PUBLICATION #890023-01-02 RediStart Solid State Starter Software Manual Control The Leader In Solid State Motor Control Technology © 2005 Benshaw Inc.
TRADEMARK NOTICE are registered trademarks of Benshaw Incorporated. Benshaw and Modbus is a registered trademark of Schneider Electric.
WARNING 1. This starter contains hazardous voltage that can cause electric shock resulting in personal injury or loss of life. 2. Before servicing, be sure all AC power is removed from the starter and the motor has stopped spinning 3. Wait at least 1 minute after turning off the AC power for the bus capacitor to discharge on the control card. 4. Do not connect or disconnect the wires to or from the starter when power is applied. 5. Ensure shielded cables are discharged. WARNING 1.
TABLE OF CONTENTS 1 INTRODUCTION................................................................................................................................................................. 1 1.1 1.2 1.3 1.4 2 USING THIS MANUAL ........................................................................................................................................................ 2 CONTACTING BENSHAW .......................................................................................................
TABLE OF CONTENTS 6.2.1 6.2.2 6.2.3 6.2.4 7 Wye Delta ............................................................................................................................................................... 91 Phase Control ......................................................................................................................................................... 93 Current Follower ..........................................................................................................
TABLE OF CONTENTS 9.7.3 9.7.4 Connectors, Functions and Ratings...................................................................................................................... 143 Measurements, Accuracy and Ratings.................................................................................................................. 143 10 APPENDIX................................................................................................................................................................
1 Introduction
1 – INTRODUCTION Using This Manual 1.1 Using this manual Layout This manual is divided into 10 sections. Each section contains topics related to the section. The sections are as follows: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Introduction Control Card Keypad Operation Parameters Parameter Descriptions Applications Troubleshooting Theory of Operation Technical Information Appendices Symbols There are 2 symbols used in this manual to highlight important information.
1 – INTRODUCTION Using This Manual General Information Benshaw offers its customers the following: • • • • • Start-up services On-site training services Technical support Detailed documentation Replacement parts NOTE: Information about products and services is available by contacting Benshaw refer to Contacting Benshaw on page 4. Start-Up Services Benshaw technical field support personnel are available to do startup and conduct on-site training on the starter operations and troubleshooting.
1 – INTRODUCTION Contacting Benshaw 1.2 Contacting Benshaw Information about Benshaw products and services is available by contacting Benshaw at one of the following offices: Benshaw Inc. Corporate Headquarters 1659 E. Sutter Road Glenshaw, PA 15116 United States of America Phone: (412) 487-8235 Fax: (412) 487-4201 Benshaw Canada Controls Inc.
1 – INTRODUCTION Interpreting Model Numbers 1.3 Inspection Before storing or installing the RediStart starter with MX control, thoroughly inspect the device for possible shipping damage. Upon receipt: • Remove the starter from its package and inspect exterior for shipping damage. If damage is apparent, notify the shipping agent and your sales representative. • Open the enclosure and inspect the starter for any apparent damage or foreign objects.
1 – INTRODUCTION General Overview 1.4 General Overview of a Reduced Voltage Starter The RediStart MX motor starter is a microprocessor-controlled starter for single or three-phase induction motors. The starter can be custom designed for specific applications. A few of the features are: • • • • • • Solid state design. Reduced voltage starting and soft stopping. Closed-loop motor current control, power control, torque control. Programmable motor protection. Programmable operating parameters.
2 Control Card
2 – CONTROL CARD Figure 1 – Control Card Layout BIPC 300050-00-01 SN 120V Control Serial Number SCR 1 Gnd Shield Grounding 120V Control SCR 4 NO1 RC1 NC1 SCR 2 NO2 Relay Output R1, R2, R3 RC2 NC2 NO3 SCR 5 RC3 NC3 START SCR 3 DI 1 Digital Inputs Start, DI1, DI2, DI3 S/DI COM DI2 Terminating Resistor Conn 3 Conn 2 DI3 DI2/D3 COM CPU Heart Beat LED Serial Com LEDs SCR 6 Modbus Serial Port Reset Button Analog Input & Config Jumper CT Input CT Burden Selector Switch LED Display & Keypa
2 – CONTROL CARD 2.1 Control Card Setup 2.1.1 CT Ratio Scaling The motor current signal scaling is set according to the motor size and the application specified when the starter is ordered. To ensure accurate operation, the motor current signal must be correctly scaled for the motor (and its application) being controlled by the starter. Motor current signal scaling may have to be changed if: • Motor size has been changed from the original specification.
2 – CONTROL CARD Table 1 – CT Ratios and Burden Switch Settings CT Ratio 72 (4 wraps 288:1) 96 (3 wraps 288:1) 144 (2 wraps 288:1) 288 864 1320 (2 wraps 2640) 2640 2880 3900 5760 8000 14400 Mult. CT-CT Combinations 28800 Mult.
2 – CONTROL CARD 2.1.4 Configuring the Analog Input The analog input can be configured for Voltage or Current loop. The input is shipped in the Current Loop configuration unless specified in a custom configuration. Next to the analog input terminal block is JP3. When the jumper is installed, the input is a current loop. When removed, it is a voltage input. The control card is shipped with the jumper JP3 installed. The analog input accepts a true differential signal through the AIN+ and AIN- terminals.
2 – CONTROL CARD Figure 5 – MX Control Card Analog Jumper Placement Analog Input Jumper Analog Output Jumper 12
2 – CONTROL CARD 2.2 Basic Control Wiring Drawing Digital inputs DI1, DI2, DI3 and relay outputs R1, R2, R3 are pre-programmed. This wiring diagram illustrates a 3-wire start/stop control by programming DI1 as a stop input. 2-wire start/stop control can be implemented by just using the start input. Refer to sections 5 & 6 for configuring the Digital and Analog input and output in software.
2 – CONTROL CARD 14
3 Keypad Operation
3 – KEYPAD OPERATION LED Keypad and Display 3.1 Introduction The MX provides a comprehensive set of parameters to allow the use of the reduced voltage solid state starter in nearly any industrial application. While the starter can meet the requirements of many applications right out of the box, customization of parameter values to better suit your particular application is easily accomplished with the standard, on-board, 4-digit, 7-segment LED display/keypad.
3 – KEYPAD OPERATION LED Keypad and Display 3.2.1.2 Changing Parameter Values Parameter change mode can be entered by: 1. 2. 3. 4. 5. At the default meter display, press the PARAM key to enter parameter mode. Use the UP and DOWN keys to scroll through the available parameters. The value of the parameter can be viewed by pressing the ENTER key. When viewing the parameter value, the parameter can be changed by using the UP and DOWN keys. To store the new value, press the ENTER key.
3 – KEYPAD OPERATION LED Keypad and Display 3.2.2.3 Running When running, the display shows the selected meter function. The following meters can be selected using the Meter display parameter. Avg. RMS current Phase 1 RMS current Phase 2 RMS current Phase 3 RMS current Current Imbalance % GF Current (% FLA) Avg.
3 – KEYPAD OPERATION LED Keypad and Display 3.2.4 Restoring Factory Parameter Settings To restore ALL parameters to the factory default settings, press and hold the PARAM and ENTER pushbutton switch on power up. The display blinks “dFLt”. Parameters unique to the motor starter applications need to be set again to appropriate values before motor operation. 3.2.5 Resetting a Fault To reset from a fault condition, press RESET. 3.2.
3 – KEYPAD OPERATION Remote LCD Keypad and Display 3.3 2x16 Remote LCD Keypad Like the standard keypad, the remote LCD keypad has the same basic functions with enhancements that allow using plain text instead of codes and a menu structure instead of a straight line of parameters. Additional keys have been added, such as “start”, “stop”, and a “left arrow” for moving the cursor around in the LCD display. Status indicators have been added, providing additional information for the starter operation.
3 – KEYPAD OPERATION Remote LCD Keypad and Display 3.3.2 Description of the Keys on the Remote LCD Keypad The UP arrow, DOWN arrow, ENTER and MENU keys on the LCD keypad perform the same functions as the UP, DOWN, ENTER and PARAM keys on the standard keypad. Three keys have been added, with one of the keys serving a dual function. Start Key The START key allows the starter to be started from the keypad.
3 – KEYPAD OPERATION Remote LCD Keypad and Display 3.3.3 Alphanumeric Display The remote LCD keypad and display uses a 32-character alphanumeric LCD display. All starter functions can be accessed by the keypad. The keypad allows easy access to starter programming with parameter descriptions on the LCD display. Power UP Screen On power up, the software part number is displayed for a few seconds. Pressing any key immediately changes the display to the operate screen.
3 – KEYPAD OPERATION Remote LCD Keypad and Display 3.3.4 Parameter Group Screens From the operate screen, the parameter group screens are accessed by pressing either the MENU or the LEFT arrow keys. The parameter group screens display the different parameter groups; QST, CFN, PFN, I/O, FUN, FL_. MMM: PPPPPPPPPPP MI VVVVVVVVVVV MMM: MI: PPP: VVV: = Parameter Group = Menu Index = Parameter Name = Parameter Value and Units Refer to Section 4 for a listing of the parameters and their ranges. 3.3.
3 – KEYPAD OPERATION Remote LCD Keypad and Display Note: Run Hours Run days kWatt Hours MWatt Hours Starts 00:00 – 23:59 0 – 2730 or 7.5 years 0 – 999 0 – 9999 0 – 65535 3.3.6 Fault Log Screen Pressing the MENU OR the LEFT arrow keys repeatedly cycles through all of the Parameter Groups either forward or reverse. More information regarding each fault is available through the remote LCD display than is available through the standard LED display.
3 – KEYPAD OPERATION Remote LCD Keypad and Display 3.3.9 Alarm Screen When an alarm is present, the word “Alarm” is displayed on the operate screen. Pressing the ENTER key displays more information about the alarm. Alarm Number Alarm Name 3.3.10 Procedure for Setting Data Select a parameter that is to be changed. To change Motor FLA from 10 Amps to 30 Amps: From the main screen: T Ready Ia= 0.0A Stopped Va= V Press MENU key and the display shows QST: (Quick Start) screen.
3 – KEYPAD OPERATION Remote LCD Keypad and Display 26
4 Parameters
4 – PARAMETERS 4.1 Introduction The MX incorporates a large 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.
4 – PARAMETERS 4.
4 – PARAMETERS Number P39 P40 P41 P42 P43 P44 Parameter DI 1 Configuration DI 2 Configuration DI 3 Configuration Setting Range OFF: Off R1 Configuration R2 Configuration R3 Configuration OFF: FLFS: FLnF: run: utS: AL: rdyr: LOC: OC: UC: OLA: ShFS: ShnF: P45 Analog Input Trip Type P46 P47 P48 P49 P50 Analog Input Trip Level Analog Input Trip Time Analog Input Span Analog Input Offset Analog Output Function P51 P52 P53 P54 P55 P56 P57 Analog Output Span Analog Output Offset Inline Configuration Byp
4 – PARAMETERS Number P58 Parameter Miscellaneous Commands P59 P60 P61 P62 P63 P64 Communication Timeout Communication Baud Rate Communication Drop Number Energy Saver Heater Level Starter Type P65 P66 Rated Power Factor Rated Voltage P67 Phase Order P68 CT Ratio Setting Range None Reset Run Time Reset KWh/MWh Enter Reflash mode Store Parameters Load Parameters Factory Reset OFF, 1 – 120 1.2, 2.4, 4.8, 9.6, 19.
4 – PARAMETERS Number P69 P70 P71 P72 P73 Parameter Meter Starter Model Number Software Part Number Passcode Fault Log Setting Range 0: Status 1: Ave Current 2: L1 Current 3: L2 Current 4: L3 Current 5: Curr Imbal 6: Ground Fault 7: Ave Volts 8: L1-L2 Volts 9: L2-L3 Volts 10: L3-L1 Volts 11: Overload 12: Power Factor 13: Watts 14: VA 15: VARS 16: kW hours 17: MW hours 18: Phase Order 19: Line Freq 20: Analog Input 21: Analog Output 22: Run Days 23: Run Hours 24: Starts 25: TruTorque % 26: Power % Model
4 – 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), CFN (Control Functions), I/O (Input/Output Functions), PFN (Protection Functions) and FUN (Function).
4 – PARAMETERS 4.4.
4 – PARAMETERS 4.4.
4 – PARAMETERS 4.4.
4 – PARAMETERS Group FUN 12 FUN 13 FUN 14 FUN 15 Display Com Timeout Starter MN Software PN Misc Command Description Communication Timeout Starter Model Number Software Part Number Miscellaneous Commands FUN 16 Passcode Passcode Setting Range Off, 1 – 120 Model Dependent Display Only None Reset RT Reset kWh Reflash Mode Factory Reset Store Parameters Load Parameters Units Seconds 4.4.
4 – PARAMETERS 38
5 Parameter Descriptions
5 – 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 4 beginning on page 33 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.
5 – PARAMETER DESCRIPTIONS P1 Motor FLA QST 01 LCD Display QST: Motor FLA 01 10 Amp Range Model dependent, 1 to 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.
5 – PARAMETER DESCRIPTIONS P3 Motor Running Overload Class QST 03, PFN 14 LCD Display QST: Running OL 03 10 PFN: Running OL 14 10 Range OFF, 1– 40 (Default 10) Description The Motor Running Overload Class parameter sets the class for starting and running if the Independent Starting/Running Overload parameter is set to OFF. If separate starting versus running overload classes are desired, set the Independent Starting/Running Overload parameter to On.
5 – PARAMETER DESCRIPTIONS P4 Local Source QST 04 LCD Display QST:Local Src 04 Terminal Range PAd, tEr, SEr (Default tEr) Description The MX can have three sources of start and stop control; Terminal, Keypad and Serial. Two parameters, Local Source and 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.
5 – PARAMETER DESCRIPTIONS P5 Remote Source QST 05 LCD Display QST:Remote SRC 05 Terminal Range PAd, tEr, SEr (Default tEr) Description The MX can have three sources of start and stop control; Terminal, Keypad and Serial. Two parameters, Local Source and 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.
5 – PARAMETER DESCRIPTIONS P6 Initial Current 1 QST 06, CFN 03 LCD Display QST: 06 Init Cur 1 100 % CFN: 03 Init Cur 1 100 % Range 50 – 600 % of FLA (Default 100%) Description The Initial Current 1 parameter is set as a percentage of the motor FLA parameter setting. The Initial Current 1 parameter sets the current that is initially supplied to the motor when a start is commanded.
5 – PARAMETER DESCRIPTIONS P7 Maximum Current 1 QST 07, CFN 04 LCD Display QST: 07 Max Cur 1 600 % CFN: 04 Max Cur 1 600 % Range 100 – 800 % of FLA (Default 600%) Description The Maximum Current 1 parameter is set as a percentage of the motor FLA parameter setting. The Maximum Current 1 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 after the ramp is completed.
5 – PARAMETER DESCRIPTIONS P8 Ramp Time 1 QST 08, CFN02 LCD Display QST: Ramp Time 1 08 15 sec CFN: Ramp Time 1 02 15 sec Range 0 – 300 seconds (Default 15 seconds) 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.
5 – PARAMETER DESCRIPTIONS P9 Up To Speed Time QST 09 LCD Display QST: 09 UTS Time 20 sec Range 1– 900 Seconds (Default 20 sec) 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-tospeed timer expires. This allows the programming of a maximum acceleration time for the motor.
5 – PARAMETER DESCRIPTIONS P10 Start Mode CFN 01 LCD Display CFN: Start Mode 01 Current Ramp Range OLrP, Curr, tt, Pr (Default Curr) Description The Start Mode parameter allows the selection of the optimal starting ramp profile based on the application. Options LED LCD OLrP: Voltage Ramp Open Loop Voltage acceleration ramp Curr: Current Ramp Current control acceleration ramp. The closed loop current control acceleration ramp is ideal for starting most general-purpose motor applications.
5 – PARAMETER DESCRIPTIONS P11 Initial Voltage/Torque/Power CFN 08 LCD Display CFN:Init V/T/P 08 25 % Range 1 – 100 % of Voltage/Torque/Power (Default 25%) Description Start Mode set to Open Loop Voltage Acceleration: When the Start Mode parameter is set to open-loop voltage acceleration, this parameter sets the starting point for the voltage acceleration ramp profile. A typical value is 25%. If the motor starts too quickly or the initial current is too high, reduce this parameter.
5 – PARAMETER DESCRIPTIONS P12 Maximum Torque/Power CFN 09 LCD Display CFN:Max T/P 09 105 % Range 10 – 325 % of Torque/Power (Default 105%) Description Start Mode 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.
5 – PARAMETER DESCRIPTIONS P13 Kick Level 1 CFN 10 LCD Display CFN: Kick Lvl 1 10 Off 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.
5 – PARAMETER DESCRIPTIONS P15 Stop Mode CFN 14 LCD Display CFN: Stop Mode 14 Coast Range CoS, SdcL, tdcL (Default CoS) Description The Stop Mode parameter allows for the most suitable stop of the motor based on the application. Options LED LCD CoS Coast Coast: A coast to stop should be used when no special stopping requirements are necessary; Example: crushers, balls mills, centrifuges, belts, conveyor.
5 – PARAMETER DESCRIPTIONS P16 Decel Begin Level CFN 15 LCD Display CFN:Decel Begin 15 40 % Range 1 % - 100% of phase angle firing (Default 40%) Description Stop Mode set to Voltage Deceleration: The voltage deceleration profile utilizes an open loop S-curve voltage ramp profile. When the Stop Mode parameter is set to Voltage Decel, the Decel Begin Level parameter sets the initial or starting voltage level when transferring from running to deceleration.
5 – PARAMETER DESCRIPTIONS P17 Decel End Level CFN 16 LCD Display CFN: 16 Decel End 20 % Range 99 – 1 % of phase angle firing (Default 20%) Description Stop Mode set to Voltage Deceleration: The voltage deceleration profile utilizes an open loop S-curve voltage ramp profile. When the Stop Mode parameter is set to Voltage Decel, the Decel End Level parameter sets the ending voltage level for the voltage deceleration ramp profile.
5 – PARAMETER DESCRIPTIONS P18 Decel Time CFN 17 LCD Display CFN: Decel Time 17 15 sec Range 1 – 180 seconds (Default 15 sec) 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 application of the final decel level.
5 – PARAMETER DESCRIPTIONS P20 Maximum Current 2 CFN 07 LCD Display CFN: 07 Max Cur 2 600 % Range 100 – 800 % of FLA (Default 600%) Description The Maximum Current 2 parameter is set as a percentage of the motor FLA parameter setting, when the second ramp is active. Refer to the Maximum Current 1 for description of operation. See Also Maximum Current 1 parameter on page 46 Digital Input Configuration parameters on page 69 Theory of Operation section 8.3.
5 – PARAMETER DESCRIPTIONS P23 Kick Time 2 CFN 13 LCD Display CFN: Kick Time 2 13 1.0 sec Range 0.1 – 10.0 seconds (Default 1.0 sec) 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 parameter for description of operation. See Also Kick Time 1 parameter on page 52 Digital Input Configuration parameters on page 69 Theory of Operation section 8.3.
5 – PARAMETER DESCRIPTIONS P25 Over Current Time PFN 02 LCD Display PFN:Over Cur Tim 02 0.1 sec Range Off, 0.1 – 90.0 seconds (Default 0.1 sec) Description The Over Current Time parameter sets the period of time that the motor current must be greater than the Over Current Level 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.
5 – PARAMETER DESCRIPTIONS P26 Under Current Level PFN 03 LCD Display PFN:Undr Cur Lvl 03 Off Range OFF, 5 – 100 % of FLA (Default OFF) Description If the MX detects a one cycle, average RMS current that is less than the level defined, an under current alarm condition exists and the alarm relay energizes, if defined. 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 the fault relay de-energizes.
5 – PARAMETER DESCRIPTIONS P28 Current Imbalance Level PFN 05 LCD Display PFN:Cur Imbl Lvl 05 15% Range OFF, 5 – 40 % (Default 15%) Description The Current Imbalance 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.
5 – PARAMETER DESCRIPTIONS P29 Ground Fault Level PFN 06 LCD Display PFN:Gnd Flt Lvl 06 Off Range OFF, 5 – 100 % FLA (Default OFF) Description The Ground Fault 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.
5 – PARAMETER DESCRIPTIONS P30 Over Voltage Level PFN 07 LCD Display PFN:Over Vlt Lvl 07 Off Range OFF, 1 – 40 % (Default OFF) Description If the MX detects for one cycle of any of the individual input phase voltages (rms) is above the over voltage level, the over/under voltage alarm is shown and the voltage trip timer begins counting. The delay time must expire before the starter faults. The over voltage condition and the phase on which occurred is displayed.
5 – PARAMETER DESCRIPTIONS P32 Voltage Trip Time PFN 09 LCD Display PFN:Vlt Trip Tim 09 0.1 sec Range 0.1 – 90.0 seconds (Default 0.1 sec) Description The Voltage Trip Time parameter sets the period of time that either an over voltage or under voltage condition must exist before a fault occurs.
5 – PARAMETER DESCRIPTIONS P35 Independent Starting/Running Overload PFN 12 LCD Display PFN:Indep S/R OL 12 Off Range OFF – On (Default OFF) Description If “OFF” When this parameter is “OFF” the overload defined by the Motor Running Overload Class 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 is used during motor acceleration and acceleration kick.
5 – PARAMETER DESCRIPTIONS P36 Motor Starting Overload Class PFN 13 LCD Display PFN:Starting OL 13 10 Range OFF, 1 – 40 (Default 10) Description The Motor Starting Overload Class parameter sets the class of the electronic overload when starting. The starter stores the thermal overload value as a percentage value between 0 and 100%, with 0% representing a “cold” overload and 100% representing a tripped overload.
5 – PARAMETER DESCRIPTIONS P37 Motor Overload Hot/Cold Ratio PFN 15 LCD Display PFN:OL H/C Ratio 15 60 % Range 0 – 99% (Default 60%) Description The Motor Overload Hot/Cold Ratio parameter defines the steady state overload content (OLss) 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.
5 – PARAMETER DESCRIPTIONS P38 Motor Overload Cooling Time PFN 16 LCD Display PFN:OL Cool Tim 16 30.0 min Range 1.0 –999.9 minutes (Default 30.0) Description The Motor Overload Cooling Time parameter is the time to cool from 100% to less than (<) 1%. When the motor is stopped, the overload content reduces exponentially based on Motor Overload Cooling Time parameter.
5 – PARAMETER DESCRIPTIONS P39, P40, P41 Digital Input Configuration I/O 01, I/O 02, I/O 03 LCD Display I/O:DI 1 Config 01 Stop I/O:DI 2 Config 02 Bypass Cnfrm I/O:DI 3 Config 03 Fault Low Description I/O parameters 1 – 3 configure which functions are performed by the D1 to D3 terminals.
5 – PARAMETER DESCRIPTIONS P42, P43, P44 Relay Output Configuration I/O 04, I/O 5, I/O 06 LCD Display I/O: R1 Config 04 Fault FS I/O: R2 Config 05 Running I/O: R3 Config 06 UTS Description I/O parameters 1 – 3 configure which functions are performed by the R1 to R3 relays Options LED LCD OFF Off OFF, Not Assigned, Output has no function or may be controlled over Modbus FLFS Fault FS Faulted – Fail Safe operation, energized when no faults present, deenergized when faulted (Default R1) FLnF Fa
5 – PARAMETER DESCRIPTIONS See Also P45 Up To Speed Time parameter on page 48 Over Current Level parameter on page 58 Under Current Level parameter on page 60 Ground Fault Level parameter on page 62 Inline Configuration parameter on page 76 Heater Level parameter on page 80 Energy Saver parameter on page 79 Application section 6.1, Application Consideration between Line Connected and Inside Delta Connected Soft Starter, on page 90 Application section 6.2.1, Wye Delta, on page 91 Application section 6.2.
5 – PARAMETER DESCRIPTIONS P46 Analog Input Trip Level I/O 08 LCD Display I/O:Ain Trp Lvl 08 50 % Range 0 – 100% (Default 50%) Description The Analog Input Trip Level parameter sets the analog input trip or fault level. This feature can be used to detect an open 4-20mA loop by setting the Analog Input Trip Type parameter to LOW and setting the Analog Input Trip Level parameter to a value less than (<) 20%.
5 – PARAMETER DESCRIPTIONS P48 Analog Input Span I/O 10 LCD Display I/O: Ain Span 10 100 % Range 0 – 100% (Default 100%) Description The analog input can be scaled using the Analog Input Span parameter. Examples: For a 0-10V input or 0-20mA input, a 100% Analog Input Span setting results in a 0% input reading with a 0V input and a 100% input reading with a 10V input.
5 – PARAMETER DESCRIPTIONS P49 Analog Input Offset I/O 11 LCD Display I/O:Ain Offset 11 0 % 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) => 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.
5 – PARAMETER DESCRIPTIONS P51 Analog Output Span I/O 13 LCD Display I/O: Aout Span 13 100 % Range 0 – 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.
5 – PARAMETER DESCRIPTIONS P53 Inline Configuration I/O 15 LCD Display I/O:Inline Confg 15 3.0 sec Range OFF, 0 – 10.0 seconds (Default 3.0 sec) Description The Inline Configuration parameter controls the behavior of the No Line warning, No Line fault, and the Ready relay function. If the Inline Configuration parameter is set to Off, then the MX assumes that there is no Inline contactor and that line voltage should be present while stopped.
5 – PARAMETER DESCRIPTIONS P55 Keypad Stop Disable I/O 17 LCD Display I/O:Kpd Stop Dis 17 Enabled Range Enabled – Disabled (Default Enabled) Description If “Disabled” When this parameter is set to Disabled, the keypad Stop button is de-activated. This should be done with caution, as the STOP will not stop the starter. If the keypad is selected as local or remote control sources, the “STOP” key cannot be disabled.
5 – PARAMETER DESCRIPTIONS P58 Miscellaneous Commands FUN 15 LCD Display FUN:Misc Command 15 None Range 0 – 6 (Default 0) Description The Miscellaneous Commands parameter is used to issue various commands to the MX starter. The Reset Run Time command resets the user run time meters back to zero (0). The Reset kWh command resetsthe accumulated kilowatt-hour and megawatt-hour meters back to zero (0). The Reflash Mode command puts the MX into a reflash program memory mode.
5 – PARAMETER DESCRIPTIONS P60 Communication Baud Rate FUN 11 LCD Display FUN:Com Baudrate 11 9600 Range 1.2, 2.4, 4.8, 9.6, 19.2 Kbps (Default 9.6) Description The Communication Baud Rate parameter sets the baud rate for Modbus communications.
5 – PARAMETER DESCRIPTIONS P63 Heater Level FUN 08 LCD Display FUN:Heater Level 08 Off Range OFF, 1 –25% FLA (Default OFF) Description The Heater Level parameter sets the level of D.C. current that reaches the motor when the motor winding heater/anti-windmilling brake is enabled. 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.
5 – PARAMETER DESCRIPTIONS P64 Starter Type FUN 07 LCD Display FUN:Starter Type 07 Normal Range nor,Id,y-d, PctL, cFol, AtL (Default nor) Description The MX has been designed to be the controller for many control applications; Solid State Starter, both Normal (outside Delta) and Inside Delta, and electromechanical starters, Wye Delta, Across the line full voltage starter, Phase Control/Voltage Follower, Current Follower.
5 – PARAMETER DESCRIPTIONS P65 Rated Power Factor FUN 06 LCD Display FUN:Rated PF 06 -0.92 Range -0.01 to 1.00 (Default –0.92) Description The Rated Power Factor parameter sets the motor power factor value that is used by the MX starter for TruTorque and Power control calculations and metering calculations.
5 – PARAMETER DESCRIPTIONS P67 Phase Order FUN 04 LCD Display FUN:Phase Order 04 Insensitive Range InS, AbC, CbA, SPH (Default InS) Description The Phase Order parameter sets the phase sensitivity of the starter. This can be used to protect the motor from a possible change in the incoming phase sequence. If the incoming phase sequence does not match the set phase rotation, the starter displays an Alarm while stopped and faults if a start is attempted.
5 – PARAMETER DESCRIPTIONS P69 Meter FUN 01, FUN02 LCD Display FUN: Meter 1 01 Ave Current FUN: Meter 2 02 Ave Volts Range 0 – 25 (Default 1 for meter 1, 7 for meter 2) Description For the LED display, parameter P69 configures which single meter is displayed on the main screen. For the LCD display, parameters FUN 01and FUN 02 configure which meters are displayed on the two lines of the main display screen.
5 – PARAMETER DESCRIPTIONS P71 Software Part Number FUN 14 LCD Display FUN:Software PN 14 810018-01-xx Description The Software Part Number parameter displays the software version. When calling Benshaw for service, this number should be recorded so it can be provided to the service technician. In addition to view 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.
5 – PARAMETER DESCRIPTIONS P72 Passcode FUN 16 LCD Display FUN: Passcode 16 Off Description The MX supports a 4-digit passcode. When the passcode is set, parameters may not be changed. 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.
5 – PARAMETER DESCRIPTIONS P73 Fault Log FL1 LCD Display FL1:Last Fault # Fault Name Range 1–9 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 Conditions, Avg. Line Current, Avg. Line Voltage, and Line Frequency at the time of the fault.
5 – PARAMETER DESCRIPTIONS 88
6 Applications
6 – APPLICATIONS Line Connected Motor 6.1 Application Consideration between Line Connected and Inside Delta Connected Soft Starter There are differences between a line connected soft starter as shown in Figure 10 and the inside delta connected soft starter as shown in Figure 11 that need to be understood. By observation of Figure 11, 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.
6 – APPLICATIONS Inside Delta Connected Motor 6.1.2 Inside Delta Connection An inside delta soft starter is shown in Figure 11, where the power poles are connected in series with the stator windings of a delta connected motor. Figure 11 – Typical Inside Delta Motor Connection L3 T6 3 T3 1 6 4 Motor T1 L1 T5 T4 T2 L2 5 2 For an Inside Delta connected motor, the inside winding’s average SCR current is less than that of the outside average line current by a factor of 1.55 (FLA/1.55).
6 – APPLICATIONS Wye Delta Starter The presence of these resistors in a closed transition starter smoothes the transition from Wye to Delta operation mode.
6 – APPLICATIONS Phase Control & Current Follower Starter 6.2.2 Phase Control When the Starter Type parameter is set to Phase Control, the MX is configured to operate as a phase controller / voltage follower. This is an open loop control mode. The firing angles of the SCRs are directly controlled based on voltage or current applied to the Analog Input. A reference-input value of 0% results in no output. A reference-input value of 100% results in full (100%) output voltage.
6 – APPLICATIONS Across The Line Starter 6.2.4 Across The Line (Full Voltage Starter) When the Starter Type parameter is set to ATL, the MX is configured to operate an electromechanical full voltage or across-the-line (ATL) starter. In the ATL configuration, the MX assumes that the motor contactor (1M) is directly controlled by a digital output relay that is programmed for the RUN function.
7 Troubleshooting
7 – TROUBLESHOOTING 7.1 General Troubleshooting Charts The following troubleshooting charts can be used to help solve many of the more common problems that may occur. 7.1.1 Motor does not start, no output to motor Condition Cause Solution Display Blank, CPU Heartbeat LED on MX card not blinking. Control voltage absent. Check for proper control voltage input. Verify fuses and wiring. MX control card problem. Consult factory. Fault Displayed. Fault Occurred.
7 – TROUBLESHOOTING 7.1.2 During starting, motor rotates but does not reach full speed Condition Cause Solution Fault Displayed. Fault Occurred. See fault code troubleshooting table for more details. Display shows Accel or Run. Maximum Motor Current setting (P7/QST07) set too low. Review acceleration ramp settings. Motor loading too high and/or current not dropping below 175% FLA indicating that the motor has not come up to speed. Reduce load on motor during starting.
7 – TROUBLESHOOTING 7.1.4 Deceleration not operating as desired Condition Cause Solution Motor stops too quickly. Decel Time (P18/CFN17) set too short. Increase Decel Time. Decel Begin and End Levels (P16/CFN15 and P17/CFN16) set improperly. Increase Decel Begin and/or Decel End levels. Decel time seems correct but motor surges (oscillates) at beginning of deceleration cycle. Decel Begin Level (P16/CFN15) set too high. Decrease Decel Begin Level until surging is eliminated.
7 – TROUBLESHOOTING 7.1.6 Metering incorrect Condition Cause Solution Power Metering not reading correctly. CTs installed or wired incorrectly. Verify correct CT wiring and verify that the CTs are installed with all the White dots towards the input line side. CT ratio parameter (P68/FUN03) set incorrectly. Verify that the CT ratio parameter is set correctly. Burden switches set incorrectly. Verify that the burden switches are set correctly. PF Meter not reading correctly.
7 – TROUBLESHOOTING 7.1.7 Other Situations Condition Cause Solution Motor Rotates in Wrong Direction Phasing incorrect If input phasing correct, exchange any two output wires. If input phasing incorrect, exchange any two input wires. Erratic Operation Loose connections Shut off all power and check all connections. 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.
7 – TROUBLESHOOTING 7.2 Fault Code Troubleshooting Table The following is a list of possible faults that can be generated by the MX starter control. Fault Code Description Detailed Description of Fault / Possible Solutions F01 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 is.
7 – TROUBLESHOOTING Fault Code Description Detailed Description of Fault / Possible Solutions F14 Input power not single phase Three-phase power has been detected when the starter is expecting singlephase 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.
7 – TROUBLESHOOTING Fault Code Description Detailed Description of Fault / Possible Solutions F25 High Line L2-L3 High voltage above the Over voltage Trip Level parameter setting (P30/PFN07) was detected for longer than the Over/Under Voltage Trip delay time (P32/PFN09). Verify that the actual input voltage level is correct. Verify that the Rated Voltage parameter (P66/FUN05) is set correctly. Line power quality problems/ excessive line distortions.
7 – TROUBLESHOOTING F34 Undercurrent Motor current dropped under the Under Current Trip Level setting (P26/PFN03) for longer than the Under Current Trip Delay time setting (P27/PFN04). Check system for cause of under current condition. F37 Current Imbalance A current imbalance larger than the Current Imbalance Trip Level parameter setting (P28/PFN05) was present for longer than ten (10) seconds. Check motor wiring for cause of imbalance.
7 – TROUBLESHOOTING F41 Current at Stop 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), CT ratio (P68/FUN03) and burden switch settings are correct. F47 Stack Protection Fault (stack thermal overload) The MX electronic power stack OL protection has detected an overload condition. Check motor for jammed or overloaded condition.
7 – TROUBLESHOOTING F61 External Fault on DI#2 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. F62 External Fault on DI#3 input DI#3 input has been programmed as a fault type digital input and input indicates a fault condition is present.
7 – TROUBLESHOOTING F95 CPU Error – Parameter EEPROM Checksum Fault The MX found the non-volatile parameter values to be corrupted. Typically occurs when the MX is re-flashed with new software. Perform a Factory Parameter reset and then properly set all parameters before resuming normal operation. If fault persists after performing a Factory Parameter reset, consult factory. F96 CPU Error The MX has detected an internal CPU problem. Consult factory.
7 – TROUBLESHOOTING 108
8 Theory of Operation
8 – THEORY OF OPERATION Motor Overload 8.1 Solid State Motor Overload Protection 8.1.1 Overview The MX contains an advanced I2t electronic motor overload (OL) protection function. For optimal motor protection, the MX has forty standard NEMA style overload curves (in steps of one) available for use. Separate overload classes can be programmed for acceleration and for normal running operation and individually or completely disabled if necessary.
8 – THEORY OF OPERATION Motor Overload Commonly Used Overload Curves 10000 Seconds to Trip 1000 100 Class 40 Class 30 Class 20 Class 15 10 Class 10 Class 5 1 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 Current % (FLA) 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 RBX power stack is designed for class 10 duty without derating.
8 – THEORY OF OPERATION Motor Overload 8.1.3 Motor Overload Operation Overload Heating When the motor is operating in the overloaded condition (motor current greater than FLAxSF), the motor overload content accumulates based on the starter’s operating mode at a rate established by the overload protection class chosen. The accumulated overload content can be viewed on the display or over the communications network.
8 – THEORY OF OPERATION Motor Overload Figure 14 – Overload Derated for Current Imbalance MX Motor OL derating vs. current imbalance 1 Derating Factor 0.95 0.9 0.85 0.8 0.75 0 5 10 15 20 Current imbalance % 25 30 8.1.5 Harmonic Compensation The MX motor overload calculation automatically compensates for the additional motor heating that can result from the presence of harmonics.
8 – THEORY OF OPERATION Motor Overload content level. The rate of the running motor overload heating or cooling is controlled by the Motor Overload Cooling Time parameter. The following diagram illustrates how the current and the Motor Overload Hot/Cold Ratio parameter determine the steady state overload content. It assumes there is no current imbalance.
8 – THEORY OF OPERATION Motor Overload NOTE: When the Independent Starting/Running Overload parameter is set to “OFF”, the running OL is used at all times. NOTE: When one or the other overload is disabled, the Hot/Cold motor compensation is still active. Therefore the motor overload content may still slowly increase or decrease depending on the measured motor current.
8 – THEORY OF OPERATION Motor Overload Frame Size Cooling Time 180 280 360 400/440 500 Larger frames 30 min 60 min 90 min 120 min 180 min 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: Motor Cooling Time (minutes) ≈ 60 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%
8 – THEORY OF OPERATION Motor Service Factor 8.2 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. 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.
8 – THEORY OF OPERATION Acceleration Control 8.3 Acceleration Control 8.3.1 Current Ramp Settings, Ramps and Times General The current ramp sets how the motor accelerates. The current ramp is a linear increase in current from the initial setting to the maximum setting. The ramp time sets the speed of this linear current increase. The following figure shows the relationships of these different ramp settings.
8 – THEORY OF OPERATION Acceleration Control 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. 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.
8 – THEORY OF OPERATION Acceleration Control 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.
8 – THEORY OF OPERATION Acceleration Control 8.3.4 Power Control Acceleration Settings and Times General Power control is a closed loop power based acceleration control. The primary purpose of Power controlled acceleration is to control and limit the power (kW) drawn from the power system and to reduce the power surge that may occur as an AC induction motor comes up to speed. This power surge can be a problem in applications that are operated on generators or other limited or “soft” power systems.
8 – THEORY OF OPERATION Acceleration Control 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.
8 – THEORY OF OPERATION Acceleration Control 8.3.5 Open Loop Voltage Ramps and Times General The open loop voltage ramp provides soft starting of a motor by increasing the voltage applied to motor from the Initial Voltage setting to full (100%) line voltage. The ramp time sets the speed at which the voltage is increased. 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.
8 – THEORY OF OPERATION Acceleration Control 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.
8 – THEORY OF OPERATION Acceleration Control 8.3.6 Dual Acceleration Ramp Control General Two independent current ramps and kick currents may be programmed. The use of two different starting profiles can be very useful with applications that have varying starting loads such as conveyors that can start either loaded or unloaded. The Current Ramp 1 profile is programmed using the parameters Initial Current 1, Maximum Current 1, and Ramp Time 1.
8 – THEORY OF OPERATION Acceleration Control 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.
8 – THEORY OF OPERATION Deceleration Control 8.4 Deceleration Control 8.4.1 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 23 – Motor Voltage Versus Decel Level Beginning Level This sets the starting voltage of the deceleration ramp.
8 – THEORY OF OPERATION Deceleration Control 8.4.2 TruTorque Deceleration Overview TruTorque deceleration control is a closed loop deceleration control. This allows TruTorque deceleration to be more consistent in cases of changing line voltage levels and varying motor load conditions. TruTorque deceleration is best suited to pumping and compressor applications where pressure surges, such as water hammer, must be eliminated.
8 – THEORY OF OPERATION Wye Delta Operation 8.5 Wye-Delta Operation When the Starter Type parameter is set to Wye-Delta, the MX is configured to operate an electromechanical Wye-Delta (Star-Delta) starter. When in Wye-Delta mode, all MX motor and starter protective functions except bad SCR detection and power stack overload, are available to provide full motor and starter protection. The MX utilizes an intelligent Wye to Delta transition algorithm.
8 – THEORY OF OPERATION Wye Delta Operation 3. When the 2S contactor pulls in, resistors are inserted in the circuit and the 1S contactor is DE-energized. 4. When the 1S contactor drops out the 2M contactor is energized. 5. When the 2M contactor is pulled in, feedback can be sent to the MX control card to confirm that the transition sequence to Delta is complete. The starter remains in the Delta or running mode until the start command is removed or a fault occurs.
8 – THEORY OF OPERATION Phase Control Phase Control When the Starter Type parameter is set to Phase Control, the MX is configured to operate as a phase controller or voltage follower. This is an open loop control mode. When a start command is given, the RUN programmed relays energize. The firing angles of the SCRs are directly controlled based on voltage or current applied to the Analog Input. Figure 26 – Phase Control Mode MX Phase Control Mode 100 90 80 70 SCR phase angle (%) 8.
8 – THEORY OF OPERATION Phase Control 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.
8 – THEORY OF OPERATION Current Follower 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.
8 – THEORY OF OPERATION Across The Line / Full Voltage Operation Across The Line / Full Voltage Operation When the Starter Type parameter is set to ATL, the MX is configured to operate an electromechanical full voltage or across-the-line (ATL) starter. In the ATL configuration, the MX assumes that the motor contactor (1M) is directly controlled by a digital output relay that is programmed for the RUN function.
8 – THEORY OF OPERATION Start/Stop Control with a Hand/Off/Auto Selector Switch 8.9 Start/Stop Control with a Hand/Off/Auto Selector Switch Often times, a switch is desired to select between local or “Hand” mode and remote or “Auto” mode. In most cases, local control is performed as 3-wire logic with a normally open, momentary contact Start pushbutton and a normally closed, momentary contact Stop pushbutton, while remote control is performed as 2-wire logic with a “Run Command” contact provided by a PLC.
8 – THEORY OF OPERATION Simplified I/O Schematics 8.10 Simplified I/O Schematics Figure 29 – Digital Input Simplified Schematic 15.0K Ω D2 475 Ω D2/D3 Com 15.0K Ω Figure 30 – Analog Input Simplified Schematic 1M Ω AIN+ 499 Ω JP 3 AIN1M Ω Figure 31 – Analog Output Simplified Schematic 20.0K Ω 20.0K Ω 365 K Ω 0.1 цf + 15V 1K Ω 36.0K Ω 10 K Ω 10 Ω AOUT 0.
8 – THEORY OF OPERATION Using Modbus Communication 8.11 Using Modbus 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.
8 – THEORY OF OPERATION Using Modbus Communication 138
9 Technical Information
9 – TECHNICAL INFORMATION Technical Specifications 9.1 General Information The physical specifications of the starter vary depending upon its configuration. The applicable motor current determines the configuration and its specific application requirements. This document covers the control electronics and several power sections: • • • 9.
9 – TECHNICAL INFORMATION Technical Specifications 9.6 List of Motor Protection Features • • • • • • • • • • • • • • ANSI 51 – Electronic motor overload (Off, class 1 to 40, separate starting and running curves available) ANSI 86 – Overload lockout ANSI 51 – Overcurrent detection (Off or 50 to 800% and time 0.1 to 90.0 sec. in 0.1 sec. intervals) ANSI 50 - Instantaneous electronic overcurrent trip ANSI 37 – Undercurrent detection (Off or 5 to 100% and time 0.1 to 90.0 sec. in 0.1 sec.
9 – TECHNICAL INFORMATION Technical Specifications 9.7 MX Control Card 9.7.1 Terminal Points, Functions and Ratings Table 9 – Terminals Function TB1 Control Power Input Relay Output R1 Relay Output R2 & R3 TB2 Digital Inputs Start & DI1 Terminal Number Description N, neutral L, line G, ground NC1: Normally Closed RC1:Common NO1:Normally Open 96 – 144V AC input, 50/60 Hz 45VA current requirements NC2, RC2, NO2 NC3, RC3, NO3 Start, DI1, S/DI1 Com Digital Inputs DI2 & DI3 Serial Comm.
9 – TECHNICAL INFORMATION Technical Specifications 9.7.2 Terminal Block Rating 9.7.2.1 Wire Gauge The terminals can support 1- 14 AWG wire or 2-16 AWG wires or smaller. 9.7.2.2 Torque rating The terminals on the control card have a torque rating of 3.5-inch lb. or 0.4nm. This MUST be followed or damage will occur to the terminals. 9.7.
9 – TECHNICAL INFORMATION Technical Specifications 144
10 Appendix
10 – APPENDIX Lists, Tables and Figures List of Tables Table 1 – CT Ratios and Burden Switch Settings ..............................................................................................................................................10 Table 2 – 2x16 Remote Keypad LED Functions................................................................................................................................................20 Table 3 – Description of the Keys on the Remote LCD Keypad..................
10 – APPENDIX Appendix A – CE Mark According to the EMC – Directive 89/336/EEC as Amended by 92/31/EEC and 93/68/EEC Product Category: Motor Controller Product Type: Reduced Voltage Solid State Motor Controller Model Numbers: Model Number RBX-1-S-027A-11C RBX-1-S-040A-11C RBX-1-S-052A-12C RBX-1-S-065A-12C RBX-1-S-077A-13C RBX-1-S-096A-13C RBX-1-S-125A-14C RBX-1-S-156A-14C RBX-1-S-180A-14C RBX-1-S-180A-15C Model Number RBX-1-S-240A-15C RBX-1-S-302A-15C RBX-1-S-361A-16C RBX-1-S-414A-17C RBX-1-S-477A-17C
10 – APPENDIX Appendix B – Fault Codes See the hardware manual for Troubleshooting Solutions Fault Code F00 F01 F02 F03 F04 F10 F11 F12 F13 F14 F15 F21 F22 F23 F24 F25 F26 F27 F28 F29 F30 F31 F34 F35 F36 F37 F38 F39 F40 F41 F47 F48 F50 F51 F52 F53 F60 F61 F62 F63 F64 F71 F72 F73 F81 F82 F94 F95 F96 F97 F98 F99 Description No fault UTS Time Limit Expired Motor Thermal Overload Trip Jog Time Limit Expired Reserved Phase Rotation Error, not ABC Phase Rotation Error, not CBA Low Line Frequency High Line Freq
10 – APPENDIX Appendix C – Alarm Codes The following is a list of all MX alarm codes. The alarm codes correspond to associated fault codes. In general, an alarm indicates a condition that if continued, will result in the associated fault.
10 – APPENDIX Alarm Code A37 Description Notes Current Imbalance A38 Ground Fault A47 A53 A71 Stack Overload Alarm Reserved Analog Input #1 Trip This alarm exists while the MX is running and a current imbalance above the defined threshold is detected, but the delay for the fault has not yet expired. When the delay expires, a Fault 37 occurs. This alarm exists while the MX is running and a ground current above the defined threshold is detected, but the delay for the fault has not yet expired.
10 – APPENDIX Appendix D – Modbus Register Map Following is the Modbus Register Map. Note that all information may be accessed either through the Input registers (30000 addresses) or through the Holding registers (40000 addresses).
10 – APPENDIX Absolute Register Address 30032/40032 Description Modbus Registers R/W Range Units R %FLA 30033/40033 30034/40034 30035/40035 30036/40036 30037/40037 30038/40038 Residual Ground Fault Current Average Voltage L1-L2 Voltage L2-L3 Voltage L3-L1 Voltage Motor Overload Power Factor R R R R R R Vrms Vrms Vrms Vrms % 0.
10 – APPENDIX Absolute Register Address 30114/40114 30115/40115 30116/40116 30117/40117 30118/40118 30119/40119 30120/40120 Description Modbus Registers R/W Range R/W R/W R/W R/W R/W R/W R/W 30121/40121 30122/40122 Maximum Current 1 Ramp Time 1 Initial Current 2 Maximum Current 2 Ramp Time 2 Up To Speed Time Initial Voltage/Torque/Power Maximum Torque/Power Stop Mode 30123/40123 30124/40124 30125/40125 30126/40126 Decel Begin Level Decel End Level Decel Time Kick 1Enable R/W R/W R/W R/W 30127/40127
10 – APPENDIX Modbus Registers R/W Range Absolute Register Address 30132/40132 Description Rated Voltage R/W 30133/40133 Phase Order R/W 30134/40134 30135/40135 Rated Power Factor Over Current Trip Enable R/W R/W 30136/40136 30137/40137 Over Current Level Over Current Time Enable Over Current Time Under Current Trip Enable Under Current Level Under Current Time Enable Under Current Time Current Imbalance Trip Enable Current Imbalance Level R/W R/W 30138/40138 30139/40139 30140/40140 30141/40141
10 – APPENDIX Modbus Registers R/W Range Absolute Register Address 30145/40145 Description Ground Fault Trip Enable R/W 30146/40146 30147/40147 Ground Fault Level Over Voltage Trip Enable R/W R/W 30148/40148 30149/40149 R/W R/W 30150/40150 30151/40151 Over Voltage Level Under Voltage Trip Enable Under Voltage Level Voltage Trip Time R/W R/W 30152/40152 Auto Reset Enable R/W 30153/40153 Auto Reset Delay Time R/W 30154/40154 R/W 30155/40155 30156/40156 30157/40157 Controlled Fault Stop En
10 – APPENDIX Absolute Register Address 30167/40167 Description Analog Output Function Modbus Registers R/W Range R/W 0: 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 30168/40168 30169/40169 30170/40170 Analog Output Span Analog Output Offset Inline Enable R/W R/W R/W 30171/40171 30172/40172 30173/40173 Inline Delay Time Bypass Feedback Time Keypad Stop Disable R/W R/W R/W 30174/40174 30175/40175 30176/40176 30177/40177 R/W 30178/40178 30179/40179 Reserved Reserved Reserved Communication Timeout Enable Co
10 – APPENDIX Modbus Registers R/W Range Absolute Register Address 30184/40184 Description LED Display Meter R/W 30185/40185 30186/40186 30187/40187 LCD Display Meter 1 LCD Display Meter 2 Custom Stack Enable R/W R/W R/W 30188/40188 30189/40189 Starter Model Number Miscellaneous Commands R/W R/W 30301/40301 Fault Code – Most Recent Fault Log Entry Fault Code – 2nd Most Recent Fault Log Entry Fault Code – 3rd Most Recent Fault Log Entry Fault Code – 4th Most Recent Fault Log Entry Fault Code – 5th
10 – APPENDIX Absolute Register Address 30308/40308 30309/40309 30311/40311 Description Fault Code – 8th Most Recent Fault Log Entry Fault Code – 9th Most Recent Fault Log Entry System State – Most Recent Fault Log Entry Modbus Registers R/W Range R - R - R 0: 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13: 14: 30312/40312 30313/40313 30314/40314 30315/40315 30316/40316 30317/40317 30318/40318 30319/40319 30321/40321 30322/40322 30323/40323 30324/40324 System State – 2nd Most Recent Fault Log Entry Syst
10 – APPENDIX Absolute Register Address 30325/40325 30326/40326 30327/40327 30328/40328 30329/40329 30331/40331 30332/40332 30333/40333 30334/40334 30335/40335 30336/40336 30337/40337 30338/40338 30339/40339 30341/40341 30342/40342 30343/40343 30344/40344 30345/40345 30346/40346 Description Current – 5th Most Recent Fault Log Entry Current – 6th Most Recent Fault Log Entry Current – 7th Most Recent Fault Log Entry Current – 8th Most Recent Fault Log Entry Current – 9th Most Recent Fault Log Entry Voltage –
10 – APPENDIX Absolute Register Address 30347/40347 30348/40348 30349/40349 Description Line Period – 7th Most Recent Fault Log Entry Line Period – 8th Most Recent Fault Log Entry Line Period – 9th Most Recent Fault Log Entry Modbus Registers R/W Range Units R microseconds R microseconds R microseconds Starter Control Register: Bit 0 – Run/Stop Bit 1 – Fault Reset Bit 2 –Emergency Overload Reset Bit 3 –Local/Remote Bit 4 –Heat Disabled Bit 5 –Ramp Select Bit 13 – Relay 3 Bit 14 – Relay 2 Bit 15 –
10 – APPENDIX Starter Status Register: Bit 0 – Ready Bit 1 – Running Bit 2 – UTS Bit 3 – Alarm Bit 4 – Fault Bit 5 – Lockout 0– 1– 0– 1– 0– 1– 0– 1– 0– 1– 0– 1– Initializing or Faulted and Decelling or Faulted and Braking or Faulted and Stopped or Lockout Otherwise Not Running Running Not UTS UTS No alarm conditions 1 or more alarm conditions No Fault Condition Fault Condition Start or Fault Reset not locked out. Start or Fault Reset locked out.
10 – APPENDIX Appendix E – Parameter Table Following is the parameter table for both the LED and LCD Display. The last column is a convenient place to write down parameter settings. Quick Start Group LED P1 P2 P3 P4 P5 LCD QST 01 QST 02 QST 03 QST 04 QST 05 Parameter Motor FLA Motor Service Factor Motor Running Overload Class Local Source Remote Source P6 P7 P8 P9 QST 06 QST 07 QST 08 QST 09 Initial Current 1 Maximum Current 1 Ramp Time 1 Up To Speed Time Setting Range 1– 6400 1.00 – 1.
10 – APPENDIX LED P33 P34 P35 LCD PFN 10 PFN 11 PFN 12 Setting Range Off, 1 – 900 Off, On Off, On PFN 13 PFN 14 PFN 15 PFN 16 Parameter Auto Reset Controlled Fault Stop Enable Independent Starting/Running Overload Motor Starting Overload Class Motor Running Overload Class Motor Overload Hot/Cold Ratio Motor Overload Cooling Time P36 P3 P37 P38 LED P39 P40 LCD I/O 01 I/O 02 Parameter DI 1 Configuration DI 2 Configuration P41 I/O 03 DI 3 Configuration P42 P43 P44 I/O 04 I/O 05 I/O 06 R1 Configur
10 – APPENDIX LED P54 P55 LCD I/O 16 I/O 17 Parameter Bypass Feedback Time Keypad Stop Disable Setting Range 0.1 – 5.0 Enabled, Disabled Units Seconds Default 2.0 Enabled Page 76 77 Setting Units Default Ave Current Ave Volts Page 84 Setting 288 83 Insens. 83 480 82 -0.
10 – APPENDIX LED P60 LCD FUN 11 Parameter Communication Baud Rate P59 P70 P71 P58 FUN 12 FUN 13 FUN 14 FUN 15 Communication Timeout Starter Model Number Software Part Number Miscellaneous Commands P72 FUN 16 Passcode Setting Range 1200 2400 4800 9600 19200 Off, 1 – 120 Model Dependent Display Only None Reset RT Reset kWh Reflash Mode Store Parameters Load Parameters Factory Reset Units bps Default 9600 Page 79 Seconds Off None 78 84 85 78 Off 86 Fault Group Group FL1 FL2 FL3 FL4 FL5 FL6
10 – APPENDIX Revision History Revision -00 -01 -02 Date 28 June, 2004 24 November, 2004 29 July 2005 Changes Initial Release Corrections and enhancements Shield grounding corrected 166 ECO# E0896 E1041
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