User manual

ManualsBrandsBENSHAW ManualsComputer equipmentENHANCED KEYPAD

August 2008

Software Version: 810023-01-08

Hardware Version: 300055-01-05

2008 Benshaw Inc.

890034-01-02

Solid State Starter

Control

RediStart

User Manual

RB2, RC2, RX2E Models

Benshaw retains the right to change specifications and illustrations in text without prior notification. The contents of this document may

not be copied without the explicit permission of Benshaw.

Summary of content (222 pages)

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RediStart TM Solid State Starter 2 Control RB2, RC2, RX2E Models User Manual 890034-01-02 August 2008 Software Version: Hardware Version: 810023-01-08 300055-01-05 © 2008 Benshaw Inc. Benshaw retains the right to change specifications and illustrations in text without prior notification. The contents of this document may not be copied without the explicit permission of Benshaw.
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Important Reader Notice 2 Congratulations on the purchase of your new Benshaw RediStart MX Solid State Starter. This manual contains the information to install and 2 2 program the MX Solid State Starter. The MX is a standard version solid state starter. If you require additional features, please review the 3 expanded feature set of the MX Solid State Starter on page 5. 2 This manual may not cover all of the applications of the RediStart MX .
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SAFETY PRECAUTIONS Safety Precautions Electric Shock Prevention • • • • • • • • While power is on or soft starter is running, do not open the front cover. You may get an electrical shock. This soft starter contains high voltage which can cause electric shock resulting in personal injury or loss of life. Be sure all AC power is removed from the soft starter before servicing. Do not connect or disconnect the wires to or from soft starter when power is applied. Make sure ground connection is in place.
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TABLE OF CONTENTS Table of Contents 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1.1 Additional MX3 Product Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2 TECHNICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.2 Electrical Ratings . . . . . . . . . . . .
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TABLE OF CONTENTS 3.6 Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 3.6.1 3.6.2 3.6.3 3.6.4 3.6.5 3.6.6 Recommended Incoming Line Protection . . . . . . . . Recommended Wire Gauges . . . . . . . . . . . . . . . . Power Wire Connections . . . . . . . . . . . . . . . . . . Motor Lead Length . . . . . . . . . . . . . . . . . . . . . Compression Lugs. . . . . . . . . . . . . . . . . . . . . . Torque Requirements for Power Wiring Terminations . .
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TABLE OF CONTENTS 5 PARAMETER GROUPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 5.2 LED and LCD Display Parameters Cross Reference . . . . . . . . . . . . . . . . . . . . . . . . . 61 5.3 LED Display Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 5.4 LCD Display Parameters. . . . . . . . . . . . . . . .
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TABLE OF CONTENTS 7.8 Wye Delta Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 7.9 Across The Line (Full Voltage Starter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 7.10 Single Phase Soft Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 7.11 Phase Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 7.11.
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TABLE OF CONTENTS APPENDIX A ALARM CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 APPENDIX B FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 APPENDIX C SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 APPENDIX D EU DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . 198 APPENDIX E MODBUS REGISTER MAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1 Introduction 1
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1 - INTRODUCTION INTRODUCTION 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: • Introduction • • • • • • • • • Symbols Technical Information Installation Keypad Operation Parameters Parameter Description Applications Theory of Operation Troubleshooting & Maintenance Appendices There are 2 symbols used in this manual to highlight important information.
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1 - INTRODUCTION Benshaw Services General Information Benshaw offers its customers the following: • Start-up services • • • • On-site training services Technical support Detailed documentation Replacement parts z NOTE: Information about products and services is available by contacting Benshaw, refer to page 4. Start-Up Services Benshaw technical field support personnel are available to customers with the initial start-up of the 2 RediStart MX .
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1 - INTRODUCTION Contacting Benshaw Contacting Benshaw Information about Benshaw products and services is available by contacting Benshaw at one of the following offices: Benshaw Inc. Corporate Headquarters 1659 E. Sutter Road Glenshaw, PA 15116 Phone: (412) 487-8235 Tech Support: (800) 203-2416 Fax: (412) 487-4201 Benshaw High Point EPC Division 645 McWay Drive High Point, NC 27263 Phone: (336) 434-4445 Fax: (336) 434-9682 Benshaw Canada Controls Inc.
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1 - INTRODUCTION MX2 & MX3 Product Comparison 1.1 3 Additional MX Product Features 2 3 The MX is a standard solid state starter. If you require additional features, please review the expanded feature set of the MX Solid 3 State Starter below. For the additional information on the MX Solid State Starter contact Benshaw.
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1 - INTRODUCTION Interpreting Model Numbers 2 Figure 1: RediStart MX Series Model Numbers RB2-1-S-052A-12C C = Open Chassis Frame Size Amp Rating, (0 - 999A) Fault Level S = Standard H = High Type of Bypass 0 = None (only available with RC) 1 = Integrated 2 = Separate, Definite Purpose (Only with 1000V Starter) 3 = Separate, ATL IEC AC3 Rated 4 = Separate, ATL NEMA Rated (AC4) Type of Control 2 2 = MX 3 3 = MX Family of RediStart Starter B = Bypass C = Continuous Example of Model Number: RX2-1S-361A-14C
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1 - INTRODUCTION General Overview of a Reduced Voltage Starter General Overview 2 The RediStart MX motor starter is a microprocessor-controlled starter for single or three-phase motors. The starter can be custom designed for specific applications. A few of the features are: • Solid state design. • Reduced voltage starting and soft stopping. • Closed-loop motor current control, power (kW) control, torque control. • Programmable motor protection. • Programmable operating parameters.
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1 - INTRODUCTION NOTES: 8
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2 Technical Specifications
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2 - TECHNICAL SPECIFICATIONS TECHNICAL 2 SPECIFICATIONS Technical Specifications 2.1 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. Specifications are subject to change without notice.
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2 - TECHNICAL SPECIFICATIONS Table 1: Terminals Terminal Block Function Terminal Number Description SCR J6 to J11 1: Gate 2: Cathode SCR gate Connections Phase C.T. J12 1: CT1 2: CT1 3: CT2 4: CT2 5: CT3 6: CT3 See CT Connector Wire Gauge: The terminals can support 1- 14 AWG wire or 2-16 AWG wire or smaller. Torque Rating: The terminals on the control card have a torque rating of 5.0-inch lb. or 0.56Nm. This MUST be followed or damage will occur to the terminals.
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2 - TECHNICAL SPECIFICATIONS 2.2.4 Solid State Motor Overload 2 2 2 The MX control has an advanced I t electronic motor overload (OL) protection function. For optimal motor protection the MX control has forty standard NEMA style overload curves available for use. Separate overloads can be programmed, one for acceleration and 2 another for normal running operation. The overloads can be individual, the same or completely disabled if necessary.
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2 - TECHNICAL SPECIFICATIONS 2.2.5 CT Ratios Table 3: CT Ratios CT Ratio Minimum FLA (A rms) Maximum FLA (A rms) 72:1 (4 wraps 288:1) 4 16 96:1 (3 wraps 288:1) 5 21 144:1 (2 wraps 288:1) 8 32 288:1 15 64 864:1 45 190 2640:1 135 590 3900:1 200 870 5760:1 295 1285 8000:1 410 1800 14400:1 (CT-CT combination) 740 3200 28800:1 (CT-CT combination) 1475 6400 z NOTE: See P78/FUN 03 (CT Ratio) parameter on page 126 for more information. Starter Power Ratings 2.
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2 - TECHNICAL SPECIFICATIONS 2.3.1 Standard Duty (350% for 30 sec) Ratings Table 4: Standard Duty Horsepower Ratings Standard Duty (350% current for 30 seconds, 115% Continuous) HORSEPOWER RATING NOMINAL AMPS 200-208V 230-240V 380-400V 440-480V 575-600V RB2-1-S-027A-11C 27 7.
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2 - TECHNICAL SPECIFICATIONS 2.3.2 Heavy Duty (500% current for 30 sec) Ratings Table 5: Heavy Duty Horsepower Ratings Heavy Duty (500% current for 30 seconds, 125% Continuous) HORSEPOWER RATING NOMINAL AMPS 200-208V 230-240V 380-400V 440-480V 575-600V RB2-1-S-027A-11C 24 7.
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2 - TECHNICAL SPECIFICATIONS 2.3.3 Severe Duty (600% current for 30 sec) Ratings Table 6: Severe Duty Horsepower Ratings Severe Duty (600% current for 30 seconds 125% Continuous) HORSEPOWER RATING NOMINAL AMPS 200-208V 230-240V 380-400V 440-480V 575-600V RB2-1-S-027A-11C 24 5 7.
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2 - TECHNICAL SPECIFICATIONS 2.3.
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18 40 52 65 77 96 125 156 180 180 240 302 361 414 477 515 590 720 838 RB_1_040A11C RB_1_052A12C RB_1_065A12C RB_1_077A13C RB_1_096A13C RB_1_125A14C RB_1_156A14C RB_1_180A14C RB_1_180A15C RB_1_240A15C RB_1_302A15C RB_1_361A16C RB_1_414A17C RB_1_477A17C RB_1_515A17C RB_1_590A18C RB_1_720A18C RB_1_838A19C 1116 1299 964 915 798 739 642 560 468 372 279 279 242 194 - - - - - - 828 679 592 549 476 415 347 276 207 207 179 144 110 89 75 60 46 3
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40 52 65 77 96 125 156 180 180 240 302 361 414 477 515 590 720 838 RB_2_040A11C RB_2_052A12C RB_2_065A12C RB_2_077A13C RB_2_096A13C RB_2_125A14C RB_2_156A14C RB_2_180A14C RB_2_180A15C RB_2_240A15C RB_2_302A15C RB_2_361A16C RB_2_414A17C RB_2_477A17C RB_2_515A17C RB_2_590A18C RB_2_720A18C RB_2_838A19C 964 828 679 592 549 476 415 347 276 207 207 179 144 110 89 75 60 46 31 1299 1116 915 798 739 642 560 468 372 279 279 242 194 - - - - - -
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20 40 52 65 77 96 124 125 156 180 240 302 361 477 590 720 840 960 1080 1200 RC_ 0 _040A31C RC_ 0 _052A31C RC_ 0 _065A32C RC_ 0 _077A32C RC_ 0 _096A33C RC_ 0 _124A34C RC_ 0 _125A34C RC_ 0 _156A34C RC_ 0 _180A35C RC_ 0 _240A35C RC_ 0 _302A35C RC_ 0 _361A35C RC_ 0 _477A35C RC_ 0 _590A36C RC_ 0 _720A36C RC_ 0 _840A36C RC_ 0 _960A37C RC_-0_1080A-37C RC_ 0_1200KA38C 1440 1350 1200 1050 900 737 596 421 377 300 225 195 155 155 120 2 Power Block wire size #2 awg
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2 - TECHNICAL SPECIFICATIONS 2.3.8 RB2 Starter Control Power Requirements Table 8: RB2 Starter CPT VA Requirements 2.3.9 Model Number Power Required (VA) Recommended Min. TX size Model Number Power Required (VA) Recommended Min.
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2 - TECHNICAL SPECIFICATIONS Mechanical Drawings 2.4 Dimensions 2.4.1 RB2 Chassis with Integral Bypass Figure 3: RB2 - 27A - 96A Model A B C D E F RB2 27-65A 14 10 12.5 8.43 0.84 0.31 RB2 77-96A 15 10 13.5 8.43 0.84 0.31 Figure 4: RB2 125 - 361A Model 22 A B C D E F RB2 125A 19.5 12.27 13.25 4 0.5 0.31 RB2 156-180A 21.25 12.00 15.25 4 0.5 0.31 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.
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2 - TECHNICAL SPECIFICATIONS Figure 5: RB2 414 - 838A A B C D E RB2 414-590A 27.66 18.5 26.25 6 0.31 RB2 720A 29.38 18.5 28 6 0.31 RB2 838A 27.75 26.6 23.5 8.7 0.
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2 - TECHNICAL SPECIFICATIONS 2.4.2 RC2 Chassis with no Bypass Figure 6: RC2 0 - 124A Model A B C RC2 27-52A 14 RC2 65-77A 18 10 RC2 96-124A 27 10 D E 4.69 8-32 TAP 4.375 4.75 ¼-20 TAP 5.313 4.75 ¼-20 TAP 9.875 3.375 Figure 7: RC2 156 - 590A 24 Model A B C D E RC2 156-180A 18 15 17 13.5 0.3 RC2 240A 24 15 23 13.5 0.5 RC2 302-361A 28 17.25 27 15.75 0.5 RC2 477A 28 20 27 18.5 0.5 RC2 590A 35 20 34 18.5 0.
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2 - TECHNICAL SPECIFICATIONS Environmental Conditions 2.5 Environmental Conditions Table 10: Environmental Ratings Operating Temperatures -10°C to +40°C (14°F to 104°F)enclosed -10°C to +50°C (14°F to 122°F)open Storage Temperatures -20°C to +70°C (-4°F to 155°F) Humidity 0% to 95% non condensing Altitude 1000m (3300ft) without derating Maximum Vibration 5.9m/s2 (19.2ft/s2 ) [0.
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2 - TECHNICAL SPECIFICATIONS Approvals 2.7 Approvals 2 MX Control Card is UL, cUL Recognized Certificate of Compliance 2.8 Certificate of Compliance CE Mark, See Appendix D on page 198.
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3 Installation
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3 - INSTALLATION INSTALLATI 3 ON Before You Start 3.1 Before You Start 3.1.1 Inspection 2 Before storing or installing the RediStart MX Series Starter, thoroughly inspect the device for possible shipping damage. Upon receipt: • Remove the starter from its package and inspect exterior for shipping damage. If damage is apparent, notify the shipping agent and your sales representative. • Open the enclosure and inspect the starter for any apparent damage or foreign objects.
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3 - INSTALLATION Installation Considerations 3.2 Installation Considerations 3.2.1 Site Preparation General Information Before the starter can be installed, the installation site must be prepared. The customer is responsible for: • Providing the correct power source. • Providing the correct power protection. • Selecting the control mechanism.
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3 - INSTALLATION Mounting Considerations 3.3 Mounting Considerations 3.3.1 Bypassed Starters Provisions should be made to ensure that the average temperature inside the enclosure never rises above 50°C. If the temperature inside the enclosure is too high, the starter can be damaged or the operational life can be reduced. 3.3.2 Non-Bypassed Starters Provisions should be made to ensure that the temperature inside the enclosure never rises above 50°C.
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3 - INSTALLATION Wiring Considerations 3.4 Wiring Considerations 3.4.1 Wiring Practices When making power and control signal connections, the following should be observed: • Never connect input AC power to the motor output terminals T1/U, T2/V, or T3/W. • Power wiring to the motor must have the maximum possible separation from all other wiring. Do not run control wiring in the same conduit; this separation reduces the possibility of coupling electrical noise between circuits.
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3 - INSTALLATION Power and Control Drawings for Bypassed and Non Bypassed Power Stacks 3.
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3 - INSTALLATION Figure 9: Power Schematic for RB2 High HP BIPC-300055-01 MX2 CARD stop reset START menu enter Starters 33
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3 - INSTALLATION Figure 10: Power Schematic for RC2 BIPC-300055-01 MX2 CARD stop reset START menu enter Starters 34
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3 - INSTALLATION Power Wiring 3.6 Power Wiring 3.6.1 Recommended Incoming Line Protection Fuses or Circuit Breaker, refer to pages 18 - 20. Input Line Requirements The input line source needs to be an adequate source to start the motor, generally 2 times the rating of the motor FLA. (This may not apply in some cases such as being connected to a generator). 3.6.2 Recommended Wire Gauges The wire gauge selection is based on the FLA of the motor.
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3 - INSTALLATION 3.6.5 Compression Lugs The following is a list of the recommended crimp-on wire connectors manufactured by Penn-Union Corp. for copper wire.
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3 - INSTALLATION 3.6.6 Torque Requirements for Power Wiring Terminations Table 15: Slotted Screws and Hex Bolts Tightening torque, pound-inches (N-m) Wire size installed in conductor Hexagonal head-external drive socket wrench Slotted head NO. 10 and larger Slot width-0.047 inch Slot width-over 0.047 (1.2mm) or less and inch (1.2mm) or slot Split- bolt connectors slot length ¼ inch length – over ¼ inch (N-m) (6.4mm) or less (6.4mm) or less Other connectors (N-m) AWG or kcmil (mm2 ) 18 – 10 (0.
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3 - INSTALLATION Table 16: Tightening Torque for Inside Hex Screws Socket size across flats Tightening torque inches (mm) Pound-inches (N-m) 1/8 (3.2) 45 (5.1) 5/32 (4.0) 100 (11.3) 3/16 (4.8) 120 (13.6) 7/32 (5.6) 150 (16.9) ¼ (6.4) 200 (22.6) 5/16 (7.9) 275 (31.1) 3/8 (9.5) 275 (42.4) ½ (12.7) 500 (56.5) 9/16 (14.3) 600 (67.8) z NOTE – For screws with multiple tightening means, the largest torque value associated with the conductor size shall be marked.
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3 - INSTALLATION Control Card Layout 3.
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3 - INSTALLATION Control Wiring 3.9 Control Wiring 3.9.1 Control Power The 120VAC control power is supplied to TB1. The connections are as follows: 1 - Ground 2 - Neutral 3 - Neutral 4 - Line (120VAC) 5 - Line (120VAC) Figure 13: Control Power Wiring Example TB1 120VAC NEUTRAL 120VAC LIVE 3.9.2 Output Relays TB2 is for the output relays.
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3 - INSTALLATION 3.9.3 Digital Input Wiring Options TB3 is for the digital inputs. The digital inputs use 120VAC.
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3 - INSTALLATION 3.9.4 Analog Input The analog input can be configured for voltage or current loop. The input is shipped in the voltage loop configuration unless specified in a custom configuration. Below TB5 is SW1-1. When the switch is in the on position, the input is current loop. When off, it is a voltage input. The control is shipped with the switch in the off position. See Figure 18. z NOTE: The analog input is a low voltage input, maximum of 15VDC.
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3 - INSTALLATION 3.9.6 SW1 DIP Switch The DIP switch on the card changes the analog input and analog output between 0-10V or 0-20mA. The picture below shows how to adjust the switch to select the desired signal. Switching to the up or top position is ON and switching towards card or down is OFF. Figure 18: DIP Switch Settings ANALOG INPUT SW1-1 ON = 0-20mA OFF = 0-10V ANALOG OUTPUT SW1-2 ON = 0-10V OFF = 0-20mA Remote LCD Keypad/Display 3.
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3 - INSTALLATION 3.10.2 Display Cutout Figure 19: Small Display Keypad Mounting Dimensions Part # : KPMX3SLCD 101.00 [3.98"] 50.50 [1.99"] 31.50 [1.24"] 63.00 [2.48"] 31.50 [1.24"] 50.50 [1.99"] Figure 20: Large Display Keypad Mounting Dimensions Part # : KPMX3LLCD 127.00 [5.00"] 63.50 [2.50"] 38.50 [1.52"] 77.00 [3.03"] 38.50 [1.52"] 63.50 [2.
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3 - INSTALLATION 3.10.3 Installing Display The remote display is installed as follows: • Install the gasket onto the display. • Insert the display through the door cutout. • Insert the mounting clips into the holes in each side of the display. • Tighten the mounting clips until they hold the display securely in place. Torque requirements for the display screen is 0.7 NM (6.195 in lbs). • Plug the cable into the display connector on the MX2 card.
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3 - INSTALLATION NOTES: 46
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4 Keypad Operation
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4 - KEYPAD OPERATION KEYPAD4 OPERATION Introduction 4.1 Introduction 2 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.
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4 - KEYPAD OPERATION Changing Parameter Values 4.4 Changing Parameter Values Parameter change mode can be entered by: 1. At the default meter display, press the [PARAM] key to enter parameter mode. 2. Use the [UP] and [DOWN] keys to scroll through the available parameters. 3. The value of the parameter can be viewed by pressing the [ENTER] key. 4. When viewing the parameter value, the parameter can be changed by using the [UP] and [DOWN] keys. 5. To store the new value, press the [ENTER] key.
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4 - KEYPAD OPERATION 4.5.3 Running When running, the display shows the selected meter function. The following meters can be selected using the Meter display parameter (P79). Avg. RMS current Phase 1 RMS current Phase 2 RMS current Phase 3 RMS current Current Imbalance % GF Current (% FLA) 4.5.4 Avg.
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4 - KEYPAD OPERATION Restoring Factory Parameter Settings 4.6 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.
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4 - KEYPAD OPERATION Remote LCD Keypad and Display 4.9 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.
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4 - KEYPAD OPERATION Description of the Keys on the Remote LCD Keypad 4.11 Description of the Keys on the Remote LCD Keypad The [UP] arrow, [DOWN] arrow, [ENTER] and [MENU] keys on the LCD keypad perform the same functions as the [UP], [DOWN], [ENTER] and [PARAM] keys on the standard keypad. Three keys have been added, with one of the keys serving a dual function.
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4 - KEYPAD OPERATION Jump Code 4.12 Jump Code At the beginning of each parameter group, there is a Jump Code parameter. By changing the value of this parameter and pressing [ENTER], you can jump directly to any parameter within that group. Alphanumeric Display 4.13 Alphanumeric Display The remote LCD keypad and display uses a 32-character alphanumeric LCD display. All starter functions can be accessed by the keypad.
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4 - KEYPAD OPERATION Table 20: Operate Screen Section B Display Stopped Fault Heater Kick Accel Kick 2 Accel 2 Run UTS Control Decel Wye Slow Spd Fwd Description Starter is stopped and no Faults Starter tripped on a Fault Starter is on and heating motor Starter is applying kick current to the motor Starter is accelerating the load Starter is applying kick current to the motor in Ramp 2 Starter is accelerating the load in Ramp 2 Starter is in Run mode and Ramp Time has expired Starter is Up To Speed Phase
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4 - KEYPAD OPERATION 4.13.2 Meter Pages Although any meter may be viewed by changing the two Meter parameters (FUN 01 & FUN 02), there are 13 “Meter Pages” that are easily accessed to view all of the meter information. These meter pages are scrolled through by pressing the [UP] or [DOWN] down arrows from the operate screen. Current I2 = 0.0A I1 = 0.0 I3 = 0.0A RS Gnd Cur= 0% Voltage V2= V1= 0 V3= 0V 0V Lst STt Tim= xx.xs Pk ST Cur = xx.xA MWatt Hour = kWatt Hour = 0 0 Frequency = 60.
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4 - KEYPAD OPERATION Press [MENU] until you get to the FL1 parameter. Pressing the [UP] and [DOWN] keys navigates through older and newer faults in the log. Repeatedly pressing the [ENTER] key rotates through the conditions the starter was in when the fault occurred. 4.13.4 Enter Step 1 2 3 4 5 6 Fault Description. Status when the fault occurred, Run, Stopped, Accel. etc. The L1 current at the time of the fault. The L2 current at the time of the fault. The L3 current at the time of the fault.
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4 - KEYPAD OPERATION Procedure for Setting Data 4.14 Procedure for Setting Data Select a parameter that is to be changed. To change Motor FLA from 10 Amps to 30 Amps: From the main screen: T Ready Ia= 0.0A Stopped Va= 480 V Press [MENU] key and the display shows QST: (Quick Start) screen. QST: Jump Code 00 1 Press [UP] key once to Motor FLA (QST 01). QST: Motor FLA 01 10 Amp Press [ENTER] key once, the cursor starts to flash in the one’s place.
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5 Parameter Groups
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5 - PARAMETER GROUPS PARAMETER 5 GROUPS Introduction 5.1 Introduction 2 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.
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5 - PARAMETER GROUPS LED & LCD Display Parameters Cross Reference 5.
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5 - PARAMETER GROUPS LED Display Parameters 5.3 LED Display Parameters Number Parameter Setting Range Units RMS Amps Default Page P1 Motor FLA 1 – 6400 10 75 P2 Motor Service Factor 1.00 – 1.99 1.
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5 - PARAMETER GROUPS Number Parameter Setting Range Units Page P41 Auto Fault Reset Time Off, 1 – 900 Off 104 P42 Auto Reset Limit Off, 1 – 10 Off 104 P43 Controlled Fault Stop Enable Off, On On 105 P44 Independent Starting/Running Overload Off, On Off 106 P45 Motor Starting Overload Class Off, 1 – 40 P46 Motor Overload Hot/Cold Ratio 0 – 99 P47 Motor Overload Cooling Time 1.0 – 999.
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5 - PARAMETER GROUPS Number Parameter Setting Range P60 Analog Output Function 0: Off (no output) 1: 0 – 100% Curr 2: 0 – 200% Curr 3: 0 – 800% Curr 4: 0 – 150% Volt 5: 0 – 150% OL 6: 0 – 10 kW 7: 0 – 100 kW 8: 0 – 1 MW 9: 0 – 10 MW 10: 0 – 100% Ain 11: 0 – 100% Firing 12: Calibration P61 Analog Output Span 1 – 125 P62 Analog Output Offset 0 – 99 P63 Inline Configuration P64 Bypass Feedback Time P65 Keypad Stop Disable Default Page 0: Off (no output) 116 % 100 117 % 0 117 Off, 1
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5 - PARAMETER GROUPS Number P78 Parameter CT Ratio P79 Meter P80 Software Version 1 P81 Passcode P82 Fault Log Setting Range 72:1, 96:1, 144:1, 288:1, 864:1, 2640:1, 3900:1, 5760:1, 8000:1, 14400:1, 28800:1 0: Status 1: Ave Current 2: L1 Current 3: L2 Current 4: L3 Current 5: Curr Imbal 6: Ground Fault 7: Ave Volts 8: L1-L2 Volts 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: Ana
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5 - PARAMETER GROUPS LCD Display Parameters 5.4 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).
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5 - PARAMETER GROUPS 5.4.
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5 - PARAMETER GROUPS 5.4.3 Protection Group Number Display Parameter Setting Range Units Default Page PFN 00 Jump Code Jump to Parameter 1 to 17 1 98 PFN 01 Over Cur Lvl Over Current Trip Level Off, 50 to 800 %FLA Off 98 PFN 02 Over Cur Tim Over Current Trip Delay Time Off, 0.1 to 90.0 Seconds 0.1 99 PFN 03 Undr Cur Lvl Under Current Trip Level Off, 5 to 100 %FLA Off 100 PFN 04 Undr Cur Tim Under Current Trip Delay Time Off, 0.1 to 90.0 Seconds 0.
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5 - PARAMETER GROUPS Number Display Parameter I/O 05 R1 Config R1 Configuration (Relay #1) I/O 06 R2 Config R2 Configuration (Relay #2) Setting Range Units Off Fault FS (Fail Safe) Fault NFS (Non Fail Safe) Running UTS Alarm Ready Locked Out Overcurrent Undercurrent OL Alarm Shunt Trip FS Shunt Trip NFS Ground Fault Energy Saver Heating Slow Spd Slow Spd Fwd Slow SPd Rev Braking Cool Fan Ctl I/O 07 R3 Config R3 Configuration (Relay #3) I/O 08 Ain Trp Type Analog Input Trip Type Off Low Le
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5 - PARAMETER GROUPS 5.4.
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5 - PARAMETER GROUPS Number Display Parameter Setting Range FUN 13 Com Parity Communications Byte Framing FUN 14 Software 1 Software 1 Part Number FUN 15 Misc Command Miscellaneous Commands FUN 16 Passcode Passcode 5.4.
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5 - PARAMETER GROUPS NOTES: 72
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6 Parameter Description
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6 - PARAMETER DESCRIPTION PARAMETER 6 DESCRIPTION Parameter Descriptions 6.1 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.
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6 - PARAMETER DESCRIPTION Jump to Parameter QST 00 By changing the value of this parameter and pressing [ ENTER ], you can jump directly to any parameter within that group. P1 Motor FLA LED Display QST 01 LCD Display: QST: Motor FLA 01 10 Amp 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.
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6 - PARAMETER DESCRIPTION P3 Motor Overload Class Running LED Display QST 03, PFN 15 LCD Display QST: Running OL 03 10 PFN: Running OL 15 10 Range Off, 1– 40 (Default 10) 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\R O/L (P44 / PFN13) parameter to "On".
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6 - PARAMETER DESCRIPTION P4 Local Source LED Display QST 04 LCD Display QST: Local Src 04 Terminal Range LED LCD Keypad Terminal Serial PAd tEr SEr Description Description The start/stop control is from the keypad. The start/stop control is from the terminal strip inputs. (Default) The start/stop control is from the network. 2 The MX can have three sources of start and stop control; Terminal, Keypad and Serial.
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6 - PARAMETER DESCRIPTION P5 Remote Source LED Display QST 05 LCD Display QST: Remote SRC 05 Terminal Range LED LCD Keypad Terminal Serial PAd tEr SEr Description Description The start/stop control is from the keypad. The start/stop control is from the terminal strip inputs. (Default) The start/stop control is from the network. 2 The MX can have three sources of start and stop control; Terminal, Keypad and Serial.
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6 - PARAMETER DESCRIPTION P6 LED Display Initial Motor Current 1 QST 06, CFN 03 LCD Display QST: Init Cur 1 06 100 % CFN: Init Cur 1 03 100 % Range 50 – 600 % of FLA (Default 100%) Description The Initial Motor Current 1 parameter is set as a percentage of the Motor FLA (P1 / QST 01) parameter setting. The Initial Current 1 parameter sets the current that is initially supplied to the motor when a start is commanded.
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6 - PARAMETER DESCRIPTION P7 LED Display Maximum Motor Current 1 QST 07, CFN 04 LCD Display QST: Max Cur 1 07 600 % CFN: Max Cur 1 04 600 % Range 100 – 800 % of FLA (Default 600%) Description The Maximum Motor Current 1 parameter is set as a percentage of the Motor FLA (P1 / QST 01) parameter setting. 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 after the ramp is completed.
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6 - PARAMETER DESCRIPTION P8 LED Display Ramp Time 1 QST 08, CFN 02 LCD Display QST: Ramp Time 1 08 15 sec CFN: Ramp Time 1 02 15 sec Range 0 – 300 seconds (Default 15) Description The Ramp Time 1 parameter is the time it takes for the starter to allow the current, voltage, torque or power (depending on the start mode) to go from its initial to the maximum value. To make the motor accelerate faster, decrease the ramp time. To make the motor accelerate slower, increase the ramp time.
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6 - PARAMETER DESCRIPTION P9 Up To Speed Time LED Display QST 09 LCD Display QST: UTS Time 09 20 sec Range 1– 900 Seconds (Default 20) Description The Up To Speed Time parameter sets the maximum time the motor can take to accelerate to full speed. A stalled motor condition is detected if the motor does not get up-to-speed before the up-to-speed timer expires. The motor is considered up-to-speed once the current stabilizes below 175 percent of the FLA value and the ramp time expires.
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6 - PARAMETER DESCRIPTION Jump to Parameter CFN 00 By changing the value of this parameter and pressing [ENTER], you can jump directly to any parameter within that group. P10 Start Mode LED Display CFN 01 LCD Display CFN: Start Mode 01 Current Ramp Range LED oLrP curr tt Pr Description LCD Voltage Ramp Current Ramp TT Ramp Power Ramp Description Open Loop Voltage acceleration ramp. Current control acceleration ramp. (Default) TruTorque control acceleration ramp.
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6 - PARAMETER DESCRIPTION P11 LED Display Initial Voltage/Torque/Power CFN08 LCD Display CFN: Init V/T/P 08 25 % Range 1 – 100 % of Voltage/Torque/Power (Default 25%) Description Start Mode (P10/CFN01) set to Open Loop Voltage Acceleration: This parameter sets the starting point for the voltage acceleration ramp profile. A typical value is 25%. If the motor starts too quickly or the initial current is too high, reduce this parameter.
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6 - PARAMETER DESCRIPTION P12 LED Display Maximum Torque/Power CFN 09 LCD Display CFN: Max T/P 09 105 % Range 10 – 325 % of Torque/Power (Default 105%) Description Start Mode (P10/CFN01) set to Open Loop Voltage Acceleration: Not used when the Start Mode parameter is set to open-loop voltage acceleration. When in open loop voltage acceleration mode, the final voltage ramp value is always 100% or full voltage.
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6 - PARAMETER DESCRIPTION P13 LED Display 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.
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6 - PARAMETER DESCRIPTION P15 Stop Mode LED Display CFN 14 LCD Display CFN: Stop Mode 14 Coast Range LED CoS SdcL tdcL dcb Description LCD Coast Volt Decel TT Decel DC Brake Description Coast to stop. (Default) Open loop voltage deceleration. TruTorque deceleration. DC Braking. Coast: A coast to stop should be used when no special stopping requirements are necessary; Example: crushers, balls mills, centrifuges, belts, conveyor.
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6 - PARAMETER DESCRIPTION P16 LED Display Decel Begin Level CFN 15 LCD Display CFN: Decel Begin 15 40 % Range 1 % – 100% of phase angle firing (Default 40%) Description Stop Mode (P15/CFN14) set to Voltage Deceleration: The voltage deceleration profile utilizes an open loop S-curve voltage ramp profile. The Decel Begin Level parameter sets the initial or starting voltage level when transferring from running to deceleration.
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6 - PARAMETER DESCRIPTION P17 LED Display Decel End Level CFN 16 LCD Display CFN: Decel End 16 20 % Range 1 – 99 % of phase angle firing (Default 20%) Description Stop Mode (P15/CFN14) set to Voltage Deceleration: The voltage deceleration profile utilizes an open loop S-curve voltage ramp profile. The Decel End Level parameter sets the ending voltage level for the voltage deceleration ramp profile.
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6 - PARAMETER DESCRIPTION P18 LED Display Decel Time CFN 17 LCD Display CFN: Decel Time 17 15 sec Range 1 – 180 seconds (Default 15) Description The Decel Time parameter sets the time that the deceleration profile is applied to the motor and sets the slope of the deceleration ramp profile. When in voltage decel mode, this time sets the time between applying the initial decel level to the final decel level.
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6 - PARAMETER DESCRIPTION P19 LED Display DC Brake Level CFN 18 LCD Display CFN: Brake Level 18 25 % Range 10 – 100 % of available brake torque (Default 25%) Description When the Stop Mode (P15 / CFN 14) is set to DC brake, the DC Brake Level parameter sets the level of DC current applied to the motor during braking. The desired brake level is determined by the combination of the system inertia, system friction, and the desired braking time.
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6 - PARAMETER DESCRIPTION P20 DC Brake Time LED Display CFN 19 LCD Display CFN: Brake Time 19 5 sec Range 1 – 180 Seconds (Default 5) Description When the Stop Mode (P15 / CFN 14) is set to "DC brake", the DC Brake Time parameter sets the time that DC current is applied to the motor. The required brake time is determined by the combination of the system inertia, system friction, and the desired braking level.
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6 - PARAMETER DESCRIPTION P21 DC Brake Delay LED Display CFN 20 LCD Display CFN: Brake Delay 20 0.2 sec Range 0.1 – 3.0 Seconds (Default 0.2) Description When the Stop Mode (P15, CFN 14) is set to "DC brake", the DC Brake Delay time is the time delay between when a stop is commanded and the DC braking current is applied to the motor. This delay allows the residual magnetic field and motor counter EMF to decay before applying the DC braking current.
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6 - PARAMETER DESCRIPTION P24 LED Display Ramp Time 2 CFN 05 LCD Display CFN: Ramp Time 2 05 15 sec Range 0 – 300 seconds (Default 15) Description The Ramp Time 2 parameter sets the time it takes for the starter to allow the current to go from the initial current to the maximum current when the second ramp is active. Refer to the Ramp Time 1 (P8 / CFN 02) parameter on page 83 for description of operation. See Also Ramp Time 1 (P8 / QST 08) parameter on page 83.
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6 - PARAMETER DESCRIPTION P27 LED Display Preset Slow Speed CFN 21 LCD Display CFN: SSpd Speed 21 Off 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.
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6 - PARAMETER DESCRIPTION P29 LED Display Slow Speed Time Limit CFN 23 LCD Display CFN: SSpd Timer 23 10 sec Range Off, 1 – 900 Seconds (Default 10) Description The Slow Speed Time Limit parameter sets the amount of time that continuous operation of slow speed may take place. 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.
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6 - PARAMETER DESCRIPTION P31 LED Display Slow Speed Kick Time CFN 25 LCD Display CFN: SSpd Kick T 25 1.0 sec Range 0.1 – 10.0 seconds (Default 1.0) Description The Slow Speed Kick Time parameter sets the length of time that the Slow Speed Kick current level (P30, CFN 24) is applied to the motor at the beginning of slow speed operation. 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.
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6 - PARAMETER DESCRIPTION Jump to Parameter PFN 00 By changing the value of this parameter and pressing [ENTER], you can jump directly to any parameter within that group. P32 Over Current Trip Level LED Display PFN 01 LCD Display PFN: Over Cur Lvl 01 Off Range Off, 50 – 800 % of FLA (Default Off) Description 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 will energize.
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6 - PARAMETER DESCRIPTION P33 LED Display Over Current Trip Delay Time PFN 02 LCD Display PFN: Over Cur Tim 02 0.1 sec Range Off, 0.1 – 90.0 seconds (Default 0.1) Description The Over Current Trip Delay Time parameter sets the period of time that the motor current must be greater than the Over Current Level (P32 / PFN 01) parameter before an over current fault and trip occurs. If "Off" is selected, the over current timer does not operate and the starter does not trip.
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6 - PARAMETER DESCRIPTION P34 Under Current Trip Level LED Display 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 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.
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6 - PARAMETER DESCRIPTION P36 Current Imbalance Trip Level LED Display PFN 05 LCD Display PFN: Cur Imbl Lvl 05 15 % Range Off, 5 – 40 % (Default 15%) Description The Current Imbalance Trip Level parameter sets the imbalance that is allowed before the starter shuts down. The current imbalance must exist for 10 seconds before a fault occurs.
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6 - PARAMETER DESCRIPTION P37 Residual Ground Fault Trip Level LED Display PFN 06 LCD Display PFN: Resid GF Lvl 06 Off 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.
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6 - PARAMETER DESCRIPTION P38 Over Voltage Trip Level LED Display PFN 07 LCD Display PFN: Over Vlt Lvl 07 Off Range Off, 1 – 40 % (Default Off) Description If the MX detects a one cycle input phase voltage that is above the Over Voltage Trip Level, the over/under voltage alarm is shown and the voltage trip timer begins counting. The delay time must expire before the starter faults. The over voltage condition and the phase is displayed.
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6 - PARAMETER DESCRIPTION P40 Over/Under Voltage Trip Delay Time LED Display PFN 09 LCD Display PFN: Vlt Trip Tim 09 0.1 sec Range 0.1 – 90.0 seconds (Default 0.1) Description The Voltage Trip Delay Time parameter sets the period of time that either an over voltage (P38 / PFN 07) or under voltage (P39 / PFN 08) condition must exist before a fault occurs. See Also Over Voltage Level (P38 / PFN 07) parameter on page 103. Under Voltage Level (P39 / PFN 08) parameter on page 103.
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6 - PARAMETER DESCRIPTION P43 Controlled Fault Stop Enable LED Display PFN 12 LCD Display PFN: Ctrl Flt En 12 On 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.
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6 - PARAMETER DESCRIPTION P44 Independent Starting/Running Overload LED Display PFN 13 LCD Display PFN: Indep S/R OL 13 Off Range Off – On (Default Off) Description If “Off” When this parameter is “Off” the overload defined by the Motor Running Overload Class (P3 / QST 03/PFN 15) parameter is active in all states. If “On” When this parameter is “On”, the starting and running overloads are separate with each having their own settings.
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6 - PARAMETER DESCRIPTION P45 LED Display Motor Overload Class Starting PFN 14 LCD Display PFN: Starting OL 14 10 Range Off, 1 – 40 (Default class 10) Description The Motor Overload Class Starting parameter sets the class of the electronic overload when starting. The starter stores the thermal overload value as a percentage value between 0 and 100%, with 0% representing a “cold” overload and 100% representing a tripped overload.
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6 - PARAMETER DESCRIPTION P46 Motor Overload Hot/Cold Ratio LED Display PFN 16 LCD Display PFN: OL H/C Ratio 16 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.
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6 - PARAMETER DESCRIPTION P47 LED Display Motor Overload Cooling Time PFN 17 LCD Display PFN: OL Cool Tim 17 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.
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6 - PARAMETER DESCRIPTION Jump to Parameter I/O 00 By changing the value of this parameter and pressing [ENTER], you can jump directly to any parameter within that group.
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6 - PARAMETER DESCRIPTION P51 LED Display Digital Fault Input Trip Time I/O 04 LCD Display I/O: Din Trp Time 04 0 .1 sec Range 0.1-90.0 Seconds (Default 0.1 Sec) Description: The Digital Fault Input Trip Time parameter sets the length of time the Digital input must be high or low before a trip occurs. This delay time only functions for fault high and fault low. See Also Digital Input Configuration (P48-50 / I/O 01-03) parameters on page 110.
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6 - PARAMETER DESCRIPTION P52, 53, 54 Relay Output Configuration LED Display LCD Display I/O: R1 Config 05 Fault FS P52 I/O: R2 Config 06 Off P53 I/O: R3 Config 07 Off P54 Range I/O 05, 06, 07 LED OFF FLFS LCD Off Fault FS FLnF run utS Fault NFS Running UTS AL rdYr LOC OC UC OLA ShFS Alarm Ready Locked Out Overcurrent Undercurrent OL Alarm Shunt FS ShnF Shunt NFS g FLt Ground Fault Energy Saver Heating Slow Spd Slow Spd Fwd Slow Spd Rev Braking Cool Fan Ctl ES HEAt SSPd SS F SS r dcb F
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6 - PARAMETER DESCRIPTION P55 Analog Input Trip Type LED Display I/O 08 LCD Display I/O: Ain Trp Type 08 Off Range LED OFF Lo HI 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.
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6 - PARAMETER DESCRIPTION P56 Analog Input Trip Level LED Display I/O 09 LCD Display I/O: Ain Trp Lvl 09 50 % Range 0 – 100% (Default 50%) Description The Analog Input Trip Level parameter sets the analog input trip or fault level. This feature can be used to detect an open 4-20mA loop by setting the parameter to "Low" and setting the parameter to a value less than (<) 20%. z NOTE: The analog input trip level is NOT affected by the Analog Input Offset or Analog Input Span parameter settings.
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6 - PARAMETER DESCRIPTION P58 Analog Input Span LED Display I/O 11 LCD Display I/O: Ain Span 11 100 % Range 1 – 100% (Default 100%) Description The analog input can be scaled using the Analog Input Span parameter. Examples: For a 0-10V input or 0-20mA input, a 100% Analog Input Span setting results in a 0% input reading with a 0V input and a 100% input reading with a 10V input.
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6 - PARAMETER DESCRIPTION P59 Analog Input Offset LED Display I/O 12 LCD Display I/O: Ain Offset 12 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.
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6 - PARAMETER DESCRIPTION P61 Analog Output Span LED Display I/O 14 LCD Display I/O: Aout Span 14 100 % Range 1 – 125% (Default 100%) Description The analog output signal can be scaled using the Analog Output Span parameter. For a 0-10V output or 0-20mA output, a 100% scaling outputs the maximum voltage (10V) or current (20mA) when the selected output function requests 100% output. A scale of 50% outputs 50% voltage/current when the analog output function requests a 100% output.
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6 - PARAMETER DESCRIPTION P63 LED Display Inline Configuration I/O 16 LCD Display I/O: Inline Confg 16 3.0 sec Range Off, 0 – 10.0 seconds (Default 3.0) Description The Inline Configuration parameter controls the behavior of the No Line warning, No Line fault, and the Ready relay function. 2 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.
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6 - PARAMETER DESCRIPTION P65 Keypad Stop Disable LED Display I/O 18 LCD Display I/O: Keypad Stop 18 Enabled Range LED OFF On Description If “Disabled” When this parameter is set to "Disabled", the keypad [STOP] button is de-activated. This should be done with caution, as the [STOP] key will not stop the starter.
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6 - PARAMETER DESCRIPTION Jump to Parameter FUN 00 By changing the value of this parameter and pressing [ENTER], you can jump directly to any parameter within that group. P67 Miscellaneous Commands LED Display FUN 15 LCD Display FUN: Misc Command 15 None Range LED 0 1 2 3 4 5 6 7 8 Description The Miscellaneous Commands parameter is used to issue various commands to the MX starter.
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6 - PARAMETER DESCRIPTION P68 Communication Timeout LED Display FUN 12 LCD Display FUN: Com Timeout 12 Off 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 77.
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6 - PARAMETER DESCRIPTION P71 Communication Byte Framing LED Display FUN 13 LCD Display FUN: Com Parity 13 Even, 1 Stop Range LED 0 1 2 3 Description The Communication Byte Framing parameter sets both the parity and number of stop bits. See Also Communication Timeout (P68 / FUN 12) parameter on page 121. Communication Baud Rate (P69 / FUN 11) parameter on page 121. Communication Address (P70 / FUN 10) parameter on page 121.
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6 - PARAMETER DESCRIPTION P73 LED Display 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.
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6 - PARAMETER DESCRIPTION P74 Starter Type LED Display FUN 07 LCD Display FUN: Starter Type 07 Normal Range Description LED nor Id Y-d PctL LCD Normal Inside Delta Wye-Delta Phase Ctl cFoL Curr Follow AtL ATL Description Normal Reduced Voltage Soft Starter RVSS. (Default) Inside Delta, RVSS. Wye Delta. Open Loop Phase control using external analog input reference. Closed Loop Current follower using external analog input reference. Across the line.
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6 - PARAMETER DESCRIPTION P75 Motor Rated Power Factor LED Display FUN 06 LCD Display FUN: Motor PF 06 -0.92 Range -0.01 – 1.00 (Default –0.92) Description The Rated Power Factor parameter sets the motor power factor value that is used by the MX starter for TruTorque and Power control calculations and metering calculations.
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6 - PARAMETER DESCRIPTION P77 Input Phase Sensitivity LED Display FUN 04 LCD Display FUN: Phase Order 04 Insensitive Range LED InS AbC CbA SPH 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.
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6 - PARAMETER DESCRIPTION P79 Meter 1 ,Meter 2 LED Display FUN 01, 02 LCD Display FUN: Meter 1 01 Ave Current FUN: Meter 2 02 Ave Volts Range LED 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 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.
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6 - PARAMETER DESCRIPTION P80 LED Display Software 1 FUN 14 LCD Display FUN: Software PN 14 810023-01-08 Description 2 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.
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6 - PARAMETER DESCRIPTION P81 Passcode LED Display FUN 16 LCD Display FUN: Passcode 16 Off Description 2 The MX supports a 4-digit passcode. When the passcode is set, parameters may not be changed. 2 The MX provides a means of locking parameter values so that they may not be changed. Once locked, the parameters values may be viewed on the display, but any attempt to change their values by pressing the [UP] or [DOWN] keys is ignored.
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6 - PARAMETER DESCRIPTION P82 Fault Log LED Display FL1 LCD Display FL1: Last Fault # Fault Name Range FL1 – FL9 Description When a fault occurs, the fault number is logged in non-volatile memory. The most recent fault is in FL1 and the oldest fault is in FL9. 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 4.13.3 on page 56 for more information. See Also 130 Fault Codes on page 196.
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7 Theory of Operation
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7 - THEORY OF OPERATION THEORY7 OF OPERATION Motor Overload 7.1 7.1.1 Solid State Motor Overload Protection Overview 2 2 2 The MX contains an advanced I t electronic motor overload (OL) protection function. For optimal motor protection, the MX has forty standard NEMA style overload curves (in steps of one) available for use. Separate overload classes can be programmed for acceleration 2 and for normal running operation and individually or completely disabled if necessary.
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7 - THEORY OF OPERATION Figure 25: Commonly Used Overload Curves 10000 Seconds to Trip 1000 100 Class 40 Class 35 Class 30 Class 25 Class 20 10 Class 15 Class 10 Class 5 1 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 Current % (FLA) z 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.
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7 - THEORY OF OPERATION 7.1.3 Motor Overload Operation Overload Heating When the motor is operating in the overloaded condition (motor current greater than FLAxSF), the motor overload content accumulates based on the starter’s operating mode at a rate established by the overload protection class chosen. The accumulated overload content can be viewed on the display or over the communications network.
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7 - THEORY OF OPERATION 7.1.5 Harmonic Compensation 2 The MX motor overload calculation automatically compensates for the additional motor heating that can result from the presence of harmonics. Harmonics can be generated by other loads connected to the supply such as DC drives, AC variable frequency drives, arc lighting, uninterruptible power supplies, and other similar loads. 7.1.
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7 - THEORY OF OPERATION The following diagram illustrates how the current and the Motor Overload Hot/Cold Ratio parameter determines the steady state overload content. It assumes there is no current imbalance. Figure 27: Motor Overload H© Ratio Example 100%FLA Motor Current 50%FLA 0%FLA 80 % OL H/C Ratio 30 % 0% 80 % Motor Overload Content 40 % 30 % 15 % 0% T0 T1 T2 T3 At time T0, the motor current is 100%FLA and the OL H© Ratio is set at 30%.
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7 - THEORY OF OPERATION 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 * e CoolingTim e t When the motor is stopped, the motor overload cools as shown in the following Figure 28.
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7 - THEORY OF OPERATION If the motor manufacturer does not specify the motor cooling time, the following approximations for standard TEFC cast iron motors based on frame size can be used: Frame Size Cooling Time 180 30 min 280 60 min 360 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: Motor Coo
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7 - THEORY OF OPERATION Motor Service Factor 7.2 General Motor Service Factor 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. z NOTE: The NEC (National Electrical Code) does not allow the service factor to be set above 1.40.
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7 - THEORY OF OPERATION Acceleration Control 7.3 Acceleration Control 7.3.1 Current Ramp Settings, Ramps and Times General The current ramp sets how the motor accelerates. The current ramp is a linear increase in current from the initial setting to the maximum setting. The ramp time sets the speed of this linear current increase. The following figure shows the relationships of these different ramp settings.
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7 - THEORY OF OPERATION Ramp Time The ramp time is the time it takes for the current to go from the initial current to the maximum current. To make the motor accelerate faster, decrease the ramp time. To make the motor accelerate slower, increase the ramp time. 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.
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7 - THEORY OF OPERATION TruTorque acceleration control can be very useful for a variety of applications. However it is best used to start centrifugal pumps, fans, and other variable torque applications. TruTorque generally should not be used in applications where the starting load varies greatly during the start such as with a reciprocating compressor, where the starting load is very low, or where the starting load varies greatly from one start to another.
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7 - THEORY OF OPERATION 7.3.4 Power Control Acceleration Settings and Times General Power control is a closed loop power based acceleration control. The primary purpose of Power controlled acceleration is to control and limit the power (kW) drawn from the power system and to reduce the power surge that may occur as an AC induction motor comes up to speed. This power surge can be a problem in applications that are operated on generators or other limited or "soft" power systems.
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7 - THEORY OF OPERATION z NOTE: Depending on loading, the motor may achieve full speed at any time during the Power ramp. This means that the Maximum Power level may not be reached. Therefore, the maximum power level is the maximum power level that is permitted. However, the motor power may not necessarily reach this value during all starts. Ramp Time 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.
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7 - THEORY OF OPERATION 7.3.5 Open Loop Voltage Ramps and Times General The open loop voltage ramp provides soft starting of a motor by increasing the voltage applied to motor from the Initial Voltage setting to full (100%) line voltage. The ramp time sets the speed at which the voltage is increased. 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.
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7 - THEORY OF OPERATION UTS Timer When the start mode is set to open-loop voltage ramp acceleration, the UTS Timer acts as an acceleration kick. When the UTS timer expires, full voltage is applied to the motor. This feature can be used to reduce motor surging that may occur near the end of an open loop voltage ramp start. If a surge occurs near the end of the ramp, set the UTS timer to expire at this time and restart the motor.
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7 - THEORY OF OPERATION 7.3.6 Dual Acceleration Ramp Control General Two independent current ramps and kick currents may be programmed. The use of two different starting profiles can be very useful with applications that have varying starting loads such as conveyors that can start either loaded or unloaded. The Current Ramp 1 profile is programmed using the parameters Initial Current 1, Maximum Current 1, and Ramp Time 1.
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7 - THEORY OF OPERATION Changing Ramp Profiles The selected ramp profile may be changed during starting by changing the Ramp Select input. When the Ramp Select input changes during ramping, control switches to the other profile as if it were already in progress. It does not switch to the beginning of the other profile. Refer to the following example below: z NOTE: Once the motor has achieved an up-to-speed status (UTS), changes to the Ramp Select input have no effect on the motor operation.
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7 - THEORY OF OPERATION Deceleration Control 7.4 Deceleration Control 7.4.1 Voltage Control Deceleration Overview 2 2 The deceleration control on the MX uses an open loop voltage ramp. The MX ramps the voltage down to decelerate the motor. The curve shows the motor voltage versus the decel setting. Figure 35: Motor Voltage Versus Decel Level Beginning Level This sets the starting voltage of the deceleration ramp.
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7 - THEORY OF OPERATION 7.4.2 TruTorque Deceleration Overview TruTorque deceleration control is a closed loop deceleration control. This allows TruTorque deceleration to be more consistent in cases of changing line voltage levels and varying motor load conditions. TruTorque deceleration is best suited to pumping and compressor applications where pressure surges, such as water 2 hammer, must be eliminated. The MX linearly reduces the motor's torque to smoothly decelerate the motor and load.
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7 - THEORY OF OPERATION Braking Controls 7.5 Braking Controls 2 Overview When the Stop Mode parameter is set to DC Brake, the MX starter provides DC injection braking for fast and 2 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.
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7 - THEORY OF OPERATION 7.5.1 DC Injection Braking, Standard Duty 2 2 The MX Standard Duty Braking allows up to approximately 250% FLA current to be applied to the motor. The MX Standard Duty package consists of an extra braking contactor that shorts Motor Terminals 2 & 3 together while braking, as DC current is applied by the 2 MX starter to provide moderate braking torque. CAUTION: Contactor MUST NOT short phase T1 and phase T3. z NOTE: Contactor sizing requires AC1 contactor rating (Motor FLA / 1.6).
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7 - THEORY OF OPERATION 7.5.
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7 - THEORY OF OPERATION 7.5.
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7 - THEORY OF OPERATION 7.5.7 DC Injection Brake Enable and Disable Digital Inputs Digital inputs can be programmed to either a Brake Enable or a Brake Disable. In the Brake Enable case the digital input must be energized for DC braking to occur. The braking will immediately stop if the brake enable is de-energized. In the Brake Disable case, DC braking will occur unless the Brake Disable digital input is energized. DC braking will cease if the brake disable is energized.
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7 - THEORY OF OPERATION 7.5.9 DC Injection Braking Parameters Brake Level: The DC Brake Level parameter sets the level of DC current applied to the motor during braking. The desired brake level is determined by the combination of the system inertia, system friction, and the desired braking time. 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.
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7 - THEORY OF OPERATION 7.6.2 Slow Speed Cyclo Converter Parameters Slow Speed: The Slow Speed parameter selects the speed of motor operation when slow speed is selected. When set to Off, slow speed operation is disabled. Slow Speed Current Level: The Slow Speed Current Level parameter selects the level of current applied to the motor during slow speed operation. The parameter is set as a percentage of motor full load amps (FLA).
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7 - THEORY OF OPERATION Inside Delta Connected Starter 7.7 Inside Delta Connected Starter There are differences between a line connected soft starter as shown in Figure 39 and the inside delta connected soft starter as shown in Figure 40 that need to be considered. By observation of Figure 40, access to all six stator-winding terminals is required for an inside delta application. For a 12-lead motor, all 12 stator terminals must be accessible.
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7 - THEORY OF OPERATION 7.7.2 Inside Delta Connected Starter An inside delta connected soft starter is shown in Figure 40, where the power poles are connected in series with the stator windings of a delta connected motor. Figure 40: Typical Inside Delta Motor Connection For an inside delta connected motor, the starter current is less than the line current by a factor of 1.55 (FLA/1.55).
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7 - THEORY OF OPERATION Wye Delta Starter 7.8 Wye Delta Starter 2 When the Starter Type parameter is set to Wye-Delta, the MX is configured to operate an Electro mechanical Wye-Delta (Star-Delta) 2 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. A typical closed transition Wye-Delta starter schematic is shown in the following figure.
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7 - THEORY OF OPERATION 2 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.
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7 - THEORY OF OPERATION 2 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.
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7 - THEORY OF OPERATION Across The Line Starter 7.9 Across The Line (Full Voltage Starter) 2 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. 2 In the ATL configuration, the MX assumes that the motor contactor (1M) is directly controlled by an output relay that is programmed to RUN.
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7 - THEORY OF OPERATION Single Phase Soft Starter 7.10 Single Phase Soft Starter There are times a single phase motor may need to be started using a soft starter. This can be accomplished with any 3 phase starter with the following modifications to the starter. • • • • • Connect Line power to terminals L1 and L3.
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7 - THEORY OF OPERATION Phase Control Phase Control 2 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. Phase control can be used to directly control the voltage applied to motors, resistive heaters, etc.
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7 - THEORY OF OPERATION 7.11.1 Master/Slave Starter Configuration: In the master / slave configuration, one "master" starter can directly control the output of one or more "slave" starters. To utilize the master / slave configuration, one starter needs to be defined as the "master" starter. The Starter Type parameter of the "master" starter should be configured appropriately as a Soft Starter (normal or ID), Phase Controller or Current Follower.
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7 - THEORY OF OPERATION Current Follower 7.12 Current Follower 2 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.
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7 - THEORY OF OPERATION Start/Stop Control with a Hand/Off/Auto Selector Switch 7.13 Start/Stop Control Logic Often times, a switch is desired to select between local or “Hand” mode and remote or “Auto” mode. In most cases, local control is performed as 3-wire logic with a normally open, momentary contact Start pushbutton and a normally closed, momentary contact Stop pushbutton, while remote control is performed as 2-wire logic with a “Run Command” contact provided by a PLC.
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7 - THEORY OF OPERATION 7.14 Hand/Off/Auto Selector Switch The MX2 has the capability to use a selector switch to change the source of control. A popular use is to switch between using the door mounted display for Hand operation and using contact input for Auto operation. The following drawing shows how to wire the unit to allow this operation.
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7 - THEORY OF OPERATION Simplified I/O Schematics 7.
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7 - THEORY OF OPERATION Remote Modbus Communications Figure 49: TB4 Connector B+ ACOM 7.16 Remote Modbus Communications 2 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 49 and 50 for connection diagrams. 7.16.
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7 - THEORY OF OPERATION 7.16.4 Figure 50: Modbus Network Wiring Example IMPORTANT DO NOT CREATE STUBS - CABLE MUST GO TO EACH STARTER.
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8 Troubleshooting & Maintenance
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8 - TROUBLESHOOTING & MAINTENANCE TROUBLESHOOTING 8 & MAINTENANCE Safety Precautions 8.1 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.
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8 - TROUBLESHOOTING & MAINTENANCE General Troubleshooting Charts 8.3 General Troubleshooting Charts The following troubleshooting charts can be used to help solve many of the more common problems that may occur. 8.3.1 Motor does not start, no output to motor Condition Cause Solution Display Blank, CPU Heartbeat LED on MX2 board not blinking. Control voltage absent. Check for proper control voltage input. Verify fuses and wiring. MX2 control board problem. Consult factory. Fault Displayed.
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8 - TROUBLESHOOTING & MAINTENANCE 8.3.2 During starting, motor rotates but does not reach full speed Condition Cause Solution Fault Displayed. Fault Occurred. See fault code troubleshooting table for more details. Display shows Accel or Run. Maximum Motor Current setting (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.
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8 - TROUBLESHOOTING & MAINTENANCE 8.3.4 Starter not decelerating 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.
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8 - TROUBLESHOOTING & MAINTENANCE 8.3.6 Metering incorrect Condition Cause Solution Power Metering not reading correctly. CTs installed or wired incorrectly. Verify correct CT wiring and verify that the CTs are installed with all the White dots towards the input line side. CT1=L1 CT2=L2 CT3=L3 CT ratio parameter (P78/FUN03) set incorrectly. Verify that the CT ratio parameter is set correctly. PF Meter not reading correctly. CTs installed or wired incorrectly.
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8 - TROUBLESHOOTING & MAINTENANCE 8.3.7 Other Situations Condition Cause Solution Motor Rotates in Wrong Direction. Phasing incorrect. If input phasing correct, exchange any two output wires. If input phasing incorrect, exchange any two input wires. Erratic Operation. Loose connections. Shut off all power and check all connections. Motor Overheats. Motor overloaded. Reduce motor load. Too many starts per hour. Allow for adequate motor cooling between starts.
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8 - TROUBLESHOOTING & MAINTENANCE Fault Code Table 8.4 Fault Code Table 2 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.
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8 - TROUBLESHOOTING & MAINTENANCE Fault Code Description Detailed Description of Fault / Possible Solutions F13 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. F14 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.
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8 - TROUBLESHOOTING & MAINTENANCE Fault Code Description Detailed Description of Fault / Possible Solutions F24 High Line L1-L2 High voltage above the Over voltage Trip Level parameter setting (P35/PFN07) was detected for longer than the Over/Under Voltage Trip delay time (P40/PFN09). Verify that the actual input voltage level is correct. Verify that the Rated Voltage parameter (P76/FUN05) is set correctly. Line power quality problems/ excessive line distortions.
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8 - TROUBLESHOOTING & MAINTENANCE Fault Code Description Detailed Description of Fault / Possible Solutions F30 I.O.C. (Instantaneous Over current) During operation, the MX2 detected a very high level of current in one or more phases. Check motor wiring for short circuits or ground faults. Check motor for short circuits or ground faults. Check if power factor or surge capacitors are installed on the motor side of the starter.
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8 - TROUBLESHOOTING & MAINTENANCE Fault Code Description Detailed Description of Fault / Possible Solutions F40 Shorted / Open SCR A shorted or open SCR condition has been detected. Verify that all SCR gate leads wires are properly connected at the SCR devices and the MX2 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.
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8 - TROUBLESHOOTING & MAINTENANCE Fault Code Description Detailed Description of Fault / Possible Solutions F51 Current Sensor Offset Error Indicates that the MX2 control card self-diagnostics have detected a problem with one or more of the current sensor inputs. Verify that the motor FLA (P1/QST01), CT ratio (P78/FUN03) and burden switch settings are correct. 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.
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8 - TROUBLESHOOTING & MAINTENANCE F82 Modbus Timeout Fault Indicates that the starter has lost serial communications. Fault occurs when the starter has not received a valid serial communications within the Communication Timeout parameter (FUN12) defined time. Verify communication parameter settings (FUN 10 - FUN13). Check wiring between the remote network and the MX2 control card.
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8 - TROUBLESHOOTING & MAINTENANCE SCR Testing 8.5 SCR Testing 8.5.1 Resistance The SCRs in the starter can be checked with a standard ohmmeter to determine their condition. Remove power from the starter before performing these checks. Check from L to T on each phase. The resistance should be over 50k ohms. Check between the gate leads for each SCR (red and white twisted pair). The resistance should be from 8 to 50 ohms.
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8 - TROUBLESHOOTING & MAINTENANCE Built-In Self Test Functions 8.6 Built In Self Test Functions 2 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.
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8 - TROUBLESHOOTING & MAINTENANCE z 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.
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8 - TROUBLESHOOTING & MAINTENANCE z 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.
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8 - TROUBLESHOOTING & MAINTENANCE SCR Replacement 8.7 SCR Replacement This section is to help with SCR replacements on stack assemblies. Please read prior to installation. 8.7.1 8.7.2 Typical Stack Assembly 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 ¼ turns until the SCR comes loose. Remove the SCRs from the heatsink.
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8 - TROUBLESHOOTING & MAINTENANCE 8.7.4 SCR Clamp Below is an exploded view of a typical SCR clamp. Refer to the Clamp Parts List below for names of the parts being used. SCR CLAMP PARTS 8.7.5 Item # Quantity Description 1 1 Loader Bar 2 2 Insulator cup 3 2 Bolt 4 2 Washer 5 2 6 1 or 2 Serrated nut (larger style clamp has 1 support bar) Indicator Washer – Quantity dependant on style of clamp Tightening Clamp Finger tighten the clamp.
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Appendices
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APPENDIX A - ALARM CODES ALARM CODES APPENDIX A Alarm Codes 2 The following is a list of all MX alarm codes. The alarm codes correspond to associate fault codes. In general, an alarm indicates a condition that if continued, will result in the associated fault.
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APPENDIX A - ALARM CODES Alarm Code Description A38 Ground Fault A47 A60 A61 A62 Stack Over temperature Alarm External Alarm on DI 1 Input External Alarm on DI 2 Input External Alarm on DI 3 Input A71 Analog Input Level Trip Alarm Notes This alarm exists while the MX2 is running and a ground current above the defined threshold is detected, but the delay for the fault has not yet expired. When the delay expires, a Fault 38 occurs. This occurs when the stack thermal rises above 105%.
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APPENDIX B - FAULT CODES FAULT CODES APPENDIX B Fault Codes Fault Code F00 F01 F02 F03 F10 F11 F12 F13 F14 F15 F21 F22 F23 F24 F25 F26 F27 F28 F30 F31 F34 F37 F38 F39 F40 F41 F46 F47 F48 F49 F50 F51 F54 F55 F60 F61 F62 F71 F81 F82 F94 F95 F96 F97 F98 F99 196 Description No fault UTS Time Limit Expired Motor Thermal Overload Trip Slow Speed Time Limit Expired Phase Rotation Error, not ABC Phase Rotation Error, not CBA Low Line Frequency High Line Frequency Input power not single phase Input power not thre
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APPENDIX C - SPARE PARTS SPARE PARTS APPENDIX C Options and Accessories Description Part Number Size 1) LCD Display (small) KPMX3SLCD H=63mm (2.48"), W=101mm (4") 2) LCD Display (large) KPMX3LLCD H=77mm (3.03"), W=127mm (5") 3) LCD display cable RI-100008-00 RI-100009-00 3' or 1 meter 6' or 2 meter 4) Communication Modules -consult factory Spare Parts Description 1) Part Number Size small = KPMX3SLCD H=63mm (2.48"), W=101mm (4") large = KPMX3LLCD H=77mm (3.
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APPENDIX D - EU DECLARATION OF CONFORMITY EU DECLARATION OF CONFORMITY EU Declaration of Conformity 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 Number: RB2-1-S-027A-11C RB2-1-S-040A-11C RB2-1-S-052A-12C RB2-1-S-096A-13C RB2-1-S-125A-14C RB2-1-S-156A-14C RB2-1-S-240A-15C RB2-1-S-302A-15C RB2-1-S-361A-16C RB2-1-S-515A-17C RB2-1-S-590A-18C RB2-1-S-720A-19C RB2-1-S-0
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APPENDIX E - MODBUS REGISTER MAP MODBUS APPENDIX REGISTER E MAP Modbus Register Map Following is the Modbus Register Map. Note that all information may be accessed either through the Input registers (30000 addresses) or through the Holding registers (40000 addresses).
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APPENDIX E - MODBUS REGISTER MAP Absolute Register Address Description Range Bit 0: Bit 1: Bit 2: Bit 3: Bit 4: Bit 5: Bit 6: Bit 7: Bit 8: Bit 9: Bit 10: Bit 11: Bit 12: Bit 13 Units “L OL” – Motor overload – Reserved - (Motor PTC) – Reserved - (RTD Stator) – Reserved - (RTD Bearing) – Reserved - (RTD Other) "L rI" – Run Interlock "L dS" – Disconnect open "L Ot" – Stack overtemperature "L CP" – Control Power Reserved – (RTD Open/Short) Reserved – (Time between starts) Reserved – (Backspin) Reserved – (S
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APPENDIX E - MODBUS REGISTER MAP Absolute Register Address Description 30104/40104 Motor Overload Running Enable 30105/40105 Motor Overload Running Class 30106/40106 Motor Overload Starting Enable 30107/40107 30108/40108 30109/40109 30110/40110 Motor Overload Starting Class Motor Overload Hot/Cold Ratio Motor Overload Cooling Time Local Source 30111/40111 Remote Source 30112/40112 Start Mode 30113/40113 30114/40114 30115/40115 30116/40116 30117/40117 30118/40118 30119/40119 30120/40120 30121/40
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APPENDIX E - MODBUS REGISTER MAP Absolute Register Address Description 30143/40143 Rated RMS Voltage 30144/40144 Input Phase Sensitivity 30145/40145 Motor Rated Power Factor 30146/40146 Overcurrent Enable 30147/40147 Overcurrent Level 30148/40148 Overcurrent Delay Time Enable 30149/40149 Overcurrent Delay Time 30150/40150 Undercurrent Trip Enable 30151/40151 Undercurrent Trip Level 30152/40152 Undercurrent Trip Delay Time Enable 30153/40153 Undercurrent Trip Delay Time 30154/40154 C
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APPENDIX E - MODBUS REGISTER MAP Absolute Register Address Description 30168/40168 Controlled Fault Stop 30169/40169 30170/40170 DI 1 Configuration DI 2 Configuration 30171/40171 DI 3 Configuration 30172/40172 30173/40173 R1 Configuration R2 Configuration 30174/40174 R3 Configuration 30175/40175 Analog Input Trip Enable 30176/40176 Analog Input Trip Type 30177/40177 30178/40178 30179/40179 30180/40180 Analog Input Trip Level Analog Input Trip Delay Time Analog Input Span Analog Input Offset
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APPENDIX E - MODBUS REGISTER MAP Absolute Register Address Description 30184/40184 Inline Enable 30185/40185 30186/40186 Inline Delay Time Bypass Feedback Time 30187/40187 Keypad Stop 30188/40188 Modbus Timeout Enable 30189/40189 Modbus Timeout 30190/40190 CT Ratio (x:1) 30191/40191 Auto Start 30192/40192 Energy Saver Enable 30193/40193 Heater / Anti-Windmill Enable 30194/40194 Heater / Anti-Windmill Level 30195/40195 Starter Type 30196/40196 LED Display Meter 204 Range 0: Disabled
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APPENDIX E - MODBUS REGISTER MAP Absolute Register Address Description Range 1: Ave Current 2: L1 Current 3: L2 Current 4: L3 Current 5: Current Imbalance % 6: Residual Ground Current 7: Ave.
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APPENDIX E - MODBUS REGISTER MAP Absolute Register Address 30641/40641 (most recent) to 30649/40649 (oldest) 30651/40651 (most recent) to 30659/40659 (oldest) 30661/40661 (most recent) to 30669/40669 (oldest) 30671/40671 (most recent) to 30679/40679 (oldest) 30681/40681 (most recent) to 30689/40689 (oldest) 30691/40691 (most recent) to 30699/40699 (oldest) 30701/40701 (most recent) to 30709/40709 (oldest) Description L3 Currents: The current that the load is drawing from Line 3 when the fault has occurred
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APPENDIX E - MODBUS REGISTER MAP The control source must be serial for the starter to be started through Modbus. The Run/Stop bit must transition from 0 to 1 for a start to occur. If the starter stops due to a fault, the action of the starter depends on the state of the AutoStart parameter (P66 – I/O19). The fault reset bit must transition from 0 to 1 for a fault to be reset. If any of the programmed digital inputs are programmed as Local/Remote inputs, then the local/Remote bit has no effect.
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APPENDIX F - PARAMETER TABLES Parameter Table Following is the parameter table for both the LED and LCD Display. The last column is a convenient place to write down parameter settings. Quick Start Group LED LCD Parameter Setting Range Units 1 – 6400 RMS Amps P1 QST 01 Motor FLA P2 QST 02 Motor Service Factor 1.00 – 1.
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APPENDIX F - PARAMETER TABLES Protection Function Group LED LCD Setting Range Units Default Page P32 PFN 01 Over Current Level Parameter Off, 50 – 800 % FLA Off 98 P33 PFN 02 Over Current Trip Delay Time Off, 0.1 – 90.0 Seconds 0.1 99 P34 PFN 03 Under Current Trip Level Off, 5 – 100 % FLA Off 100 P35 PFN 04 Under Current Trip Delay Time Off, 0.1 – 90.0 Seconds 0.
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APPENDIX F - PARAMETER TABLES LED P52 P53 LCD I/O 05 I/O 06 Parameter R1 Configuration R2 Configuration Setting Range OFF: FLFS: FLnF: dcb: FAn: Off Fault (fail safe) Fault (non fail safe) Running UTS Alarm Ready Locked Out Over Current 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 OFF: Lo: Hi: Disabled Low Level High Level run: utS: AL: rdyr: LOC: OC: UC: OLA:
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APPENDIX F - PARAMETER TABLES Function Group LED LCD Parameter Setting Range 0: 1: 2: 3: 4: 5: 6: P79 FUN 01 Meter 1 FUN 02 Meter 2 7: 8: 9: 10: 11: 12: 13: 14: 15: 16: 17: 18: 19: 20: 21: 22: 23: 24: 25: 26: 27: 28: P78 FUN 03 CT Ratio 72:1, 96:1,144:1, 288:1, 864:1, 2640:1, 3900:1, 5760:1, 8000:1, 14400:1, 28800:1 P77 FUN 04 Input Phase Sensitivity InS AbC CbA SPH 100, 110, 120, 200, 208, 220, 230, 240, 350, 380, 400, 415, 440, 460, 480, 500, 525, 575, 600, 660, 690, 800, 1000, 1140, P
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APPENDIX F - PARAMETER TABLES LED LCD Parameter P71 FUN 13 Communication Byte Framing P80 FUN 14 Software Version 1 Setting Range Units 0: Even Parity, 1 Stop bit 1: Odd Parity, 1 Stop bit 2: No Parity, 1 Stop bit 3: No Parity, 2 Stop bits Default Page Even Parity, 1 Stop bit 122 Display Only P67 FUN 15 Miscellaneous Commands P81 FUN 16 Passcode 0: 1: 2: 3: 4: 5: 6: 7: 8: Setting 128 None Std.
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Publication History; Revision Date ECO# 00 12/15/06 Initial Release 01 09/10/07 02 08/21/08 Revisions based on shared review
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BENSHAW 615 Alpha Drive Pittsburgh, PA 15238 Phone: (412) 968-0100 Fax: (412) 968-5415 BENSHAW Canada 550 Bright Street Listowel, Ontario N4W 3W3 Phone: (519) 291-5112 Fax: (519) 291-2595