN 2 1 1 PROGRAMMABLE E i jm KI 8 an G I Z coq 1 gt 5 Aout 5 182 0 2 c PROGRAMMABLE proce r8 SHiELD 7 a Tx Rx SLM G 182 MM 8 o 1 5 21 SERIAL COMMUNICATION PROGRAMMABLE 8 ROARS EON RELAY K3 s COM a TWO WIRE CONTROL Rc ol x SZ f hu J PWR CPU 1 T 1 i STOP START bg 185 alo E OVERTEMP SWITCH NOUS T1 9 4 4 1 Ad1 START H ON HEATSINK 1 1 a Dii 022 _ __ 1 o o o 89 a E Dos 5 4k HEATSINK FANS i 5 5 RJ45 5 DISPLAY CABLE 14 OPTION
17. _ sonsons w sema Upto Speed Tine 1 90 Sm 3 Voltage Ramp 30112 40112 Start Mode Power Ramp Emi a Tee Meimmrewetowr os CoS Coast SdcL Volt Decel 2 PIS 30122 40122 Stop Mode tdcL TT Decel CoS 42 dcb DC Braking _ pcm me IX ses fs a ww soma DC Brk bey Sm a e2 sosa IM 2 sosoo vs orm Maximum Moor ren ma eser kiekTime2 oro ses 10 ww sonsons ommus a or Ls eros Siow seed uere I0 40 as rs www Stow Speed OXi ww sees _ a ES a CR 30159 40159 Over Voltage Trip Level 1 1 40 1 40 20 Modbus 30162 40162 a Voltage Trip Delay 0 90 0 Auto Fault Reset Time Off 1 900 30165 40165 P40 41 P43 30168 40168 Controlled Fault Stop Enable Off On Ss p44 Independent Starting Running Off On 30103 40103 Overload 045 30107 40107 Motor Starting Overload Class Off 1 4 EE P47 48 30108 40108 Motor Overload Hot ColdRatiol 0 99 30109 40109 Motor Overload Cooling Time 1 0 999 9 P 30169 40169 DI 1 Configuration P49 30170 40170 DI 2 Configuration 30171 40171 DI 3 Configuration 30163 40163 Digit
18. LA Current Imbalance Derate Factor The running OL content is also adjusted based on the derating factor due to the presence of any current imbalances and or harmonics If the existing motor overload content is less than the calculated running OL content the motor overload exponentially increases the overload content until the appropriate running overload content level is achieved If the existing motor overload content is greater than the calculated running OL content level the overload exponentially cools down or decreases to the appropriate running overload content level The rate of the running motor overload heating or cooling is controlled by the Motor Overload Cooling Time parameter 81 6 THEORY OF OPERATION 82 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 14 Motor Overload HO Ratio Example 100 FLA Motor 9 Current 3006 O FLA 80 OL H C Ratio 30 0 80 Motor Overload 40 Content 30 15 0 TO At time TO the motor current is 100 FLA and the OL Ratio is set at 30 It is assumed that the motor has been running for some time and the motor overload content has reached a steady state value of 30 30 HO Ratio x 100 FLA 30 At time the motor current drops to 50 FLA The motor overload content exponentially cools to a new steady state value of 15
19. 30 HO Ratio x 50 FLA 15 At time T2 the OL HO Ratio is set to 80 The motor overload content exponentially rises to a new steady state value of 40 80 HO Ratio x 50 FLA 40 At time T3 the motor current rises back up to 100 FLA The motor overload content exponentially rises to a new steady state value of 80 80 HO Ratio x 100 FLA 80 Separate Starting and Running Motor Overload Settings If desired separate overload classes can be programmed for use during starting and during running The motor overload protection may also be disabled during starting or during normal running In order to enable separate overload settings the Independent Starting Running Overload parameter needs to be set to On to allow independent overload operation Once set to On the individual Motor Starting Overload Class and Motor Running Overload Class parameters can be set to either Off or the desired overload class settings The Motor Starting Overload Class parameter value is used for the motor overload calculations when the starter is starting the motor kick mode acceleration and running before up to speed has been declared Once the motor has reached full speed and during deceleration or braking the Motor Running Overload Class is used for the motor overload calculations As the motor protection curves shift from the acceleration curve to the running curve the accumulated overload content is retained to provide a seamless transition from
20. Default tt TT Ramp TruTorque control acceleration ramp Pr Power Ramp Power kW control acceleration ramp The Start Mode parameter allows the selection of the optimal starting ramp profile based on the application The closed loop current control acceleration ramp is ideal for starting most general purpose motor applications Ex crushers ball mills reciprocating compressors saws centrifuges and most other applications The closed loop TruTorque control acceleration ramp is suitable for applications that require a minimum of torque transients during starting or for consistently loaded applications that require a reduction of torque surges during starting Ex centrifugal pumps fans and belt driven equipment The closed loop power control acceleration ramp is ideal for starting applications using a generator or other limited capacity source Initial Current 1 P6 QST 06 parameter on page 37 Maximum Current 1 P7 QST 07 parameter on page 37 Ramp Time 1 P8 QST 08 parameter on page 38 Initial Voltage Torque Power P11 CFN 08 parameter on page 40 Kick Level 1 P13 CFN 10 parameter on page 41 Kick Time 1 P14 CFN 11 parameter on page 41 Theory of Operations http www benshaw com literature manuals 890034 1 1 xx pdf 39 5 PARAMETER DESCRIPTION P11 Initial Voltage Torque Power CFN08 LED Display LCD Display Range 1 100 of Voltage Torque Power Default 25 Description Start Mode
21. L2 WC pel 24 T3 p L3 W l e 104 6 THEORY OF OPERATION 6 7 2 Inside Delta Connected Starter An inside delta connected soft starter is shown in Figure 27 where the power poles are connected in series with the stator windings of a delta connected motor Figure 27 Typical Inside Delta Motor Connection uc cs L2 oes L3 POOE Na i 1 1 i cn T L1 w 1 4 gt 2 L2 Er w eJ P i gt 13 L3 4 w 1C g 2 2 2 2 2222 22 2 22 2 22 For an inside delta connected motor the starter current is less than the line current by a factor of 1 55 FLA 1 55 By comparison of Figure 26 and Figure 27 the most obvious advantage of the inside delta starter is the reduction of current seen by the soft starter The soft starter can be downsized by a factor of 1 55 providing significant savings in cost and size of the starter An inside delta soft starter can also be considered for motors with more than 6 leads including 12 lead dual voltage motors NEMA and use different nomenclature for motor terminal markings for 3 and 6 leaded motors NEMA labels motors leads 1 2 3 4 5 6 IEC labels motor leads U1 V1 W1 U2 V2 W2 105 6 THEORY OF OPERATION Wye Delta Starter 6 8 Wye Delta Starter When the Starter Type parameter
22. PFN 17 parameter on page 58 Relay Output Configuration P52 54 I O 05 07 parameters on page 60 Theory of Operations http www benshaw comliterature manuals 890034 1 1 xx pdf 57 5 PARAMETER DESCRIPTION P47 Motor Overload Cooling Time PFN 17 LED Display LCD Display Range 1 0 999 9 minutes Default 30 0 Description The Motor Overload Cooling Time parameter is the time to cool from 100 to less than lt 1 When the motor is stopped the overload content reduces exponentially based on Motor Overload Cooling Time parameter Refer to the following equation 5 OL Content OL Content when Stopped e CoolingTime So a motor with a set cooling time of 30 minutes 1800 sec with 100 accumulated OL content cools to lt 1 OL content in 30 minutes 96 NOTE Consult motor manufacturer data to determine the correct motor cooling time See Also Motor Running Overload Class P3 QST 03 parameter on page 34 Independent Starting Running Overload P44 PFN 13 parameter on page 56 Motor Starting Overload Class P45 PFN 14 parameter on page 56 Motor Overload Hot Cold Ratio P46 PFN 16 parameter on page 57 Theory of Operations http www benshaw com literature manuals 890034 1 1 xx pdf 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 58 P48 49 50 Range Description See Also S PARAMETER D
23. SW1 2 Z ON 0 10V O comm 115 6 THEORY OF OPERATION Remote Modbus Communications 6 15 6 15 1 6 15 2 6 15 3 6 15 4 6 15 5 6 15 6 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 Please refer to Figures 38 and 39 for connection diagrams Supported Commands The MX supports the following Modbus commands Read Holding Registers 03 hex Read Input Registers 04 hex Preset Single Register 06 hex Preset Multiple Registers 10 hex Up to 64 registers may be read or written with a single command Modbus Register Addresses The Modbus specification defines holding registers to begin at 40001 and input registers to begin at 30001 Holding registers may be read and written Input registers may only be read Inthe MX the register maps are identical for both the holding registers and the input registers For example the Motor FLA parameter is available both in holding register 40101 and in input register 30101 This is why the register addresses in the Modbus Register Map are listed with both numbers e g 30101 40101 For more information please see the Modbus manual or the full version of the User Manual at www Benshaw com Cable Specifications Good quality twisted shielded communicati
24. gt Up To Speed Timer gt 87 6 THEORY OF OPERATION Initial Torque Maximum Torque Ramp Time 88 TruTorque acceleration control can be very useful for a variety of applications However it is best used to start centrifugal pumps fans and other variable torque applications TruTorque generally should not be used in applications where the starting load varies greatly during the start such as with a reciprocating compressor where the starting load is very low or where the starting load varies greatly from one start to another TruTorque control is not recommended for the starting of AC synchronous motors This parameter sets the initial torque level that the motor produces at the beginning of the starting ramp profile A typical value is 10 to 20 If the motor starts too quickly or the initial motor torque is too high reduce this parameter If the motor does not start rotating within a few seconds after a start is commanded increase this parameter If the value is set too low a No Current at Run fault may occur This parameter sets the final or maximum torque level that the motor produces at the end of the acceleration ramp time For a loaded motor the maximum torque value initially should be set to 100 or greater If maximum torque value is set too low the motor may not produce enough torque to reach full speed and may stall On lightly loaded motors this parameter may be reduced below 100 to produce smooth
25. is programmed as L r then the local remote bit in the starter control Modbus register selects the control source The default value of the bit is Local 0 Remote Source P5 QST 05 parameter on page 36 Digital Input Configuration P45 P50 T O 01 I O 03 parameters on page 59 Keypad Stop Disable P65 I O 18 parameter on page 67 Communication Timeout P68 FUN 12 parameter on page 69 Communication Baud Rate P69 FUN 11 parameter on page 69 Communication Address P70 FUN 10 parameter on page 69 3 NOTE By default the Stop key is always enabled regardless of selected control source It may be disabled though using the P65 1 018 Keypad Stop Disable parameter on page 67 35 5 PARAMETER DESCRIPTION P5 LED Display Range Description See Also 36 Remote Source OST 05 LCD Display LED LCD Description PRd Keypad The start stop control is from the keypad Terminal The start stop control is from the terminal strip inputs Default SEr Serial The start stop control is from the network The MX can have three sources of start and stop control Terminal Keypad and Serial Two parameters P4 QST 04 Local Source and P5 QST 05 Remote Source select the sources of the start and stop control If a digital input is programmed as L r Local Remote then that input selects the control source When the input is low the local source is used When the input is high the r
26. techniques are that the low speed motor rotation is done without any additional hardware such as additional mechanical contactors and or extra SCRs the peak phase currents are reduced compared with other jogging techniques motor heating is minimized and higher shaft torque can be generated Operation Slow speed forward and reverse operation is achieved by energizing a digital input that has been programmed to either Slow Speed Forward or Slow Speed Reverse refer to the Digital Input Configuration parameters on page 59 for more information The active Control Source local or remote source must be set to terminal Slow Speed Start Stop control is not available from the optional LCD keypad The starter must be in the idle state in order to enter slow speed operation Relay outputs can be programmed to energize during slow speed operation refer to the Relay Output Configuration parameters on page 60 for more information This feature can be used to disable mechanical brakes or energize clutches during slow speed operation Motor Overload Calculations During Slow Speed Operation During Slow Speed Operation the Solid State Motor Overload Protection is fully active During slow speed operation the Running Motor overload setting is used 3 NOTE When the motor is operating at slow speeds its cooling capacity can be greatly reduced Therefore the running time of the motor at a given current level is dependant on the motor s thermal capac
27. 120 VAC Out B Control 77 Power g 120 151 s a 2 17 a gt Auxiliary Relays P52 54 x 05 7 14 17 D 1 k Digital Inputs 3 48 50 e IC 1 3 a E Modbus PE Communications Port P68 71 FUN1043 1 Keypad Port F P65 1 0 18 EN Analog Input gt P55 59 a 8 12 a 1135 Analog Output P60 62 IC 13 15 Analog Voltage Current Selector Switch SW1 H Part Serial Gone 2711 a t a eras x 120 VAC Stack In Benshaw Only Stack Control CT Inputs P78 FUN 03 5 16 Parameter Groups 4 1 4 PARAMETER GROUPS Introduction 18 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 etc When the remote LCD display is used the parameters are divided into groups of related functionality and within the groups the parameters are identified by a short descriptive name The parameters are subdivided into six groups The groups are QST Quick Start Control Functions PFN Protection Functions I O Input Output
28. 2 RC2 Chassis with no Bypass Figure 4 RC2 0 124A B eee O MI Model A B E RC2 27 52A 14 9 875 3 375 4 69 8 32 TAP RC2 65 77A 18 10 4 375 4 75 20 TAP RC296 124A 27 10 5313 475 4 20 TAP E Figure 5 RC2 156 590A B D y Model A B C D E RC2 156 180A 18 15 17 135 03 RC2 240A 24 15 23 135 0 5 UNE RC2 302 361A 28 1725 27 1575 05 RC2 477A 28 20 27 185 0 5 RC2 590A 35 20 34 185 055 LLC 2 TECHNICAL SPECIFICATIONS NOTES Installation INSTALLATION Power and Control Drawings for Bypassed and Non Bypassed Power Stacks 3 1 Power and Control drawings for Bypassed and Non Bypassed Power Stacks Figure 6 Power Schematic for RB2 Low HP SCRE 100 600 a 3e50 60Hz e 7 _ CUSTOMER SUPPLIED 120 VAC 1 Ju LL I 1 i 12 s P68 FUNO3 NEUTRAL 37 som 1 NEUTRAL g SCR2 t Mere ed ed i reo KEIRA NC AA CERO ne 5 j BIPC 300055 01 i MX2 CARD m 1 AIN I 3 power 7 AIN PROGRAMMABI RELAY Kl 2 e 3 com 1 aout 5 1 1 6 1 PROGRAMMABL RELAY K2 F SHIELD 7 8 RK 1 MODBUS SLAVE B i SE
29. 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 Analog Input A reference input value of 0 results in no output A reference input value of 100 results in a current output equal to the Motor FLA setting The actual voltage or current input that results in a given output can be adjusted through the use of the Analog Input Offset and Analog Input Span parameters 96 NOTE The power stack must be rated for continuous non bypassed duty in order to operate in Current Follower mode 96 NOTE When operating in Current Follower mode the acceleration ramp kick and deceleration settings have no effect on operation 96 NOTE The following motor starter protective functions are available when in Current Follower mode Current Imbalance Phase Loss Over Current Phase Rotation Under Current Current while Stopped Over Voltage Motor OL Under Voltage Residual Ground Fault Over Frequency Instantaneous Over Current IOC Under Frequency 113 6 THEORY OF OPERATION Start Stop Control with a Hand Off Auto Selector Switch 6 13 Start Stop Control with a Hand Off Auto Selector Switch Often times a switch is desired to select between local or Hand mode and remote or Auto mode In most cases local control is performed as 3 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
30. 56 Independent Starting Running Overload PFN 13 LCD Display Off On Default Off If Off When this parameter is Off the overload defined by the Motor Running Overload Class QST 03 PFN 15 parameter is active in all states If On When this parameter is On the starting and running overloads are separate with each having their own settings The starting overload class P45 PFN 14 is used during motor acceleration and acceleration kick The running overload class is used during all other modes of operation If both the running overload and the starting overload classes are set to Off then the existing accumulated motor OL is erased and no motor overload is calculated in any state If the starting overload class is set to Off and the running overload class is set to On then the I t motor overload does NOT accumulate during acceleration kick and acceleration ramping states However the existing accumulated OL remains during starting and the hot cold motor compensation is still active The OL is capped at 99 during starting Although there is really no reason to do so the starting overload class could be set to On and the running overload class set to Off Motor Running Overload Class P3 QST 03 parameter on page 34 Motor Starting Overload Class P45 PFN 14 parameter on page 56 Motor Overload Hot Cold Ratio P46 PFN 16 parameter on page 57 Motor Overload Cooling Tim
31. 6 1 on page 133 The powered BIST command will put the starter into a powered BIST test See section 7 6 2 on page 134 Theory of Operations http www benshaw com literature manuals 890034 1 1 xx pdf S PARAMETER DESCRIPTION P68 Communication Timeout FUN 12 LED Display LCD Display Range Off 1 120 seconds Default Off Description The Communication Timeout parameter sets the time that the starter continues to run without receiving a valid Modbus request If a valid Modbus request is not received for the time that is set the starter declares an F82 Modbus Time Out The starter performs a controlled stop See Also Local Source P4 QST 04 parameter on page 35 Remote Source P5 QST 05 parameter on page 36 Stop Mode P15 CFN 14 parameter on page 42 Controlled Fault Stop Enable P43 PFN 12 parameter on page 55 Communication Address P70 FUN 10 parameter on page 69 Communication Baud Rate P69 FUN 11 parameter on page 69 Modbus Register Map http www benshaw com literature manuals 890034 1 1 xx pdf P69 Communication Baud Rate FUN 11 LED Display LCD Display Range 1200 2400 4800 9600 19200 bps Default 19200 Description The Communication Baud Rate parameter sets the baud rate for Modbus communications See Also Local Source P4 QST 04 parameter on page 35 Remote Source P5 QST 05 parameter on page 36 Communication Address P70 FUN 10 parameter on page 69 Communicati
32. Maximum Torque level until either the motor reaches full speed UTS timer expires or the motor thermal overload protection trips 36 NOTE Setting the ramp time to a specific value does not necessarily mean that the motor takes that exact amount of time to accelerate to full speed The motor and load may achieve full speed before the ramp time expires if the load does not require the set ramp time or set torque level to reach full speed Alternately the motor and load may take longer than the set ramp time to achieve full speed depending on the parameter settings and load level 6 THEORY OF OPERATION 6 3 4 Power Control Acceleration Settings and Times General Initial Power Maximum Power Optional Kick Power control is a closed loop power based acceleration control The primary purpose of Power controlled acceleration is to control and limit the power kW drawn from the power system and to reduce the power surge that may occur as an AC induction motor comes up to speed This power surge can be a problem in applications that are operated on generators or other limited or soft power systems Power control also reduces the torque surge that can also occur as an AC induction motor comes up to speed Figure 18 Power Ramp Motor Input Power Max Power Motor Running ___ _2 ___ Power Level Start command Current Initial Power Time Kick Time Ramp Time gt lt Up
33. OPERATION The ramp time is the time it takes for the current to go from the initial current to the maximum current To make the motor accelerate faster decrease the ramp time To make the motor accelerate slower increase the ramp time If the ramp time expires before the motor reaches full speed the starter maintains the maximum current level until either the motor reaches full speed the Up to Speed time expires or the motor thermal overload trips 3 NOTE Setting the ramp time to a specific value does not necessarily mean that the motor will take this time to accelerate to full speed The motor and load may achieve full speed before the ramp time expires if the application does not require the set ramp time and maximum current to reach full speed Alternatively the motor and load may take longer than the set ramp time to achieve full speed 6 3 2 Programming A Kick Current General Kick Level Kick Time The kick current sets a constant current level that is applied to the motor before the ramp begins The kick current is only useful on motor loads that are hard to get rotating but then are much easier to move once they are rotating An example of a load that is hard to get rotating is a ball mill The ball mill requires a high torque to get it to rotate the first quarter turn 90 Once the ball mill is past 90 of rotation the material inside begins tumbling and it is easier to turn The kick current parameter is usually set to
34. P17 CFN 16 parameter on page 43 Controlled Fault Stop Enable P43 PFN 12 parameter on page 55 Theory of Operations http www benshaw com literature manuals 890034 1 1 xx pdf P19 DC Brake Level CFN 18 LED Display LCD Display 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 The desired brake level is determined by the combination of the system inertia system friction and the desired braking time If the motor is braking too fast the level should be reduced If the motor is not braking fast enough the level should be increased Refer to Nema Parts 12 and 20 for maximum load inertia A Thermistor Thermostat or RTD MUST be installed to protect the motor DC Brake Function Programming Steps 1 The DC Brake function may be enabled by setting the stop mode P15 14 to DC Brake 44 S PARAMETER DESCRIPTION 2 Once this function is enabled a relay output configuration P52 53 54 I O 05 06 07 must be used to control the DC brake contactor or 7th SCR gate drive card during braking It is recommended to use Relay P54 07 3 NOTE Standard braking For load inertia less than 6 x motor inertia 3 NOTE Heavy duty braking For NEMA MGI parts 12 and 20 maximum load inertia 3 NOTE When DC injection braking is utilized d
35. P78 FUNO3 and burden switch settings are correct Motor load exceeds power stack rating Consult factory An incorrect bypass feedback has been detected for longer than the Bypass Confirm time parameter setting P64 I O17 Verify that the bypass 2M contactor coil and feedback wiring is correct Verify that the relay connected to the bypass 2M contactor s is programmed as the UTS function Verify that the bypass 2M contactor power supply is present Verify that the appropriate Digital Input Configuration parameter has been programmed correctly Verify that the bypass contactor s are not damaged or faulty Verify that the appropriate Digital Input Configuration parameter has been programmed correctly Verify that the inline contactor s are actually not damaged or faulty Low control power below 90V has been detected while running Verify that the control power input level is correct especially during starting when there may be significant line voltage drop Check control power transformer tap setting if available Check control power transformer fuses if present Check wiring between control power source and starter 7 TROUBLESHOOTING amp MAINTENANCE Fault Code Current Sensor Offset Error BIST Fault BIST CT Fault External Fault on DI 1 Input External Fault on DI 2 Input External Fault on DI 3 input Analog Input Level Fault Trip SPI Keypad Communication Fault Detailed Description of Fault Possi
36. Profile 1 Kick Level 1 Maximum Current 1 2 Initial Current 1 Kick Time 1 Maximum Current 2 Kick Level 2 Initial Current 2 Kick Time 2 Ramp Select Changed During Start Ramp 1 Selected Ramp Time 2 94 6 THEORY OF OPERATION Deceleration Control 6 4 Deceleration Control 6 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 22 Motor Voltage Versus Decel Level rm dE rJ MEN NM S Ll as o j IJ S Tr 50 8 5 I L1 1 gt S EN NE EN 100 90 80 70 60 50 40 30 20 10 0 Programmed Decel Level Beginning Level This sets the starting voltage of the deceleration ramp Most motors require the voltage to drop to around 60 or lower before any significant deceleration is observed Therefore a good first setting for this parameter is 35 To adjust this parameter it is necessary to observe the motor operation as soon as a stop is commanded If the motor hunts speed oscillations at the beginning of the deceleration then lower the parameter by 5 If the motor has a big drop in speed as soon as a stop is commanded then raise the parameter by 5 So
37. 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 Otherwise when the inline test is performed the inline contactor will be energized applying line voltage to the starter and a BIST test fault will occur The standard BIST tests comprise of Programming Test Instructions Step 1 LED Display LCD Display Go to P67 and press ENTER Go to FUN 15 misc commands and press ENTER Press UP button to 7 and press ENTER Increment up to Std BIST and press ENTER Powered BIST test will commence Std BIST test will commence 96 NOTE Designed to run with no line voltage applied to starter Step 2 RUN relay test and Inline Feedback Test In this test the RUN assigned relays are cycled on and off once and the feedback from an inline contactor is verified In order to have a valid inline contactor feedback a digital input needs to be set to Inline Confirm and the input needs to be wired to an auxiliary contact of the inline contactor The feedback is checked in both the open and closed state If the feedback does not match the state of the RUN relay within the amount of time set by the Inline Config parameter an Inline fault will occur 3 NOTE If no digital input is assigned as an Inline Confirm input th
38. The MX DC injection brake timing is shown below Figure 25 DC Injection Brake Timing DC Brake Delay Time I DC Brake Delay after 1 Time DC Brake 1 I Brake Relay On Braking Relay Energized Brake Relay Off DC Injection On Starter SCRs On DC Current Applied DC Injection Off I II time LI I I Stop Delay to allow DC Brake Braking Relay Commanded contactor to Time opens after a close before Expired delay to allow applying DC residual DC current current to decay After the DC Brake Time has expired the Braking Relay is held energized to allow the DC current to decay before opening the freewheel path This delay prevents a contactor if used from having to open significant DC current which greatly prolongs the life of the contactor This delay time is based on motor FLA the larger the motor the longer the delay time The delay after DC brake time is approximately Motor FLA Delay after DC Brake Time 10A 0 4 seconds 100A 0 8 seconds 500A 2 3 seconds 1000 A 4 3 seconds Motor Overload Calculations During DC Injection Braking During DC braking the MX Solid State Motor Overload Protection is fully active During braking the Running Motor Overload setting is used The adjusts the overload calculations based on whether Standard Duty or Heavy Duty braking is used The overload calculations are also adjusted based on whether the
39. To Speed Timer gt Power control acceleration can be very useful for a variety of applications Power control generally should not be used in applications where the starting load varies greatly during the start such as with a reciprocating compressor Power control is not recommended for starting of AC synchronous motors This parameter sets the initial power level that the motor draws at the beginning of the starting ramp profile A typical value is usually 10 to 30 If the motor starts too quickly or the initial power level is too high reduce this parameter If the motor does not start rotating within a few seconds after a start is commanded increase this parameter If this value is set too low a No Current at Run fault may occur This parameter sets the final or maximum power level that the motor produces at the end of the acceleration ramp For a loaded motor the maximum power level initially should be set to 100 or greater If the maximum power level value is set too low the motor may not produce enough torque to reach full speed and may stall On lightly loaded motors this parameter may be reduced below 100 to produce smoother starts If the motor can be started by using the default Power acceleration parameter values or the Current control ramp the Maximum Power level can be determined more precisely so that the motor comes up to speed in approximately the preset ramp time In this case while the motor is running fully loaded displ
40. before the starter recognizes a ground fault condition Once the starter recognizes a ground fault condition it shuts down the motor and declares a Fault 38 Ground Fault If a programmable relay is set to ground fault GND the starter energizes the relay when the condition exists A typical value for the ground fault current setting is 10 to 20 of the full load amps of the motor 3 NOTE This is often referred to as residual ground fault protection This type of protection is meant to provide machine ground fault protection only It is not meant to provide human ground fault protection Alarm Fault Condition Trip FLA Resid GF Lvl PFN 06 P37 C Time tc Delay Fixed 3 seconds 38 NOTE The MX residual ground fault protection function is meant to detect ground faults on solidly grounded systems Use on a high impedance or floating ground power system may impair the usefulness of the MX residual ground fault detection feature 36 NOTE Due to uneven CT saturation effects and motor and power system variations there may be small values of residual ground fault currents measured by the MX during normal operation See Also Auto Reset Limit P42 PFN 11 parameter on page 55 Controlled Fault Stop Enable P43 PFN 12 parameter on page 55 Relay Output Configuration P52 54 I O 05 07 parameters on page 60 Theory of Operations http www benshaw comliterature manuals 890034 1 1 xx pdf P38 Over Voltage Trip L
41. compensates for the additional motor heating that can result from the presence of harmonics Harmonics can be generated by other loads connected to the supply such as DC drives AC variable frequency drives arc lighting uninterruptible power supplies and other similar loads Hot Cold Motor Overload Compensation If a motor has been in operation for some time it will have heated up to some point Therefore there is typically less overload content available in the case where a motor is restarted immediately after it has been running when compared to the situation where a motor has been allowed to cool down before restarting The MX provides adjustable hot motor overload compensation to fully protect the motor in these cases If the hot and cold maximum locked rotor times are provided the MX Hot Cold Ratio parameter value can be calculated as follows If no motor information is available a Hot Cold ratio value of 60 is usually a good starting point OL H C Ratio 1 Max Hot Locked Rotor Time x 10094 Max Cold Locked Rotor Time The MX adjusts the actual motor overload content based on the programmed Hot Cold Ratio set point and the present running current of the motor so that the accumulated motor overload content accurately tracks the thermal condition of the motor If the motor current is constant the overload content eventually reaches a steady state value This value is derived as follows OL CHEERS l
42. content has cooled below 15 Current Imbalance Negative Sequence Current Compensation The MX motor overload calculations automatically compensate for the additional motor heating which results from the presence of unbalanced phase currents There can be significant negative sequence currents present in the motor when a current imbalance is present These negative sequence currents have a rotation opposite the motor rotation and are typically at two times the line frequency Due to the negative sequence currents opposite rotation and higher frequency these currents can cause a significant increase in rotor heating The overload curves provided by a motor manufacturer are based on balanced motor operation Therefore if a current imbalance is present the MX motor overload compensates for the additional heating effect by accumulating overload content faster and tripping sooner to protect the motor The current imbalance compensation also adjusts the Hot Cold motor protection as described below in section 6 1 6 The MX derating factor is based on NEMA 1 14 35 specifications and is shown in Figure 13 Figure 13 Overload Derating for Current Imbalance MX Motor OL derating vs current imbalance 0 95 0 9 Derating Factor 0 8 0 75 0 5 10 15 20 25 30 Current imbalance 6 1 5 6 THEORY OF OPERATION Harmonic Compensation The MX motor overload calculation automatically
43. during starting dropping below 175 FLA indicating that the motor has not come up to speed Motor FLA P1 QSTO1 or CT ratio Verify that Motor FLA and CT ratio P78 FUNO3 parameter set incorrectly parameters are set correctly Abnormally low line voltage Fix cause of low line voltage A mechanical or supplemental brake is Verify that any external brakes are still engaged disengaged Motor Hums before turning Initial current to low FLA or CT incorrect Verify FLA and CT settings 7 3 3 Starter not accelerating as desired Motor accelerates too quickly Ramp time P8 QST08 too short tit dni high Kick start current P13 CFN10 too high Decrease or turn off Kick current Motor FLA P1 QSTO01 or CT ratio Verify that Motor FLA and CT ratio P78 FUNO3 parameter set incorrectly parameters are set correctly Starter Type parameter P64 FUNO7 set Verify that Starter Type parameter is set incorrectly correctly Motor accelerates too slowly Maximum Motor Current setting Review acceleration ramp settings P7 QST07 set too low P78 FUNO3 parameter set incorrectly parameters are set correctly 122 7 TROUBLESHOOTING amp MAINTENANCE 7 3 4 Starter not decelerating as desired Decel Time P18 CFN17 set too short Increase Decel Time Motor stops too quickly Decel time seems correct but motor surges oscillates at beginning of deceleration cycle Decel time seems correct but motor stops before en
44. entering the appropriate value into the FUN 15 Miscellaneous Command user parameter 3 NOTE The powered BIST test is only for use with SCR based reduced voltage soft starters Powered BIST can not be used with wye delta or ATL types of starters 134 7 TROUBLESHOOTING amp MAINTENANCE 3 NOTE The motor wiring MUST be fully connected before starting the powered BIST tests Also the motor must be at rest stopped Otherwise the powered BIST tests will not function correctly 3 NOTE Before using the powered BIST test function the following Mx user parameters MUST be set for correct operation of the powered BIST test Motor FLA P1 QST 01 CT Ratio P78 FUN 03 Phase Order P77 FUN 04 Rated Voltage P76 FUN 05 and Starter Type P74 FUN 07 The powered BIST tests comprise of Programming Test Instructions Step 1 LED Display LCD Display Go to P67 and press ENTER Go to FUN 15 and press ENTER Press UP button to 8 and press ENTER Increment up to Powered BIST and press ENTER Powered BIST test will commence Powered BIST test will commence Step 2 Shorted SCR and Ground Fault Test In this test each power pole is energized individually If current flow is detected the controller attempts to differentiate whether it is ashorted SCR shorted power pole condition or a ground fault condition and either a Bad SCR Fault or Ground Fault will occur LED Display LCD Display BIST Mode b
45. give correct output not set correctly Analog Output Function parameter P60 Verify that the Analog Output Function 7012 set incorrectly parameter is set correctly Analog Output Offset and or Span Verify that the Analog Output Span and parameters P61 I O13 and P62 I O14 Offset parameters are set correctly set incorrectly Load on analog output too high Verify that load on analog output meets the MX analog output specifications Ground loop or noise problems Verify correct grounding of analog output connection to prevent noise and or ground loops from affecting output Remote Keypad does not operate Keypad cable not plugged in properly or Verify that the remote keypad cable has correctly cable is damaged not been damaged and that it is properly seated at both the keypad and the MX control card Heater Level P73 FUNO8 parameter is Turn Heater Level P73 FUN08 On parameter Off 125 7 TROUBLESHOOTING amp MAINTENANCE Fault Code Table 7 4 Fault Code Table The following is a list of possible faults that can be generated by the MX starter control Fault Code Detailed Description of Fault Possible Solutions UTS Time Limit Expired Motor did not achieve full speed before the UTS timer P9 QST09 expired Check motor for jammed or overloaded condition Verify that the combined kick time P14 CFN11 and acceleration ramp time P8 QST08 is shorter than the UTS timer setting Evaluate acceler
46. in damage to the starter T Highlight marking an important point in the documentation Please follow the instructions of both safety levels as they are important to personal safety Introduction 1 INTRODUCTION Benshaw Services General Information Benshaw offers its customers the following e Start up services On site training services Technical support Detailed documentation Replacement parts 3 NOTE Information about products and services is available by contacting Benshaw refer to page 3 Start Up Services Benshaw technical field support personnel are available to customers with the initial start up of the RediStart Information about start up services and fees are available by contacting Benshaw On Site Training Services Benshaw technical field support personnel are available to conduct on site training on RediStart Mx operations and troubleshooting Technical Support Benshaw technical support personnel are available at no charge to answer customer questions and provide technical support over the telephone For more information about contacting technical support personnel refer to page 3 Documentation Benshaw provides all customers with Quick Start manual Wiring diagram All drawings are produced in AutoCADO format The drawings are available on standard CD DVD or via e mail by contacting Benshaw On Line Documentation All RediStart MX documentation including Operations Manua
47. is set to Wye Delta the MX is configured to operate an Electro mechanical Wye Delta Star Delta starter When in Wye Delta mode all motor and starter protective functions except bad SCR detection and power stack overload are available to provide full motor and starter protection A typical closed transition Wye Delta starter schematic is shown in the following figure Figure 28 Wye Delta Motor Connection to the 2M T6 2s 100 600 3e50 60Hz ch CUSTOMER SUPPLIED 120 VAC AL 4 1 KO GROUND Ji2 5 068 FUNO3 NEUTRAL s NEUTRAL I LALIVE 3 8 Live BIPC 300055 01 ss 63 ES w MX2 CARD P M3 66 J11 1 m 2 TB5 AIN POWER 1M 82 7 is Ont 2 PROGRAMMABLE L 2 Bp M an 3 2M 25 15 ici L ta OO E 5 aout 5 m 8 02 2 com 6 PROGRAMMABLE t RC2 4 RELAY K2 L8 7 RUN x d 02 r _ 184 2s 182 8 C Chal P MS a SERIAL COMMUNICATION PROGRAMMABLE RC3H RELAY K3 8 UTS ER GJ 663 6 C 4 PWR STOP START alo 2 e START H H H H 22 1 g 2 C o 2M z NA 3 302 RESET PARAMETER DOWN UP ENTER 25 5 4 Dos s 9 com 6 106
48. on page 61 Analog Input Trip Time P57 I O 10 parameter on page 62 Analog Input Offset P59 I O 12 parameter on page 63 Starter Type P74 FUN 07 parameter on page 72 Theory of Operations http www benshaw comliterature manuals 890034 1 1 xx pdf P59 Analog Input Offset I O 12 LED Display LCD Display Range 0 99 Default 0 Description The analog input can be offset so that a 0 reading can occur when a non zero input signal is being applied Example Input level of 2V 4mA gt 0 input In this case the Analog Input Offset parameter should be set to 20 so that the 2v 4mA input signal results in a 0 input reading 96 NOTE For a 4 20mA input set the Analog Input Span to 80 and the Analog Input Offset to 20 96 NOTE The measured input reading is clamped at 0 minimum See Also Analog Input Trip Level P56 I O 09 parameter on page 61 Analog Input Trip Time P57 I O 10 parameter on page 62 Analog Input Span P58 I O 11 parameter on page 62 Starter Type P74 FUN 07 parameter on page 72 Theory of Operations http www benshaw comliterature manuals 890034 1 1 xx pdf 63 5 PARAMETER DESCRIPTION P60 Analog Output Function I O 13 LED Display LCD Display Range LED LCD Description Off Off Disabled Default 0 200 Curr Based on per cycle RMS values e 0 800 Curr Based on per cycle RMS values 3 0 150 Volt Based on per cycle RMS values q 0 150 OL
49. on page 66 Heater Level P73 FUN 08 parameter on page 71 Energy Saver P72 FUN 09 parameter on page 70 Theory of Operations http www benshaw comliterature manuals 890034 1 1 xx pdf P55 Analog Input Trip Type YO 08 LED Display LCD Display Range LED LCD Description OFF Off Off Disabled Default Lo Low Level Low Fault if input signal below preset trip level I High Level High Fault if input signal above preset trip level Description The analog input is the reference input for a starter configured as a Phase Controller or Current Follower In addition the Analog Input Trip Type parameter allows the user to set a high or low comparator based on the analog input If the type is set to Low then a fault occurs if the analog input level is below the trip level for longer than the trip delay time Ifthe type is set to High then a fault occurs if the analog input level is above the trip level for longer than the trip delay time This function is only active when the motor is running This feature can be used in conjunction with using the analog input as a reference for a control mode in order to detect an open 4 20mA loop providing the reference Set the Analog Input Trip Type parameter to Low and set the Analog Input Trip Level P56 I O 09 parameter to a value less than lt 20 See Also Analog Input Trip Level P56 I O 09 parameter on page 61 Analog Input Trip Time P57 I O 10 parameter on page 62 Ana
50. page 60 http www benshaw com literature manuals 890034 1 xx pdf P35 Under Current Trip Delay Time PFN 04 LED Display LCD Display Range Off 0 1 90 0 seconds Default 0 1 Description The Under Current Trip Delay Time parameter sets the period of time that the motor current must be less than the Under Current Trip Level P34 PFN 03 parameter before an under current fault and trip occurs If Off is selected the under current timer does not operate and the starter does not trip It energizes any relay set to Undercurrent until the current rises 51 5 PARAMETER DESCRIPTION See Also Under Current Trip Level P34 PFN 03 parameter on page 51 Auto Reset Limit P42 PFN 11 parameter on page 55 Controlled Fault Stop Enable P43 PFN 12 parameter on page 55 Relay Output Configuration P52 54 I O 05 07 parameters on page 60 http www benshaw com literature manuals 890034 1 1 xx pdf P36 Current Imbalance Trip Level PFN 05 LED Display LCD Display 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 At average currents less than or equal to full load current FLA the current imbalance is calculated as the percentage difference between the phase current that has the maximum deviation from the average current Imax and the
51. should be investigated to ensure that the motor is capable of restarting without causing undesired motor or load damage When the emergency motor overload reset is used the accumulated motor overload content is reset back to zero 0 Therefore MX s motor protection functions may not be able to fully protect the motor from damage during a restart after performing an emergency motor overload reset 6 THEORY OF OPERATION Motor Service Factor 6 2 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 3 NOTE The NEC National Electrical Code does not allow the service factor to be set above 1 40 Check with other local electrical codes for their requirements The National Electrical Code article 430 Part C allows for different overload multiplier factors depending on the motor and operating conditions NEC section 430 32 outlines the allowable service factor for different motors as follows Motor Overload Multiplier Service factor 1 15 or more 1 25 Motor temp rise 40 C or less 1 25 All others 1 15 NEC section 430 34 permits further modifications if the service factor is not sufficient to start the motor Motor Overload Multiplier Service fact
52. start no output to motor Display Blank CPU Heartbeat LED on Control voltage absent Check for proper control voltage input MX board not blinking Verify fuses and wiring MX control board problem Consult factory Fault Displayed Fault Occurred See fault code troubleshooting table for more details Start command given but nothing Start Stop control input problems Verify that the start stop wiring and start happens input voltage levels are correct Control Source parameters QST 04 05 Verify that the parameters are set P4 5 not set correctly correctly NOL or No Line is displayed and a start No line voltage has been detected by the Check input supply for inline contactor command is given it will fault in F28 MX when a start command is given open disconnects open fuses open circuit breakers or disconnected wiring Verify that the SCR gate wires are properly connected to the MX control board On medium voltage systems verify wiring of the voltage feedback measurement circuit See fault code troubleshooting table for more details 121 7 TROUBLESHOOTING amp MAINTENANCE 7 3 2 During starting motor rotates but does not reach full speed 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 P7 QST07 set too low Motor loading too high and or current not Reduce load on motor
53. to 30 If the motor starts too quickly or the initial power level is too high reduce this parameter If the motor does not start rotating within a few seconds after a start is commanded increase this parameter If the value is set too low a No Current at Run fault may occur during acceleration 96 NOTE It is important that the P75 FUN06 Rated Power Factor parameter is set properly so that the actual initial power level is the value desired See Also Initial Current 1 P6 QST 06 parameter on page 37 Ramp Time 1 P8 QST 08 parameter on page 38 Start Mode P10 01 parameter on page 39 Maximum Torque Power P12 CFN 09 parameter on page 40 Rated Power Factor P75 FUN 06 parameter on page 72 Theory of Operations http www benshaw com literature manuals 890034 1 1 xx pdf P12 Maximum Torque Power CFN 09 LED Display LCD Display Range 10 325 of Torque Power Default 105 Description Start Mode P10 CFNO1 set to Open Loop Voltage Acceleration Not used when the Start Mode parameter is set to open loop voltage acceleration When in open loop voltage acceleration mode the final voltage ramp value is always 100 or full voltage Start Mode P10 CFNO1 set to Current Control Acceleration Not used when the Start Mode parameter is set to Current control acceleration mode Refer to the Initial Current 1 P6 parameter to set the maximum current level 40 S PARAMETER DESCR
54. 1140 FUN 06 Motor PF Motor Rated Power Factor E 0 92 72 Normal Inside Delta Wye Delta FUN 07 Starter Type Starter Type Phase Ctl Normal 72 Curr Follow ATL FUN 09 Energy Saver Energy Saver Off On FUN 10 Com Drop Communication Address 1 to 247 III FUN 11 Communication Baud Rate 19200 8 28 4 4 6 4 4 7 4 PARAMETER GROUPS u Communications Byte Framing Even 1 Stop Bit Odd 1 Stop Bit None 1 Stop Bit Even 0 None 2 Stop Bit Miscellaneous Commands None Reset RT Reset kWh Reflash Mode Store Params None Load Params Factory Rst Std BIST Powered BIST FONTS Tee OO LCD Fault Group Fault Starter Group Fault Description v2 V3 kW Hz EN Time 29 4 PARAMETER GROUPS NOTES Parameter Description 5 PARAMETER DESCRIPTION Parameter Descriptions 5 1 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 Each parameter has a detailed description that is displayed with the following format Theory of Operation For Theory of Starter Operation refer to our website http www benshaw com literature manuals 890034 10 xx pdf 1 Motor Overload 2 Motor Service Factor 3 Acce
55. 5 p 4666 90 190 59 97 6 THEORY OF OPERATION 6 5 1 6 5 2 6 5 3 6 5 4 DC Injection Braking Standard Duty The MX Standard Duty Braking allows up to approximately 25096 FLA current to be applied to the motor The Mx Standard Duty package consists of an extra braking contactor that shorts Motor Terminals 2 amp 3 together while braking as DC current is applied by the MX starter to provide moderate braking torque CAUTION Contactor MUST NOT short phase T1 and phase T3 3 NOTE Contactor sizing requires contactor rating Motor FLA 1 6 The three contacts must be paralleled DC Injection Braking Heavy Duty The MX Heavy Duty Braking allows up to 400 FLA current to be applied to the motor for maximum braking performance The Mx Heavy Duty braking package includes a freewheel current path between phases 1 and 3 that consists of a fuse and a 7 SCR with gating In combination with the applied DC current from the MX starter the freewheeling current path greatly enhances available braking torque When Braking the stop must be counted as another motor start when looking at the motor starts per hour limit 38 NOTE Semi Conductor Fuse and 7th SCR supplied by Benshaw Braking Output Relay To utilize DC injection braking one of the user output Relays needs to be programmed as a Braking relay Refer to the Relay Outp
56. 5 parameter on page 36 Theory of Operations http www benshaw com literature manuals 890034 11 xx pdf Auto Start Selection YO 19 LCD Display LED LCD Description Disabled When Disabled the Start input must always transition from low to high for a start to occur Default Power When set to Power a start will occur if the Start input is high while control power is applied Fault When set to Fault a start will occur if the Start input is high when a fault is reset 3 Power Fault When set to Power and Fault a start will occur if the Start input is high while control power is applied and a start will occur if the Start input is high when a fault is reset The Auto Start parameter determines whether or not a transition from low to high is required on the Start input for a start to occur after either a power up or a fault reset 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 67 5 PARAMETER DESCRIPTION P67 LED Display Range Description See Also 68 Miscellaneous Commands FUN 15 LCD Display LED LCD Description None No commands Default Reset Run Time Meter 2 Reset kWh Reset kWh MWh Meters 3 Reflash Mode Activate Reflash Mode 4 Store Params The current parameter values are stored in non volatile memory 5 Load Params All parameter are retrieved from non volatil
57. 59 Gating individual SCRs Shorted SCR GF Step 3 Open SCR and Current Transformer CT Test In this test a low level closed loop controlled current is selectively applied to various motor phases to verify that the motor is connected all SCRs are turning on properly and that the CTs are wired and positioned properly If current is detected on the wrong phase then a BIST CT Fault fault will be declared If an open motor lead open SCR or non firing SCR is detected then a Bad SCR Fault will occur 3 NOTE When this test is in progress 6 audible humming or buzzing sounds will be heard from the motor LED Display LCD Display BIST Mode b oc Open SCR CTs Step 4 LED Display LCD Display b tests completed Tests completed Pressing ENTER on the keypad at any time will abort the current test in progress and proceed to the next BIST test 36 NOTE If line voltage is lost during the powered tests a BIST Abnormal Exit fault will occur 36 NOTE The powered BIST tests will verify that the input phase order is correct If the measured phase order is not the same as the Phase Order FUN 04 parameter a phase order fault will occur 135 7 TROUBLESHOOTING amp MAINTENANCE SCR Replacement 7 7 SCR Replacement This section is to help with SCR replacements on stack assemblies Please read prior to installation 7 7 1 Typical Stack Assembly APPLY TWO 2 1 LONG BEADS OF SILICONE TO SECURE O T
58. AL DOOR MOUNT DISPLAY INSTALLATION Current Transformers 3 2 Current Transformers 3 2 1 CT Mounting For starters larger than 124 amps the CTs are shipped loose from the power stack and need to be mounted on the power wiring Thread the motor or incoming lead through the CT with the polarity mark towards the line side The polarity marks may be a white or yellow dot an X on the side of the CT or the white wire Each phase has its own CT The CT must then be attached to the power wiring at least three inches from the power wire lugs using two tie wraps Figure 9 Typical CT Mounting Input of Starter CUSTOMER MUST FASTEN CT TO POWER WIRE WITH TWO 1 4 NYLON WRAPS TO PREVENT MOVEMENT DURING RUNNING Dot or X White Wire MUST BE A 3 MIN 4 SPACE BETWEEN CT AND TOP OF LUG 9 6 FRONT VIEW SIDE VIEW DETAIL 3 2 2 CT Polarity The CT has a polarity that must be correct for the starter to correctly measure Watts kW Hours Power Factor and for the Power and TruTorque motor control functions to operate properly Each CT has a dot on one side of the flat surfaces This dot normally white in color must be facing in the direction of the line must be on Line L1 CT2 must be on Line L2 CT3 must be on Line L3 15 INSTALLATION Control Card Layout 3 3 Control Card Layout Figure 10 Control Card Layout A Unfused z m
59. BENSH W Ih 1659 East Sutter Road 2 Standard Drives to 1000HP Glenshaw Sutter sil Phone 412 487 8235 Custom Industrial Packaged Drives Fax 412 487 4201 HVAC Packaged Drives BENSHAW West 18 Pulse IEEE 519 Compliant Drives 14715 North 78th Way Suite 600 Scottsdale AZ 85260 Phone 480 905 0601 Fax 480 905 0757 RSC Series Contactors BENSHAW High Point SPO SPE SPD Motor Protection Relays EPC Division 645 McWay Drive Enclosed Full Voltage Wye Delta Two Speed High Point NC 27263 Phone 336 434 4445 Part Winding and Reversing Starters Fax 336 434 9682 BENSHAW Mobile CSD Division Custom OEM Controls 5821 Rangeline Road Suite 202 Theodor AL 36582 Phone 251 443 5911 Fax 251 443 5966 BENSHAW Pueblo Trane Division 1 Jetway Court Pueblo CO 81001 Phone 719 948 1405 Fax 719 948 1445 Ben Tech Industrial Automation 2904 Bond Street Rochester Hills MI 48309 Phone 248 299 7700 Fax 248 299 7702 BENSHAW Canada 550 Bright Street Listowel Ontario N4W 3W3 Phone 519 291 5112 Fax 519 291 2595
60. Class 20 overload setting 2 0 4 Severe Duty 600 current for 30 sec Ratings 96 NOTE Do not exceed Class 30 overload setting 2 0 5 Inside Delta Connected Standard Duty 350 for 30 sec Ratings 96 NOTE Do not exceed Class 10 overload setting 2 0 6 RB2 Power Stack Ratings and Protection Requirements 2 TECHNICAL SPECIFICATIONS Mechanical Drawings 2 1 Dimensions 2 1 1 RB2 Chassis with Integral Bypass Figure 1 RB2 96 830A B D Model A B C D E F RB2 27 65A 14 10 12 5 843 0 84 0 31 RB2 77 96A 15 10 13 5 843 0 84 0 31 a Figure 2 RB2 125 361A B LI E E rr oum 6 1 Model A B C D E F RB2 125A 19 5 12 27 13 25 4 0 5 0 31 C RB2 156 180A 21 25 12 00 15 25 4 0 5 0 31 A RB2 180 302A 22 75 12 16 16 75 4 0 5 0 31 RB2 361A 23 91 13 16 18 63 4 31 0 5 0 31 2 2 TECHNICAL SPECIFICATIONS Figure 3 RB2 414 838A B a er Model A B C D E F RB2 414 590A 27 66 18 5 26 25 6 N A 0 31 RB2 720A 29 38 18 5 28 6 N A 0 31 RB2 838A 27 75 26 6 23 5 8 7 N A 0 31 2 TECHNICAL SPECIFICATIONS 2 1
61. ESCRIPTION Digital Input Configuration I O 01 02 03 LED Display LCD Display LED OFF stQP FH L Fr EQLr 5 rSEL 55 12 SS iF bd 5 LCD Off Stop Fault High Fault Low Fault Reset Disconnect Inline Cnfrm Bypass Cnfrm E OL Reset Local Remote Heat Disable Heat Enable Ramp Select Slow Spd Fwd Slow Spd Rev Brake Disabl Brake Enabl Description Off Not Assigned Input has no function Default DI 2 amp DI 3 Stop Command for 3 wire control Default DI 1 Fault High Fault when input is asserted 120V applied Fault Low Fault when input is de asserted applied Reset when input asserted 120V applied Disconnect switch monitor Inline contactor feedback Bypass 2M bypass contactor feedback 2M contactor feedback in full voltage or Wye delta Emergency Motor Overload content reset After an OL trip has occurred Reset when input asserted 120V applied Local Remote control source Selects whether the Local Source parameter or the Remote Source parameter is the control source Local Source is selected when input is de asserted 0V applied Remote Source selected when input asserted 120V applied Heater disabled when input asserted 120V applied Heater enabled when input asserted 120V applied Ramp 2 is enabled when input asserted 120V applied Operate starter in slow speed forward mode Operate starter in slow speed reverse mode Disable DC injection
62. FLA current The equation for the current imbalance if running at current lt FLA ave Imax FLA imbalance x 100 At average currents greater than full load current FLA the current imbalance for each phase is calculated as the percentage difference between the phase current that has the maximum deviation from the average current Imax and the average current Iave The equation for the current imbalance if running at current gt FLA Clave Imax imbalance x 100 lave If the highest calculated current imbalance is greater than the current imbalance level for 10 seconds the starter shuts down the motor and declares a Fault 37 Current Imbalance Alarm Fault Imbalance Condition Trip 1 Current Imbl Lvl 05 P36 7 p Time Delay Fixed 10 Seconds See Also Auto Reset Limit P42 PFN 11 parameter on page 55 Controlled Fault Stop Enable P43 PFN 12 parameter on page 55 52 5 PARAMETER DESCRIPTION P37 Residual Ground Fault Trip Level PEN 06 LED Display LCD Display 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 The starter monitors the instantaneous sum of the three line currents to detect the ground fault current The ground fault current has to remain above the ground fault level for 3 seconds
63. Functions FUN Function and FL1 Faults The Quick Start Group provides a collection of the parameters that are most commonly changed when commissioning a starter Many of the parameters in the Quick Start group are duplicates of the parameters in the other groups This chapter lists all of the parameters and their possible values Section 4 3 lists the parameters in the order in which they appear on the LED display Section 4 4 lists them in the order in which they appear on the LCD display Section 4 2 is a cross reference between the two LED amp LCD Display Parameters Cross Reference 4 2 4 PARAMETER GROUPS LED and LCD Display Parameters Cross Reference Parameter Number 2 125 P4 P5 P6 Pi P8 P10 12 P13 P14 15 16 1217 18 19 P20 p P22 23 P24 525 P26 527 28 29 P30 P31 P32 P33 P34 P35 P36 P37 P38 559 P40 P41 zE ae Parameter QST 01 Motor FLA QST 03 Motor Running Overload Class Page PFN 12 Controlled Fault Stop Enable 2 PSE oe ps Pen 1a Motor Staring Overload Cass C pas RN 16 Motor Ovenond Ratio mr PEN 17 Motor Overioad Cooling Time Cra woo _ roo D12 Configuration oo Dis Configuration I O 14 Analog Output Span 2 6 i 6 i 7 gt E Ps roo Analg input Trip Type _ 6i rse E ip Ti
64. IPTION Start Mode P10 CFNO1 set to TruTorque Control Acceleration This parameter sets the final or maximum torque level that the motor produces at the end of the acceleration ramp time For a loaded motor the maximum torque value initially should be set to 100 or greater If the maximum torque value is set too low the motor may not produce enough torque to reach full speed and may stall On lightly loaded motors this parameter may be reduced below 100 to produce smoother starts 96 NOTE It is important that the P75 FUN06 Rated Power Factor parameter is set properly so that the desired maximum torque level is achieved Start Mode P10 CFNO1 set to Power Control Acceleration This parameter sets the final or maximum power KW consumption level that will be achieved at the end of the ramp time For a loaded motor the maximum power value initially should be set to 100 or greater If the maximum power level is set too low the motor may not produce enough torque to reach full speed and may stall On lightly loaded motors this parameter may be reduced below 100 to provide for smoother starts 3 NOTE It is important that the P75 FUN06 Rated Power Factor parameter is set properly so that the actual maximum power level is achieved See Also Initial Current 1 P6 CFN03 on page 37 Maximum Current 1 P7 QST 07 parameter on page 37 Ramp Time 1 P8 QST 08 parameter on page 38 Start Mode P10 CFN 01 parameter
65. METER DESCRIPTION See Also Over Current Level P32 PFN 01 parameter on page 50 Auto Reset Limit P42 PFN 11 parameter on page 55 Controlled Fault Stop Enable P43 PFN 12 parameter on page 55 Relay Output Configuration P52 54 I O 05 07 parameters on page 60 http www benshaw com literature manuals 890034 1 1 xx pdf P34 Under Current Trip Level PEN 03 LED Display LCD Display Range Off 5 100 of FLA Default Off Description If the MX detects a one cycle average current that is less than the level defined an under current alarm condition exists and any relays programmed as alarm will energize The under current timer starts a delay time If the under current still exists when the delay time expires the starter Under Current Trips F34 and any relay programmed as fault relay changes state The Under Current Trip Level is only active in the UTS state Energy Saver state Current follower or while in the Phase Control mode A relay can be programmed to change state when an under current alarm condition is detected Alarm Fault Condition Trip Current Motor FLA QST 01 P1 Under Cur Ly rmn PFN 03 P34 Time lt gt Delay PFN 04 P35 See Also Under Current Time P35 PFN 04 parameter on page 51 Auto Reset Limit P42 PFN 11 parameter on page 55 Controlled Fault Stop Enable P43 PFN 12 parameter on page 55 Relay Output Configuration P52 54 I O 05 07 parameters on
66. MS voltage must be set properly in order for the starter to operate properly P77 Input Phase Sensitivity FUN 04 LED Display LCD Display Range LED LCD Description 5 Insensitive Runs with any three phase sequence Default Only runs with ABC phase sequence CBA Only runs with CBA phase sequence SPH Single phase Single Phase Description The Input Phase Sensitivity parameter sets the phase sensitivity of the starter This can be used to protect the motor from a possible change in the incoming phase sequence If the incoming phase sequence does not match the set phase rotation the starter displays an Alarm while stopped and faults if a start is attempted See Also Theory of Operations http www benshaw comliterature manuals 890034 1 1 xx pdf P78 CT Ratio FUN 03 LED Display LCD Display Range 72 1 96 1 144 1 288 1 864 1 2640 1 3900 1 5760 1 8000 1 14400 1 28800 1 Default 288 1 73 5 PARAMETER DESCRIPTION Description 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 The CT ratio is then normalized to a 1A secondary value The supplied CT ratio can be confirmed by reading the part number on the CT label The part number is of t
67. Motor Thermal Overload 5 0 10 kW Based on filtered V and I values 6 0 100 kW Based on filtered and I values 1 0 1 MW Based on filtered V and I values 8 0 10MW Based on filtered V and I values q 0 100 Ain The output value takes into account the inputs span and offset settings 10 0 100 Firing Output Voltage to Motor based on SCR firing angle LI Calibration Calibration full 100 output Description The Analog Output Function parameter selects the function of the analog output The available analog output function selections and output scaling are shown below The analog output is updated every 25msec See Also Analog Output Span P61 I O 14 parameter on page 65 Analog Output Offset P62 I O 15 parameter on page 65 Theory of Operations http www benshaw com literature manuals 890034 1 1 xx pdf 64 5 PARAMETER DESCRIPTION P61 Analog Output Span I O 14 LED Display LCD Display Range 1 125 Default 100 Description The analog output signal can be scaled using the Analog Output Span parameter For a 0 10V output or 0 20mA output a 100 scaling outputs the maximum voltage 10V or current 20mA when the selected output function requests 100 output A scale of 50 outputs 50 voltage current when the analog output function requests a 100 output 96 NOTE For a 4 20mA output set the Analog Output Span to 80 and the Analog Output Offset P62 I O 15 parameter to 20 96 NOTE The output d
68. NTER key Off is displayed to indicate that no passcode is currently set 4 Press the UP or DOWN keys and ENTER for each digit to be defined select a value from 0000 to 9999 starting at the most significant digit 5 Press the ENTER key to set the passcode The following steps must be performed to clear a passcode 1 At the default meter display press the PARAM key to enter the parameter mode 2 Press the UP or DOWN keys to get to the Passcode parameter P81 FUN 16 3 Press the ENTER key is displayed to indicate that a passcode is presently set 4 Press the UP or DOWN keys and ENTER after each digit to select the previously set passcode value 5 Press the ENTER key The passcode is then cleared P82 Fault Log FL1 LED Display LCD Display Range FLI FL9 Description When a fault occurs the fault number is logged in non volatile memory The most recent fault is in FL1 and the oldest fault is in FL9 If the starter is equipped with an LCD display pressing ENTER toggles through the Starter data recorded at the time of the fault See section 2 on page 29 for more information See Also Fault Codes on page 126 76 Theory of Operation 6 THEORY OF OPERATION Motor Overload 6 1 6 1 1 78 Solid State Motor Overload Protection Overview The MX contains an advanced rt electronic motor overload OL protection function For optimal motor protection the MX has forty stand
69. P10 CFNO1 set to Open Loop Voltage Acceleration This parameter sets the starting point for the voltage acceleration ramp profile A typical value is 2596 If the motor starts too quickly or the initial current is too high reduce this parameter If the motor does not start rotating within a few seconds after a start is commanded increase this parameter Start Mode P10 CFNO01 set to Current Control Acceleration Not used when the Start Mode parameter is set to Current control acceleration Refer to the P6 Initial Current 1 parameter to set the initial current level Start Mode P10 CFNO1 set to TruTorque Control Acceleration This parameter sets the initial torque level that the motor produces at the beginning of the starting ramp profile A typical value is 10 to 20 If the motor starts too quickly or the initial torque level is too high reduce this parameter If the motor does not start rotating within a few seconds after a start is commanded increase this parameter If the value is set too low a No Current at Run fault may occur during acceleration 96 NOTE It is important that the P75 FUN06 Rated Power Factor parameter is set properly so that the actual initial torque level is the value desired Start Mode P10 CFNOI set to KW Power Control Acceleration This parameter sets the initial motor power KW level that will be achieved at the beginning of the starting ramp profile A typical value is 10
70. Pk accel Curr Peak starting current cd Last Start T Last starting duration Description For the LED display this parameter configures which single meter is displayed on the main screen For the LCD display parameters FUN 01 and FUN 02 configure which meters are displayed on the two lines of the main display screen 74 P80 LED Display Description P81 LED Display Description S PARAMETER DESCRIPTION Software 1 FUN 14 LCD Display 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 On the LED display the software version is flashed one character at a time on power up On the LCD display the software PN is fully displayed on power up 96 NOTE The seven segment LED in position one will flash the current software version currently in use when first powered on The full software part number will flash consecutively one digit per second For Example 8 1 0 0 2 3 0 1 0 3 Passcode FUN 16 LCD Display The supports 4 digit passcode When the passcode is set parameters may not be changed The provides means of locking parameter values so that they may not be changed Once locked the paramete
71. Publication 890034 23 01 BENSHAW ADVANCED CONTROLS amp DRIVES RediStart Solid State Starter Condensed User Manual MX Control RB2 RC2 RX2E Models For full user manual including Installation ModBus Tables and more visit www Benshaw com The Leader In Solid State Motor Control Technology Os April 2007 Software Version 810023 01 02 Hardware Version 300055 01 04 2007 Benshaw Inc Benshaw Inc 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 Inc TABLE OF CONTENTS Table of Contents J INTRODUCTION 4 s v s weas s aS w a w KOR YO X Qe ss EENE 2 2 TECHNICAL SPECIFICATIONS esa e w a aq x w w ES P TR P 6 20 1 CT Ratios snack aaa e dox E eem ER A Ae Re ae 6 2 0 2 Standard Duty 350 for 30 sec Ratings ee 6 2 0 3 Heavy Duty 500 current for 30 sec Ratings 2 6 2 0 4 Severe Duty 600 current for 30 sec Ratings 2 eee 6 2 0 5 Inside Delta Connected Standard Duty 350 for 30 sec 6 2 0 6 RB2 Power Stack Ratings and Protection Requirements 6 2 1 Dimensions amp x eS vh oO RAPI SORS Wow WR Ee S OXON 7 211 Chassis with Integral Bypass usu 8 nias Cu oue
72. RIAL COMMUNICATION PROGRAMAS 8 5485 5V LAY K Fo wise 1 eb db L 1 be 1 1 l stop START OVERTEMP SWITCH t b p alo 5 H H MTD ON HEATSINK L 022 1 THREE WIRE CONTROL 2 o E 9 8 RESET PARAMETER DOWN ENTER J5 4 5 RJA5 r DISPLAY 5 fume seas SSS a __ I DISPLAY 1 ma Were susu T 1 1 H 1 GD Ge Qm 1 1 1 1 CIN C220 fa Clo Cl CS MI P OPTIONAL DOOR MOUNT DISPLAY 12 INSTALLATION Figure 7 Power Schematic for RB2 High HP 100 600 VAC 3050 60Hz e e CUSTOMER SUPPLIED 120 vac OT SWITCH T B Shoo sens pees pe N i n h2 2 q 1 Y 1 gt G3 i 1 cn 7 ETUR e p Round 2 aad 65 52 gt 5 P68 FUNO3 ta TO DVDT 3 8 34 MX CARD 4 W neutrat Z J7 1 M amp M4X 6 PO i 9 1 H NEUTRAL 2 5SY Ke _ LIVE z TO DVDT 2 DVDT 1 Qos 8 pr qM 81 TO 5006 1 1 eri LIVE BIPC 300055 01
73. Rated Voltage parameter P76 FUN05 must be set correctly 96 NOTE The voltage level is only checked when the starter is running See Also Over Voltage Level P38 PFN 07 parameter on page 53 Voltage Trip Time P40 PFN 09 parameter on page 54 Auto Reset Limit P42 PFN 11 parameter on page 55 Controlled Fault Stop Enable P43 PFN 12 parameter on page 55 Rated Voltage P76 FUN 05 parameter on page 73 P40 Over Under Voltage Trip Delay Time PFN 09 LED Display LCD Display 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 See Also Over Voltage Level P38 PFN 07 parameter on page 53 Under Voltage Level P39 PFN 08 parameter on page 54 Auto Reset Limit P42 PFN 11 parameter on page 55 Controlled Fault Stop Enable P43 12 parameter on page 55 54 5 PARAMETER DESCRIPTION P41 Auto Fault Reset Time PFN 10 LED Display LCD Display Range Off 1 900 seconds Default Off Description The Auto Fault Reset Time parameter sets the time delay before the starter will automatically reset a fault For the list of faults that may be auto reset refer to Appendix B Fault Codes on page 96 NOTE A start command needs to be initiated once the timer resets the fault See Also Auto Reset Limit P42 PFN 11 para
74. Speed Kick Level and or reduce the Slow Speed Kick Time Kick Level 1 P13 10 parameter page 41 Slow Speed Kick Time P31 25 parameter on page 49 http www benshaw com literature manuals 890034 1 xx pdf Slow Speed Kick Time CEN 25 LCD Display 0 1 10 0 seconds Default 1 0 The Slow Speed Kick Time parameter sets the length of time that the Slow Speed Kick current level P30 24 is applied to the motor at the beginning of slow speed operation After the Slow Speed Kick Level is set the Slow Speed Kick Time should be adjusted so that the motor starts rotating when a slow speed command is given If the motor initially accelerates too fast then reduce the Slow Speed Kick Level P30 CFN 24 and or reduce the Slow Speed Kick Time Slow Speed Kick Level P30 CFN 24 parameter on page 49 http www benshaw com literature manuals 890034 1 1 xx pdf Jump to Parameter PEN 00 By changing the value of this parameter and pressing ENTER you can jump directly to any parameter within that group 49 5 PARAMETER DESCRIPTION P32 LED Display Range Description See Also P33 LED Display Range Description 50 Over Current Trip Level PFN 01 LCD Display Off 50 800 of FLA Default Off If the MX detects a one cycle average current that is greater than the level defined an over current alarm condition exists and any relays programmed as alarm wil
75. WIRES BETWEEN HEATSINK FINS 7 1 2 SCR Removal To remove the SCR from the heatsink loosen the two bolts 3 on the loader bar side of the clamp Do not turn on the nuts 5 The nuts have a locking ridge that sink into the aluminum heatsink Do turns until the SCR comes loose Remove the SCRs from the heatsink 3 NOTE Do not loosen nut on indicator washer 6 This will change the clamping pressure of the clamp and the clamp will be defective 773 SCR Installation Coat the faces of the SCRs to be installed with a thin layer of EJC Electrical Joint Compound Place the SCRs onto the dowel pins The top SCR will have the cathode to the left and the bottom SCR will have the cathode to the right The SCR symbol has a triangle that points to the cathode Finger tighten nuts on the bolts 136 7 7 4 7 7 5 7 7 6 7 TROUBLESHOOTING amp MAINTENANCE 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 2 Serrated nut larger style clamp has 1 support bar Indicator Washer Quantity dependant on style of clamp Tightening Clamp Finger tighten the clamp Ensure both bolts are tightened an equal amount so that the loader bar item 1 is square in the heatsink Tighten the bolts equally in 1 8 turn increments until the indicator washer s item 6 which are under the nut s in the center of the loader bar becomes loo
76. WITCH O 120VAC NEUTRAL 2 Z When the Hand Off Auto selector switch is in the Hand position current flows to the Stop push button contact and to the Stop input on the If the Stop is not pressed and the Start push button is pressed the starter starts This is a typical 3 wire control The seal for the Start push button input is accomplished in software When the stop is pressed the starter stops When the Hand Off Auto selector switch is in the Auto position current flows to the user supplied run contact but the Stop input remains low When the user supplied run contact closes and the stop input is low no power applied the starter is in 2 wire control CAUTION It is important that the Stop push button be wired in front of the Start push button otherwise the starter could be started when the Stop bush button is pressed and the Start button is pressed 114 6 THEORY OF OPERATION Simplified I O Schematics 6 14 Simplified I O Schematics Figure 35 Digital Input Simplified Schematic 15 0 KQ 02 AW s Q WC e 15 0 KQ Figure 36 Analog Input Simplified Schematic 100 KQ 100 KQ AIN e 503 75 Q e 100 KQ AIN swi 1 ON 0 20mA 100 KQ 100 KQ AIN e e imd Figure 37 Analog Output Simplified Schematic 15 KQ 274 KQ 15V W e W 100 W aout 500 Q AOUT
77. X control card to confirm that the transition sequence to Delta is complete The starter remains in the Delta or running mode until the start command is removed or a fault occurs 107 6 THEORY OF OPERATION Usually the MX intelligent Wye to Delta transition algorithm provides an optimal transition point that minimizes the transient current and torque surges that can occur However the Wye to Delta transition will occur when the Up To Speed Time parameter has expired In order to reduce the current surge during the transition from Wye to Delta mode the Up To Speed Time parameter should be adjusted so that the transition occurs as close to full speed as possible within the constraints of the load If the Up To Speed Time is set too short the starter will transition too soon and a large current and torque surge will occur If the Up To Speed Time is set too long the motor may not have sufficient torque to continue accelerating when in Wye mode and may stop accelerating at a low speed until the transition to Delta mode occurs If this occurs the start is unnecessarily prolonged and motor heating is increased A typical closed transition Wye Delta starting current profile is shown in Figure 29 Figure 29 Wye Delta Profile Wye Delta Closed Transition Current Profile 600 500 E Full 400 Load Motor Current 300 7T7 200 1008 70 Xj speed Transiti
78. a low value and then the kick time is adjusted to get the motor rotating If the kick time is set to more than 2 0 seconds without the motor rotating increase the kick current by 100 and re adjust the kick time The kick time adjustment should begin at 0 5 seconds and be adjusted by 0 1 or 0 2 second intervals until the motor begins rotating If kick time is adjusted above 2 0 seconds without the motor rotating start over with a higher kick current setting 6 3 3 TruTorque Acceleration Control Settings and Times General TruTorque acceleration control is a closed loop torque based control The primary purpose of TruTorque acceleration control is to smoothly start motors and to reduce the torque surge that can occur as an AC induction motor comes up to speed This torque surge can be a problem in applications such as pumps and belt driven systems In pumping applications this torque surge can result in a pressure peak as the motor comes up to speed In most situations this small pressure peak is not a problem However in selected cases even a small pressure rise can be highly undesirable In belt driven applications TruTorque can prevent the slipping of belts as the motor reaches full speed Figure 17 TruTorque Ramp Motor Torque Max Torque Motor Running lt 2 ____ ____ TEN Torque Start command Optional Kick Current Initial Torque F Time Kick Time lt lt Ramp Time
79. abled When the DI 1 DI 2 or DI 3 inputs are programmed as Heat Enable Inputs the input may be used to control when heating anti windmilling is applied The Heater Anti Windmill Level parameter must be set the starter stopped and this input must be high for heating to occur Disabled When the DI 1 DI 2 or DI 3 inputs are programmed as Heat Disable Inputs the input may be used to control when heating anti windmilling is applied The Heater Anti Windmill Level parameter must be set and this input must be low for heating to occur If no digital inputs are programmed as heater enabled or disabled the heater is applied at all times when the motor is stopped The level of D C current applied to the motor during this operation needs to be monitored to ensure that the motor is not overheated The current level should be set as low as possible and then slowly increased over a long period of time While this is being done the temperature of the motor should be monitored to ensure it is not overheating The Motor should be labeled as being live even when not rotating The heater feature should not be used to dry out a wet motor 96 NOTE When in single phase mode the heater function is disabled 3 NOTE When this function is on all of the other parameters cannot be programmed until this parameter is turned off Digital Input Configuration P48 50 I O 01 03 parameters on page 59 71 5 PARAMETER DESCRIPTION P74 LED Displ
80. ach SCR red and white twisted pair The resistance should be from 8 to 50 ohms 96 NOTE The resistance measurements may not be within these values and the SCR may still be good The checks are to determine if an SCR is shorted L to T of if the gate in an SCR is shorted or open An SCR could also still be damaged even though the measurements are within the above specifications Voltage When the starter is running the operation of the SCRs can be confirmed with a voltmeter Extreme caution must be observed while performing these checks since the starter has lethal voltages applied while operating While the starter is running and up to speed use an AC voltmeter check the voltage from L to T of each phase The voltage should be less than 1 5 Volts If the starter has a bypass contactor the voltage drop should be less than 0 3 volts Using a DC voltmeter check between the gate leads for each SCR red and white twisted pair The voltage should between 0 5 and 2 0 volts Integral Bypass A voltage check from L to T of each phase of the RediStart starter should be preformed every 6 months to confirm the bypass contactors are operating correctly Extreme caution must be observed while performing these checks since the starter has lethal voltages applied while operating While the starter is running and Up to Speed use an AC voltmeter check the voltage from L to T of each phase The voltage drop across the contactor contacts s
81. ad sie 120 7 21 General Information x 4 de gun rk hom Ro OR Em dee d ha De E ES 120 7 2 2 Preventative Maintenance sai do meg OR we ORO CAD e go op ORC SR Cos 120 TABLE OF CONTENTS 7 3 General Troubleshooting Charts v wra damme sok s E 2 220 a 121 7 3 1 Motor does not start output to motor s 2 121 7 3 2 During starting motor rotates but does not reach full speed 122 7 3 8 Starter not accelerating asdestred uz us w sys que des BUT us arik ous E dne eR 122 7 3 4 Starter not decelerating as desired 123 7 3 5 Motor stops unexpectedly whilerunning eA 123 7 3 6 Metering ss a oo kon Ene e OR UR UE Rog BOX UAORUR Yos Yo 124 7 9 7 OfherSituationsc uec 66 Rt Rod Q PORE BERS EEO OE rA Yu RE qu 125 7A Fault Code Table v sse AMEE Sek x wok xoa E doe x 126 79 OCR Testing uad SS EROS EA eue eae dU RI UR each 6 ER Sx WIN E os 132 yc gea PME ai 132 7 5 2 Voltage ant wawapa qd beue SRA Gadde Q 45 EDS Las qe d pou ke 132 7 9 9 Integral Bypass aa eu sce Vus eae ee e ee BG er ote 132 7 6 Built In Self Test Functions skip monk Ro PRG EE RR DER 133 7 6 1 Stan
82. after the ramp is completed If the ramp time expires before the motor has reached full speed the starter holds the current at the maximum current level until either the UTS timer expires the motor reaches full speed or the overload trips Typically the maximum current is set to 600 unless the power system or load dictates the setting of a lower maximum current Initial Current 1 P6 QST 06 parameter on page 37 Ramp Time 1 P8 QST 08 parameter on page 38 Up To Speed Time P9 QST 09 parameter on page 38 37 5 PARAMETER DESCRIPTION Start Mode P10 01 parameter on page 39 Kick Level 1 P13 CFN 10 parameter on page 41 Kick Time 1 P14 CFN 11 parameter on page 41 Theory of Operations http www benshaw com literature manuals 890034 1 1 xx pdf P8 Ramp Time 1 OST 08 CFN 02 LED Display LCD Display Range 0 300 seconds Default 15 Description The Ramp Time 1 parameter is the time it takes for the starter to allow the current voltage torque or power depending on the start mode to go from its initial to the maximum value To make the motor accelerate faster decrease the ramp time To make the motor accelerate slower increase the ramp time A typical ramp time setting is from 15 to 30 seconds If the ramp time expires before the motor reaches full speed the starter maintains the maximum current level until either the motor reaches full speed the UTS timer expires or the motor ther
83. al Fault Input Trip Time 0 1 90 0 30172 40172 Configuration P53 30173 40173 R2 Configuration P54 30174 40174 R3 Configuration P55 P56 Analog Input Trip Level 0 100 Analog Input Trip Delay Time Analog Input Span 1 100 5 30178 40178 30179 40179 Hi 0 1 90 0 1 gt gt gt gt gt 4 PARAMETER GROUPS 5 5 5 5 5 5 5 d Off Off On Off 10 0 0 Off 0 3 S Off Stop Fault High Fault Low Fault Reset Disconnect Inline Cnfrm Bypass Cnfrm E OL Reset Local Remote Heat Disable Heat Enable Ramp Select Slow Speed Forward Slow Speed Reverse DC Brake Disable DC Brake Enable Off Fault fail safe Fault non fail safe Running UTS FLFS Alarm Ready Locked Out Over Current Off Under Current OL Alarm Shunt Trip fail safe Shunt Trip non fail safe Ground Fault Energy Saver Heating Slow Speed Slow Speed Forward Slow Speed Reverse DC Braking Cooling Fan Disabled Low Level High Level 61 61 62 62 21 4 PARAMETER GROUPS Modbus Off no output 0 200 Curr 800 0 150 Volt 150 OL 0 10KW oro Analog Output Function no 30181 40181 0 100 kW 1 MW 0 10 MW 9 0 100 Ain 10 0 100 Firing 11 Calibration wa amigopas i us Ja C means AnstogOupwomser o fo
84. ameter setting P63 I O16 when a start command was given to the starter If an inline contactor is being used verify that the setting of the Inline Configuration time delay parameter P53 I O16 allows enough time for the inline contactor to completely close Check input supply for open disconnects open fuses open circuit breakers or disconnected wiring Verify that the SCR gate wires are properly connected to the MX control card On medium voltage systems verify wiring of the voltage feedback measurement circuit 128 7 TROUBLESHOOTING amp MAINTENANCE Fault Code Detailed Description of Fault Possible Solutions During operation the MX detected a very high level of current in one or more phases Check motor wiring for short circuits or ground faults Instantaneous Over current Check motor for short circuits or ground faults Check if power factor or surge capacitors are installed on the motor side of the starter Verify that the motor FLA P1 QST01 and CT ratio P78 FUN03 settings are correct Overcurrent Motor current exceeded the Over Current Trip Level setting P32 PFNO1 for longer than the Over Current Trip Delay Time setting P33 PFN02 Check motor for a jammed or an overload condition Undercurrent Motor current dropped under the Under Current Trip Level setting P26 PFNO3 for longer than the Under Current Trip Delay time setting P27 PFN04 Check system for cause of under current condition
85. an auxiliary contact from the bypass contactor s or in the case of a wye delta starter the 2M contactor The digital input is expected to be in the same state as the UTS relay If it is not the MX trips on Fault 48 Bypass Fault The Bypass Confirmation input must be different from the UTS relay for the time period specified by the parameter before a fault is declared There is no alarm associated with this fault Digital Input Configuration P48 P50 I O 01 03 parameters on page 59 Theory of Operations http www benshaw com literature manuals 890034 1 1 xx pdf P65 LED Display Range Description See Also P66 LED Display Range Description 5 PARAMETER DESCRIPTION Keypad Stop Disable YO 18 LCD Display LED LCD Description OFF Disabled Keypad Stop does not stop the starter Dn Enabled Keypad Stop does stop the starter Default If Disabled When this parameter is set to Disabled the keypad STOP button is de activated This should be done with caution as the STOP will not stop the starter If the keypad is selected as local or remote control sources the STOP key cannot be disabled If Enabled When this parameter is set to Enabled the keypad STOP button is enabled and stops the starter regardless of the selected control source P4 QST 04 or P5 QST 05 selected as keypad terminal or serial Local Source P4 QST 04 parameter on page 35 Remote Source P5 QST 0
86. ard NEMA style overload curves in steps of one available for use Separate overload classes can be programmed for acceleration and for normal running operation and individually or completely disabled if necessary The MX motor overload function also implements a NEMA based current imbalance overload compensation adjustable hot and cold motor compensation and adjustable exponential motor cooling CAUTION Ifthe Mx motor overload protection is disabled during any mode of operation external motor overload protection must be provided to prevent motor damage and or the risk of fire in the case of a motor overload Setting Up The Mx Motor Overload Motor overload protection is easily configured through seven parameters please refer to the descriptions of each parameter in section 6 of this manual for additional parameter information 1 Motor FLA QST 01 Motor Service Factor QST 02 Motor Running Overload Class PFN 15 Motor Starting Overload Class PEN 14 Independent Starting Running Overload PFN 13 Motor Overload Hot Cold Ratio PFN 16 Motor Overload Cooling Time PFN 17 Un dee The Motor FLA and Service Factor parameter settings define the motor overload pickup point For example if the motor service factor is set to 1 00 the motor overload begins accumulating or incrementing when the measured motor current is gt 100 FLA 100 1 00 The overload will NOT trip if the motor current is 10096 If the motor ser
87. arge horsepower motor may require longer delays Stop Mode P15 14 parameter on page 42 DC Brake Level P19 CFN 18 parameter on page 44 DC Brake Time P20 19 parameter on page 45 Theory of Operations http www benshaw com literature manuals 890034 1 1 xx pdf Initial Motor Current 2 06 LCD Display 50 600 of FLA Default 100 The Initial Current 2 parameter is set as a percentage of the Motor FLA P1 QST 01 parameter setting when the second ramp is active Refer to the Initial Current 1 P6 CFN 03 parameter on page 37 for description of operation Initial Current 1 P6 QST 06 parameter on page 37 Digital Input Configuration P48 50 I O 01 03 parameters on page 59 Theory of Operations http www benshaw com literature manuals 890034 1 1 xx pdf Maximum Motor Current 2 CEN 07 LCD Display 100 800 of FLA Default 600 The Maximum Current 2 parameter is set as a percentage of the Motor FLA P1 QST 01 parameter setting when the second ramp is active Refer to the Maximum Current P7 CFN 04 parameter on page 37 for description of operation Maximum Current 1 P7 QST 07 parameter on page 37 Digital Input Configuration P48 I O 01 03 parameters on page 59 Theory of Operations http www benshaw com literature manuals 890034 1 1 xx pdf Ramp Time 2 CFN 05 LCD Display 0 300 seconds Default 15 The Ramp Time 2 parameter set
88. ass Running PFN 15 See Quickstart group QST 03 Motor Overload Class Running on page 34 for details P46 Motor Overload Hot Cold Ratio PEN 16 LED Display LCD Display Range 0 99 Default 60 Description The Motor Overload Hot Cold Ratio parameter defines the steady state overload content OL that is reached when the motor is running with a current less than full load current FLA Service Factor SF This provides for accurate motor overload protection during a warm start The steady state overload content is calculated by the following formula The rise or fall time for the overload to reach this steady state is defined by the Motor Overload Cooling Time parameter OL H C Ratio x Current x l A Current Imbalance Derate Factor The default value of 60 for Motor Overload Hot Cold Ratio parameter is typical for most motors A more accurate value can be derived from the hot and cold locked rotor times that are available from most motor manufacturers using the following formula Max Hot Locked Rotor Time Max Cold Locked Rotor Time OL H C Ratio 100 36 NOTE Consult motor manufacturer data to determine the correct motor overload settings See Also Motor Running Overload Class P3 QST 03 parameter on page 34 Independent Starting Running Overload P44 13 parameter on page 56 Motor Starting Overload Class P45 PFN 14 parameter on page 56 Motor Overload Cooling Time P47
89. ation ramp settings The acceleration ramp settings may be too low to permit the motor to start and achieve full speed If so revise acceleration ramp settings to provide more motor torque during starting Evaluate UTS timer setting and if acceptable increase UTS timer setting P9 QST09 Motor Thermal Overload Trip Check motor for mechanical failure jammed or overloaded condition Verify the motor thermal overload parameter settings P3 QST03 and P44 P47 PFN12 PFN16 and motor service factor setting P2 QST02 Verify that the motor FLA P1 QST01 and CT ratio P78 FUN03 are correct If motor OL trip occurs during starting review acceleration ramp profile settings Verify that there is not an input line power quality problem or excessive line distortion present Reset overload when content falls below 15 Phase Rotation Error not ABC Input phase rotation is not ABC and Input Phase Sensitivity parameter P77 FUN04 is set to ABC only Verify correct phase rotation of input power Correct wiring if necessary Verify correct setting of Input Phase Sensitivity parameter P77 FUN04 Phase Rotation Error not CBA Input phase rotation is not CBA and Input Phase Sensitivity parameter P77 FUN04 is set to CBA only Verify correct phase rotation of input power Correct wiring if necessary Verify correct setting of Input Phase Sensitivity parameter P77 FUN04 Low Line Frequency Line frequency below 23 Hz was detected Verify in
90. ault Off The Energy Saver feature lowers the voltage applied to a lightly loaded motor It continues to lower the voltage until it finds the point where the current reaches its lowest stable level and then regulates the voltage around this point If the load on the motor increases the starter immediately returns the output of the starter to full voltage 96 NOTE This function does not operate if a bypass contactor is used 96 NOTE In general Energy Saver can save approximately 1000 watts per 100 HP Consult Benshaw for further detail P73 LED Display Range Description See Also S PARAMETER DESCRIPTION Heater Level FUN 08 LCD Display Off 1 25 FLA Default Off The Heater Level parameter sets the level of D C current that reaches the motor when the motor winding heater anti windmilling brake is enabled The motor winding heater anti windmilling brake can be used to heat a motor in order to prevent internal condensation or it can be used to prevent a motor from rotating 96 NOTE The motor can still slowly creep when the anti windmilling brake is being used If the motor has to be held without rotating a mechanical means of holding the motor must be used The motor winding heater anti windmilling brake operation may be controlled by a digital input and by a heater disable bit in the starter control Modbus register There are two methods using the digital inputs either the input is an enable or disable En
91. ay Range Description See Also P75 LED Display Range Description See Also 72 Starter Type FUN 07 LCD Display LED LCD Description nor Normal Normal Reduced Voltage Soft Starter RVSS Default Inside Delta Inside Delta RVSS d d Wye Delta Wye Delta Phase Ctl Open Loop Phase control using external analog input reference cFoL Curr Follow Closed Loop Current follower using external analog input reference RtL ATL Across the line Full Voltage The MX has been designed to be the controller for many control applications Solid State Starter both Normal outside Delta and Inside Delta and Electro mechanical starters Wye Delta Across the line full voltage starter Phase Control Voltage Follower Current Follower In each case the MX is providing the motor protection and the necessary control for these applications 36 NOTE For single phase operation select Normal for the Starter Type parameter and Single Phase for the phase order parameter Phase Order P77 FUN 04 parameter on page 73 Theory of Operations http www benshaw comliterature manuals 890034 1 1 xx pdf Motor Rated Power Factor FUN 06 LCD Display 0 01 1 00 Default 0 92 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 If TruTorque or Power acceleration and or deceleration contr
92. ay the Power percent K W meter on the display Record the value displayed The Maximum Power level should then be set to the recorded full load value of K W plus an additional 5 to 10 Restart the motor with this value to verify correct operation 96 NOTE When setting the Maximum Power level the motor must be monitored to ensure that the starting power is high enough to allow the motor to reach full speed under worst case load conditions 89 6 THEORY OF OPERATION Ramp Time 90 3 NOTE Depending on loading the motor may achieve full speed at any time during the Power ramp This means that the Maximum Power level may not be reached Therefore the maximum power level is the maximum power level that is permitted However the motor power may not necessarily reach this value during all starts When in Power acceleration mode the ramp time setting is the time it takes for the power to go from the initial power setting to the maximum power setting To make the motor accelerate faster decrease the ramp time To make the motor accelerate slower increase the ramp time If the ramp time expires before the motor reaches full speed the starter maintains the Maximum Power level until either the motor reaches full speed the UTS timer expires or the motor thermal overload protection trips 36 NOTE Setting the ramp time to a specific value does not necessarily mean that the motor takes that exact amount of time to accelerate to full spe
93. ble Solutions 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 PI OSTO1 CT ratio P78 FUN03 and burden switch settings are correct Verify that no actual current is flowing through any of the starter s CTs when the starter is not running Consult factory if fault persists The starter has detected a voltage or a current Remove line power from input of starter Disconnect must be open Verify CT location on L1 CT2 on L2 CT3 on L3 or CTs are connected backwards the polarity dot must be facing the supply line DI 1 has been programmed as a fault type digital input and the input indicates a fault condition is present Verify that the appropriate Digital Input Configuration parameter has been programmed correctly Verify wiring and level of input DI 2 has been programmed as a fault type digital input and input indicates a fault condition is present Verify that the appropriate Digital Input Configuration parameter has been programmed correctly Verify wiring and level of input DI 3 input has been programmed as a fault type digital input and input indicates a fault condition is present Verify that the appropriate Digital Input Configuration parameter has been programmed correctly Verify wiring and level of input Based on the Analog Input parameter settings the analog input level has either exceede
94. braking Enable DC injection braking I O parameters 1 3 configure which features are performed by the D1 to D3 terminals Local Source P4 QST 04 parameter on page 35 Remote Source P5 QST 05 parameter on page 36 Bypass Feedback Time P64 I O 17 parameter on page 66 Heater Level P73 FUN 08 parameter on page 71 Theory of Operations http www benshaw comliterature manuals 890034 1 1 xx pdf 59 5 PARAMETER DESCRIPTION P51 LED Display Range Description See Also P52 53 54 Range Description 60 Digital Fault Input Trip Time I O 04 LCD Display 0 1 90 0 Seconds Default 0 1 Sec The Digital Fault Input Trip Time parameter sets the length of time the Digital input must be high or low before a trip occurs This delay time only functions for fault high and fault low Digital Input Configuration P48 50 I O 01 03 parameters on page 59 Relay Output Configuration 05 06 07 LED Display LED OFF FLFS utS I rddr LO ni Ul uc OLA ShF5 ShnF SFL t ES HEAL S5Pd S5 F S5 3 deb FAR LCD Off Fault FS Fault NFS Running UTS Alarm Ready Locked Out Overcurrent Undercurrent OL Alarm Shunt FS Shunt NFS Ground Fault Energy Saver Heating Slow Spd Slow Spd Fwd Slow Spd Rev Braking Cool Fan Ctl LCD Display Description Off Not Assigned May be controlled over Modbus Default R2 amp R3 Faulted Fail Saf
95. cription See Also 42 The Kick Time 1 parameter sets the length of time that the kick current level P13 10 is applied to the motor The kick time adjustment should begin at 0 5 seconds and be adjusted by 0 1 or 0 2 second intervals until the motor begins rotating If the kick time is adjusted above 2 0 seconds without the motor rotating start over with a higher kick current setting 36 NOTE The kick time adds to the total start time and must be accounted for when setting the UTS time Start Mode P10 01 parameter on page 39 Up To Speed P9 QST 09 parameter on page 38 Kick Level 1 P13 10 parameter on page 41 Theory of Operations http www benshaw com literature manuals 890034 1 1 xx pdf Stop Mode 14 LCD Display LED LCD Description CoS Coast Coast to stop Default SdeL Volt Decel Open loop voltage deceleration tdcL TT Decel TruTorque deceleration dcb DC Brake DC Braking Coast A coast to stop should be used when no special stopping requirements are necessary Example crushers balls mills centrifuges belts conveyor The bypass contactor is opened before the SCRs stop gating to reduce wear on the contactor contacts Voltage Decel In this mode the starter linearly phases back the SCRs based on the parameters Decel Begin Level Decel End Level and Decel Time TruTorque Decel In this mode the starter linearly reduces the motor torque based on the Decel En
96. ction in the system The MX starter supports two different levels of DC injection braking 1 Standard Duty Brake For less than 6 x motor inertia 2 Heavy Duty Brake For NEMA specified inertia and two motor current feedback methods a Standard Current Transformers CTs b Optional Hall Effect Current Sensor LEM The optional Hall Effect Current sensor can be used when a more precise measurement of braking current is necessary This can occur if the DC injection braking is applied when the source supply has a very high short circuit capability very stiff or in special instances when more precise braking current control is required The appropriate brake type and feedback method is preset from the factory Please consult Benshaw for more information if changes need to be made Maximum Load Inertia The following table shows maximum load inertia NEMA MGI parts 12 and 20 A thermostat thermistor or RTD MUST be installed to protect the motor from overheating meu 3 no 7 60 s H Inertia Ib ft2 2 24 n 3 183 28 99 2 35 208 6 s 25 75 un 2594 389 5680 640 179 3456 5940 9230 1722 228 458 7750 12060 250 20 1017 2744 5540 1 9530 14330 30 26 117 33 650 uwo j 2 j 44 3
97. d Level and Decel Time DC Brake In this mode the starter provides D C injection for frictionless braking of a three phase motor 3 NOTE The stops the motor when fault occurs Depending on application it may be desirable for the motor to be stopped in a controlled manner Voltage Decel TT Decel or D C Braking instead of being allowed to coast to a stop when this occurs This may be achieved by setting the Controlled Fault Stop Enable P43 PFN12 parameter to On Be aware however that not all fault conditions allow for a controlled fault stop Decel Begin Level P16 15 parameter on page 43 Decel End Level P17 CFN 16 parameter on page 43 Decel Time P18 CFN 17 parameter on page 44 DC Brake Level P19 CFN 18 parameter on page 44 DC Brake Time P20 CFN 19 parameter on page 45 DC Brake Delay P21 CFN 20 parameter on page 45 Controlled Fault Stop Enable P43 PFN 12 parameter on page 55 Digital Input Configuration P48 P50 I O 01 03 parameters on page 59 Relay Output Configuration P52 P54 I O 05 07 parameters on page 60 Theory of Operations http www benshaw com literature manuals 890034 1 1 xx pdf S PARAMETER DESCRIPTION P16 Decel Begin Level CEN 15 LED Display LCD Display 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 curv
98. d of deceleration cycle Water hammer still occurs at end of cycle Decel and P17 CFN 16 set improperly 1 Begin Level P16 CFN15 set too high 1 End Level P17 CFN16 set too low Begin and End Levels P16 CFN15 Increase Decel Begin and or Decel End levels Decrease Decel Begin Level until surging is eliminated Increase Decel End Level until motor just stops at the end of the deceleration cycle Decel End Level P17 CFNI06 set too high Decrease Decel End Level until water hammer is eliminated Decel Time P18 CFN17 too short If possible increase Decel Time to decelerate system more gently Motor speed drops sharply before decel Decel begin level to low Increase the Decel Begin Level until drop in speed is eliminated 7 3 5 Motor stops unexpectedly while running Fault Displayed Fault Occurred See fault code troubleshooting table for more details Ready Displayed Display Blank Heartbeat LED on MX card not blinking Start command lost Verify start command input signal is present or serial communications start command is present Check any permissive that may be wired into the run command Start Stop Control voltage absent Check for proper control voltage input Verify wiring and fuses control card problem Consult factory 123 7 TROUBLESHOOTING amp MAINTENANCE 7 3 6 Metering incorrect Power Metering not reading correctly CTs installed or wired incorrectly Ver
99. d or dropped below the Analog Input Trip Level setting P56 I O 09 for longer than the Analog Input Trip Delay time P57 I O 010 Measure value of analog input to verify correct reading Verify settings of all Analog Input parameters P55 P59 T O 08 T O 12 Verify correct positioning of input switch SW1 Voltage or Current on the MX control card Verify correct grounding of analog input connection to prevent noise or ground loops from affecting input Indicates that communication has been lost with the remote keypad This fault normally occurs if the remote keypad is disconnected while the MX control card is powered up Only connect and disconnect a remote keypad when the control power is off Verify that the remote keypad cable has not been damaged and that its connectors are firmly seated at both the keypad and the MX control card Verify that the display interface card when present is firmly attached to MX control card Route keypad cables away from high power and or high noise areas to reduce possible electrical noise pickup 131 7 TROUBLESHOOTING amp MAINTENANCE SCR Testing 7 5 7 5 1 7 5 2 7 5 3 SCR Testing 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 e
100. dard BIST Tests 42 5 ede wee wed Re E S Pe be er See BA si e we 133 7 6 2 Powered BIST Teste J eedem ROAD eek RO GE UR lee 134 74 SCR Replacement WE MS ERG X Don Re Rat 136 771 Typical Stack Assembly 9 68 Aye EERO EHD REM DRANG COTA Oa d 136 222 OCR REMOVAL s rap a b k G ga wad oS td Doe qk EEE E IEEE 136 Installation 94 aa Ae upa ese A DD ap od E dod 136 714A SCR Clamp ss 4 uA a ede RR Rara eR hip A pr Ron DR ee ER pus 137 4 75 Tightening Clamps cce geen We bebe duo an O Og aqa p Ge Rey Basa a eee vn ded 137 7 6 Testing SCI 2 secu ase k seg E REP ad siehe Bhs d 0e Gries des 137 Modbus Tables http www benshaw com literature manuals index shtml Do not attempt to install operate maintain or inspect the starter until you have thoroughly read this manual and related documents carefully and can use the equipment correctly Do not use the starter until you have a full knowledge of the equipment safety procedures and instructions Always follow NFPA 70E guidelines Electrical Hazard that could result in injury or death Caution that could result
101. df P27 Preset Slow Speed CEN 21 LED Display LCD Display 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 Slow speed operation is commanded by programming one of the digital inputs to either Slow Speed Forward or Slow Speed Reverse Energizing the Slow Speed Input when the starter is in idle will initiate slow speed operation 47 5 PARAMETER DESCRIPTION 96 NOTE When the motor is operating at slow speeds its cooling capacity can be greatly reduced Although the Motor OL is active if not set to Off during slow speed operation it is recommended that the motor temperature be monitored when slow speed is used for long periods of time See Also Slow Speed Current Level P27 CFN 22 parameter on page 48 Slow Speed Time Limit P29 CFN 23 parameter on page 48 Digital Input Configuration P48 P50 I O 01 03 parameters on page 59 Relay Output Configuration P52 54 I O 05 07 parameters on page 60 Theory of Operations http www benshaw com literature manuals 890034 1 1 xx pdf P28 Preset Slow Speed Current Level 22 LED Display LCD Display Range 10 400 FLA Default 100 Description The Preset Slow Speed Current Level parameter selects the level of current applied to the motor during slow speed operation The parameter is set as a percentage of motor full load amps FLA This
102. e P47 PEN 17 parameter on page 58 Theory of Operations http www benshaw com literature manuals 890034 1 1 xx pdf Motor Overload Class Starting PEN 14 LCD Display Off 1 40 Default 10 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 overload and 100 representing a tripped overload The starting overload class is active during Kicking and Ramping when the Independent Starting Running Overload P44 PFN 13 parameter is set to On When the Motor Starting Overload Class parameter is set to Off the electronic overload is disabled while starting the motor 36 NOTE Care must be taken not to damage the motor when turning the starting overload class off or setting to a high value 96 NOTE Consult motor manufacturer data to determine the correct motor OL settings S PARAMETER DESCRIPTION See Also Motor Running Overload Class P3 QST 03 parameter on page 34 Independent Starting Running Overload P44 PFN 13 parameter on page 56 Motor Overload Hot Cold Ratio P46 PFN 16 parameter on page 57 Motor Overload Cooling Time P47 PFN 17 parameter on page 58 Relay Output Configuration P52 P54 I O 05 07 parameters on page 60 Theory of Operations http www benshaw com literature manuals 890034 1 1 xx pdf Motor Overload Cl
103. e Motor Overload Hot Cold Ratio parameter settings control the motor OL content If the motor overload content is above the steady state OL running level See section 6 1 6 Hot Cold Motor Overload Compensation for more details the motor OL exponentially cools to the appropriate steady state OL level When the motor is running the cooling time is adjusted based on the measured current level and current imbalance level at which the motor is operating Measured Running Current 1 Motor FLA Current Imbalance Derate Factor In all cases the running motor cooling time is shorter motor will cool faster than when the motor is stopped The faster cooling results because it is assumed that when a motor is running cooling air is being applied to the motor Emergency Motor Overload Reset The MX has an emergency motor overload reset feature that allows the user to override the overload starter lockout This resets the motor overload content to 0 It does not reset the overload fault To perform an emergency overload reset simultaneously press the RESET and DOWN buttons on the keypad An emergency overload reset may also be performed by applying 120 Volts to a digital input that is configured as an emergency overload reset input or by setting the emergency overload reset bit in the starter control Modbus register CAUTION This feature should only be used in an emergency Before an emergency reset is performed the cause of the motor overload
104. e Volts 11 12 Volts 9 L2 L3 Volts L3 L1 Volts Overload Power Factor E79 30196 40196 Meter kW hours MW hours Phase Order Line Freq Analog Input Analog Output Run Days Run Hours Starts TruTorque 96 Power P Peak Starting Current 8 Last Starting Duration Software Version 1 MEE Only 30601 40601 to Fault Log IFXX 9FXX 23 4 PARAMETER GROUPS LCD Display Parameters 4 4 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 Control Functions I O Input Output Functions PFN Protection Functions and FUN Function The Quick Start Group provides a collection of the parameters that are most commonly changed when commissioning a starter Many of the parameters in the Quick Start group are duplicates of the same parameters in other groups 2 F The MX incorporates a number of parameters that allow you to configure the starter to meet the special requirements of your particular application The parameters are divided into groups of related functionality and within the groups the parameters are identified by a short descriptive name They are numbered by the group name followed by an index within the group This chapter lists all o
105. e and Cathode connections to MX for loose connections Check for inline contactor or disconnect 129 7 TROUBLESHOOTING amp MAINTENANCE Fault Code Detailed Description of Fault Possible Solutions Shorted Open SCR Current at Stop Disconnect Fault Bypass 2M Contactor Fault Inline Contactor Fault Control Power Low F47 Stack Protection Fault stack thermal overload 130 A shorted or open SCR condition has been detected Verify that all SCR gate leads wires are properly connected at the SCR devices and the MX control card Check all SCRs with ohmmeter for shorts Verify that the Input Phase Sensitivity parameter setting P77 FUN04 is correct Verify that the Starter Type parameter setting P74 FUN07 is correct Verify the motor wiring Verify dual voltage motors for correct wiring configuration Motor current was detected while the starter was not running Examine starter for shorted SCRs Examine bypass contactor if present to verify that it is open when starter is stopped Verify that the motor FLA P1 QST01 and CT ratio P78 FUN03 settings are correct A signal on the disconnect digital input was not present when a start was commanded Verify that disconnect feedback wiring is correct Verify that the disconnect is not faulty The MX electronic power stack OL protection has detected an overload condition Check motor for jammed or overloaded condition Verify that the CT ratio
106. e deceleration is very easy to use with only two parameters to set Figure 23 TruTorque Deceleration Motor Torque Stop command Motor Torque Before Stop Command End Torque Level Time Decel Time Ending Level The Decel End Level parameter sets the ending torque level for the TruTorque deceleration ramp profile A typical TruTorque decel end level setting is between 10 and 20 Ifthe motor stops rotating before the deceleration time has expired increase this parameter value If the motor is still rotating when the deceleration time has expired decrease this parameter value Decel Time The decel time sets the ramp time between the motor torque level when stop was commanded and the decel end torque level If the motor stops rotating before the decel time has expired decrease the decel time parameter If the motor is still rotating when the decel time expires increase the decel time parameter 96 Braking Controls 6 THEORY OF OPERATION 6 5 Braking Controls Overview When the Stop Mode parameter is set to DC Brake the MX starter provides DC injection braking for fast and frictionless braking of a three phase motor The MX starter applies a controlled DC current to the motor in order to induce a stationary magnetic field that then exerts a braking torque on the motor s rotating rotor The braking current level and braking time required depends on the motor characteristics the load inertia and the fri
107. e memory 6 Factory Rst All parameters are restored to the factory defaults Std BIST Built In Self Test with no line voltage applied to the starter 8 Powered BIST Built In Self Test with line voltage applied to the starter The Miscellaneous Commands parameter is used to issue various commands to the Mx starter The Reset Run Time command resets the user run time meters back to zero 0 The Reset kWh command resets the accumulated kilowatt hour and megawatt hour meters back to zero 0 The Reflash Mode command puts the MX into reflash program memory mode The reflash mode can only be entered if the MX starter is idle When the reflash mode is entered the MX waits to be programmed The onboard LED display shows FLSH The remote display is disabled after entering reflash mode The MX does not operate normally until reflash mode is exited Reflash mode may be exited by cycling control power The Store Parameters command allows the user to copy the parameters into non volatile memory as a backup If changes are being made store the old set of parameters before any changes are made If the new settings do not work the old parameter values can be loaded back into memory The Load Parameters command loads the stored parameters into active memory The Factory Reset command restores all parameters to the factory defaults These can be found in chapter 5 The standard BIST command will put the starter into the unpowered BIST test See section 7
108. e operation Energized when no faults present de energized when faulted Default R1 Faulted Non Fail Safe operation Energized when faulted Running starter running voltage applied to motor Up to Speed motor up to speed or transition to for Wye Delta Operation Alarm any alarm condition present Ready starter ready for start command Locked Out Overcurrent Alarm overcurrent condition detected Undercurrent Alarm undercurrent condition detected Overload Alarm Shunt Trip Relay Fail Safe operation energized when no shunt trip fault present de energized on shunt trip fault Shunt Trip Relay Non Fail Safe operation de energized when no shunt trip fault present energized on shunt trip fault A Ground Fault trip has occurred Operating in Energy Saver Mode Motor Heating starter applying heating pulses to motor Starter operating in slow speed mode Starter operating in slow speed forward mode Starter operating in slow speed reverse mode Starter is applying DC brake current to motor Heatsink fan control I O parameters 1 3 configure which functions are performed by the R1 to R3 relays S PARAMETER DESCRIPTION See Also Up To Speed Time P9 QST 09 parameter on page 38 Over Current Level P32 PFN 01 parameter on page 50 Under Current Level P34 03 parameter on page 51 Residual Ground Fault Level P37 PFN 06 parameter on page 53 Inline Configuration P63 I O 16 parameter
109. e voltage ramp profile The Decel Begin Level parameter sets the initial or starting voltage level when transferring from running to deceleration The deceleration beginning level is not a precise percentage of actual line voltage but defines a point on the S curve deceleration profile A typical voltage decel begin level setting is between 30 and 40 If the motor initially surges oscillates when a stop is commanded decrease this parameter value If there is a sudden drop in motor speed when stop is commanded increase this parameter value Stop Mode P15 CFN14 set to TruTorque Deceleration Not used when the Stop Mode parameter is set to TruTorque Decel The TruTorque beginning deceleration level is automatically calculated based on the motor load at the time the stop command is given 96 NOTE It is important that the P75 FUN06 Rated Power Factor parameter is set properly so that the actual deceleration torque levels are the levels desired See Also Stop Mode P10 CFN 14 parameter on page 42 Decel End Level P17 CFN 16 parameter on page 43 Decel Time P18 CFN 17 parameter on page 44 Controlled Fault Stop Enable P43 PFN 12 parameter on page 55 Rated Power Factor P75 FUN 06 parameter on page 72 Theory of Operations http www benshaw com literature manuals 890034 1 1 xx pdf P17 Decel End Level 16 LED Display LCD Display Range 1 99 of phase angle firing Default 20 Descript
110. ed The motor and load may achieve full speed before the ramp time expires if the load does not require the set ramp time or set power level to reach full speed Alternately the motor and load may take longer than the set ramp time to achieve full speed depending on the parameter settings and load level 6 THEORY OF OPERATION 6 3 5 Open Loop Voltage Ramps and Times General Initial Voltage Ramp Time The open loop voltage ramp provides soft starting of a motor by increasing the voltage applied to motor from the Initial Voltage setting to full 100 line voltage The ramp time sets the speed at which the voltage is increased Because this is an open loop control profile the motor current during starting tends to be reduced however the current is not limited to any particular level This starting mode old is not commonly used except in special circumstances In most applications the use of one of the other closed loop starting profiles is recommended Figure 19 Voltage Ramp Voltage Full Voltage Start command Optional Kick Current Initial Voltage Time Kick Time 4 B4 Ramp Time This parameter sets the initial voltage level that is applied to the motor To adjust the starting voltage level give the starter a run command and observe the motor operation If the motor starts too quickly reduce the initial voltage level I
111. el won anome 995 o fe Off 0 20096 Curr 0 800 Curr 0 150 Volt 0 150 OL 0 10 kW I O 13 Aout Fctn Analog Output Function 0 100 kW Off 64 0 1MW 0 10MW 0 10096 Ain 0 100 Firing Calibration 1015 Analog Oupa 109 fo o fes 1016 tne Conte im Line Configuaion 001L0 100 secon 30 __ _ 6 Lor ex Tin Bypass 12M Contin 01050 _____ seconds 20 66 _ Keisuppis Keypad Sop Disable runa Disabled I O 19 Auto Start Power On Start Selection Disabled 67 Power and Fault 27 4 PARAMETER GROUPS 4 4 5 Function Group P ave Curent _ L1 Current L2 Current L3 Current Curr Imbal Ground Fault Ave Volts 11 12 Volts L2 L3 Volts L3 L1 Volts Overload Power Factor Watts bee 74 FUN 02 Meter 2 Meter 2 Vals Ave Volts kW hours MW hours Phase Order Line Freq Analog Input Analog Output Run Days Run Hours Starts TruTorque Power Pk Accel Cur Last Start T 72 1 96 1 144 1 288 1 864 1 2640 1 FUN 03 CT Ratio CT Ratio 3900 1 5760 1 288 1 73 8000 1 14400 1 28800 1 Insensitive ee ABC FUN 04 Phase Order Input Phase Sensitivity CBA Insens 13 Single Phase 100 110 120 200 208 220 230 240 350 380 400 415 RMS FUN 05 Rated Volts Rated RMS Voltage 440 460 480 500 Voltage 480 73 525 575 600 660 690 800 1000
112. emote source is used If no digital input is programmed as L r then the local remote bit in the Modbus starter control register selects the control source The default value of the bit is Local 0 Local Source P4 QST 04 parameter on page 35 Digital Input Configuration P45 P50 I O 01 I O 03 parameters on page 59 Keypad Stop Disable P65 I O 18 parameter on page 67 Communication Timeout P68 FUN 12 parameter on page 69 Communication Baud Rate P69 FUN 11 parameter on page 69 Communication Address P70 FUN 10 parameter on page 69 For Modbus Register Map http www benshaw com literature manuals 890034 1 1 xx pdf Figure 11 Local Remote Source Local Source Keypad Terminal L Serial v Start Source Remote Source Keypad Terminal sess L r Input DI1 DI3 Serial configured by Parameter P48 P49 P50 1 001 1 002 1 003 ies Modbus Starter Control Register Local Remote Bit P6 LED Display Range Description See Also P7 LED Display Range Description See Also S PARAMETER DESCRIPTION Initial Motor Current 1 OST 06 CEN 03 LCD Display 50 600 of FLA Default 100 The Initial Motor Current 1 parameter is set as a percentage of the Motor FLA P1 QST 01 parameter setting The Initial Current 1 parameter sets the current that is initially supplied to the motor when a start is commanded The initial current should be set to the level that allo
113. er starts If the motor can be started by using the default TruTorque acceleration parameter values or another ramp profile the Maximum Torque level can be determined more precisely so that the motor comes up to speed in approximately the preset ramp time In this case while the motor is running fully loaded display the TruTorque percent TT meter on the display Record the value displayed The Maximum Torque level should then be set to the recorded full load value of TT plus an additional 10 Restart the motor with this value to verify correct operation 3 NOTE When setting the Maximum Torque value the motor must be monitored to ensure that the torque level is high enough to allow the motor to reach full speed under worst case load conditions 3 NOTE Depending on loading the motor many achieve full speed at any time during the TruTorque ramp This means that the Maximum Torque level many never be achieved Therefore the maximum torque level is the maximum TruTorque level that is permitted However the motor torque may not necessarily reach this value during all starts When in TruTorque acceleration mode the ramp time setting is the time it takes for the torque to go from the initial torque setting to the maximum torque setting To make the motor accelerate faster decrease the ramp time To make the motor accelerate slower increase the ramp time If the ramp time expires before the motor reaches full speed the starter maintains the
114. ering not CT ratio parameter P78 FUNO3 set Verify that the CT ratio parameter is set reading correctly incorrectly 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 124 7 TROUBLESHOOTING amp MAINTENANCE 7 3 7 Other Situations 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 Motor Overheats Motor overloaded Reduce motor load Too many starts per hour Allow for adequate motor cooling between starts Set Hot Cold ratio higher or lengthen cooling time High ambient temperature Reduce ambient temperature or provide for better cooling Set OL class lower to compensate for ambient temperature Acceleration time too long Reduce starting load and or review acceleration ramp settings Incorrect motor OL settings Review and correct motor OL settings Motor cooling obstructed damaged Remove cooling air obstructions Check motor cooling fan Starter cooling fans do not operate Fan power supply lost Verify fan power supply check fuses When Present Fan wiring problem Check fan wiring Analog Output not functioning properly Voltage Current output switch S WI 2 Set switch SWI to
115. evel PEN 07 LED Display LCD Display Range Off 1 40 Default Off 53 5 PARAMETER DESCRIPTION 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 The delay time must expire before the starter faults The over voltage condition and the phase is displayed 36 NOTE For the over voltage protection to operate correctly the rated voltage parameter P76 FUN05 must be set correctly 96 NOTE The voltage level is only checked when the starter is running See Also Under Voltage Level P39 PFN 08 parameter on page 54 Voltage Trip Time P40 PFN 09 parameter on page 54 Auto Reset Limit P42 PEN 11 parameter on page 55 Controlled Fault Stop Enable P43 PFN 12 parameter on page 55 Rated Voltage P76 FUN 05 parameter on page 73 Theory of Operations http www benshaw com literature manuals 890034 1 1 xx pdf P39 Under Voltage Trip Level 08 LED Display LCD Display Range Off 1 40 Default Off Description If the detects a cycle input phase voltage that is below the Under Voltage Trip Level the over under voltage alarm is shown and the voltage trip timer begins counting The delay time must expire before the starter faults The under voltage condition and the phase is displayed 3 NOTE For the under voltage protection to operate correctly the
116. f the motor does not start rotating immediately or starts too slowly then increase the initial voltage level until the motor just starts to rotate when a start command is given If the initial voltage level is set too low a Fault 39 No Current at Run may occur In this case increase the initial voltage level to permit more current to initially flow to the motor The ramp time setting is the time that it takes for the applied voltage to go from the initial voltage level to the full voltage 100 level To make the motor accelerate faster decrease the ramp time To make the motor accelerate slower increase the ramp time 91 6 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 If a surge occurs near the end of the ramp set the UTS timer to expire at this time and restart the motor If the surge still occurs set the UTS time to a lower time until the surging subsides If motor surging continues to be a problem it is recommended that one of the other standard MX closed loop starting profiles be used Figure 20 Effect of UTS Timer on Voltage Ramp Voltage Full Voltage 4 command Optional Kick Current Initial Voltage
117. f the parameters and their possible values The following shows the menu structure for the LCD display as well as the text that is displayed for the parameters on the display 4 4 1 Quick Start Group gstor MotrFLA MotorFLA 1 to 6400 KUYEEEECWKEEEI Amps QST 03 Running OL Motor Overload Class Running Off 1 to 40 35 Terminal e Terminal Pastor MaxmumMerCummi 100800 oo 24 4 PARAMETER GROUPS 4 4 2 Control Function Group Voltage Ramp 01 Start Mode Start Mode Current Ramp Current Ramp 39 TT Ramp Power Ramp CFN 02 Ramp Time 1 Ramp Time 1 0 to 300 CFN 03 Initial Motor Current 1 50 to 600 FLA CFN 04 Maximum Motor Current 1 100 to 800 FLA w CFN 06 Initial Motor Current 2 50 to 600 FLA 25 0 0 CEN 13 Kick Time 2 Kick Time 2 0 1 to 10 0 0 0 Coast Volt Decel CEN 14 Stop Mode Stop Mode TT Decel DC Brake CEN 05 Ramp Time 2 Ramp Time 2 0 to 300 15 0 0 0 CEN 22 SSpd Curr Slow Speed Current Level 10 to 400 23 SSpd Timer Slow Speed Time Limit Off 1 to 900 CEN 25 SSpd Kick T Slow Speed Kick Time 0 1 to 10 0 CEN 07 Maximum Motor Current 2 100 to 800 FLA 60 46 iti 40 gt RY gt 5 gt I gt gt gt gt MC C nm gt N gt 25 4 PARAMETER GROUPS 4 4 3 Protection Group
118. fied using a DC voltage meter or oscilloscope The voltage on each red and white wire pair should be between 0 5VDC and 2 0VDC LED Display LCD Display BIST Mode b 96 gate 6 on Gate 6 On b 93 gate 3 on Gate 3 On b 95 gate 5 on Gate 5 On b 92 gate 2 on Gate 2 On b 94 gate 4 on Gate 4 On b 91 gate on Gate 1 On Step 5 Simultaneous SCR gate firing In this test the SCR gate outputs are simultaneously fired all gates on This test can be used to verify that the SCR gate leads are connected properly The gate voltage can be verified using a DC voltage meter or oscilloscope The voltage on each red and white wire pair should be between 0 5VDC and 2 0VDC Pressing ENTER on the keypad at any time will abort the current test in progress and proceed to the next BIST test During the standard BIST tests if line voltage or phase current is detected the will immediately exit BIST mode and declare a BIST Abnormal Exit fault LED Display LCD Display b 9A all gates on All Gates On Step 6 LED Display LCD Display b tests completed Tests completed 7 6 2 Powered BIST Tests P67 8 FUN 15 Powered BIST The powered BIST tests are designed to be run with normal line voltage applied to the starter and a motor connected Powered BIST verifies that the power poles are good no ground faults exist CTs are connected and positioned correctly and that the motor is connected Powered BIST mode can be entered by
119. he form BICTxxx1M where xxx is the CT primary and the 1 indicates the normalized 1 amp 36 NOTE It is very important that the CT ratio is set correctly Otherwise many starter functions will not operate correctly Refer to Table 1 CT Ratios on page 6 P79 Meter1 Meter 2 FUN 01 02 LED Display LCD Display Range LED LCD Description Status Running State LED meter only Default LED meter Ave Current Average current Default LCD Meter 1 L1 Current Current in phase 1 3 L2 Current Current in phase 2 4 L3 Current Current in phase 3 5 Curr Imbal Current Imbalance 6 Ground Fault Residual Ground Fault FLA 7 Ave Volts Average Voltage L L RMS Default LCD Meter 2 8 11 12 Volts Voltage in L1 to L2 RMS q L2 L3 Volts Voltage in L2 to L3 RMS 0 L3 L1 Volts Voltage in L3 to LI RMS Overload Thermal overload in e Power Factor Motor power factor 3 Watts Motor real power consumed Motor apparent power consumed 5 vars Motor reactive power consumer 6 kW hours Kilo watt hour used by the motor wraps at 1 000 1 MW hours Mega watt hour used by the motor wraps at 10 000 8 Phase Order Phase Rotation 9 Line Freq Line Frequency eu Analog In Analog Input 96 cl Analog Out Analog Output ee Run Days Running time in days wraps at 2 730 days Run Hours Running time in Hours and Minutes wraps at 24 00 Starts Number of Starts wraps at 65 536 co TruTorque TruTorque co Power Power Al
120. he sensor measures both the applied DC current from the starter as well as the freewheel current The sensor is connected to the analog input of the card along with a burden resistor The analog input must be set to be a 0 10V voltage input for correct operation The sensor scaling and burden resistance are factory selected Please consult factory if changes to either the sensor scaling or burden resistance is required D 4 24VDC 30W POWER SUPPLY GND S82K 03024 5 5 N v 5 24VDC 30W POWER SUPPLY GND S82K 03024 6 6 N v TB5 2 AN POWER E 7 n i 0 24 5 RESISTOR A 3 S L com 6 7 4 5 aout 5 I T1 DVE e 94 COM e 2 gt 5000 1 LEM SHIELD 7 12 LT 2005 S gt e 3 gt 2 T3 e 36 NOTE Hall effect current sensor must be used when load inertia exceeds motor manufactures recommended specifications 101 6 THEORY OF OPERATION 6 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 If the motor is braking too fast the level should be reduced If the motor is not braking fast enough the level shou
121. hould be less than 300mV If greater that 300mV the integral bypass should be disassembled It may be necessary to clean the contact tips or replace the contactor 132 7 TROUBLESHOOTING amp MAINTENANCE Built In Self Test Functions 7 6 7 6 1 Built In Self Test Functions The MX has two built in self test BIST modes The first test is the standard self test and is used to test many of the basic functions of the starter without line voltage being applied The second test is a line powered test that is used to verify the current transformer s locations and connections and to test for shorted SCRs power poles open or non firing SCRs power poles and ground fault conditions Standard BIST Tests P67 7 FUN 15 Std BIST N N The standard BIST tests are designed to be run with no line voltage applied to the starter In selected low voltage systems where a disconnect switch is used the Disconnect Switch must be opened before starting the standard tests Standard BIST mode can be initiated by entering the appropriate value into P67 or FUN 15 Misc Command user parameter CAUTION In order to prevent back feeding of voltage through the control power transformer if used control power must be carefully applied to the MX control and contactors so that self testing can occur safely In low voltage applications the user must verify that the applied test control power cannot be fed backwards through the system Run
122. ify correct CT wiring and verify that the CTs are installed with all the White dots towards the input line side CTI LI CT2 L2 CT3 L3 CT ratio parameter P78 FUNO3 set Verify that the CT ratio parameter is set incorrectly correctly PF Meter 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 Motor Current or Voltage meters Energy Saver active Turn off Energy Saver if not desired fluctuating with steady load Loose connections Shut off all power and check all connections SCR fault Verify that the SCRs gate leads are connected properly and the SCRs are ok Load actually is not steady Verify that the load is actually steady and that there are not mechanical issues Other equipment on same power feed Fix cause of power fluctuations and or causing power fluctuations and or distortion distortion Voltage Metering not reading correctly In medium voltage systems Rated Verify that Rated Voltage parameter is Voltage parameter P76 FUNO5 set set correctly incorrectly Current Metering not reading correctly CT ratio parameter P78 FUNO3 set Verify that the CT ratio parameter is set incorrectly 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 Ground Fault Current Met
123. imer is set the starter will declare an up to speed fault every time a start is attempted 3 NOTE When the Start Mode P10 01 parameter is set to Voltage Ramp the UTS timer acts as an acceleration kick When the UTS timer expires full voltage is applied to the motor This feature can be used to reduce motor oscillations if they occur near the end of an open loop voltage ramp start 38 See Also S PARAMETER DESCRIPTION 3 NOTE When the Starter Type P74 FUN 07 parameter is set to Wye Delta the UTS timer is used as the transition timer When the UTS timer expires the transition from Wye starting mode to Delta running mode takes place if it has not already occurred Fault Code 01 Up to Speed Fault is declared when a stalled motor condition is detected Ramp Time 1 P8 QST 08 parameter on page 38 Start Mode P10 CFN 01 parameter on page 39 Kick Time 1 P14 11 parameter on page 41 Ramp Time 2 P24 CFN 05 parameter on page 46 Kick Time 2 P26 CFN 13 parameter on page 47 Starter Type P74 FUN 07 parameter on page 72 Jump to Parameter CEN 00 By changing the value of this parameter and pressing ENTER you can jump directly to any parameter within that group P10 LED Display Range Description See Also Start Mode CEN 01 LCD Display LED LCD Description oLrP X Voltage Ramp Open Loop Voltage acceleration ramp curr Current Ramp Current control acceleration ramp
124. ingle Phase Soft Starter euo m RR UR Reg Ro AG oko 110 6 11 Phase Control ss 44 2246 ch ceno m X Roper RO PO ROAD RHEE EE EOE 111 6 11 21 Phase Controller site p uy Ee ri Roe opos eter qe np OR d Ee ER deb eere a 111 6 11 2 Master Slave Starter Configuration s u 2 112 612 Current Followert acca ba uec BA ox cR A Rex EUR Mose ox dab Ode de 322 113 6 13 Start Stop Control with a Hand Off Auto Selector Switch 114 6 14 Simplified I O Schematics Uu ul u sc w Rr m oko on 115 6 15 Remote Modbus Communications ee 116 6 15 1 Supported Commands 4 zu Haren ks ER ESOS Fu per 6 E FER 2 6 6 116 6 15 2 Modbus Register Addresses 2 eh heh tn 116 61153 Cable Specifications gt gt boe dor ES ew or gh e 116 Terminating Resistors 5 uyu zu pans Ep RUE Ao 6 ae HER 116 615 5 Grounding oe Y Gd Qh vsque es 116 6 15 6 Shielding Ls ene Rub eet sa 116 615 7 Wiring haee RR 8 Sa s 0 UR ee Roc N 117 7 TROUBLESHOOTING amp MAINTENANCE eee nn 120 7 1 Safety PECCAUHONS td Sr te dd k 120 7 2 Preventative Maintenance s 2 4 4 4 0 vndc x rose ed xus b id ates t
125. ion 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 The deceleration ending level is not a precise percentage of actual line voltage but defines an ending point on the S curve deceleration profile A typical voltage decel end level setting is between 10 and 20 If the motor stops rotating before the deceleration time has expired increase this parameter value If the motor is still rotating when the deceleration time has expired decrease this parameter value If the value is set too low a Current at Run fault may occur during deceleration 36 NOTE The deceleration end level cannot be set greater than the decel begin level Stop Mode P15 CFN14 set to TruTorque Deceleration The decel end level parameter sets the ending torque level for the TruTorque deceleration ramp profile A typical TruTorque decel end level setting is between 10 and 20 If the motor stops rotating before the deceleration time has expired increase this parameter value If the motor is still rotating when the deceleration time has expired decrease this parameter value 43 5 PARAMETER DESCRIPTION See Also Stop Mode P15 CFN 14 parameter on page 42 Decel Begin Level P16 15 parameter on page 43 Decel Time P18 CFN 17 parameter on page 44 Con
126. is test will always pass 96 NOTE If the Inline Config 16 parameter on page 66 is set to Off this test will be skipped LED Display LCD Display BIST Mode b ic inline closed Inline Closed b io inline open Inline Open Step 3 UTS relay test and Bypass Feedback Test In this test the dedicated bypass relay 1f assigned and the UTS assigned relays are cycled on and off once and the feedback from a bypass contactor is verified In order to have a valid bypass contactor feedback the individual bypass input and any other inputs set to Bypass Confirm input needs to be wired to an auxiliary contact of the bypass contactor The feedback is checked in both the open and closed state If the feedback does not match the state of the UTS relay within the amount of time set by the Bypass Feedback parameter a Bypass 2M Fault will occur 133 7 TROUBLESHOOTING amp MAINTENANCE 3 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 LED Display LCD Display BIST Mode b be bypass closed Bypass Closed b bo bypass open Bypass Open Step 4 Sequential SCR gate firing L1 L1 L2 L2 L3 L3 In this test the SCR gate outputs are sequentially fired starting with the L1 device s and ending with the L3 device s This test can be used to verify that the SCR gate leads are connected properly In LV systems the gate voltage can be veri
127. iscretion must be used when setting up the DC Brake Level Motor heating during DC braking is similar to motor heating during starting Even though the Motor OL is active if not set to Off during DC injection braking excessive motor heating could still result if the load inertia is large or the brake level is set too high Caution must be used to assure that the motor has the thermal capacity to handle braking the desired load in the desired period of time without excessive heating 96 NOTE Consult motor manufacturer for high inertia applications 36 NOTE Not to be used as an emergency stop When motor braking is required even during a power outage an Electro mechanical brake must be used See Also Stop Mode P15 CFN 14 parameter on page 42 DC Brake Time P20 CFN 19 parameter on page 45 DC Brake Delay P21 20 parameter on page 45 Controlled Fault Stop Enable P43 PFN 12 parameter on page 55 Digital Input P48 50 I O 01 03 parameters on page 59 Theory of Operations http www benshaw com literature manuals 890034 1 1 xx pdf P20 DC Brake Time 19 LED Display LCD Display 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 The required brake time is determined by the combination of the system inertia system friction and the desired braking level If the motor is sti
128. ity Although the Motor OL is active if it has not been intentionally disabled during slow speed operation it is recommended that the motor temperature be monitored if slow speed is used for long periods of time 102 6 THEORY OF OPERATION 6 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 The parameter is set as a percentage of motor full load amps FLA This value should be set to the lowest possible current level that will properly operate the motor Slow Speed Time Limit The Slow Speed Time Limits parameter sets the amount of time that continuous operation of slow speed may take place When this parameter is set to OFF the timer is disabled This parameter can be used to limit the amount of continuous slow speed operation to protect the motor and or load 3 NOTE The Slow Speed Time Limit includes the time used for the Slow Speed Kick if kick is enabled 3 NOTE The Slow Speed Time Limit resets when the motor is stopped This timer does not prevent the operator from stopping and re starting the motor which can result in the slow speed operation time of the motor being exceeded Slow Speed Kick Level The Slow Speed Kick Level sets the short ter
129. ivision 1 Jetway Court Pueblo CO 81001 Phone 719 948 1405 Fax 719 948 1445 Technical support for the RediStart Mx Series is available at no charge by contacting Benshaw s customer service department at one of the above telephone numbers A service technician is available Monday through Friday from 8 00 a m to 5 00 p m EST 85 NOTE An on call technician is available after normal business hours and on weekends by calling Benshaw and following the recorded instructions To help assure prompt and accurate service please have the following information available when ontacting Benshaw Name of Company Telephone number where the caller can be contacted Fax number of caller Benshaw product name Benshaw model number Benshaw serial number Name of product distributor Approximate date of purchase Voltage of motor attached to Benshaw product FLA of motor attached to Benshaw product A brief description of the application 1 INTRODUCTION NOTES 2 Technical Specifications 2 TECHNICAL SPECIFICATIONS Technical Specifications 2 0 1 CT Ratios Table 1 CT Ratios Minimum FLA Maximum FLA 72 1 4 16 4 wraps 288 1 96 1 144 1 14400 1 CT CT combination T 28800 1 CT CT combination we Starter Power Ratings 2 0 2 Standard Duty 350 for 30 sec Ratings 96 NOTE Do not exceed Class 10 overload setting 2 0 3 Heavy Duty 500 current for 30 sec Ratings 3 NOTE Do not exceed
130. l energize The over current timer starts a delay time If the over current still exists when the delay timer expires the starter Over Current Trips F31 and any relay programmed as fault relay changes state The Over Current Trip is only active in the UTS state Energy Saver state Current follower or while in the Phase Control mode A relay can be programmed to change state when an over current alarm condition is detected Alarm Felt Current Condition Tup 1 Over Cur Lvl 01 P32 Motor FLA QST 01 P1 Time Delay PFN 02 P33 Over Current Time P33 PFN 02 parameter on page 50 Auto Reset Limit P42 PFN 11 parameter on page 55 Controlled Fault Stop Enable P43 PFN 12 parameter on page 55 Relay Output Configuration P52 P54 I O 05 07 parameters on page 60 http www benshaw com literature manuals 890034 1 1 xx pdf Over Current Trip Delay Time 02 LCD Display Off 0 1 90 0 seconds Default 0 1 The Over Current Trip Delay Time parameter sets the period of time that the motor current must be greater than the Over Current Level P32 PFN 01 parameter before an over current fault and trip occurs If Off is selected the over current timer does not operate and the starter does not trip It energizes any relay 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 5 PARA
131. l is available on line at http www benshaw com Replacement Parts Spare and replacement parts can be purchased from Benshaw Technical Support Software Number This manual pertains to the software version numbers 810023 01 02 Hardware Number This manual pertains to the hardware version numbers 300055 01 04 Warranty Benshaw provides a 3 year standard warranty with its starters All recommended maintenance procedures must be followed throughout the warranty period to ensure validity This information is also available by going online to register at www benshaw com 1 INTRODUCTION Contacting Benshaw Contacting Benshaw following offices Benshaw Inc Corporate Headquarters 1659 E Sutter Road Glenshaw PA 15116 Phone 412 487 8235 Tech Support 800 203 2416 Fax 412 487 4201 Benshaw Canada Controls Inc 550 Bright Street East Listowel Ontario N4W 3W3 Phone 519 291 5112 Tech Support 877 236 7429 BEN SHAW Fax 519 291 2595 Benshaw West 14715 North 78th Way Suite 600 Scottsdale AZ 85260 Phone 480 905 0601 Fax 480 905 0757 Information about Benshaw products and services is available by contacting Benshaw at one of the Benshaw High Point EPC Division 645 McWay Drive High Point NC 27263 Phone 336 434 4445 Fax 336 434 9682 Benshaw Mobile CSD Division 5821 Rangeline Road Suite 202 Theodor AL 36582 Phone 251 443 5911 Fax 251 443 5966 Benshaw Pueblo Trane D
132. ld be increased Brake Time The DC Brake Time parameter sets the time that DC current is applied to the motor The desired brake time is determined by the combination of the system inertia system friction and the desired braking level If the motor is still rotating faster than desired at the end of the brake time increase the brake time if possible If the motor stops before the desired brake time has expired decrease the brake time to minimize unnecessary motor heating Brake Delay The DC Brake Delay Time is the time delay between when a stop is commanded and the DC braking current is applied to the motor This delay allows the residual magnetic field and motor counter EMF to decay before applying the DC braking current If a large surge of current is detected when DC braking is first engaged increase the delay time If the delay before the braking action begins is too long then decrease the delay time In general low horsepower motors can utilize shorter delays while large horsepower motor may require longer delays Slow Speed Cyclo Converter 6 6 6 6 1 Slow Speed Cyclo Converter The MX Soft Starter implements a patented Slow Speed algorithm that can be used to rotate a three phase AC motor with control of the stator current at speeds less than the rated synchronous speed of the motor The algorithm is used with a standard three phase six switch SCR based soft starter The advantages of the MX starter algorithm over other jogging
133. leration Control 4 Deceleration Control 5 Braking Control 6 Slow Speed Cyclo Converter 7 Inside Delta Connected Starter 8 Wye Delta Starter 9 Across the Line Starter 10 Single Phase Soft Starter 11 Phase Control 12 Current Follower 13 Stop Start Control with a Hand Off Auto Selector Switch 14 Simplified I O Schematics 15 Remote Modbus Communications Modbus Register Map For details refer to http www benshaw com literature manuals 890034 11 xx pdf Parameter Name MMM LED Display LCD Display Range Parameter Value Default Constant OR LED LCD EEE Keypad Description The description of the function See Also Cross references to related parameters or other chapters 32 S PARAMETER DESCRIPTION In the above format the header box for the parameter contains the P number as it appears in the menu on the LED display the parameter name and the parameter group number as it appears in the menu on the LCD display The LCD Display section shows an example of what actually appears on the remote mounted keypad The LED display shows an example of what actually appears on the built in display The parameter group represented above by MMM and the possibly abbreviated parameter name are shown on the first line The parameter group number represented above by MI for menu index and the parameter s value and units are shown on the second line Some parameters appear in two different me
134. lied to motors resistive heaters etc When in Phase Control mode the phase angle of the SCRs and hence the voltage applied is directly controlled based on the analog input signal The MX reference command can be generated from any 0 10V 0 20mA or similar source such as a potentiometer another MX or an external controller such as PLC 111 6 THEORY OF OPERATION 6 11 2 Master Slave Starter Configuration In the master slave configuration one master starter can directly control the output of one or more slave starters To utilize the master slave configuration one starter needs to be defined as the master starter The Starter Type parameter of the master starter should be configured appropriately as a Soft Starter normal or ID Phase Controller or Current Follower If configured as a soft starter the acceleration and deceleration profiles need to be configured for proper operation To configure a master slave application 1 The analog output of the master MX control card needs to be connected to the analog input s of the slave card s 2 The master MX s analog output needs to be configured Set the Analog Output Function parameter to option 10 or 0 100 firing The Analog Output Span parameter should be set to provide a 0 10V or 0 20 milliamp output to the slave starter s Adjust analog output jumper JP1 to provide either a voltage or a current output Set the slave MX Starter Type parameter to Phase Co
135. ll rotating faster than desired at the end of the brake time increase the brake time if possible If the motor stops before the desired brake time has expired decrease the brake time to minimize unnecessary motor heating See Also Motor Running Overload Class P3 QST 03 parameter on page 34 Stop Mode P15 CFN 14 parameter on page 42 DC Brake Level P19 CEN 18 parameter on page 44 DC Brake Delay P21 CEN 20 parameter on page 45 Controlled Fault Stop Enable P43 PFN 12 parameter on page 55 Theory of Operations http www benshaw com literature manuals 890034 1 1 xx pdf P21 DC Brake Delay CEN 20 LED Display LCD Display 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 This delay allows the residual 45 5 PARAMETER DESCRIPTION See Also P22 LED Display Range Description See Also P23 LED Display Range Description See Also P24 LED Display Range Description 46 magnetic field and motor counter EMF to decay before applying the DC braking current Ifa large surge of current is detected when DC braking is first engaged increase the delay time Ifthe delay before the braking action begins is too long then decrease the delay time In general low horsepower motors can utilize shorter delays while l
136. log Input Span P58 I O 11 parameter on page 62 Analog Input Offset P59 I O 12 parameter on page 63 Starter Type P74 FUN 07 parameter on page 72 Theory of Operations http www benshaw com literature manuals 890034 1 1 xx pdf P56 Analog Input Trip Level I O 09 LED Display LCD Display Range 0 100 Default 50 Description The Analog Input Trip Level parameter sets the analog input trip or fault level This feature can be used to detect an open 4 20mA loop by setting the parameter to Low and setting the parameter to a value less than lt 20 36 NOTE The analog input trip level is NOT affected by the Analog Input Offset or Analog Input Span parameter settings Therefore if the trip level is set to 10 and the Analog Input Trip Type P55 I O 08 parameter is set to Low a fault occurs when the analog input signal level is less than lt or 2mA regardless of what the Analog Input and Analog Input Span parameters values are set to 61 5 PARAMETER DESCRIPTION See Also Analog Input Trip Type P55 I O 08 parameter on page 61 Analog Input Trip Level P56 09 parameter page 61 Analog Input Span P58 I O 11 parameter on page 62 Analog Input Offset P59 T O 12 parameter on page 63 Theory of Operations http www benshaw com literature manuals 890034 1 1 xx pdf P57 Analog Input Trip Delay Time I O 10 LED Display LCD Display Range 0 1 90 0 seconds Default 0 1
137. lt and the Ready relay function If the Inline Configuration parameter is set to Off then the MX assumes that there is no Inline contactor and that line voltage should be present while stopped If no line is detected then a No Line alarm condition exists and the ready condition does not exist If a start is commanded then a No Line fault is declared If the Inline Configuration parameter is set to a time delay then the MX assumes that there is an Inline contactor and that line voltage need not be present while stopped If no line is detected then the No Line alarm condition does not exist and the ready condition does exist If a start is commanded and there is no detected line voltage for the time period defined by this parameter then noL No Line fault is declared In order to control an inline contactor program a relay as a Run relay 3 NOTE This fault is different than over under voltage trip delay time P40 PFN 09 since it detects the presence of NO line Relay Output Configuration P52 54 I O 05 07 parameters on page 60 Theory of Operations http www benshaw com literature manuals 890034 1 1 xx pdf Bypass 2M Feedback Time I O 17 LCD Display 0 1 5 0 seconds Default 2 0 sec The starter contains a built in dedicated bypass feedback input that is enabled when the dedicated stack relay is factory programmed to bypass The programmable inputs DI 1 DI 2 or DI 3 may also be used to monitor
138. m current level that is applied to the motor to accelerate the motor for slow speed operation The Slow Speed Kick feature is disabled if it is set to off Slow Speed Kick can be used to break loose difficult to start loads while keeping the operating slow speed current level lower This parameter should be set to a midrange value and then the Slow Speed Kick Time should be increased in 0 1 second intervals until the kick is applied long enough to start the motor rotating If the motor does not start rotating with the set Slow Speed Kick Level increase the level and begin adjusting the kick time from 1 0 seconds again If the motor initially accelerates too fast then reduce the Slow Speed Kick Level and or reduce the Slow Speed Kick Time Slow Speed Kick Time The Slow Speed Kick Time parameter sets the length of time that the Slow Speed Kick current level is applied to the motor at the beginning of slow speed operation After the Slow Speed Kick Level is set the Slow Speed Kick Time should be adjusted so that the motor starts rotating when a slow speed command is given If the motor initially accelerates too fast then reduce the Slow Speed Kick Level and or reduce the Slow Speed Kick Time 103 6 THEORY OF OPERATION Inside Delta Connected Starter 6 7 6 7 1 Inside Delta Connected Starter There are differences between a line connected soft starter as shown in Figure 26 and the inside delta connected soft starter as shown in Figu
139. mal overload trips 36 NOTE Setting the ramp time to a specific value does not necessarily mean that the motor will take this time to accelerate to full speed The motor and load may achieve full speed before the ramp time expires if the application does not require the set ramp time and maximum current to reach full speed Alternatively the motor and load may take longer than the set ramp time to achieve full speed See Also Initial Current 1 P6 QST 06 parameter on page 37 Maximum Current 1 P7 QST 07 parameter on page 37 Up To Speed Time P9 QST 09 parameter on page 38 Start Mode P10 CEN 01 parameter on page 39 Kick Level 1 P13 10 parameter on page 41 Kick Time 1 P14 CFN 11 parameter on page 41 P9 Up To Speed Time QST 09 LED Display LCD Display Range 1 900 Seconds Default 20 Description The Up To Speed Time parameter sets the maximum acceleration time to full speed that the motor can take A stalled motor condition is detected if the motor does not get up to speed before the up to speed timer expires The motor is considered up to speed once the current stabilizes below 175 percent of the FLA value and the ramp time expires 3 NOTE During normal acceleration ramps the up to speed timer has to be greater than the sum of the highest ramp time in use and the kick time The up to speed timer does not automatically change to be greater than the ramp time If a ramp time greater than the up to speed t
140. me motors are very sensitive to the adjustment of this parameter If a 5 adjustment changes the motor from hunting to dropping in speed then a smaller change of 1 or 2 may be necessary Ending Level This sets the final voltage for the deceleration ramp In most cases this parameter can be set to 10 and the decel time can be used to adjust the deceleration rate If the motor is coming to a stop too quickly or if the starter continues to apply current to the motor after the motor has stopped this parameter can be increased in 5 increments to fix this Decel Time The decel time sets how quickly the motor decelerates Usually a time of 30 seconds is a good starting point To make the motor take longer to decelerate increase this parameter or to make the motor decelerate quicker decrease this parameter 3 NOTE Deceleration control provides a smoother stop However the motor will take longer to stop than if it was just allowed to coast to stop 6 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 95 6 THEORY OF OPERATION hammer must be eliminated The MX linearly reduces the motor s torque to smoothly decelerate the motor and load TruTorqu
141. meter on page 55 P42 Auto Fault Reset Count Limit PEN 11 LED Display LCD Display Range Off 1 10 Default Off Description The Auto Fault Reset Count Limit parameter sets the number of times that an auto reset may occur Once the Auto Reset Limit is reached faults will no longer be automatically reset See Also Auto Fault Reset Time P41 PFN 10 parameter on page 55 P43 Controlled Fault Stop Enable PEN 12 LED Display LCD Display Range Off On Default On Description A Controlled Fault Stop Enable can occur if this parameter is On The controlled stop will occur before the starter trips During a controlled fault stop the action selected by the Stop Mode parameter is performed before the starter is tripped This prevents the occurrence of water hammer etc in sensitive systems when a less than fatal fault occurs 96 NOTE All relays except the UTS relay are held in their present state until the stop mode action has been completed 96 NOTE Only certain faults can initiate a controlled fault stop Some faults are considered too critical and cause the starter to stop immediately regardless of the Controlled Fault Stop Enable parameter Refer to Appendix B Fault Codes to determine if a fault may perform a controlled stop See Also Stop Mode P15 14 parameter on page 42 55 5 PARAMETER DESCRIPTION P44 LED Display Range Description See Also P45 LED Display Range Description
142. nder Voltage Trip delay time 9 Verify that the actual input voltage level is correct Verify that the Rated Voltage parameter P76 FUNOS is set correctly Check input supply for open fuses or open connections On medium voltage systems verify wiring of the voltage feedback measurement circuit Low Line L3 L1 Low voltage below the Under voltage Trip Level parameter setting P39 PFNO8 was detected for longer than the Over Under Voltage Trip delay time P40 PFNO09 Verify that the actual input voltage level is correct Verify that the Rated Voltage parameter P76 FUNOS5 is set correctly Check input supply for open fuses or open connections On medium voltage systems verify wiring of the voltage feedback measurement circuit 127 F21 Low Line L1 L2 Low voltage below the Under voltage Trip Level parameter setting P39 PFNO8 was detected for longer than the Over Under Voltage Trip delay time 9 Verify that the actual input voltage level is correct Verify that the Rated Voltage parameter P76 FUNOS5 is set correctly Check input supply for open fuses or open connections On medium voltage systems verify wiring of the voltage measurement circuit 7 TROUBLESHOOTING amp MAINTENANCE Fault Code Detailed Description of Fault Possible Solutions High Line L2 L3 High voltage above the Over voltage Trip Level parameter setting P38 PFNO7 was detected for longer than the Over Under Voltage Trip dela
143. ng Figure 15 Figure 15 Motor Cooling While Stopped Curves MX Motor OL Cooling Motor Stopped 100 90 80 70 60 50 40 Remaining OL Content ELLE 20 0 200 400 600 800 1000 1200 1400 1600 1800 2000 Time sec 6 THEORY OF OPERATION 6 1 9 6 1 10 Cooling Time Running Cooling Time Stopped 84 If the motor manufacturer does not specify the motor cooling time the following approximations for standard TEFC cast iron motors based on frame size can be used Frame Size Cooling Time 189 30 min oe 60 min 300 90 min 400 440 120 min 500 180 min Larger frames Consult Manufacturer For motors less than 300hp another approximation based on allowable motor starts per hour can also be used to set an initial value of the Motor Overload Cooling Time parameter 60 minutes Motor Cooling Time minutes Starts per hour The Motor Overload Cooling Time parameter is defined as the time that it takes for the motor to cool from 100 overload content to less than 1 overload content Sometimes a motor manufacturer may provide a cooling time constant t or tau value In these cases the Motor Overload Cooling Time parameter should be set to five 5 times the specified time constant value Motor Cooling While Running When the motor is running the Motor Overload Cooling Time parameter and th
144. nning of those ramps The following table summarizes which parameters affect the starting profile when a digital input is programmed to the Ramp Select function and that input is either energized or de energized Ramp Modes Ramp Select De energized Ramp Select Energized Initial Current 1 Maximum Current 1 Initial Current 2 Maximum Current 2 Current Ramp Ramp Time 1 Ramp Time 2 Kick Level 1 Kick Level 2 Kick Time 1 Kick Time 2 Initial Voltage Torque Power Maximum Torque Power TruTorque Ramp Ramp Time 1 Kick Level 1 Kick Level 2 Kick Time 1 Kick Time 2 Initial Voltage Torque Power Maximum Torque Power Power KW Ramp Ramp Time 1 Kick Level 1 Kick Level 2 Kick Time 1 Kick Time 2 Initial Voltage Torque Power Ramp Time 1 Voltage Ramp Kick Level 1 Kick Level 2 Kick Time 1 Kick Time 2 93 6 THEORY OF OPERATION Changing Ramp Profiles The selected ramp profile may be changed during starting by changing the Ramp Select input When the Ramp Select input changes during ramping control switches to the other profile as if it were already in progress It does not switch to the beginning of the other profile Refer to the following example below 3 NOTE Once the motor has achieved an up to speed status UTS changes to the Ramp Select input have effect on the motor operation Figure 21 Changing Ramps During Acceleration Example Ramp
145. nning time of the motor at a given current level is dependant on the motor s thermal capacity Although the Motor OL is active if not set to Off during slow speed operation it is recommended that the motor temperature be monitored if slow speed is used for long periods of time See Also Motor Running Overload Class P3 QST 03 parameter on page 34 Slow Speed Current Level P28 CFN 22 parameter on page 48 Theory of Operations http www benshaw com literature manuals 890034 1 1 xx pdf 48 P30 LED Display Range Description See Also P31 LED Display Range Description See Also 5 PARAMETER DESCRIPTION Slow Speed Kick Level CFN 24 LCD Display Off 100 800 FLA Default Off The Slow Speed Kick Level sets the short term current level that is applied to the motor to accelerate the motor for slow speed operation If set to Off the Slow Speed Kick feature is disabled Slow speed kick can be used to break loose difficult to start loads while keeping the normal slow speed current level at a lower level This parameter should be set to a midrange value and then the Slow Speed Kick Time should be increased in 0 1 second intervals until the kick is applied long enough to start the motor rotating If the motor does not start rotating then increase the Slow Speed Kick Level and begin adjusting the kick time from 1 0 seconds again If the motor initially accelerates too fast then reduce the Slow
146. ntrol and verify that the Analog Input Offset and Analog Input Span parameters are set to accept the master signal 3 The slave MX needs to be provided with a start command from the master MX ARUN programmed relay from the master MX can be used to provide the start command to the slaves The slave s Control Source parameters Local Source and Remote Source settings need to be set appropriately 4 The slave MX analog input s needs to be configured for the appropriate voltage or current input signal type Set the analog input jumper SWI 1 to the desired input type For additional master slave application information consult the factory 112 6 THEORY OF OPERATION Current Follower 6 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 The MX s reference command can be generated from any 0 10V 0 20mA or 4 20mA source such as a potentiometer another MX or an external controller such as a PLC Figure 33 Current Follower Mode MX Current Follower Mode Current Output Motor FLA Setting 0 0 5 10 15 20
147. nus of the LCD display This is the case for those parameters that are in the Quick Start Group In this case both LCD menu groups are listed in the header box and two example LCD displays are shown For some parameters the Range section is enough to describe the parameter For others there may be an additional Options section to describe each of the options that a parameter may be set to The form that the options take may be different for the LED and LCD displays so this section shows how the options appear on both displays The See Also section lists cross references to other parameters that may be related as well as references to further detail in other chapters 33 5 PARAMETER DESCRIPTION Jump to Parameter OST 00 By changing the value of this parameter and pressing ENTER you can jump directly to any parameter within that group P1 Motor FLA OST 01 LED Display LCD Display Range Model Dependent 1 6400 Amps RMS Default 10A Description The Motor FLA parameter configures the motor full load amps and is obtained from the nameplate on the attached motor If multiple motors are connected the FLA of each motor must be added together for this value 3 NOTE Incorrectly setting this parameter prevents proper operation of the motor overload protection motor over current protection motor undercurrent protection ground fault protection and acceleration control P2 Motor Service Factor QST 02 LED Display LCD Di
148. oes not exceed 100 10V or 20mA Example 096 output 4mA 10096 output 20ma Analog Output JA B 20 Aout Span 80 2V AMA TET A Aout Offset 0 V OmA I 20 Selected Output Selected Output value 0 value 100 See Also Analog Output Offset P62 I O 15 parameter on page 65 Theory of Operations http www benshaw comliterature manuals 890034 1 1 xx pdf P62 Analog Output Offset I O 15 LED Display LCD Display Range 0 99 Default 0 Description The analog output signal can be offset using the Analog Output Offset parameter A 50 offset outputs a 50 output 5V in the 10V case when 0 is commanded If the selected variable requests 100 output the span should be reduced to 100 minus offset so that a 100 output request causes a 100 output voltage x offset 100 x span 100 3 NOTE For a 4 20mA output set the Analog Output Span P61 I O 14 to 80 and the Analog Output Offset to 20 See Also Analog Output Span P61 I O 14 parameter on page 65 Theory of Operations http www benshaw comliterature manuals 890034 1 1 xx pdf 65 5 PARAMETER DESCRIPTION P63 LED Display Range Description See Also P64 LED Display Range Description See Also 66 Inline Configuration I O 16 LCD Display Off 0 10 0 seconds Default 3 0 The Inline Configuration parameter controls the behavior of the No Line warning No Line fau
149. ol is used it is very important to properly set this parameter to the motor s full load rated power factor usually available on the motor nameplate or from the motor manufacturer For a typical induction motor this value is between 0 80 and 0 95 If the motor rated Power Factor is not available from either the motor nameplate or the motor manufacturer the value can be obtained by viewing the power factor meter With the motor running at full name plate current view the power factor meter either by setting the LED display s Meter parameter to PF or by pressing the UP arrow key until the Motor PF meter is displayed using the LCD display The meter value can be entered into the Rated Power Factor parameter Meter P79 FUN 01 parameters on page 74 5 PARAMETER DESCRIPTION P76 Rated RMS Voltage FUN 05 LED Display LCD Display Range 100 110 120 200 208 220 230 240 350 380 400 415 440 460 480 500 525 575 600 660 690 800 1000 1140 Default 480 Description The Rated Voltage parameter sets the line voltage that is used when the starter performs Over and Under line voltage calculations This value is the supply voltage NOT the motor utilization voltage See Also Meter P79 FUN 01 parameter on page 74 Under Voltage Level P39 PFN 08 parameter on page 54 Voltage Trip Time P40 PFN 09 parameter on page 54 NOTE Settings above 1140 volts are for medium voltage applications 3 NOTE The rated R
150. on Timeout P68 FUN 12 parameter on page 69 Communication Byte Framing P71 FUN 13 parameter on page 70 Modbus Register Map http www benshaw com literature manuals 890034 1 1 xx pdf P70 Communication Address FUN 10 LED Display LCD Display Range 1 247 Default 1 Description The Communication Address parameter sets the starter s address for Modbus communications See Also Local Source P4 QST 04 parameter on page 35 Remote Source P5 QST 05 parameter on page 36 Communication Baud Rate P69 FUN 11 parameter on page 69 Communication Timeout P68 FUN 12 parameter on page 69 Communication Byte Framing P71 FUN 13 parameter on page 70 Modbus Register Map http www benshaw com literature manuals 890034 1 1 xx pdf 69 5 PARAMETER DESCRIPTION P71 LED Display Range Description See Also 72 LED Display Range Description 70 Communication Byte Framing FUN 13 LCD Display LED LCD 0 Even Stop Default Odd 1 Stop e None 1 Stop 3 None 2 Stop The Communication Byte Framing parameter sets both the parity and number of stop bits Communication Timeout P68 FUN 12 parameter on page 69 Communication Baud Rate P69 FUN 11 parameter on page 69 Communication Address P70 FUN 10 parameter on page 69 Modbus Register Map http www benshaw com literature manuals 890034 1 xx pdf Energy Saver FUN 09 LCD Display On Off Def
151. on from Wye to Delta mode A digital input can be programmed as a 2M contactor feedback input This input provides verification that the 2M contactor has fully closed preventing operation when the transition resistors are still connected in the motor circuit The use of this feedback is recommended to prevent the overheating of the transition resistors if the 2M contactor does not close properly The 2M confirmation trip time can be adjusted by modifying the Bypass Feedback Time parameter 38 NOTE When in Wye Delta mode the acceleration ramp kick and deceleration settings have no effect on motor operation 3 NOTE When in Wye Delta mode the SCR gate outputs are disabled 108 6 THEORY OF OPERATION Across The Line Starter 6 9 Across The Line Full Voltage Starter When the Starter Type parameter is set to ATL the MX is configured to operate an Electro mechanical full voltage or across the line ATL starter In the ATL configuration the MX assumes that the motor contactor 1M is directly controlled by an output relay that is programmed to RUN Therefore when a start command is given the RUN programmed relay energizes the motor contactor which applies power to the motor When the MX determines that the motor is at full speed the up to speed UTS condition is indicated by energizing the UTS programmed relays When configured as an ATL starter all MX motor and starter protective functions except bad SCR detection and power stack
152. on page 39 Initial Voltage Torque Power P11 CFN 08 parameter on page 40 Rated Power Factor P75 FUN 06 parameter on page 72 Theory of Operations http www benshaw com literature manuals 890034 1 1 xx pdf P13 Kick Level 1 CEN 10 LED Display LCD Display Range Off 100 800 of FLA Default Off Description The Kick Level 1 parameter sets the current level that precedes any ramp when a start is first commanded The kick current is only useful on motor loads that are hard to get rotating but then are much easier to move once they are rotating An example of a load that is hard to get rotating is a ball mill The ball mill requires a high torque to get it to rotate the first quarter turn 90 Once the ball mill is past 90 of rotation the material inside begins tumbling and it is easier to turn The kick level is usually set to a low value and then the kick time is adjusted to get the motor rotating If the kick time is set to more than 2 0 seconds without the motor rotating increase the kick current by 100 and re adjust the kick time See Also Start Mode P10 CFN 01 parameter on page 39 Kick Time 1 P14 11 parameter on page 41 Theory of Operations http www benshaw com literature manuals 890034 1 1 xx pdf P14 Kick Time 1 CEN 11 LED Display LCD Display Range 0 1 10 0 seconds Default 1 0 41 5 PARAMETER DESCRIPTION Description See Also P15 LED Display Range Des
153. one mode of operation to the other Disabling the Starting OL function or using a higher OL class for the Starting OL can be useful on extremely high inertial loads such as large centrifuges or high friction loads that require very long starting periods NOTE When the Independent Starting Running Overload P44 PFN 13 parameter is set to OFF the running OL is used at all times 3 NOTE The Hot Cold motor compensation is still active when either the starting or running overload is disabled Therefore the motor overload content may still slowly increase or decrease depending on the measured motor current However if the motor overload is disabled the motor overload content is limited to a maximum of 99 Therefore a motor overload trip can not occur CAUTION When both overloads are disabled the accumulated overload content is set to zero 0 and the starter does not provide any motor overload protection External motor overload protection must be provided to prevent motor damage and or the risk of fire in the case of a motor overload 6 THEORY OF OPERATION 6 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 5 OL Content OL Content when Stopped 0 When the motor is stopped the motor overload cools as shown in the followi
154. ons cable should be used when connecting to the Modbus port on the MX The cable should contain two twisted pairs and have an overall shield Use one pair of conductors for the A and B signals Use the other pair of conductors for the Common signal The cable should adhere to the following specifications Conductors 2 twisted pair Impedance 100 Ohm to 120 Ohm Capacitance 16 pF ft or less Shield Overall shield or individual pair shields Examples of cables that meet these specifications are Belden part number 9842 and Alpha Wire part number 6412 Terminating Resistors The MX does not have a terminating resistor for the end of the trunk line If a terminating resistor is required the resistor must be wired to the terminal block The purpose of terminating resistors is to eliminate signal reflections that can occur at the end of a network trunk line In general terminating resistors are not needed unless the bit rate is very high or the network is very long In fact terminating resistors place a large load on the network and may reduce the number of drops that may be placed on the network The maximum baudrate of 19 200 supported by the MX is not high enough to warrant a terminating resistor unless the network is extremely long 3 000 feet more A terminating resistor should only be installed on the MX if signal reflection is known to be a problem and only if the is at the end of the network Terminating resisto
155. or 1 15 or more 1 40 Motor temp rise 40 C or less 1 40 All others 1 30 Although the NEC does not address the effect of the ambient temperature of the motor location guidance can be derived by examining NEC limits If the motor is operating in an ambient temperature that is less than 40 C then the overload multiplier can be increased while still protecting the motor from exceeding its maximum designed temperature The following curve gives the ambient temperature versus the correction factor Temperature vs Correction Factor 100 80 60 amp 40 20 0 Correction Factor Example If a motor operates at 0 C then a 1 36 correction factor could be applied to the overload multiplier This could give a theoretical overload multiplier of 1 36 x 1 25 or 1 70 The highest legal NEC approved value of overload multiplier is 1 40 so this could be used 85 6 THEORY OF OPERATION Acceleration Control 6 3 Acceleration Control 6 3 1 Current Ramp Settings Ramps and Times General The current ramp sets how the motor accelerates The current ramp is a linear increase in current from the Initial Current Maximum Current 86 initial setting to the maximum setting The ramp time sets the speed of this linear current increase The following figure shows the relationships of these different ramp settings Figure 16 Current Ramp Current Max Current Start command Kick Current Initial Current
156. overload are available to provide full motor and starter protection Figure 30 A Typical ATL Starter Schematic with the 100 600 VAC 12 MN 3es0 60Hz a ge a 13 Fa I ANALOG OUTPUT ANALOG INPUT 10V MAX SERIAL COMMUNICATION RS485 5V Cy cy t LI OPTIONAL DOOR MOUNT DISPLAY 3 NOTE When in ATL mode the acceleration ramp kick and deceleration parameter settings have no effect on motor operation 3 NOTE When in ATL mode the SCR gate outputs are disabled 109 6 THEORY OF OPERATION Single Phase Soft Starter 6 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 110 Connect Line power to terminals L1 and L3 Remove gate leads from J8 and J9 and tie off so the leads will not touch anything Remove gate leads from J6 and reinstall to J8 from J7 and reinstall to J9 Change Input Phase Sensitivity P77 FUN 04 to SPH Single Phase Connect motor to terminals T1 and T3 100 600 VAC 1050 60Hz rh Figure 31 Power Schematic for RB2 Integral Bypass Power Stack for Single Phase Operation CUSTOMER SUPPLIED gt gt gt gt gt _
157. put line frequency If operating on a generator check generator speed governor for malfunctions Check input supply for open fuses or open connections Line power quality problem excessive line distortion Slow Speed Timer Limit Expired Verify that PF caps if installed are ahead of CTs 126 7 TROUBLESHOOTING amp MAINTENANCE Fault Code 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 Input power not single phase Three phase power has been detected when the starter is expecting single phase power Verify that input power is single phase Verify that single phase power is connected to the L1 and L2 inputs Correct wiring if necessary Verify that the SCR gate wires are properly connected to the MX control card Input power not three phase Single phase power has been detected when the starter is expecting three phase power Verify that input power is three phase Correct wiring if necessary Verify that the SCR gate wires are properly connected to the MX control card On medium voltage systems verify wiring of the voltage feedback measurement circuit Low Line L2 L3 Low voltage below the Under voltage Trip Level parameter setting P39 PFNO8 was detected for longer than the Over U
158. put relay needs to be programmed to the UTS output function Refer to the Relay Output Configuration parameters on page 60 for more information Based on the typical closed transition schematic shown in Figure 28 when a start command is given the starter enters the Wye starting mode by energizing the relay programmed as RUN The transition to Wye Starting mode occurs as follows 1 Start command is given to the starter 2 The RUN relay is energized which energizes the 1S contactor 3 When the 1S contactor pulls in the 1M contactor is energized The starter remains in the Wye mode until either 1 The start command is removed 2 The Up To Speed Time expires 3 The measured motor current is less than 85 of FLA and more than 25 of the Up To Speed Timer setting has elapsed 4 A fault occurs When the Up To Speed Time expires the starter changes from Wye starting mode to the Delta or normal running mode by energizing the relay programmed as UTS In Delta mode the RUN and UTS relays are both energized and the motor is connected in the normal running Delta configuration The transition to Delta Run mode occurs as follows I The UTS relay is energized which energizes the 2S contactor 2 When the 2S contactor pulls in resistors are inserted in the circuit and the 1S contactor is de energized 3 When the 1S contactor drops out the 2M contactor is energized 4 When the 2M contactor is pulled in feedback can be sent to the M
159. r aet de 356 p EROR Sek Se Pa 8 29 44 7 LED Fault Group ue s Sq s Seo db 29 5 PARAMETER DESCRIPTION 2 2 eh 32 5 1 Parameter Descriptions sss e ue ss MS 32 5 11 Theory of Operation 5 5061 Sed rm RS US Wqee a hac sS E 32 512 Modbus Register Map y soa sys y yasa SENS CGN pad OEE XX Yd hs 32 6 THEORY 2 2 78 6 1 Solid State Motor Overload Protection gt s s so sesse asesi tadinya rana aiat 78 6 11 OVerVIe Wiss aa aude bse iN Coon ae ale apte diodes 78 6 1 2 Setting Up The MX MotorOverload a ee 78 6 1 3 Motor Overload gt es ae tae ec ee dot oe Sa E deer 80 6 1 4 Current Imbalance Negative Sequence Current 80 6 19 Harmonie Compensation 234 444 Agee Bee e eGo ME RU 81 6 1 6 Hot Cold Motor Overload Compensation 81 6 1 7 Separate Starting and Running Motor Overload Settings 82 6 1 8 Motor Cooling While Stopped uu u heh ee hs 83 6 1 9 Motor Cooling While Runnings ssp a sasa s son e Upon
160. r to the 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 6 THEORY OF OPERATION 6 1 3 6 1 4 80 Motor Overload Operation Overload Heating When the motor is operating in the overloaded condition motor current greater than FLAxSF the motor overload content accumulates based on the starter s operating mode at a rate established by the overload protection class chosen The accumulated overload content can be viewed on the display or over the communications network Overload Alarm An overload alarm condition is declared when the accumulated motor overload content reaches 90 An output relay can be programmed to change state when a motor overload alarm condition is present to warn of an impending motor overload fault Overload Tri The MX starter trips when the motor overload content reaches 100 protecting the motor from damage The starter first performs the defined deceleration or DC braking profile before stopping the motor if the controlled fault stop feature ofthe MX is enabled The motor overload trip time accuracy is 0 2 seconds or 3 of total trip time Overload Start Lockout After tripping on an overload restarting is prevented and the starter is locked out until the accumulated motor overload
161. re 27 that need to be considered By observation of Figure 27 access to all six stator winding terminals is required for an inside delta application For a 12 lead motor all 12 stator terminals must be accessible In the line connected soft starter of Figure 26 access to only three leads of the stator windings of the motor is required One failed SCR on any phase of the inside delta soft starter results in a single phase condition A shunt trip circuit breaker is recommended to protect the motor in this case A programmable relay can be configured as a shunt trip relay and can be used to trip the breaker When certain faults occur the shunt trip relay energizes The SCR control for an inside delta application is different than the SCR control for a standard soft starter The Starter Type parameter needs to be properly set so that the SCRs are gated correctly If a circuit breaker is the only means to disconnect the soft starter and motor from the line then one leg of the motor leads in the inside delta soft starter is always electrically live when the circuit breaker is closed This requires caution to ensure these leads of the motor are not exposed to personnel Line Connected Soft Starter In Figure 26 the power poles of the soft starter are connected in series with the line The starter current equals the line current Figure 26 Typical Motor Connection T1 L1 W e 714 N gt T2
162. rs should never be installed on nodes that are not at the end of the network Grounding RS 485 buses with isolated nodes are most immune to noise when the bus is not connected to earth ground at any point If electrical codes require that the bus be connected to earth ground then the Common signal should be connected to earth ground at one point and one point only If the Common signal is connected to earth ground at more than one point then significant currents can flow through the Common signal when earth ground potentials are different at those points This can cause damage to devices attached to the bus Shielding The shield should be continuous from one end of the trunk to the other The shield must be tied to the RS 485 Common signal at one point and one point only Ifthe shield is not tied to Common at any point or is tied to Common at more than one point then its effectiveness at eliminating noise is greatly reduced 116 6 THEORY OF OPERATION 6 15 7 Wiring Figure 38 shows the wiring of TB4 to a Modbus 485 Network If the starter is the end device in the network a 120Q 1 4W terminating resistor may be required Please refer to Figure 39 for wire and termination practices Figure 38 TB4 Connector 2419 COM 6 THEORY OF OPERATION Figure 39 Modbus Network Wiring Example M 1 MX 2 MODBUS SLAVE MODBUS SLAVE O gt 00 O gt 6 Om e MW e 1200
163. rs values may be viewed on the display but any attempt to change their values by pressing the UP or DOWN keys is ignored Viewing the Passcode parameter indicates whether or not the parameters are locked If they are locked the Passcode parameter displays On If they are not locked the Passcode parameter displays To lock the parameters press the ENTER key while viewing the Passcode parameter This allows entry of a 4 digit number Press the UP or DOWN keys and ENTER for each of the four digits After entering the fourth digit the number is stored as the passcode and the parameters are locked Once parameters are locked the same 4 digit number must be re entered into the Passcode parameter in order to unlock them Any other 4 digit number entered will be ignored When a passcode is set and an attempt is made to change a parameter through the display keypad the UP and DOWN keys simply have no effect When a passcode is set and an attempt is made to change a parameter through Modbus MX returns an error response with an exception code of 03 Illegal Data Value to indicate that the register can not be changed 75 5 PARAMETER DESCRIPTION LED Display The following steps must be performed to set a passcode using the LED Display 1 At the default meter display press the PARAM key to enter the parameter mode 2 Press the UP or DOWN keys to get to the Passcode parameter P81 FUN 16 3 Press the E
164. s a phase controller or voltage follower This is an open loop control mode When a start command is given the RUN programmed relays energize The firing angles of the SCRs are directly controlled based on voltage or current applied to the Analog Input Figure 32 Phase Control Mode Output Voltage vs Analog Input Output Voltage a o o a o A 100 Analog Input A reference input value of 0 results in no output A reference input value of 100 results in full 100 output voltage The actual input voltage current that results in a given output can be adjusted through the use of the Analog Input Offset and the Analog Input Span parameters 3 NOTE The power stack must be rated for continuous non bypassed duty in order to operate in Phase Control mode continuously NO BYPASS 3 NOTE When operating in Phase Control mode the acceleration ramp kick and deceleration settings have no effect on operation 3 NOTE When in Phase Control mode the following motor starter protective functions are available Residual Ground Fault Instantaneous Over Current IOC Phase Rotation Phase Loss Under Frequency Current Imbalance Over Current Current while Stopped Under Current Over Voltage Under Voltage Motor OL Phase Controller Over Frequency Phase control can be used to directly control the voltage app
165. s current curves When the parameter is set to Off the electronic overload is disabled when up to speed and a separate motor overload protection device must be supplied 36 NOTE Care must be taken not to damage the motor when turning the running overload class off or setting to a high value 3 NOTE Consult motor manufacturer data to determine the correct motor overload settings Independent Starting Running Overload P44 PFN 13 on page 56 Motor Starting Overload Class P45 PFN 14 on page 56 Motor Overload Hot Cold Ratio P46 PFN 16 on page 57 Motor Overload Cooling Time P47 PFN 17 on page 58 Relay Output Configuration P52 54 05 07 on page 60 Theory of Operations http www benshaw com literature manuals 890034 10 xx pdf Local Source OST 04 LCD Display LED LCD Description PAd Keypad The start stop control is from the keypad tEr Terminal The start stop control is from the terminal strip inputs Default SEr Serial The start stop control is from the network The MX can have three sources of start and stop control Terminal Keypad and Serial Two parameters P4 QST 04 Local Source and P5 QST 05 Remote Source select the source of the start and stop control If a digital input is programmed as L r Local Remote then that input selects the control source When the input is low the local source is used When the input is high the remote source is used If no digital input
166. s the time it takes for the starter to allow the current to go from the initial current to the maximum current when the second ramp is active Refer to the Ramp Time 1 P8 CEN 02 parameter on page 83 for description of operation 5 PARAMETER DESCRIPTION See Also Ramp Time 1 P8 QST 08 parameter on page 83 Digital Input Configuration P48 P50 I O 01 03 parameters on page 59 Theory of Operations http www benshaw com literature manuals 890034 1 1 xx pdf P25 Kick Level 2 CEN 12 LED Display LCD Display Range Off 100 800 of FLA Default Off Description The Kick Level 2 parameter sets the current level that precedes any ramp when a start is first commanded when the second ramp is active Refer to the Kick Level 1 P13 CFN 10 parameter on page 88 for description of operation See Also Kick Level 1 P13 CFN 10 parameter on page 88 Digital Input Configuration P48 50 I O 01 03 parameters on page 5993 Theory of Operations http www benshaw com literature manuals 890034 1 1 xx pdf P26 Kick Time 2 CEN 13 LED Display LCD Display Range 0 1 10 0 seconds Default 1 0 Description The Kick Time 2 parameter sets the length of time that the kick current level is applied to the motor when the second ramp is active Refer to the Kick Time 1 P14 11 parameter on page 88 for description of operation See Also Theory of Operations http www benshaw com literature manuals 890034 1 1 xx p
167. se indicating the clamp is tight On the loader bars with two indicator washers it may be necessary to tighten or loosen one side of the clamp to get both indicator washers free Testing SCR After the SCRs have been replaced conduct the resistance test as defined in section 7 5 137 7 TROUBLESHOOTING amp MAINTENANCE NOTES 138 Publication History Sales and Service United States Pittsburgh Pennsylvania Indianapolis Indiana Syracuse New York Boston Massachusetts Charlotte North Carolina BENSHAW PRODUCTS ch Ane Los Angeles California Detroit Michigan Milwaukee Wisconsin Phoenix Arizona Seattle Washington Low Voltage Solid State Reduced Voltage Starters ae RB2 RC2 SSRV Non or Separate Bypass Minneapolis Minnesota Newark New Jersey RB2 RC2 DC Injection Braking Reversing Canada Listowel Ontario Toronto Ontario Montreal Quebec Calgary Alberta Quebec City Quebec WRB SSRV Wound Rotor SMRSM6 SSRV Synchronous DCB3 Solid State DC Injection Braking South America Sao Paulo Brazil Santiago Chile Medium Voltage Solid State Reduced Voltage Starters Lima Peru Bogota Columbia MVRMX 5 Induction or Synchronous to 10 000HP Buenos Aires Argentina Santa Cruz Bolivia MVRMX 7 2kV Induction or Synchronous to 10 000HP Guayaqil Ecuador Mexico MVRMX 15 Induction or Synchronous to 60 000HP China Australia Singapore Low Voltage AC Drives
168. splay Range 1 00 1 99 Default 1 15 Description The Motor Service Factor parameter should be set to the service factor of the motor The service factor is used for the overload calculations If the service factor of the motor is not known then the service factor should be set to 1 00 3 NOTE The NEC National Electrical Code does not allow the service factor to be set above 1 40 Check with other local electrical codes for their requirements The National Electrical Code article 430 Part C allows for different overload multiplier factors depending on the motor and operating conditions NEC section 430 32 outlines the allowable service factor for different motors See Also Theory of Operations http www benshaw com literature manuals 890034 10 xx pdf P3 Motor Overload Class Running OST 03 PEN 15 LED Display LCD Display Range Off 1 40 Default 10 Description See Also P4 LED Display Range Description See Also S PARAMETER DESCRIPTION The Motor Running Overload Class parameter sets the class of the electronic overload for starting and running If separate starting versus running overload classes are desired set the independent S O L P44 PFN13 parameter to On The starter stores the thermal overload value as a percentage value between 0 and 100 with 0 representing a cold overload and 100 representing a tripped overload See section 6 1 for the overload trip time versu
169. standard Current Transformers CTs are used for current feedback or if the optional Hall Effect Current sensor is used for current feedback 3 NOTE Discretion must be used when DC injection braking Motor heating during DC injection braking is similar to motor heating during starting Although the Motor OL is active if it has not been intentionally disabled excessive rotor heating could still result if the load inertia is very large braking level is high or the brake time is set too long Caution must be used to assure that the motor has the thermal capacity to brake the desired load in the desired period of time without excessive heating 6 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 100 6 5 8 6 THEORY OF OPERATION In the Brake Disable case DC braking will occur unless the Brake Disable digital input is energized DC braking will cease if the brake disable is energized 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 Use of Optional Hall Effect Current Sensor The Hall Effect Current Sensor should be located on Phase 1 of the motor output wiring The sensor should be located so that t
170. trolled Fault Stop Enable P43 PFN 12 parameter on page 55 Theory of Operations http www benshaw com literature manuals 890034 1 1 xx pdf P18 Decel Time CEN 17 LED Display LCD Display 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 When in voltage decel mode this time sets the time between applying the initial decel level to the final decel level 96 NOTE If the motor is not up to speed when a stop is commanded the voltage decel profile begins at the lower of either the decel begin level setting or at the motor voltage level when the stop is commanded Although the profile may be adjusted the deceleration time remains the same When in the TruTorque deceleration mode the decel time sets the time between when a stop is commanded and when the decel end torque level is applied If the motor stops rotating before the decel time expires decrease the decel time parameter If the motor is still rotating when the decel time expires increase the decel time parameter A typical decel time is 20 to 40 seconds 3 NOTE Depending on the motor load and the decel parameter settings the motor may or may not be fully stopped at the end of the deceleration time See Also Stop Mode P15 CFN 14 parameter on page 42 Decel Begin Level P16 CFN 15 parameter on page 43 Decel End Level
171. ut Configuration parameters on page 60 for more information The output of a Braking relay is needed to control the contactor and or 7 SCR gating control card used during braking 3 NOTE Verify that the correct output relay is programmed to Braking and that the wiring of this relay is correct Damage to the starter can result if the braking relay is not programmed and or wired properly Stand Alone Overload Relay for emergency ATL Across The Line operation Due to the currents being drawn on Line 1 and Line 3 for braking this stand alone overload relay will cause nuisance current imbalance trips For a solution consult factory 98 100 600 VAC 3050 60Hz e DC Injection Brake Wiring Example CUSTOMER SUPPLIED 120 VAC 1 z 6 THEORY OF OPERATION Figure 24 DC Injection Brake Wiring Example cRousp NEUTRAL NEUTRAL X 182 120 VAC POWER INPUT gO 55 4 182 183 TD START L L D on C2 I R p 4 PROGRAMMABLE Eje MI ac E RELAY OUTPUTS PROGRAMMABLE RELAY K3 J2 P68 FUNO3 BIPC 300055 01 MX2 CARD L OPTIONAL DOOR MOUNT DISPLAY ANALOG 10V MAX r SCRA SERIAL COMMUNICATION RS485 5V MAX OVERTEMP SWITCH MTD ON HEATSINK r HEAVY DUTY 99 6 THEORY OF OPERATION 6 5 6 DC Brake Timing
172. value should be set to the lowest possible current level that will properly operate the motor 38 NOTE When the motor is operating at slow speeds its cooling capacity can be greatly reduced Although the Motor OL is active if not set to Off during slow speed operation it is recommended that the motor temperature be monitored when slow speed is used for long periods of time See Also Motor Running Overload Class P3 QST 03 parameter on page34 Slow Speed Time Limit P29 CFN 23 parameter on page 48 Theory of Operations http www benshaw com literature manuals 890034 11 xx pdf P29 Slow Speed Time Limit CFN 23 LED Display LCD Display 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 When this parameter is set to Off the timer is disabled This parameter can be used to limit the amount of slow speed operation to protect the motor and or load 96 NOTE The Slow Speed Time Limit includes the time used for the Slow Speed Kick if kick is enabled 96 NOTE The Slow Speed Time Limit resets when the motor is stopped Therefore this timer does not prevent the operator from stopping slow speed operation and re starting the motor which can result in the operation time of the motor being exceeded 3 NOTE When the motor is operating at slow speeds its cooling capacity can be greatly reduced Therefore the ru
173. ventative maintenance performed on a regular basis will help ensure that the starter continues to operate reliably and safely The frequency of preventative maintenance depends upon the type of maintenance and the installation site s environment 96 NOTE A trained technician should always perform preventative maintenance Preventative Maintenance During Commissioning Torque all power connections during commissioning This includes factory wired equipment Check all of the control wiring in the package for loose connections If fans are installed ensure proper operation One month after the starter has been put in operation Re torque all power connections This includes factory wired equipment Inspect the cooling fans to ensure proper operation After the first month of operation Re torque all power connections every year Cleanany accumulated dust from the starter using a clean source of compressed air Inspect the cooling fans every three months to ensure proper operation Cleanor replace any air vent filters on the starter every three months NOTE If mechanical vibrations are present at the installation site inspect the electrical connections more frequently 120 7 TROUBLESHOOTING amp MAINTENANCE General Troubleshooting Charts 73 General Troubleshooting Charts The following troubleshooting charts can be used to help solve many of the more common problems that may occur 7 3 1 Motor does not
174. vice factor is set to 1 15 the overload starts accumulating content when the motor current 211596 FLA 100 1 15 The overload will NOT trip if the measured motor current is 11596 of rated FLA The available overload classes are based on the trip time when operating at 600 of rated motor current For example a Class 10 overload trips in 10 seconds when the motor is operating at 600 rated current a Class 20 overload trips in 20 seconds when the motor is operating at 60095 rated current The equation for the MX standard overload curves after the pick up point has been reached is 35seconds Class 1 Current Imbal Derate Factor 1 Motor FLA Time to Trip seconds Measured Current 6 THEORY OF OPERATION Figure 12 Commonly Used Overload Curves 10000 4 IN IL 1000 gt V g E E 8 2 100 8 E Em o o m M Class 30 Class 25 40 I TI Class 20 Class 15 Class 10 a Class 5 1 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 Current FLA 96 NOTE In some cases the power stack rating may determine what motor overload settings are available Each power stack is designed to support specific motor overload classes The RB2 power stack is designed for class 10 duty without derating Refe
175. ws the motor to begin rotating within a couple of seconds of receiving a start command To adjust the initial current setting give the starter a run command Observe the motor to see how long it takes before it begins rotating and then stop the unit For every second that the motor doesn t rotate increase the initial current by 20 Typical loads require an initial current in the range of 50 to 175 If the motor does not rotate within a few seconds after a start command the initial current should be increased If the motor accelerates too quickly after a start command the initial current should be decreased The Initial Current 1 parameter must be set to a value that is lower than the Maximum Current 1 P7 QST 07 parameter setting Maximum Current 1 P7 QST 07 parameter on page 37 Ramp Time 1 P8 QST 08 parameter on page 38 Start Mode P10 CFN 01 parameter on page 39 Kick Level 1 P13 CFN 10 parameter on page 41 Kick Time 1 P14 11 parameter on page 41 Theory of Operations http www benshaw com literature manuals 890034 1 1 xx pdf Maximum Motor Current 1 OST 07 CEN 04 LCD Display 100 800 of FLA Default 600 The Maximum Motor Current 1 parameter is set as a percentage of the Motor FLA P1 QST 01 parameter setting This parameter performs two functions It sets the current level for the end of the ramp profile It also sets the maximum current that is allowed to reach the motor
176. y time P40 PFNO9 Verify that the actual input voltage level is correct Verify that the Rated Voltage parameter P76 FUN0S is set correctly Line power quality problems excessive line distortions F26 High Line L3 L1 High voltage above the Over voltage Trip Level parameter setting P38 PFNO7 was detected for longer than the Over Under Voltage Trip delay time P40 PFNO9 Verify that the actual input voltage level is correct Verify that the Rated Voltage parameter P76 FUNO5 is set correctly Line power quality problems excessive line distortions High Line L1 L2 High voltage above the Over voltage Trip Level parameter setting 35 7 was detected for longer than the Over Under Voltage Trip delay time P40 PFNO09 Verify that the actual input voltage level is correct Verify that the Rated Voltage parameter P76 FUNO5 is set correctly Line power quality problems excessive line distortions Phase Loss The MX has detected the loss of one or more input or output phases when the starter was running Can also be caused by line power dropouts Check input supply for open fuses Check power supply wiring for open or intermittent connections Check motor wiring for open or intermittent connections On medium voltage systems verify wiring of the voltage feedback measurement circuit Check Gate and Cathode connections to MX card No Line No input voltage was detected for longer than the Inline Configuration time delay par

MX2 Control (RB2, RC2, RX2E Models) (Publication # 890034-23

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