RediStartTM

TM

RediStart

Solid State Starter

Control

MVRMX & MVRXE Models

1500 to 7200VAC

User Manual

890034-03-00

Motor Starter Card Set: BIPC-450100-01-01

Software Version 1: 810023-02-01

Software Version 2: 810024-01-01

Gate Driver Card: 300047-01 Rev. 13

©

2006 Benshaw Inc.

Benshaw retains the right to change specifications and illustrations in text without prior notification. The contents of this document may not be copied without the explicit permission of Benshaw.

BENSHAW

ADVANCED CONTROLS & DRIVES

Important Reader Notice

Congratulations on the purchase of your new Benshaw RediStart MVRMX

3 and program the MVRMX

3

Solid State Starter.

Solid State Starter. This manual contains the information to install

This manual may not cover all of the applications for the RediStart MVRMX

3

. Also, it may not provide information on every possible contingency concerning installation, programming, operation, or maintenance specific to the RediStart MVRMX

3

Series Starters.

The content of this manual will not modify any prior agreement, commitment or relationship between the customer and Benshaw. The sales contract contains the entire obligation of Benshaw. The warranty enclosed within the contract between the parties is the only warranty that

Benshaw will recognize and any statements contained herein do not create new warranties or modify the existing warranty in any way.

Any electrical or mechanical modifications to Benshaw products without prior written consent of Benshaw will void all warranties and may also void cUL listing or other safety certifications, unauthorized modifications may also result in product damage operation malfunctions or personal injury.

Incorrect handling of the starter may result with an unexpected fault or damage to the starter. For best results on operating the RediStart MX

3 starter, carefully read this manual and all warning labels attached to the starter before installation and operation. Keep this manual on hand for reference.

Do not attempt to install, operate, maintain or inspect the starter until you have thoroughly read this manual and related documents carefully and can use the equipment correctly.

Do not use the starter until you have a full knowledge of the equipment, safety procedures and instructions.

This instruction manual classifies safety instruction levels under "WARNING" and "CAUTION".

Electrical Hazard that could result in injury or death.

Caution that could result in damage to the starter.

Highlight marking an important point in the documentation.

Please follow the instructions of both safety levels as they are important to personal safety.

High Voltage

Motor control equipment and electronic controllers are connected to hazardous line voltages. When servicing starters and electronic controllers, there may be exposed components with housings or protrusions at or above line potential. Extreme care should be taken to protect against shock.

Stand on an insulating pad and make it a habit to use only one hand when checking components. Always work with another person in case an emergency occurs. Disconnect power before checking controllers or performing maintenance. Be sure equipment is properly grounded. Wear safety glasses whenever working on electronic controllers or rotating machinery.

TRADEMARK NOTICE

Benshaw and are registered trademarks of Benshaw Incorporated.

UL is a trademark of Underwriters Laboratories, Incorporated.

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.

•

Always install the soft starter before wiring. Otherwise, you may get an electrical shock or be injured.

•

Operate the switches with dry hands to prevent an electrical shock.

•

Risk of Electric Shock - More than one disconnect switch may be required to de-energize the equipment before servicing.

Injury Prevention

•

Service only by qualified personnel.

•

Make sure power-up restart is off to prevent any unexpected operation of the motor.

•

Make certain proper shield installation is in place.

•

Apply only the voltage that is specified in this manual to the terminals to prevent damage.

Transportation and Installation

•

Use proper lifting gear when carrying products, to prevent injury.

•

Make certain that the installation position and materials can withstand the weight of the soft starter. Refer to the installation information in this manual for correct installation.

•

If parts are missing, or soft starter is damaged, do not operate the RediStart MVRMX

3

.

•

Do not stand or rest heavy objects on the soft starter, as damage to the soft starter may result.

•

Do not subject the soft starter to impact or dropping.

•

Make certain to prevent screws, wire fragments, conductive bodies, oil or other flammable substances from entering the soft starter.

Trial Run

•

Check all parameters, and ensure that the application will not be damaged by a sudden start-up.

Emergency Stop

•

To prevent the machine and equipment from hazardous conditions if the soft starter fails, provide a safety backup such as an emergency brake.

Disposing of the RediStart MVRMX

3

•

Never dispose of electrical components via incineration. Contact your state environmental agency for details on disposal of electrical components and packaging in your area.

i

TABLE OF CONTENTS

Table of Contents

1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 TECHNICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.2 Electrical Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.2.1 Terminal Points and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.2.2 Measurements and Accuracies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.2.3 List of Motor Protection Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.2.4 Solid State Motor Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.2.5 CT Ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.2.6 Optional RTD Module Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.2.7 Optional Zero Sequence Ground Fault CT. . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.3 Sample RediStart MVRMX

3

Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.4 Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.5 Altitude Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.6 Real Time Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.7 Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.8 Certificate of Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.1 Before You Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.1.1 Installation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.1.2 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.2 Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.2.1 Site Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.2.2 EMC Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.2.3 R-Rated Motor Starter Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.2.4 Use of Electro-Mechanical Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.2.5 Reversing Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.2.6 Use of Power Factor Capacitors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.3 Mounting Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.3.1 Bypassed Starters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.4 Wiring Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.4.1 Wiring Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.4.2 Considerations for Control and Power Wiring . . . . . . . . . . . . . . . . . . . . . . . 21

3.4.3 Considerations for Signal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.4.4 Meggering a Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.4.5 High Pot Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.5 Typical Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.5.1 MVRMX

3

3.5.2 MVRMX

3

Power Wiring Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Control Wiring Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 ii


3.6 Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.6.1 Recommended Wire Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.6.2 Power Wire Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.6.3 Motor Lead Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.6.4 Compression Lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.6.5 Torque Requirements for Power Wiring Terminations. . . . . . . . . . . . . . . . . . . 25

3.7 Current Transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.7.1 CT Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.7.2 CT Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.7.3 Zero Sequence Ground Fault Current Transformer. . . . . . . . . . . . . . . . . . . . . 26

3.8 MVRMX

3

Control Card Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.9 MVRMX

3

I/O Card Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.10 MVRMX

3

Terminal Block Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.11 Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.11.1 Control Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.11.2 Output Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.11.3 Digital Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.11.4 Analog Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.11.5 Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.11.6 SW1 DIP Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.11.7 Motor PTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.11.8 RTD Module Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.12 Remote LCD Keypad/Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.12.1 Remote Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.12.2 Display Cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

3.12.3 Installing Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

3.13 RTD Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3.13.1 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3.13.2 Modbus Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3.13.3 Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3.13.4 RS-485 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3.13.5 RTD Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3.13.6 RTD Temperature vs. Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

4 KEYPAD OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4.2 Description of the LEDs on the Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4.3 Description of the Keys on the Remote LCD Keypad . . . . . . . . . . . . . . . . . . . 41

4.4 Alphanumeric Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

4.4.1 Power Up Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

4.4.2 Operate Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

4.4.3 Parameter Group Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4.4.4 Meter Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

4.4.5 Fault Log Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4.4.6 Fault Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4.4.7 Event Recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4.4.8 Lockout Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

4.4.9 Alarm Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

4.5 Procedure for Setting Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 iii


4.6 Jump Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

4.7 Restoring Factory Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

4.8 Resetting a Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

4.9 Emergency Overload Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

4.10 LED Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

5 PARAMETER GROUPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

5.2 LCD Display Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

5.2.1 Quick Start Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

5.2.2 Control Function Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

5.2.3 Protection Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

5.2.4 I/O Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

5.2.5 RTD Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

5.2.6 Function Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

5.2.7 Fault Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

5.2.8 Event Log Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

6 PARAMETER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

6.1 Parameter Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

7 THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

7.1 Solid State Motor Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

7.1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

7.1.2 Setting Up The MX 3 Motor Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

7.1.3 Motor Overload Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

7.1.4 Current Imbalance / Negative Sequence Current Compensation . . . . . . . . . . . . . 116

7.1.5 Harmonic Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

7.1.6 Hot / Cold Motor Overload Compensation . . . . . . . . . . . . . . . . . . . . . . . . . 116

7.1.7 RTD Overload Biasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

7.1.8 Overload Auto Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

7.1.9 Separate Starting and Running Motor Overload Settings . . . . . . . . . . . . . . . . . 119

7.1.10 Motor Cooling While Stopped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

7.1.11 Motor Cooling While Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

7.1.12 Emergency Motor Overload Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

7.2 Motor Service Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

7.3 Acceleration Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

7.3.1 Current Ramp Settings, Ramps and Times . . . . . . . . . . . . . . . . . . . . . . . . . 123

7.3.2 Programming A Kick Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

7.3.3 TruTorque Acceleration Control Settings and Times . . . . . . . . . . . . . . . . . . . . 124

7.3.4 Power Control Acceleration Settings and Times . . . . . . . . . . . . . . . . . . . . . . 126

7.3.5 Open Loop Voltage Ramps and Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

7.3.6 Dual Acceleration Ramp Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

7.3.7 Tachometer Ramp Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

7.4 Deceleration Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

7.4.1 Voltage Control Deceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

7.4.2 TruTorque Deceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 iv


7.5 Braking Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

7.5.1 DC Injection Braking, Standard Duty . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

7.5.2 DC Injection Braking, Heavy Duty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

7.5.3 Braking Output Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

7.5.4 Stand Alone Overload Relay for emergency ATL (Across The Line) Operation . . . . . 134

7.5.5 DC Injection Brake Wiring Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

7.5.6 DC Brake Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

7.5.7 DC Injection Brake Enable and Disable Digital Inputs . . . . . . . . . . . . . . . . . . . 136

7.5.8 Use of Optional Hall Effect Current Sensor . . . . . . . . . . . . . . . . . . . . . . . . . 137

7.5.9 DC Injection Braking Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

7.6 Slow Speed Cyclo Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

7.6.1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

7.6.2 Slow Speed Cyclo Converter Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . 138

7.7 Wye Delta Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

7.8 Across The Line (Full Voltage Starter). . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

7.9 Start/Stop Control with a Hand/Off/Auto Selector Switch . . . . . . . . . . . . . . . 144

7.10 Simplified I/O Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

7.11 Remote Modbus Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

7.11.1 Supported Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

7.11.2 Modbus Register Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

7.11.3 Cable Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

7.11.4 Terminating Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

7.11.5 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

7.11.6 Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

7.11.7 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

8 TROUBLESHOOTING & MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . 150

8.1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

8.2 Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

8.2.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

8.2.2 Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

8.3 LED Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

8.4 General Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

8.4.1 Stack Overtemp Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

8.4.2 Motor does not start, no output to motor . . . . . . . . . . . . . . . . . . . . . . . . . . 153

8.4.3 During starting, motor rotates but does not reach full speed . . . . . . . . . . . . . . . 154

8.4.4 Starter not accelerating as desired . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

8.4.5 Starter not decelerating as desired . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

8.4.6 Motor stops unexpectedly while running . . . . . . . . . . . . . . . . . . . . . . . . . . 155

8.4.7 Metering incorrect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

8.4.8 Other Situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

8.5 Fault Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

8.6 Minimum Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 v


8.7 Ohm Meter Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

8.7.1 Fuse Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

8.7.2 Shorted SCR Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

8.7.3 Alternative Shorted SCR Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

8.7.4 Shorted SCR Found . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

8.7.5 SCR Gate to Cathode Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

8.8 SCR Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

8.8.1 Card Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

8.8.2 SCR Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

8.8.3 SCR Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

8.8.4 SCR Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

8.8.5 Re-Test SCR's . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

8.8.6 Re-Assemble Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

8.9 Built-In Self Test (BIST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

8.9.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

8.9.2 Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

8.9.3 BIST Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

8.9.4 Conducting a BIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

8.9.5 Begin BIST Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

8.9.6 RUN relay and In-line Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

8.9.7 UTS relay and Bypass Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

8.9.8 Sequential SCR Gate Firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

8.9.9 All SCR Gates Firing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

8.9.10 Resetting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

8.9.11 BIST Test Cancelled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

8.10 High Pot Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

8.11 Vacuum Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

8.12 RTD Module Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

8.13 VACUUM contactor and Power Pole assembly Maintenance . . . . . . . . . . . . . . 176

APPENDIX A EVENT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

APPENDIX B ALARM CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

APPENDIX C FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

APPENDIX D SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

APPENDIX E EU DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . 186

APPENDIX F MODBUS REGISTER MAP . . . . . . . . . . . . . . . . . . . . . . . . . . 187

APPENDIX G APPLICATION GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . 201

APPENDIX H 3-YEAR WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

APPENDIX I PARAMETER TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

vi

1 Introduction

1

1 - INTRODUCTION

Using This Manual

Layout

This manual is divided into 9 sections. Each section contains topics related to the section. The sections are as follows:

•

Introduction

•

Technical Information

•

Installation

•

Keypad Operation

•

Parameters

•

Parameter Descriptions

•

Theory of Operation

•

Troubleshooting & Maintenance

•

Appendices

Symbols

There are 2 symbols used in this manual to highlight important information. The symbols appear as the following:

Electrical Hazard

warns of situations in which a high voltage can cause physical injury, death and/or damage equipment.

Caution

warns of situations in which physical injury and/damage to equipment may occur by means other than electrical.

Highlight

mark an important point in the documentation.

2

DANGER

HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH

Only qualified personnel familiar with low voltage equipment are to perform work described in this set of instructions.

Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See NFPA 70E.

Turn off all power before working on or inside equipment.

Use a properly rated voltage sensing device to confirm that the power is off.

Before performing visual inspections, tests, or maintenance on the equipment, disconnect all sources of electric power.

Assume that circuits are live until they have been completely de-energized, tested, and tagged. Pay particular attention to the design of the power system. Consider all sources of power, including the possibility of backfeeding.

Replace all devices, doors, and covers before turning on power to this equipment.

Failure to follow these instructions will result in death or serious injury.


General Information

Start-Up Services

On-Site Training Services

Technical Support

Documentation

On-Line Documentation

Replacement Parts

Software Number

Hardware Number

Publication History

Warranty

Benshaw Services

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.

Benshaw technical field support personnel are available to customers with the initial start-up of the RediStart

MVRMX

3

. Information about start-up services and fees are available by contacting Benshaw.

Benshaw technical field support personnel are available to conduct on-site training on RediStart MVRMX

3 operations and troubleshooting.

Benshaw technical support personnel are available (at no charge) to answer customer questions and provide technical support over the telephone. For more information about contacting technical support personnel, refer to page 4.

Benshaw provides all customers with:

•

Operations manual.

•

Wiring diagram.

All drawings are produced in AutoCAD© format. The drawings are available on standard CD / DVD or via e-mail by contacting Benshaw.

All RediStart MVRMX

3 documentation is available on-line at http://www.benshaw.com.

Spare and replacement parts can be purchased from Benshaw Technical Support.

This manual pertains to the software version number 1) 810023-02-01.

2) 810024-01-01.

This manual pertains to the hardware assembly version number BIPC-450100-01-01.

See page 213.

Benshaw provides a 1 year standard warranty with its starters. An extension to the 3 year warranty is provided when a Benshaw or Benshaw authorized service technician completes the installation and initial start up. The warranty data sheet must also be signed and returned. The cost of this service is not included in the price of the Benshaw soft starter and will be quoted specifically to each customers needs. All recommended maintenance procedures must be followed throughout the warranty period to ensure validity. This information is also available by going online to register at www.benshaw.com.

3


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.

550 Bright Street East

Listowel, Ontario N4W 3W3

Phone: (519) 291-5112

Tech Support: (877) 236-7429 (BEN-SHAW)

Fax: (519) 291-2595

Benshaw West

14715 North 78th Way, Suite 600

Scottsdale, AZ 85260

Phone:

Fax:

(480) 905-0601

(480) 905-0757

Benshaw Mobile

CSD Division

5821 Rangeline Road, Suite 202

Theodor, AL 36582

Phone: (251) 443-5911

Fax: (251) 443-5966

Benshaw Pueblo

Trane Division

1 Jetway Court

Pueblo, CO 81001

Phone: (719) 948-1405

Fax: (719) 948-1445

Technical support for the RediStart MVRMX

3

Series is available at no charge by contacting Benshaw’s customer service department at one of the above telephone numbers. A service technician is available Monday through Friday from 8:00 a.m. to 5:00 p.m. EST.

z NOTE: An on-call technician is available after normal business hours and on weekends by calling

Benshaw and following the recorded instructions.

To help assure prompt and accurate service, please have the following information available when contacting

Benshaw:

•

Name of Company

•

Telephone number where the caller can be contacted

•

Fax number of caller

•

Benshaw product name

•

Benshaw model number

•

Benshaw serial number

•

Name of product distributor

•

Approximate date of purchase

•

Voltage of motor attached to Benshaw product

•

FLA of motor attached to Benshaw product

•

A brief description of the application

4


Interpreting Model Numbers

Figure 1: RediStart MVRMX

3

Series Model Numbers

CFMVRMX18-3500-4160-1

1 - Nema 1

3R - Nema 3R

12 - Nema 12

Voltage

HP

12 - 2300 Volts

- 2400 Volts

- 3300 Volts

18 - 4160 Volts

- 4800 Volts

- 7200 Volts

Combination Fusable

Example of Model Number: CFMVRMX18-3500-4160-1

3

A Combination Fusable RediStart starter with MV MX control, 4160 Volts, 3500 Horse Power, NEMA 1 Enclosure.

5


General Overview Of A Reduced Voltage Starter

General Overview

The RediStart MVRMX

3 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

•

Programmable metering

•

Communications

Each starter can operate within applied frequency values 23 to 72Hz and line voltage of:

2,200VAC to 2,400VAC



10,000VAC to 12,000VAC

12,470VAC to 13,800VAC

The starter can be programmed for any motor FLA and all of the common motor service factors. It enables operators to control both motor acceleration and deceleration. The RediStart MVRMX

3 can also protect the motor and its load from damage that could be caused by incorrect phase order wiring.

The starter continually monitors the amount of current being delivered to the motor. This protects the motor from overheating or drawing excess current.

Features

The enhanced engineering features of the starter include:

•

Multiple frame sizes

•

Universal voltage operation

•

Universal frequency operation

•

Programmable motor overload multiplier

•

Controlled acceleration and deceleration

•

Phase rotation protection

•

Regulated current control

•

Electronic motor thermal overload protection

•

Electronic over/under current protection

•

Single phase protection

•

Line-to-line current imbalance protection

•

Stalled motor protection

•

Programmable metering

•

Passcode protected

•

Programmable Relays

•

Analog output with digital offset and span adjustment

•

Analog input with digital offset and span adjustment

•

Voltage and Current Accuracy of 3%

•

Slow speed (Cyclo Conversion) 1.0 – 40.0% forward and reverse

•

Motor Winding Heater (Anti-Condensation)

•

Anti-windmilling brake

•

PTC Thermistor

•

99 Event Recorder

•

9 Fault Log

•

Real Time Clock

•

Zero Sequence Ground Fault

•

Backspin Timer

•

Starts per Hour

•

Time between Starts

•

PORT (Power Outage Ride Through)

•

16 RTD with O/L Biasing

•

D.C. Injection Braking

6

2 Technical Specifications

7

2 - TECHNICAL SPECIFICATIONS

2.1

Technical Specifications


The physical specifications of the starter vary depending upon its configuration. The applicable motor current determines the configuration and its specific application requirements. Specifications are subject to change without notice.

This document covers the control electronics and several power sections:

•

MX

3

Control Card Set

•

Power Stacks with inline and bypass vacuum contactors

2.2

2.2.1

Electrical Ratings

Terminal Points and Functions

Function

Control Power

Relay 1 (R1)

Table 1: Terminals

Terminal

Block

TB1

TB2

Terminal Number

G, ground

N, 120VAC neutral

N, 120VAC neutral

L, 120VAC line

L, 120VAC line

NO1:Normally Open Contact

RC1:Common

NC1: Normally Closed Contact

Description

96 – 144 VAC input, 50/60 Hz

45VA required for control card

Relay 2 (R2)

Relay 3 (R3)

Relay 4 (R4)

Relay5 (R5)

Relay6 (R6)

Digital Inputs

Digital Inputs

TB2

TB2

J3

J3

J3

TB3

J6

NO2: Normally Open Contact

RC2: Common Contact


NO3: Normally Open Contact

RC3: Common Contact


R4A: Normally Open Contact

R4B: Normally Open Contact





1: Start

2: DI1

3: DI2

4: DI3

5: Common

1: DI4

2: DI5

3: DI6

4: DI7

5: DI8

6: Common

Relay Output, SPDT form C

NO Contact (resistive) NC Contact(resistive)

5A at 250VAC

5A at 125VAC

5A at 30VDC

1250VA

3A at 250VAC

3A at 125VAC

3A at 30VDC

750VA

Relay Output, SPDT form C

NO Contact (resistive) NC Contact(resistive)

5A at 250VAC

5A at 125VAC

5A at 30VDC

1250VA

3A at 250VAC

3A at 125VAC

3A at 30VDC

750VA

10A at 250VAC

10A at 125VAC

10A at 30VDC

2500VA

Relay Output, SPST-NO form A

Resistive:

5A at 250VAC

5A at 125VAC

5A at 30VDC

1250VA


Resistive:

5A at 250VAC

5A at 125VAC

5A at 30VDC

1250VA


Resistive:

5A at 250VAC

5A at 125VAC

5A at 30VDC

1250VA

120VAC digital input

2500V optical isolation

4mA current draw

Off: 0-35VAC

On: 60-120VAC

120VAC digital input

2500V optical isolation

4mA current draw

Off: 0-35VAC

On: 60-120VAC

8


Function

Serial Comm

Analog I/O

PTC Thermistor Input

Zero Sequence

Ground Fault

Terminal

Block

TB4

TB5

J7

J15

Terminal Number

1: B+

2: A-

3: COM

1: Ain Power

2: Ain +

3: Ain -

4: Common

5: Aout

6: Common

7: Shield

1: Motor PTC

2: Motor PTC

1: CT input

2: CT input

Description

Modbus RTU serial communication port.

RS-485 interface

19.2k baud maximum

2500V Isolation

Input:

Voltage or Current

Voltage: 0-10VDC, 67K

W impedance

Current: 0-20mA, 500

W impedance

Output:

Voltage or Current

Voltage: 0-10VDC, 120mA maximum

Current: 0-20mA, 500

W load maximum

Positive Temperature Coefficient Thermistor

- Trip resistance 3.5K, ± 300 Ohms.

- Reset resistance 1.65K, ± 150 Ohms.

- Open terminal voltage is 15V.

- PTC voltage at 4Kohms = 8.55V. (>7.5V)

- Response time adjustable between 1 and 5 seconds.

- Maximum cold resistance of PTC chain = 1500 Ohms.

Zero Sequence Ground Fault

CT Type: 50:0.025 (2000:1 ratio)

Measurement range: 0.1A - 25.0 Amps Accuracy : +/- 3%

Burden at 25Amps : 0.0089VA.

Door Mounted Display Connector

Fiber Optic connector

Display

SCR

Stack OT

Phase C.T.

(5 Amp input)

RJ45

SCR 1A-F

SCR 2A-F

SCR 3A-F

Phase 1

Phase 2

Phase 3

J10

ISO 1 to ISO 18

LS1

LS2

LS3

1: CT1+

2: CT1

3: CT2+

4: CT2

5: CT3+

6: CT3

Fiber Optic connector

Phase CT Connector

Wire Gauge:

The terminals can support 1- 14 AWG wire or 2-16 AWG wires or smaller.

Torque Rating:

The terminals on the control cards have a torque rating of 5.0-inch lb. or 0.56Nm. This MUST be followed or damage will occur to the terminals.

z NOTE: Refer to Control Card Layout starting on page 28.

9


2.2.2

Measurements and Accuracies

Table 2: Measurements and Accuracies

Internal Measurements

CT Inputs

Line Voltage Inputs

Metering

Current

Voltage

Watts

Volts-Amps

Watt-Hours

PF

Line Frequency

Ground Fault

Run Time

Analog Input

Analog Output

Zero Seq GF

Conversion: True RMS, Sampling @ 1.562kHz

Range: 1-6400A

Conversion: True RMS, Sampling @ 1.562kHz

Range: 2,000 - 8,000VAC, 23 to 72 Hz

0 – 40,000 Amps ± 3%

0 – 8,000 Volts ± 3%

0 – 9,999 MW ± 5%

0 – 9,999 MVA ± 5%

0 – 10,000 MWh ± 5%

-0.01 to +0.01 (Lag & Lead) ± 5%

23 – 72 Hz ± 0.1 Hz

5 – 100% FLA ± 5% (Machine Protection)

± 3 seconds per 24 hour period

Accuracy ± 3% of full scale (10 bit)

Accuracy ±2% of full scale (12 bit)

0.1 – 25.0 Amps ± 3% z NOTE: Percent accuracy is percent of full scale of the given ranges, Current = Motor FLA,

Voltage = 8,000V, Watts/Volts-Amps/Watt-Hours = Motor & Voltage range

2.2.3

List of Motor Protection Features

•

ANSI 14 – Speed Switch and Tachometer Trip

•

ANSI 19 – Reduced Voltage Start

•

ANSI 27 / 59 – Adjustable over/under voltage protection (Off or 1 to 40%, time 0.1 to 90.0 sec. in 0.1 sec. intervals, independent over and under voltage levels)

•

ANSI 37 – Undercurrent detection (Off or 5 to 100% and time 0.1 to 90.0 sec. in 0.1 sec. intervals)

•

ANSI 38 – Bearing RTD

Other RTD

Open RTD Alarm

•

ANSI 46 – Current imbalance detection (Off or 5 to 40%)

•

ANSI 47 – Phase rotation (selectable ABC, CBA, Insensitive, or Single Phase)

•

ANSI 48 – Adjustable up-to-speed / stall timer (1 to 900 sec. in 1 sec. intervals)

•

ANSI 49 – Stator RTD

•

ANSI 50 – Instantaneous electronic overcurrent trip

•

ANSI 51 – Electronic motor overload (Off, class 1 to 40, separate starting and running curves available)

•

ANSI 51 – Overcurrent detection (Off or 50 to 800% and time 0.1 to 90.0 sec. in 0.1 sec. intervals)

•

ANSI 51G – Residual Ground fault detection (Off or 5 to 100% of motor FLA)

Zero Sequence Ground Fault Detection (Off, 0.1 - 25Amps)

•

ANSI 66 – Starts/Hour & Time Between Starts

Restart Block (Backspin Timer)

•

ANSI 74 – Alarm relay output available

•

ANSI 81 – Over / Under Frequency

•

ANSI 86 – Overload lockout

•

Single Phase Protection

•

Shorted SCR Detection

•

Mechanical Jam

10


2.2.4

Solid State Motor Overload

The MVRMX

3

MVRMX

3 control has an advanced I

2 t electronic motor overload (OL) protection function. For optimal motor protection the control has forty standard NEMA style overload curves available for use. Separate overloads can be programmed, one for acceleration and another for normal running operation. The overloads can be individual, the same or completely disabled if necessary.

The MVRMX

3 motor overload function also implements a NEMA based current imbalance overload compensation, RTD Biasing, user adjustable hot and cold motor compensation and user adjustable exponential motor cooling.

Figure 2: Commonly Used Overload Curves

10000

1000

100

10

1

100 150 200 250 300 350 400 450

Current % (FLA)

500 550 600 650 700 750 800

Class 40

Class 35

Class 30

Class 25

Class 20

Class 15

Class 10

Class 5

The motor overload will NOT trip when the current is less than motor Full Load Amps (FLA) * Service Factor (SF).

The motor overload "pick up" point current is at motor Full Load Amps (FLA) * Service Factor (SF).

The motor overload trip time will be reduced when there is a current imbalance present.

z NOTE: Refer to Theory of Operation, Chapter 7 in section 7.1 for more motor overload details and a larger graph.

Refer to http://www.benshaw.com/olcurves.html for an automated overload calculator.

11


2.2.5

CT Ratios

CT Ratio (x:5)

50:5

150:5

250:5

800:5

2000:5

5000:5

Table 3: CT Ratios

Minimum FLA

(A rms)

11

33

55

176

440

1100

Maximum FLA

(A rms)

45

135

225

720

1800

4500

2.2.6

Optional RTD Module Specifications

The starter has the option of operating with up to two Benshaw SPR-100P remote RTD modules.

Model Number

RTD Type

TCR ( a)

Maximum Lead Resistance

Recommended Lead Resistance

Shorted Lead Detection

Open Lead Detection

RTD Sensing Current

RTD Sensing Voltage

Range

Resolution

Accuracy

Sampling Rate

Number of RTDs

Input Voltage

Communication Type

Modbus

®

Addresses

Operating Environment

Terminal Strips

Dimensions

Listing

Table 4: Remote RTD Module Specifications

SPR-100P

100

W Platinum, 3 lead

0.00385

W/W/°C

(DIN 43760)

25

W per lead

Less than 16

W per lead

< 60

W

> 260

W

10 mA DC

10V DC maximum

0 to 200

°C (32 to 392 °F)

1

°C (1.8 °F)

±1.0% full scale (±2 °C or ±3.6 °F)

1 RTD per second

8

24 Volts DC

± 20%, 2.5W

Modbus RTU, RS-485, 19.2Kbps

16 to 23

-40 to 60

°C (-40 to 140 °F), up to 95% R.H., non-condensing

Accepts one or two stranded copper wires of the same size from 12 to 30 AWG

5 ½" W x 3 ½" H x 2 ¼" D cUL

12


2.2.7

Optional Zero Sequence Ground Fault CT

The Benshaw BICT 2000/1-6 CT has the following excitation curve.

Figure 3: BICT2000/1-6 Excitation Curve

13


2.3

Sample RediStart MVRMX

3

Unit

Sample RediStart MVRMX

3

Unit

LINE BUS

SECTION

DISCONNECT

SECTION

ZERO SEQUENCE

GROUND FAULT CURRENT

TRANSFORMER (GFCT)

OPTIONAL

LINE

HORIZONTAL POWER BUS

TIN PLATED COPPER

OPTIONAL

DISCONNECT GROUNDING ARM

DISCONNECT SWITCH

400 AMP

MEDIUM VOLTAGE DOOR

ELECTRO-MECHANICAL INTERLOCK

MEDIUM VOLTAGE DIVIDER CARD

MOTOR STARTING FUSES

(R RATED)

CURRENT TRANSFORMERS (CT)

BYPASS CONTACTOR (BP) c/w 2-HOLE COPPER LANDING PAD

INLINE CONTACTOR (IL)

MEDIUM

VOLTAGE

SECTION

T1

T2 T3

FIBER OPTIC

PHASE ASSEMBLY

1kVA, 1-PHASE

TRANSFORMER

CONTROL WIRE WAY

2"W X 4"H

OPTIONAL

COPPER GROUND BUS

(2"W X 1/4"T)

z NOTE: This is only a sample diagram drawing for component identification purposes. Component locations may change to meet end users specifications.

14


2.4

Environmental Conditions

Environmental Conditions

Operating Temperatures

Storage Temperatures

Humidity

Altitude

Maximum Vibration

Cooling

Table 6: Environmental Ratings

-10°C to +40°C (14°F to 104°F)enclosed

-10°C to +50°C (14°F to 122°F)open

-20°C to +70°C (-4°F to 155°F)

0% to 95% non condensing

1000m (3300ft) without derating

5.9m/s

2

(19.2ft/s

2

) [0.6G]

Natural convection

(Fans optional)

2.5

2.6

2.7

2.8

Altitude Derating

Altitude Derating

Benshaw's starters are capable of operating at altitudes up to 3,300 feet (1000 meters) without requiring altitude derating. Table 7 provides the derating percentage to be considered when using a starter above 3,300 feet (1000 meters).

Table 7: Altitude Derating

3300 Feet

4300 Feet

5300 Feet

6300 Feet

7300 Feet

8300 Feet

9300 Feet

Altitude

1006 meters

1311 meters

1615 meters

1920 meters

2225 meters

2530 meters

2835 meters

Percent Derating (Amps)

0.0%

3.0%

6.0%

9.0%

12.0%

15.0%

18.0%

For derating above 10,000 feet consult Benshaw Inc.

Real Time Clock

Real Time Clock

The MX

3 comes with a real time clock. The user can enter the actual time and the starter will use this time when it logs faults in the fault recorder as well as events in the event recorder. This can help with troubleshooting. The system clock does not recognize daylight savings time.

Accuracy: +- 1 minute per month

Range: 1/1/1972 to 1/1/2107 with automatic leap year compensation.

Approvals

Approvals

MX

3

Control Card Set is UL, cUL Recognized

Certificate of Compliance

Certificate of Compliance

CE Mark, see Appendix E on page 186.

15


NOTES:

16

3 Installation

17

3 - INSTALLATION

Before You Start

3.1

3.1.1

Before You Start

Installation Precautions

Inspection

Before storing or installing the RediStart MVRMX

3 receipt:

Series Starter, thoroughly inspect the device for possible shipping damage. Upon

•

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. Ensure that all of the mounting hardware and terminal connection hardware is properly seated, securely fastened, and undamaged.

•

Ensure all connections and wires are secured.

•

Read the technical data label affixed to the starter and ensure that the correct horsepower and input voltage for the application has been purchased.


Installation of some models may require halting production during installation. If applicable, ensure that the starter is installed when production can be halted long enough to accommodate the installation. Before installing the starter, ensure:

•

The wiring diagram (supplied separately with the starter) is correct for the required application.

•

The starter is the correct current rating and voltage rating for the motor being started.

•

All of the installation safety precautions are followed.

•

The correct power source is available.

•

The starter control method has been selected.

•

The connection cables have been obtained (lugs) and associated mounting hardware.

•

The necessary installation tools and supplies are procured.

•

The installation site meets all environmental specifications for the starter NEMA/CEMA rating.

•

The motor being started has been installed and is ready to be started.

•

Any power factor correction capacitors (PFCC) are installed on the power source side of the starter and not on the motor side.

Failure to remove power factor correction or surge capacitors from the load side of the starter will result in serious damage to the starter that will not be covered by the starter warranty. The capacitors must be connected to the line side of the starter. The up-to-speed (UTS) contact can be used to energize the capacitors after the motor has reached full speed.

3.1.2


To ensure the safety of the individuals installing the starter, and the safe operation of the starter, observe the following guidelines:

•

Ensure that the installation site meets all of the required environmental conditions (refer to Site Preparation, page 19).

•

LOCK OUT ALL SOURCES OF POWER.

•

Install circuit disconnecting devices (i.e., circuit breaker, fused disconnect or non-fused disconnect) if they were not previously installed by the factory as part of the package.

•

Install short circuit protection (i.e., circuit breaker or fuses) if not previously installed by the factory as part of the package.

•

Follow all NEC (National Electrical Code) and/or C.S.A. (Canadian Standards Association) standards or Local Codes as applicable.

•

Remove any foreign objects from the interior of the enclosure, especially wire strands that may be left over from installation wiring.

•

Ensure that a qualified electrician installs wiring.

•

Ensure that the individuals installing the starter are wearing ALL protective eyewear and clothing.

•

Ensure the starter is protected from debris, metal shavings and any other foreign objects.

The opening of the branch circuit protective device may be an indication that a fault current has been interrupted. To reduce the risk of electrical shock, current carrying parts and other components of the starter should be inspected and replaced if damaged.

18


3.2

3.2.1

3.2.2

3.2.3

3.2.4

3.2.5

3.2.6

Installation Considerations

Installation Considerations

Site Preparation


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

•

Obtaining the connection cables, lugs and all other hardware

•

Ensuring the installation site meets all environmental specifications for the enclosure NEMA rating

•

Installing and connecting the motor

Power Cables

The power cables for the starter must have the correct NEC/CSA current rating for the unit being installed. Depending upon the model, the power cables can range from a single #14 AWG conductor to four 750 MCM cables. (Consult local and national codes for selecting wire size).

Site Requirements

The installation site must adhere to the applicable starter NEMA/CEMA rating. For optimal performance, the installation site must meet the appropriate environmental and altitude requirements.

EMC Installation Guidelines

General

In order to help our customers comply with European electromagnetic compatibility standards, Benshaw Inc. has developed the following guidelines.

Attention

Enclosure

This product has been designed for Class A equipment. Use of the product in domestic environments may cause radio interference, in which case the installer may need to use additional mitigation methods.

Install the product in a grounded metal enclosure.

Grounding

Connect a grounding conductor to the screw or terminal provided as standard on each controller. Refer to layout/power wiring schematic for grounding provision location.

Wiring

Filtering

Refer to Wiring Practices on page 21.

To comply with Conducted Emission Limits (CE requirement), a high voltage (1000V or greater) 0.1 uF capacitor should be connected from each input line to ground at the point where the line enters the cabinet.

R-Rated Motor Starter Fuses

R-rated fuses are current-limiting, high interrupting rating fuses intended for the short-circuit protection of medium voltage motors and motor controllers. R-rated fuses are back up fuses that have a minimum interrupting rating, and must be coordinated with overload relays in combination motor starters.

Use of Electro-Mechanical Brakes

If an electro-mechanical brake is used with the starter, it must be powered from the line side of the starter to ensure full voltage is applied to the brake during a start so it will properly release. A programmable relay can be configured as a run relay and then used to pull-in a contactor to power the brake whenever the starter is providing power to the motor.

Reversing Contactor

If the application requires a reversing contactor, it should be connected on the output side (load) of the soft starter. The contactor must be closed before starting the soft starter. The soft starter must be off before switching the direction of the reversing contactor. The reversing contactor must never be switched while the soft starter is operating.

Use of Power Factor Capacitors

Power factor correction capacitors and surge capacitors CAN NOT be connected between the starter and the motor. These devices can damage the SCRs during ramping. These devices appear like a short circuit to the SCR when it turns on, which causes a di/dt level greater than the SCR can handle. If used, power factor correction capacitors or surge capacitors must be connected ahead of the starter and sequenced into the power circuit after the start is completed. A programmable relay can be configured as an up-to-speed (UTS) relay and then used to pull-in a contactor to connect the capacitors after the motor has reached full speed.

z NOTE: If the motor manufacturer supplies surge capacitors they must be removed before starting.

19


3.3

3.3.1

Mounting Considerations

Mounting Considerations

Bypassed Starters

Provisions should be made to ensure that the temperature inside the enclosure never rises above 50°C. If the temperature inside the enclosure is too high, the starter can be damaged or the operational life can be reduced.

Figure 4: Separate Power Factor Correction Disconnect

Figure 5: Integral Power Factor Correction Disconnect

20


3.4

3.4.1

3.4.2

3.4.3

3.4.4

3.4.5

Wiring Considerations

Wiring Considerations

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. Minimum spacing between metallic conduits containing different wire groups should be three inches (8cm).

•

Minimum spacing between different wiring groups in the same tray should be six inches.

•

Wire runs outside an enclosure should be run in metallic conduit or have shielding/armor with equivalent attenuation.

•

Whenever power and control wiring cross it should be at a 90 degree angle.

•

Different wire groups should be run in separate conduits.

•

With a reversing application, the starter must be installed in front of the reversing contactors.

z NOTE: Local electrical codes must be adhered to for all wiring practices.

Considerations for Control and Power Wiring

Control wiring refers to wires connected to the control terminal strip that normally carry 24V to 115V and Power wiring refers to wires connected to the line and load terminals that normally carries 2200VAC to 7200VAC respectively. Select power wiring as follows:

•

Use only UL or CSA recognized wire.

•

Grounding must be in accordance with NEC, CEC or local codes. If multiple starters are installed near each other, each must be connected to ground. Take care to not form a ground loop. The grounds should be connected in a STAR configuration.

Considerations for Signal Wiring

Signal wiring refers to the wires connected to the control terminal strip that are low voltage signals, below 15V.

•

Shielded wire is recommended to prevent electrical noise interference from causing improper operation or nuisance tripping.

•

Signal wire rating should carry as high of a voltage rating as possible, normally at least 300V.

•

Routing of signal wire is important to keep as far away from control and power wiring as possible.

Meggering a Motor

If the motor needs to be meggered, remove the motor leads from the starter before conducting the test. Failure to comply may damage the

SCRs and WILL damage the control board, which WILL NOT be replaced under warranty.

High Pot Testing

If the starter needs to be high pot tested, perform a DC high pot test. The maximum high pot voltage must not exceed 2.0 times rated

RMS voltage + 2000VAC (High pot to 75% of factory). Failure to comply WILL damage the control board, which WILL NOT be replaced under warranty. An example to find the maximum high pot voltage is (2.0 * rated RMS voltage + 2000) * 0.75.

21


3.5

3.5.1

Typical Wiring Schematics

Typical Wiring Schematics

MVRMX

3

Power Wiring Schematic

Figure 6: MVRMX

3

Power Wiring Schematic

ISO

ISO

ISO

ISO

ISO

ISO

STA S

4

3

6

5

2

1

TU

F3F

F3E

FS3

F3B

F3A

F3C

F3D

ISO

ISO

ISO

ISO

ISO

ISO

STA S

4

3

2

1

6

5

TU

F2F

FS2

F2C

F2D

F2E

F2B

F2A

ISO

ISO

ISO

ISO

ISO

ISO

STA S

4

3

6

5

2

1

TU

F1F

F1E

FS1

F1B

F1A

F1C

F1D

1 -0 BIPC-300032

22

3.5.2

MVRMX

3

Control Wiring Schematic

Figure 7: MVRMX

3

Control Wiring Schematic


23


3.6

Power Wiring

Power Wiring

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).

3.6.1

3.6.2

3.6.3

3.6.4

Recommended Wire Gauges

The wire gauge selection is based on the FLA of the motor. Refer to NEC table 310-16 or CEC Part 1, Table 2 or local code requirements for selecting the correct wire sizing. Ensure appropriate wire derating for temperature is applied. If more than three current carrying conductors are in one conduit, ensure NEC table 310.15(B)(2) or CEC Part 1 Table 5C is adhered to. In some areas local codes may take precedence over the NEC. Refer to your local requirements.

Power Wire Connections

Attach the motor cables:

•

Use the T1, T2 and T3 terminals. Use lugs/crimps or terminals (lugs and crimps are to be provided by the user).

Attach the power source cables:

•

Use the L1, L2 and L3 terminals. Use lugs/crimps or terminals (lugs and crimps are to be provided by the user).

Motor Lead Length

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

Compression Lugs

The following is a list of the recommended crimp-on wire connectors manufactured by Penn-Union Corp. for copper wire.

Wire Size

1/0

2/0

3/0

4/0

250 MCM

300 MCM

350 MCM

400 MCM

450 MCM

Table 8: Single Hole Compression Lugs

Part #

BLU-1/0S20

BLU-2/0S4

BLU-3/0S1

BLU-4/0S1

BLU-025S

BLU-030S

BLU-035S

BLU-040S4

BLU-045S1

Wire Size

500 MCM

600 MCM

650 MCM

750 MCM

800 MCM

1000 MCM

1500 MCM

2000 MCM

Part #

BLU-050S2

BLU-060S1

BLU-065S5

BLU-075S

BLU-080S

BLU-100S

BLU-150S

BLU-200s

Wire Size

1/0

2/0

3/0

4/0

250 MCM

300 MCM

350 MCM

400 MCM

450 MCM

Table 9: Two Hole Compression Lugs

Part #

BLU-1/0D20

BLU-2/0D4

BLU-3/0D1

BLU-4/0D1

BLU-025D

BLU-030D

BLU-035D

BLU-040D4

BLU-045D1

Wire Size

500 MCM

600 MCM

650 MCM

750 MCM

800 MCM

1000 MCM

1500 MCM

2000 MCM

Part #

BLU-050D2

BLU-060D1

BLU-065D5

BLU-075D

BLU-080D

BLU-100D

BLU-150D

BLU-200D

24


3.6.5

Torque Requirements for Power Wiring Terminations

Table 10: Slotted Screws and Hex Bolts

Wire size installed in conductor

AWG or kcmil (mm

2

)

Tightening torque, pound-inches (N-m)

Slotted head NO. 10 and larger

Hexagonal head-external drive socket wrench

Slot width-0.047 inch

(1.2mm) or less and slot length ¼ inch

(6.4mm) or less

Slot width-over 0.047

inch (1.2mm) or slot length – over ¼ inch

(6.4mm) or less

Split- bolt connectors Other connectors

18 – 10

8

6 – 4

3

2

1

1/0 – 2/0

(0.82 – 5.3)

(8.4)

(13.3 – 21.2)

(26.7)

(33.6)

(42.4)

(53.5 – 64.4)

35

40

—

—

20

25

35

(2.3)

(2.8)

(4.0)

(4.0)

(4.5)

—

—

50

50

50

50

35

40

45

(4.0)

(4.5)

(5.1)

(5.6)

(5.6)

(5.6)

(5.6)

80

80

165

275

275

275

385

(9.0)

(9.0)

(18.6)

(31.1)

(31.1)

(31.1)

(43.5)

75

75

110

150

150

150

180

3/0 – 4/0

250 – 350

400

500

(85.0 – 107.2)

(127 – 177)

(203)

(253)

—

—

—

—

—

—

—

—

50

50

50

50

(5.6)

(5.6)

(5.6)

(5.6)

500

650

825

825

(56.5)

(73.4)

(93.2)

(93.2)

250

325

375

375

(28.2)

(36.7)

(36.7)

(42.4)

600 – 750

800 – 1000

(304 – 380)

(406 – 508)

—

—

—

—

50

50

(5.6)

(5.6)

1000

1100

(113.0)

(124.3)

375

500

(42.4)

(56.5)

1250 – 2000 (635 – 1010) — — — — 1100 (124.3) 600 (67.8) z NOTE – For a value of slot width or length not corresponding to those specified above, the largest torque value associated with the conductor size shall be marked. Slot width is the nominal design value. Slot length is measured at the bottom of the slot.

(8.5)

(8.5)

(12.4)

(16.9)

(16.9)

(16.9)

(20.3)

Table 11: Tightening Torque for Inside Hex Screws

Socket size across flats Tightening torque inches (mm) Pound-inches (N-m)

1/8

5/32

3/16

7/32

1/4

5/16

3/8

1/2

(3.2)

(4.0)

(4.8)

(5.6)

(6.4)

(7.9)

(9.5)

45

100

120

150

200

275

275

(5.1)

(11.3)

(13.6)

(16.9)

(22.6)

(31.1)

(42.4)

(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. Slot length shall be measured at the bottom of the slot.

25


Current Transformers

3.7

3.7.1

Current Transformers

CT Mounting

If the CTs are shipped loose they need to be mounted on the power wiring. Thread the power wire through the CT and supplied sleeving, ensuring the polarity mark is towards the line side. (The polarity marks may be a white or yellow dot, an “X” on the side of the CT, or the white wire.) Each phase has its own CT. The CT must then be attached to the power wiring using two tie-wraps.

Figure 8: Typical CT Mounting

POWER WIRE

5kV RATED

INSULATING SLEEVE/TUBE

WHITE POLARITY DOT ON CT

MUST POINT TOWARDS

INCOMING LINE

CT TWISTED LEADS c/w HIGH VOLTAGE

SLEEVING

CUSTOMER MUST FASTEN CT TO

POWER WIRE WITH TWO 1/4"

NYLON WRAPS TO PREVENT

MOVEMENT DURING OPERATION

CT

POWER CABLE MUST BE COVERED WITH

VOLTAGE RATED SLEEVING/TUBING

EXTENDING A MINIMUM OF 3" PAST BOTH

SIDES OF THE CT

MAINTAIN 3" MINIMUM SPACE

BETWEEN CT AND LIVE NON

INSULATED COMPONENTS

(TYPICAL ALL SIDES OF THE CT)

TOP VIEW DETAIL SIDE VIEW DETAIL

3.7.2

3.7.3

CT Polarity

The CT has a polarity that must be correct for the starter to correctly measure Watts, kW Hours, Power Factor, and for the Power and

TruTorque motor control functions to operate properly.

Each CT has a dot on one side of the flat surfaces. This dot, normally white in color, must be facing in the direction of the line.

CT1 must be on Line L1, CT2 must be on Line L2, CT3 must be on Line L3.

Zero Sequence Ground Fault Current Transformer

The Zero Sequence Ground Fault CT can be installed over the three phase conductors for sensitive ground current detection or for use with high resistance grounded systems.

Figure 9: BICT 2000/1-6 Mechanical Dimensions

26


The correct installation of the current transformer on the motor leads is important. The shield ground wire should also be passed through the CT window if the motor conductors use shielded cable. Otherwise, capacitive coupling of the phase current into the cable shield may be measured as ground fault current. See Figure 10 below for proper installation.

z NOTE: Power cable must be covered with voltage rated sleeving/tubing extending a minimum of 3" past both sides of the CT. See

Figure 8 for sleeve installation.

Figure 10: Zero Sequence CT Installation Using Unshielded Cable

LUGS TO LOAD

TERMINALS ON

STARTER

CORE BALANCE

CT SECONDARY

CONNECTION TO

J15 ON MX

³

CARD

50:0.025 CORE

BALANCE CT

GROUND WIRE DOES

NOT PASS THROUGH CT

GROUND ON STARTER

POWER CABLE

TO MOTOR

Figure 11: Zero Sequence CT Installation Using Shielded Cable

LUGS TO LOAD

TERMINALS ON

STARTER

STRESS CONES

GROUND

CORE BALANCE

CT SECONDARY

CONNECTION TO

J15 ON MX

³

CARD

POWER CABLE

TO MOTOR

GROUND WIRE MUST

PASS THROUGH CT

WINDOW

50:0.025 CORE

BALANCE CT

GROUND ON STARTER

27

28


3.8

MVRMX

3

Control Card Layout

MVRMX

3


Figure 12: MVRMX

3


A

B

Unfused

120 VAC Out

Control

Power

120 VAC

{

{ { { { {

F

C

D

Digital

Inputs

P48-50

I/O 1-3

{ { { { {

E

Modbus

Communications

Port P68-71

{ { { { {

FUN 10-13

{ {

Auxiliary

Relays

P52-54

I/O 5-7

{ { {

J2 Keypad Port

P65 I/O 18

{ { { { {

H

G

Analog Input

P55-59

I/O 8-12

{ { { { {

Analog Output

P60-62

I/O 13-15

{ { { { {

Analog Voltage/Current

Selector Switch SW1

{ { { { {

Part/Serial #

{ { { { {

1

4x7 LED Display

2

Reset Parameter Enter

3 4

Software Part #

5 6

} 120 VAC

Stack In

(Benshaw Only)

} } } } }

Stack

Control

3.9

MVRMX

3

I/O Card Layout


3

I/O Card Layout


MVRMX

3

I/O Card Layout

29

J3

Relay

Outputs

R4 to R6

J6

Digital

Inputs

DI4 to DI8

J7

MOT PTC

Motor

Thermistor

J8

LINE

Voltage Divider

Card

J9

LINE PTs

J10

Phase CTs

J13

LOAD

Voltage Divider

Card

J14

LOAD PTs


MVRMX

3

Terminal Block Layout

3.10

MVRMX

3



3


J1

Remote

RTD Module(s)

RJ45 Socket

J4

Auxiliary Power

J5

Phase Connector

TB1

120VAC

Control

Power

Input

TB2

Relay

Outputs

R1 to R3

TB3

Digital

Inputs

DI1 to DI3

TB4

Modbus

Slave

RS485

J2

Remote

Keypad

RJ45 Socket

TB5

Analog I/O

J2

STAT FBK

SCR 1A to 1F

Phase 1

Fiber Optic

SCR 2A to 2F

Phase 2

Fiber Optic

SCR 3A to 3F

Phase 3

Fiber Optic

J15

Zero

Sequence

Ground

Fault CT

S1 to S3

Phase 1 to 3

Stack O/T

Fiber Optic

30

3.11

3.11.1

Control Wiring

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 15: Control Power Wiring Example

TB1

120VAC NEUTRAL

120VAC LIVE


Control Wiring

3.11.2

Output Relays

TB2 is for output relays R1, R2 and R3. These relays connect as follows:

1 - NO1: Relay 1 normally open

2 - RC1: Relay 1 common

3 - NC1: Relay 1 normally closed







Terminal block J3 is for output relays R4, R5 and R6. These relays connect as follows:

1 - R4A: Relay 4 common

2 - R4B: Relay 4 open





Figure 16: Relay Wiring Examples

TB2

120VAC LIVE

120VAC NEUTRAL

TRIP

120VAC NEUTRAL

120VAC LIVE

RUN

STOP

TRIP PILOT LIGHT

(RELAY 1 SET TO FLFS - FAULT FAILSAFE)

See Also

Relay Output Configuration (I/O 10-15) on page 91.

TB2

RUN & STOPPED PILOT LIGHT

(RELAY 2 SET TO RUN)

31


3.11.3

Digital Input

TB3 is for digital inputs Start, DI1, DI2 and DI3. These digital inputs use 120VAC. These digital inputs connect as follows:

1 - Start: Start Input

2 - DI1: Digital Input 1



5 - Com: 120VAC neutral

Terminal block J6 is for digital inputs DI4 to DI8. These digital inputs use 120VAC. These digital inputs connect as follows:

1 - DI4: Digital input 4





6 - Com: 120VAC neutral

Figure 17: Digital Input Wiring Examples

120VAC LIVE

START

DI1

DI2

DI3

TB3

120VAC LIVE

STOP

START

120VAC NEUTRAL

DIGITAL INPUT WIRING

TB3

TB3

120VAC LIVE

120VAC NEUTRAL

3-WIRE START / STOP BUTTONS

(DI1 SET TO STOP)

PLC

OUTPUT CONTACT

STOP

START TB3

120VAC LIVE

120VAC NEUTRAL

2-WIRE ON / OFF SELECTOR SWITCH

120VAC NEUTRAL

HAND / OFF / AUTO SELECTOR SWITCH

(DI1 SET TO STOP)

120VAC LIVE

SLOW SPEED

120VAC NEUTRAL

SLOW SPEED CONTROL BUTTON

(DI2 SET TO SSPD - SLOW SPEED)

TB3

See Also

Digital Input Configuration (I/O 01-08) on page 90.

120VAC LIVE

120VAC NEUTRAL

TRIP

EXTERNAL TRIP INPUT

(DI3 SET TO FL - FAULT LOW)

TB3

32


3.11.4

Analog Input

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

z NOTE: The analog input is a low voltage input, maximum of 15VDC. The input will be damaged if control power (115VAC) or line power is applied to the analog input.

The terminals are as follows:

1) +10VDC Power (for POT)

2) + input

3) - input

4) common

7) shield

(5K-10K ohm)

Figure 18: Analog Input Wiring Examples

TB5

+

4-20mA SOURCE

-

TB5

POTENTIOMETER 4-20mA

3.11.5

See Also

Analog Input (I/O 16-20) on page 92.

Starter Type (FUN 07) on page 103.

Theory of Operation section 7.11, Phase Control on page 145.

Theory of Operation section 7.12, Current Follower on page 145.

Analog Output

The analog output can be configured for Voltage or Current loop. The output is shipped in the Voltage loop configuration unless specified in a custom configuration. Below TB5 is SW1-2. When the switch is in the off position, the output is current. When on, it is a

Voltage loop output. The control is shipped with the Switch on.

z NOTE: The analog output is a low voltage output, maximum of 15VDC. The output will be damaged if control power (115VAC) or line power is applied to the analog output.

The terminals are as follows:

5) analog output

6) common

7) shield

Figure 19: Analog Output Wiring Example

TB5

TO METER / ANALOG INPUT CARD

+

V/I

-

3.11.6

See Also

SW1 DIP Switch

Analog Output (I/O 21-23) on page 94.

The SW1 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.

33


3.11.7

Motor PTC

Terminal block J7 is for a PTC (positive temperature co-efficient) motor thermistor. This input is designed to use standard DIN 44081 or

DIN 44082 thermistors. The specifications of the input are as follows;

Figure 20: SW1 DIP Switch Settings

ANALOG INPUT

SW1-1

ON = 0-20mA

OFF = 0-10V

- Trip resistance 3.5K, ± 300 Ohms

- Reset resistance 1.65K, ± 150 Ohms

- Open terminal voltage is 15V

- PTC voltage at 4Kohms = 8.55v. (>7.5V)

- Response time adjustable between 1 and 5 seconds

- Maximum cold resistance of PTC chain = 1500 Ohms

An example of the thermistor wiring is shown below in Figure 21.

ANALOG OUTPUT

SW1-2

ON = 0-10V

OFF = 0-20mA

Figure 21: PTC Thermistor Wiring

J7

See Also

Motor PTC Trip Time (PFN 27) on page 86.

3.11.8

RTD Module Connector

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

4 - B(+)

5 - A(-)

8 - common

34


3.12

3.12.1

Remote LCD Keypad/Display

Remote LCD Keypad/Display

The display has a NEMA 13 / IP65 service rating. The display is available in 2 versions, a small display as P/N KPMX3SLCD and large display as P/N KPMX3LLCD.

Remote Display

The LCD keypad is mounted remotely from the MX

3 terminal and remote display's RJ45 terminal.

Control via a straight through display cable which connects between the MX

3

RJ45

Figure 22: Mounting Remote Keypads

CLIP

GASKET

MX³ DISPLAY

ENCLOSURE DOOR

CLIP

MX³ DISPLAY CABLE

35


3.12.2

Display Cutout

Figure 23: Small Display Keypad Mounting Dimensions

Part # : KPMX3SLCD

101.00

[3.98"]

50.50

[1.99"]

50.50

[1.99"]

Figure 24: Large Display Keypad Mounting Dimensions

Part # : KPMX3LLCD

127.00

[5.00"]

63.50

[2.50"]

63.50

[2.50"]

3.12.3

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 are 0.7 NM or 6.195 in lbs).

•

Plug the cable into the display connector on the MX

3 card. See Figure 12 – Control Card Layout on page 28 for the connector location.

•

Route the cable through the enclosure to the display. Observe the wiring considerations as listed in Section 3.4.3 on page 21.

•

Plug the other end of the cable into the LCD display.

36


3.13

3.13.1

RTD Module Installation

RTD Module Installation

Location

The mounting location for the Remote RTD Module should be chosen to give easy access to the RTD wiring, control terminals and indicator LEDs as well as providing a location to mount the power supply. The Remote RTD Module is specifically designed to be mounted close to the equipment it is monitoring. This eliminates long RTD wire lengths which save time and money on installation and wiring. The Benshaw Remote RTD Module is designed to mount on industry standard 35mm wide by 7.5mm deep DIN rail.

Figure 25: Remote RTD Module Mechanical Layout

3.13.2

3.13.3

3.13.4

Modbus Address

Set the rotary switch on the top of the Remote RTD Module to the desired Modbus address. Up to 2 modules can be connected to the

MVRMX

3 starter. The address set by the rotary switch must match the setting in RTD 01 or RTD 02. For example, setting both the rotary switch and RTD 01 to 16 would make the connected module be module #1. The connected RTDs would then represent #1 to #8 in the RTD programming.

Power Connections

The 24VDC power source is connected to the following terminals.

•

24VDC-: Negative connection to 24VDC power supply

•

24VDC+: Positive connection to 24VDC power supply

•

" g": Chassis ground connection

RS-485 Communication

The RS-485 communications wiring should use shielded twisted pair cable. The shield should only be terminated at one end. The connections are as follows:

MX RJ45

pin 5 pin 4 pin 8

Module

A(-)

B(+)

Com

Description

RS-485 negative communications connection

RS-485 positive communications connection

RS-485 common connection

37


3.13.5

RTD Connections

Each Remote RTD Module has connections for up to 8 RTDs. The terminals for the RTD wires are as follows:

•

R- RTD return wire

•

C- RTD compensation wire

•

H- RTD hot wire

Each RTD is connected to the three terminals with the common number. For example, RTD number 5 connects to the terminals numbered 5R, 5C and 5H.

Figure 26: Remote RTD Module Wiring

REMOTE RTD MODULE

³

3.13.6

RTD Temperature vs. Resistance

50

60

70

80

90

10

20

30

40 o

C

-50

-40

-30

-20

-10

0

Temperature

122

140

158

176

194

50

68

86

104

o

F

-58

-40

-22

-4

14

32

100

W Pt

(DIN 43760)

111.67

115.54

119.39

123.24

127.07

130.89

134.70

80.13

84.27

88.22

92.16

96.09

100.00

103.90

107.79

190

200

210

220

150

160

170

180

o

C

100

110

120

130

140

230

240

250

374

392

410

428

302

320

338

356 o

F

212

230

248

266

284

446

464

482

164.76

168.47

172.46

175.84

179.51

183.17

186.82

190.45

194.08

100

W Pt

138.50

142.29

146.06

149.82

153.58

157.32

161.04

38

4 Keypad Operation

39

4 - KEYPAD OPERATION

4.1

Introduction

Introduction

The MX

3 has a 2x16 character, back-lit LCD display/keypad that is mounted remotely from the MX

3 control card.

The remote keypad is NEMA 13 / IP65 when mounted directly on the door of an enclosure with the correct gasket.

Figure 27 - Remote LCD Keypad

4.2

Description of the LEDs on the Keypad

Description of the LEDs on the Keypad

The keypad provides three LED indicators in addition to the 2x16 character display. The LEDs provide starter status information.

LED

STOP

RUN

State

On

Flashing

On

Flashing

Flashing

Table 12: Remote Keypad LED Functions

Indication

Stopped

Faulted

Running and up-to-speed

Running and not up-to-speed (ramping, decelerating, braking etc).

Alarm condition exists. If condition persists, a fault occurs.

ALARM z NOTE: By default, the [STOP] key is always active, regardless of selected control source (Local Source and Remote Source parameters). It may be disabled though using the Keypad Stop Disable (I/O 26) parameter. For more information refer to the Keypad

Stop Disable (I/O 26) parameter on page 96.

40


4.3

Description of the Keys on the Remote LCD Keypad

Description of the Keys on the Remote LCD Keypad

Key

start

menu menu stop

Table 13: Function of the Keys on the LCD Keypad

Function

•

This key causes the starter to begin the start sequence. The direction is dependent on wiring and phase selection.

•

In order for this key to work, the Local Source (QST 04) parameter must be set to "Keypad".

•

Increase the value of a numeric parameter.

•

Select the next value of an enumerated parameter.

•

It scrolls forward through a list of parameters within a group (when the last parameter is displayed, it scrolls to the beginning of the list).

•

When a list of faults is displayed, it moves from one fault to the next.

•

When a list of events is displayed, it moves from one event to the next.

•

When the starter is in the Operate Mode, pressing [UP] allows you to change which group of meter values is monitored.

•

Decrease the value of a numeric parameter.

•

Select the previous value of an enumerated parameter.

•

It scrolls backward through a list of parameters within a group (when the first parameter is displayed, it scrolls to the end of the list).

•

When a list of faults is displayed, it moves from one fault to the previous fault.

•

When a list of events is displayed, it moves from one event to the previous event.

•

When the starter is in the Operate Mode, pressing [DOWN] allows you to change which group of meter values is monitored.

•

When editing a numeric parameter, the [LEFT] arrow key moves the cursor one digit to the left. If cursor is already at the most significant digit, it returns to the least significant digit on the right.

•

When in Menu mode, the [LEFT] arrow allows groups to be scrolled through in the opposite direction of the [MENU] Key.

•

Stores the change of a value.

•

When in Fault History, [ENTER] key scrolls through information logged when a fault occurred.

•

When in Event History, [ENTER] key scrolls through information logged when an event occurred.

•

When an alarm condition exists, [ENTER] scrolls through all active alarms.

•

[MENU] scrolls between the operate screen and the available parameter groups.

•

When viewing a parameter, pressing [MENU] jumps to the top of the menu.

•

When a parameter is being edited and [MENU] is pressed, the change is aborted and the parameter’s old value is displayed.

•

The [STOP/RESET] key halts the operation of the starter (Stop Key).

•

If a fault has occurred, the [STOP/RESET] key is used to clear the fault (Reset Key).

•

The [STOP/RESET] key always halts the operation of the starter if the control source is set to

"Keypad". If the Control Source (QST 04/QST 05) is not set to "Keypad", the [STOP/RESET] key may be disabled using the Keypad Stop Disable (I/O 26) parameter.

41


4.4

Alphanumeric Display

4.4.1

Alphanumeric Display

The remote LCD keypad and display uses a 32-character alphanumeric LCD display. All starter functions can be accessed by the keypad. The keypad allows easy access to starter programming with parameter descriptions on the LCD display.

Power Up Screen

On power up, the software part numbers are displayed for a few seconds. Pressing any key immediately changes the display to the operate screen.

810023-02-01

810024-01-01

4.4.2

Operate Screen

The operate screen is the main screen. The operate screen is used to indicate the status of the starter, if it’s running, what state it’s in, and display the values of Meter 1 and Meter 2, which are selectable.

The Operate Screen is divided into five sections:

•

Sections A and B display status information

•

Sections C and D display the meters selected by the Meter 1 and 2 parameters, see FUN 01, 02

•

Section S displays the source for the start command

Figure 28: Operate Screen

SECTION S

SECTION A

SECTION C

K n o L

S T O P P E D V

I a = 0 .0

A a = 0 V

SECTION B SECTION D

Display

NoL

Ready

Alarm

Run

Table 14: Operate Screen Section A

Description

L1, L2, L3 not present

Starter ready to run

A fault condition is present. If it continues, a fault occurs

Starter is running

42


Display

Stopped

Fault

Heater

Kick

Accel

Kick 2

Accel 2

Run

UTS

Control

Decel

Wye

Slow Spd Fwd

Slow Spd Rev

Braking

PORT

Table 15: Operate Screen Section B

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 Control or Current Follower mode

Starter is decelerating the load

In Wye-delta control indicates motor is accelerating in Wye mode

Preset slow speed forward

Preset slow speed reverse

DC Injection Braking.

Power Outage Ride Through

T

S

Display

K

Table 16: Operate Screen Section S

Description

Keypad Control

Terminal Block Wiring Control

Serial Communication Connection Control

4.4.3

Parameter Group Screens

From the operate screen, the parameter group screens are accessed by pressing either the menu or the left arrow keys. The parameter group screens display the different parameter groups; QST, CFN, PFN, I/O, RTD, FUN, FL1, E01.

MMM: PPPPPPPPPP

MI VVVVVVVVVV

MMM: = Parameter Group

MI: = Menu Index

PPP:

VVV:

= Parameter Name

= Parameter Value and Units

Refer to Chapter 5 for a listing of the parameters and their ranges.

43


4.4.4

Meter Pages

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

Current

I1= 0.0

I2=

I3=

Voltage V2=

V1=

MWatt Hour = kWatt Hour = 0

Watts

VA

= 0

= 0

Motor PF = 0.00

VARS = 0

TruTorque = 0

Power = 0%

Overload = 0%

Curr Imbal = 0.0%

RS Gnd Cur = 0%

ZS Gnd Cur = 0.0A

LST ST Tim = xx.xs

PK ST Cur = xx.xA

Frequency = 0.0H

Phase = noL

z NOTE:

0 V3=

0.0A

0.0A

0V

0V

0

Run Hours

Run Days kWatt Hours

MWatt Hours

Starts

RS Gnd Cur

Run Days = xxxx

Run Hours = xx:xx

Analog In = 0.1%

Analog Out = 0.0%

Starts = xxxx

Temps

To= ---

1= Off

2= Off

5= Off

6= Off

9= Off

10= Off

13= Off

14= Off

Ts= ---

Tb= ---

3= Off

4= Off

7= Off

8= Off

11= Off

12= Off

15= Off

16= Off hh:mm:ssA mm/dd/yy

00:00 – 23:59

0 – 2730 days or 7.5 years

0 – 999

0 – 9999

0 – 65535

% motor FLA

44


4.4.5

Fault Log Screen

Information regarding each fault is available through the remote MX

3

LCD display.

FL#: Fault ##

NNNNNNNNNNNNN

FL#: = Fault Log Number. FL1 is the most recent fault and FL9 is the oldest fault.

Fault ## = Fault Code

NNN… = Fault Name, or the condition when the fault occurred.

Press [MENU] until you get to the FL1 parameter.

Pressing the [UP] and [DOWN] keys navigates through older and newer faults in the log.

When you get to your fault on the screen begin pressing the [ENTER] key repeatedly. This will rotate through the steps below to show the conditions the starter was in when the fault occurred.

9

10

11

7

8

4

5

2

3

Enter Step

1

6

Fault Description.

Status when the fault occurred, Run, Stopped, Accel. etc.

The L1 current at the time of the fault.



L1-2 voltage at the time of the fault.



kW at the time of the fault.

Frequency at the time of the fault.

Run time since last run time reset.

4.4.6

4.4.7

Fault Screen

When a Fault occurs, the main screen is replaced with a fault screen. The screen shows the fault number and the name of the fault. The main status screen is not shown until the fault is reset.

When a fault occurs, the STOP LED flashes.

Fault ##

Fault Name

z NOTE: For a list of the Faults, refer to Appendix C - Fault Codes on page 183.

Event Recorder

An event is anything that changes the present state of the starter. Examples of events include a start, a stop, an overload alarm or a fault.

The event recorder stores the last 99 events.

E##: Event ###

Event

Press [MENU] until you get to the E01 parameter.

Pressing [UP] or [DOWN] will scroll through the last 99 events and displays the event or fault code on top, and the event or fault that changed the starter's state on the bottom.

Pressing [ENTER] gives the starter state condition at the time of event.

Press [ENTER] again to give you the time of the event.

Press [ENTER] again to give you the date that the event occurred.

z NOTE: After pressing [ENTER] you can shift through all the different starter states, times and dates by using the [UP] and [DOWN] arrows.

45


4.4.8

Lockout Screen

When a lockout is present, one of the following screens will be displayed. The main status screen is not shown until the lockout is cleared.

The overload lockout displays the overload content and the time until reset if an overload occurs.

Overload Lockout

96% xx.xx

The stack over temperature lockout will be displayed if a stack over temperature is detected.

Stack Overtemp

Lockout

The control power lockout will be displayed if the control power is not within specifications.

Control Power

Lockout

The disconnect open lockout will be displayed if a digital input is programmed to "disconnect" and the input is not on.

Disconnect Open

Lockout

The time between starts lockout displays the time until the next start is allowed when PFN 21 is programmed.

Time btw Starts

Lockout XX:XX

The backspin timer lockout displays the time until the next restart when PFN 20 is programmed.

Backspin Timer

Lockout XX:XX

The starts per hour lockout displays the time until the next start is allowed when PFN 22 is programmed.

Starts per Hour

Lockout XX:XX

The motor PTC lockout is displayed when the motor thermistor is overheated or defective.

Motor PTC

Lockout

The RTD lockout displays the hottest RTD that tripped the starter.

RTD Lockout

RTD## = XXX C

The communications loss is displayed when the starter loses communication with the remote RTD modules.

RTD Lockout

RTD## comm loss

The open lockout is displayed when the RTD module senses an open RTD.

RTD Lockout

RTD## = Open

The short lockout is displayed when the RTD module senses a shorted RTD.

RTD Lockout

RTD## = Shrt

z NOTE: XX:XX is the time remaining until the lockout releases.

46


4.4.9

4.5

Alarm Screen

When an alarm is present, the word “Alarm” is displayed on the operate screen. Pressing the [ENTER] key displays more information about the alarm.

Alarm ##

Alarm Name

Procedure for Setting Data

Select a parameter that is to be changed. To change Motor FLA from 10 Amps to 30 Amps:

Procedure for Setting Data

From the main screen:

T Ready Ia = 0.0A

Stopped Va= 4160V

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.

QST: Motor FLA

01 1

0

Amp

Press [LEFT] key once, the cursor flashes in the ten’s place.

QST: Motor FLA

01

1

0 Amp

Press [UP] arrow to increase the value, for a value of 30, press twice.

QST: Motor FLA

01

3

0 Amp

Press [ENTER] to store the value.

QST: Motor FLA

01 30 Amp

Press [UP] arrow to change another parameter in QST.

Press [MENU] to change another parameter in another group.

Press [LEFT] arrow to go back to the main screen.

47


4.6

Jump Code

Jump Code

At the beginning of each parameter group, there is a Jump Code parameter. By changing the value of this parameter and pressing

[ENTER], you can jump directly to any parameter within that group.

4.7

Restoring Factory Parameter Settings

Restoring Factory Parameter Settings

Go to the FUN group by pressing [MENU]. Scroll through to Miscellaneous Commands (FUN 22) and press [ENTER]. Now set to

"Factory Rst" and press [ENTER]. The display will return to "None" but the parameters will be reset to the factory defaults.

z NOTE: If a factory reset is performed, the following minimum parameters will need to be programmed so a F47 - "Stack Overtemp" does not occur:

FUN05 - Rated RMS Voltage (set to specified equipment rating)

FUN03 - CT Ratio

I/O01 - 08 - Digital Inputs

I/O09 - 15 - Relay Outputs

zNOTE: You must consult the wiring schematic for other digital inputs and relay output configuration.

4.8

Resetting a Fault

Resetting a Fault

To reset from a fault condition, press [RESET].

4.9

Emergency Overload Reset

Emergency Overload Reset

To perform an emergency overload reset, press [RESET] and [DOWN] pushbuttons together. This sets the motor thermal overload content to "0".

LED Display

4.10

LED Display

The card mounted LED display can be used to access most of the parameters when the standard remote mounted display is not connected. The LED parameter numbers (Pxx) are shown in the parameter table, see Chapter 5.

48

5 Parameter Groups

49

5 - PARAMETER GROUPS

5.1

Introduction

Introduction

The MVRMX

3 incorporates a number of parameters that allow you to configure the starter to meet the special requirements of your particular application.

The parameters are divided into groups of related functionality, and within the groups the parameters are identified by a short, descriptive name. They are numbered by the group name followed by an index within the group.

This chapter lists all of the parameters and their possible values.

5.2

LCD Display Parameters

The parameters are subdivided into six groups. The groups are QST (Quick Start), CFN (Control Functions), PFN (Protection

Functions), I/O (Input/Output Functions), RTD (Resistance Temperature Device), FUN (Function), FL1(Fault Log) and E01 (Event

Recorder).

The Quick Start Group provides a collection of the parameters that are most commonly changed when commissioning a starter. Many of the parameters in the Quick Start group are duplicates of the same parameters in other groups.

The following shows the menu structure for the LCD display as well as the text that is displayed for the parameters on the display.

If the LCD is not connected, most parameters shown on the LED display will turn on when LCD is unplugged.

5.2.1

Quick Start Group

Group

QST 00

QST 01

QST 02

QST 03

QST 04

QST 05

QST 06

QST 07

QST 08

QST 09

LED

P5

P6

P7

P8

P9

P1

P2

P3

P4

Display

Jump Code

Motor FLA

Motor SF

Running OL

Local Src

Remote Src

Init Cur 1

Max Cur 1

Ramp Time 1

UTS Time

Description

Jump to Parameter

Motor FLA

Motor Service Factor

Motor Overload Class Running

Local Source

Remote Source

Initial Current 1

Maximum Current 1

Ramp Time 1

Up To Speed Time/Transition time

Setting Range

1 to 9

1 to 6400

1.00 to 1.99

Off, 1 to 40

Keypad

Terminal

Serial

50 to 600

100 to 800

0 to 300

1 to 900

Units

RMS

Amps

1

Default

10

1.15

10

Terminal

%FLA 100

%FLA 600

Seconds 15

Seconds 20

Page

58

58

58

59

59

60

61

61

62

62

50


5.2.2

Control Function Group

Group

CFN 00

LED Display

Jump Code

Parameter

Jump to Parameter

CFN 01 P10 Start Mode Start Mode

CFN 02

CFN 03

CFN 04

CFN 05

CFN 06

CFN 07

CFN 08

CFN 09

CFN 10

CFN 11

CFN 12

CFN 13

CFN 14

CFN 15

P8

P6

P7

P24 Ramp Time 2

P22 Init Cur 2

P23 Max Cur 2

P11 Init V/T/P

P12 Max T/P

P13 Kick Lvl 1

P14 Kick Time 1

P25 Kick Lvl 2

P26 Kick Time 2

P15

Ramp Time 1

Init Cur 1

Max Cur 1

Accel Prof

Stop Mode

Ramp Time 1

Initial Motor Current 1

Maximum Motor Current 1

Ramp Time 2



Initial Voltage/Torque/Power

Maximum Torque/Power

Acceleration Ramp Profile

Kick Level 1

Kick Time 1

Kick Level 2

Kick Time 2

Stop Mode

CFN 16

CFN 17

CFN 18

CFN 19

CFN 20

CFN 21

CFN 22

CFN 23

CFN 24

CFN 25

CFN 26

CFN 27

P16 Decel Begin

P17 Decel End

P18 Decel Time

Decel Prof

Decel Begin Level

Decel End Level

Decel Time

Decel Ramp Profile

P19 Brake Level

P20 Brake Time

P21 Brake Delay

P27 SSpd Speed

P28 SSpd Curr

P29 SSpd Timer

P30 SSpd Kick Curr

P31 SSpd Kick T

DC Brake Level

DC Brake Time

DC Brake Delay

Slow Speed

Slow Speed Current Level

Slow Speed Time/Limit

Slow Speed Kick Level

Slow Speed Kick Time

100 to 1

99 to 1

1 to 180

Linear

Squared

S-Curve

10 to 100

1 to 180

0.1 to 3.0

Off, 1 – 40

10 to 400

Off, 1 to 900

Off, 100 to 800

0.1 to 10.0

Setting Range

1 to 27

Voltage Ramp

Current Ramp

TT Ramp

Power Ramp

Tach Ramp

0 to 300

50 to 600

100 to 800

0 to 300

50 to 600

100 to 800

1 to 100

10 to 325

Linear

Squared

S-Curve

Off, 100 to 800

0.1 to 10.0

Off, 100 to 800

0.1 to 10.0

Coast

Volt Decel

TT Decel

DC Brake

Units

1

Default Page

63

Current

Ramp

Seconds 15

%FLA

%FLA

100

600

Seconds 15

%FLA 100

%FLA

%

%

600

25

105

Linear

%FLA Off

Seconds 1.0

%FLA Off

Seconds 1.0

Coast

%

%

40

20

Seconds 15

Linear

% 25

Seconds 5

Seconds 0.2

% Off

% FLA 100

Seconds 10

% FLA Off

Seconds 1.0

63

67

68

69

69

69

65

65

66

66

67

64

64

65

70

70

71

71

72

74

74

75

75

72

73

73

73

51


5.2.3

Protection Group

PFN 28

PFN 29

PFN 30

PFN 31

PFN 32

PFN 33

PFN 34

PFN 35

PFN 18

PFN 19

PFN 20

PFN 21

PFN 22

PFN 23

PFN 24

PFN 25

PFN 26

PFN 27

Group

PFN 00

PFN 01

PFN 02

PFN 03

PFN 04

PFN 05

PFN 06

PFN 07

PFN 08

PFN 09

PFN 10

PFN 11

PFN 12

PFN 13

PFN 14

PFN 15

PFN 16

PFN 17

LED Display

Jump Code

P32 Over Cur Lvl

P33 Over Cur Time

P34 Undr Cur Lvl

P35 Undr Cur Time

P36 Cur Imbl Lvl

Cur Imbl Time

P37 Resid GF Lvl

ZS GF Lvl

Gnd Flt Time

P38 Over Vlt Lvl

P39 Undr Vlt Lvl

P40 Vlt Trip Time

Ph Loss Time

Over Frq Lvl

Undr Frq Lvl

Frq Trip Time

PF Lead Lvl

PF Lag Lvl

PF Trip Time

Backspin Time

Time Btw St

Starts/Hour

P41 Auto Reset

P42 Auto Rst Lim

P43 Ctrl Flt En

Speed Sw Time

M PTC Time

P44 Indep S/R OL

P45 Starting OL

Running OL

P46 OL H/C Ratio

P47 OL Cool Time

OL Alarm Lvl

OL Lock Lvl

OL Lock Calc

Parameter Setting Range

Jump to Parameter

Over Current Trip Level

Over Current Trip Delay Time

Under Current Trip Level

1 - 35

Off, 50 - 800

Off, 0.1 - 90.0

Off, 5 - 100

Under Current Trip Delay Time

Current Imbalance Trip Level

Off, 0.1 - 90.0

Off, 5 - 40

Current Imbalance Trip Time 0.1 - 90

Residual Ground Fault Trip Level Off, 5 - 100

Zero Sequence Ground Fault Trip

Level

Off, 1.0 - 25

Ground Fault Trip Time

Over Voltage Trip Level

Under Voltage Trip Level

Over/Under Voltage Trip Delay

Time

Phase Loss Trip Time

Over Frequency Trip Level

Under Frequency Trip Level

Frequency Trip Time

PF Lead Trip Level

PF Lag Trip Level

0.1 - 90.0

Off, 1 - 40

Off, 1 - 40

0.1 - 90.0

0.1 - 5.0

24 - 72

23 - 71

0.1 - 90.0

Off, -0.80 lag to +0.01

lead

Off, -0.01 lag to +0.80

lead

PF Trip Time

Backspin Timer

Time Between Starts

Starts per Hour

Auto Fault Reset Time

Auto Fault Reset Count Limit

Controlled Fault Stop

Speed Switch Trip Time

Motor PTC Trip Time

Independent Starting/Running

Overload

Motor Overload Class Starting


Motor Overload Hot/Cold Ratio

Motor Overload Cooling Time

Motor OL Alarm Level

Motor OL Lockout Level

Motor OL Auto Lockout Level

0.1 - 90.0

Off, 1 - 180

Off, 1 - 180

Off, 1 - 6

Off, 1 - 900

Off, 1 - 10

Off, On

Off, 1 - 250

Off, 1 - 5

Off, On

Off, 1 - 40

Off, 1 - 40

0 - 99

1.0 - 999.9

1 - 100

1 - 99

Off, Auto

Off

Seconds 10.0

Minutes Off

Minutes Off

Off

Seconds Off

Off

On

Seconds Off

Seconds Off

Off

10

10

% 60

Minutes 30

%

%

90

15

Off

Units Default

%FLA

1

Off

Seconds 0.1

%FLA Off

Seconds 0.1

% 15

Seconds 10

%FLA Off

Amps Off

Seconds 3.0

% Off

% Off

Seconds 0.1

Seconds 0.2

Hz 72

Hz 23

Seconds 0.1

Off

80

80

81

81

Page

77

78

78

79

76

76

76

77

81

82

82

82

83

83

86

89

89

89

87

87

88

88

83

84

85

85

85

86

83

84

84

84

52


5.2.4

I/O Group

Number LED

I/O 00

I/O 01

I/O 02

I/O 03

I/O 04

I/O 05

I/O 06

I/O 07

Display

Jump Code

P48 DI 1 Config

P49 DI 2 Config

P50 DI 3 Config

DI 4 Config

DI 5 Config

DI 6 Config

DI 7 Config

I/O 08

I/O 09

I/O 10

DI 8 Config

P51 Dig Trp Time

P52 R1 Config

I/O 11

I/O 12

P53

P54

R2 Config

R3 Config

I/O 13

I/O 14

I/O 15

R4 Config

R5 Config

R6 Config

I/O 16

I/O 17

I/O 18

I/O 19

I/O 20

I/O 21

I/O 22

I/O 23

I/O 24

I/O 25

I/O 26

I/O 27

P55 Ain Trp Type

P56 Ain Trp Lvl

P57 Ain Trp Tim

P58 Ain Span

P59 Ain Offset

P60

P61 Aout Span

P62 Aout Offset

P63 Inline Confg

P64 Bypas Fbk Tim

P65 Kpd Stop

P66

Aout Fctn

Auto Start

Parameter Setting Range

Jump to Parameter 1 to 27

Digital Input #1 Configuration Off

Digital Input #2 Configuration

Stop

Fault High



Fault Low

Fault Reset


Disconnect

Inline Cnfrm




Bypass Cnfrm

E OL Reset

Local/Remote

Heat Disable

Heat Enable

Ramp Select

Digital Fault Input Trip Time 0.1 to 90.0

Relay Output #1

Configuration

Relay Output #2

Configuration

Relay Output #3

Configuration

Relay Output #4

Configuration

Relay Output #5

Configuration

Relay Output #6

Configuration

Slow Spd Fwd

Slow Spd Rev

Brake Disable

Brake Enable

Speed Sw NO

Speed Sw NC

Off

Fault FS

Fault NFS

Running

UTS

Alarm

Ready

Locked Out

Shunt NFS

Ground Fault

Energy Saver

Heating

Slow Spd

Slow Spd Fwd

Slow Spd Rev

Braking

Overcurrent Cool Fan Ctl

Undercurrent PORT

OL Alarm

Shunt FS

Tach Loss

Analog Input Trip Type

Analog Output Function

Analog Output Span

Off

Low Level

High Level

0 to 100 Analog Input Trip Level

Analog Input Trip Delay Time 0.1 to 90.0

Analog Input Span 1 to 100

Analog Input Offset 0 to 99

Off

0 – 200% Curr

0 – 800% Curr

0 – 150% Volt

0 – 150% OL

0 – 10 kW

0 – 100 kW

0 – 1 MW

0 – 10 MW

0 – 100% Ain

0 – 100% Firing

Calibration

1 to 125

Analog Output Offset

Inline Configuration

Bypass / 2M Confirm

Keypad Stop Disable

Power On Start Selection

0 to 99

Off, 1.0 to 10.0

0.1 to 5.0

Enabled, Disabled

Disabled

Power

Fault

Power

Fault

Units

Sec.

%

Seconds

%

%

%

%

Seconds

Seconds

Default Page

1

Stop

Off

Off

Off

Off

Off

Off

90

90

Off

0.1

Fault FS

91

Off

Off

Off

Off

Off

Off

50

0.1

100

0

Off

100

0

3.0

2.0

Enabled

Disabled

91

92

92

93

93

94

94

95

95

96

96

96

97

53


5.2.5

Group

RTD 00

RTD 01

RTD Group

RTD9 Group

RTD10 Group

RTD11 Group

RTD12 Group

RTD13 Group

RTD14 Group

RTD15 Group

RTD16 Group

Stator Alrm

Bearing Alrm

Other Alrm

Stator Trip

Bearing Trip

Other Trip

RTD Voting

RTD Biasing

RTD Bias Min

RTD Bias Mid

RTD Bias Max

Display

Jump Code

RTDMod1

Addr

RTDMod2

Addr

RTD1 Group

RTD2 Group

RTD3 Group

RTD4 Group

RTD5 Group

RTD6 Group

RTD7 Group

RTD8 Group

RTD 02

RTD 19

RTD 20

RTD 21

RTD 22

RTD 23

RTD 24

RTD 25

RTD 26

RTD 27

RTD 28

RTD 29

RTD 11

RTD 12

RTD 13

RTD 14

RTD 15

RTD 16

RTD 17

RTD 18

RTD 03

RTD 04

RTD 05

RTD 06

RTD 07

RTD 08

RTD 09

RTD 10

Description

Jump to Parameter

RTD Module #1 Address

Setting Range

1 - 29

Off, 16 - 23


RTD1 Group

RTD2 Group

RTD3 Group

RTD4 Group

RTD5 Group

RTD6 Group

RTD7 Group

RTD8 Group

RTD9 Group

RTD10 Group

RTD11 Group

RTD12 Group

RTD13 Group

RTD14 Group

RTD15 Group

RTD16 Group

Off

Stator

Bearing

Other

Stator Alarm Level

Bearing Alarm Level

Other Alarm Level

Stator Trip Level

1 - 200

Bearing Trip Level

Other Trip Level

RTD Voting

RTD Motor OL Biasing

Disabled, Enabled

Off, On

RTD Bias Minimum Level 0 - 198

RTD Bias Mid Point Level 1 - 199

RTD Bias Maximum Level 105 - 200

Units

C

C

C

C

Default

1

Off

Page #

97

97

98

Off 98

200

200

200

200

200

200

Disabled

Off

40

130

155

99

99

100

100

98

98

99

99

100

101

101

54


5.2.6

Function Group

Number

FUN 00

FUN 01

FUN 02

FUN 03

FUN 04

FUN 05

FUN 06

FUN 07

LED

P71

P78

P77 Phase Order

P76 Rated Volts

P75

Display

Jump Code

Meter 1

Meter 2

CT Ratio

Motor PF

P74 Starter Type

Parameter

Jump to Parameter

Meter 1

Meter 2

CT Ratio

Input Phase Sensitivity

Rated RMS Voltage

Motor Rated Power Factor

Starter Type

Setting Range

1 to 24

Ave Current

L1 Current

L2 Current

L3 Current

Curr Imbal

Ground Fault

Ave Volts

L1-L2 Volts

L2-L3 Volts

L3-L1 Volts

Overload

Power Factor

Watts

VA vars kW hours

MW hours

Phase Order

Line Freq

Analog Input

Analog Output

Run Days

Run Hours

Starts

TruTorque %

Power %

Pk Accel Cur

Last Start T

Zero Sequence GF

Stator Temp

Bearing Temp

Other Temp

All Temp

72:1, 96:1, 144:1,

288:1, 864:1, 2640:1,

3900:1, 5760:1,

8000:1, 14400:1,

28800:1, 50:5, 150:5,

250:5, 800:5, 2000:5,

5000:5

Insensitive

ABC

CBA

Single Phase

100, 110, 120, 200,

208, 220, 230, 240,

350, 380, 400, 415,

440, 460, 480, 500,

525, 575, 600, 660,

690, 800, 1000, 1140,

2200, 2300, 2400,

3300, 4160, 4600,

4800, 6000, 6600,

6900, 10.00K, 11.00K,

11.50K, 12.00K

12.47K, 13.20K,

13.80K

-0.01 (Lag) to 1.00

(Unity)

Normal

Inside Delta

Wye-Delta

Phase Ctl

Curr Follow

ATL

Units

RMS

Voltage

1

Default

Ave Current

Ave Volts

288:1

Insens.

480

-0.92

Normal

Page

101

101

102

102

103

103

103

55


FUN 13

FUN 14

FUN 15

FUN 16

FUN 17

FUN 18

FUN 19

FUN 20

FUN 21

Number

FUN 08

FUN 09

FUN 10

FUN 11

LED Display

P73 Heater Level

P72 Energy Saver

PORT Flt Tim

PORT Flt Tim

Parameter

Heater Level

Energy Saver

P.O.R.T. Fault Time

P.O.R.T. Bypass Hold Time

FUN 12

FUN 22

FUN 23

PORT Recover

Tach FS Lvl

Tach Los Tim

Tach Los Act

P70 Com Drop #

P.O.R.T. Recovery Method

P69 Com Baud rate Communication Baud Rate

P68 Com Timeout Communication Timeout

P71

P80

P67

Com Parity

Software 1

Software 2

Misc

Command

T/D Format

Tachometer Full Speed

Voltage

Tachometer Loss Time

Tachometer Loss Action

Communication Address

Communications Byte

Framing

Software Part Number 1

Software Part Number 2

Miscellaneous Commands

Time and Date Format

Setting Range

Off, 1 to 40

Off, On

Off, 0.1 - 90.0

Off, 0.1 - 5.0

Voltage Ramp

Fast Recover

Current Ramp

Curr Ramp 2

Ramp Select

Tach Ramp

1.00 - 10.00

0.1 - 90.0

Fault Current

TruTorque KW

1 to 247

1200, 2400, 4800,

9600, 19200

Off, 1 to 120

Even, 1 Stop Bit

Odd, 1 Stop Bit

None, 1 Stop Bit

None, 2 Stop Bit

Display Only

Display Only

None

Reset RT

Reset kWh

Reflash Mode

Store Parameters

Load Parameters

Factory Reset

Std BIST

Powered BIST mm/dd/yy 12h mm/dd/yy 24h yy/mm/dd 12h yy/mm/dd 24h dd/mm/yy 12h dd/mm/yy 24h

FUN 24

FUN 25

FUN 26

Time

Date

Passcode

Time

Date

Passcode

Units Default

%FLA Off

Seconds Off

Seconds Off

Seconds Off

Fast Recover 106

Volts 5.00

Seconds 1.5

Fault

1 bps 19200

Seconds Off

106

106

106

107

107

107

Even, 1 Stop 108

108

108

None mm/dd/yy

12h

Present Time

Present Date

Off

Page

104

105

105

105

108

109

109

109

110

5.2.7

Fault Group

Group

Fault

Number

Fault

Description

Starter

State

I1

5.2.8

Event Log Group

Group Event Number

Event

Description

I2 I3 V1 V2 V3 KW Hz

Run

Time

Page #

110

212

Condition Time Date

Page #

110

212

56

6 Parameter Description

57

6 - PARAMETER DESCRIPTION

6.1

Parameter Descriptions

Parameter Descriptions

The detailed parameter descriptions in this chapter are organized in the same order as they appear on the LCD display.

Each parameter has a detailed description that is displayed with the following format.

Parameter Name MMM__

LCD Display

Range

Description

See Also

MMM: Parameter

MI Value

Parameter Value (Default: Constant)

OR

LCD

Keypad

The description of the function.

Cross references to related parameters or other chapters.

Jump to Parameter QST 00

LCD Display

Description

QST: Jump Code

00 1

By changing the value of this parameter and pressing [ENTER], you can jump directly to any parameter within that group.

Motor FLA QST 01

LCD Display

Range

Description

QST: Motor FLA

01 10 Amp

1 – 6400 Amps RMS (Default: 10A)

The Motor FLA parameter configures the motor full load amps, and is obtained from the nameplate on the attached motor.

If multiple motors are connected, the FLA of each motor must be added together for this value.

z NOTE: Incorrectly setting this parameter prevents proper operation of the motor overload protection, motor over current protection, motor undercurrent protection, ground fault protection and acceleration control.

Motor Service Factor QST 02

LCD Display

Range

QST: Motor SF

02 1.15

1.00 – 1.99 (Default: 1.15)

58

Description

See Also

LCD Display:

Range

Description

See Also

LCD Display

Range

Description


The Motor Service Factor parameter should be set to the service factor of the motor. The service factor is used for the overload calculations. If the service factor of the motor is not known, then the service factor should be set to 1.00.

z NOTE: The NEC (National Electrical Code) does not allow the service factor to be set above 1.40. Check with other local electrical codes for their requirements.

The National Electrical Code, article 430 Part C, allows for different overload multiplier factors depending on the motor and operating conditions. NEC section 430-32 outlines the allowable service factor for different motors.

Theory of Operation section 7.2, Motor Service Factor on page 122.

Motor Running Overload Class QST 03

QST: Running OL

03 10

Off, 1 – 40 (Default: 10)

The Motor Running Overload Class parameter sets the class of the electronic overload for starting and running if the Indep S/R OL (PFN 28) parameter is set to "Off". If separate starting versus running overload classes are desired, set the Indep S/R OL (PFN 28) parameter to "On".

The starter stores the thermal overload value as a percentage value between 0 and 100%, with 0% representing a “cold” overload and 100% representing a tripped overload.

When the parameter is set to "Off", the electronic overload is disabled in all states, starting and running. A separate motor overload protection device must be supplied.

z NOTE: Care must be taken not to damage the motor when turning the running overload class off or setting a high value.

z NOTE: Consult motor manufacturer data to determine the correct motor overload settings.

Independent Starting/Running Overload (PFN 28) on page 86.

Motor Starting Overload Class (PFN 29) on page 87.

Motor Overload Hot/Cold Ratio (PFN 31) on page 88.

Motor Overload Cooling Time (PFN 32) on page 88.

Motor OL Alarm Level (PFN 33) on page 89.

Motor OL Lockout Level (PFN 34) on page 89.

Motor OL Auto Lockout Level (PFN 35) on page 89.

Relay Output Configuration (I/O 10-15) on page 91.

Theory of Operation section 7.1, Solid State Motor Overload Protection on page 114.

Local Source QST 04

QST: Local Src

04 Terminal

LCD

Keypad

Terminal

Serial

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.

The MVRMX

3 can have three sources of start and stop control: Terminal, Keypad and Serial. Two parameters, Local Source (QST 04) and Remote Source (QST 05) select the source of the start and stop control.

If a digital input is programmed as Local / Remote, then that input selects the control source. When the input is low, the local source is used. When the input is high, the remote source is used. If no digital input is

59


See Also

LCD Display

Range

Description

programmed as Local / Remote, then the local/remote bit in the starter control Modbus register selects the control source. The default value of the bit is Local (0).

z NOTE: By default, the [STOP] key is always enabled, regardless of selected control source. It may be disabled though using the Keypad Stop Disable (I/O 26) parameter.

Remote Source (QST 05) on page 60.


Keypad Stop Disable (I/O 26) on page 96.

Communication Address (FUN 16) on page 107.

Communication Baud Rate (FUN 17) on page 107.

Communication Timeout (FUN 18) on page 107.

Remote Source QST 05

QST: Remote Src

05 Terminal

LCD

Keypad

Terminal

Serial

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.

The MVRMX

3 can have three sources of start and stop control: Terminal, Keypad and Serial. Two parameters, Local Source (QST 04) and Remote Source (QST 05) select the sources of the start and stop control.

If a digital input is programmed as Local / Remote, then that input selects the control source. When the input is low, the local source is used. When the input is high, the remote source is used. If no digital input is programmed as Local/Remote, then the local/remote bit in the Modbus starter control register selects the control source. The default value of the bit is Local (0).

Figure 29: Local / Remote Source

Local Source

·

Keypad

See Also

60

Local/Remote Input, DI1 - DI8, configured by Parameter

I/O 01 - I/O 08

Modbus Starter Control Register

Local/Remote Bit

Local Source parameter (QST 04) on page 59.

Digital Input Configuration parameters (I/O 01 - 08) on page 90.

Keypad Stop Disable parameter (I/O 26) on page 96.

Communication Address parameter (FUN 16) on page 107.

Communication Baud Rate parameter (FUN 17) on page 107.

Communication Timeout parameter (FUN 18) on page 107.

LCD Display

Range

Description

See Also

LCD Display

Range

Description

See Also


Initial Current 1 QST 06

QST: Init Cur 1

06 100 %

50 – 600 % of FLA (Default: 100%)

The Initial Current 1 parameter is set as a percentage of the Motor FLA (QST 01) parameter setting. This parameter sets the current that is initially supplied to the motor when a start is commanded. The initial current should be set to the level that allows the motor to begin rotating within a couple of seconds of receiving a start command.

To adjust the initial current setting, give the starter a run command. Observe the motor to see how long it takes before it begins rotating and then stop the unit. For every second that the motor doesn’t rotate, increase the initial current by 20%. Typical loads require an initial current in the range of 50% to 175%.

If the motor does not rotate within a few seconds after a start command, the initial current should be increased.

If the motor accelerates too quickly after a start command, the initial current should be decreased.

The Initial Current 1 parameter must be set to a value that is lower than the Maximum Current 1 (QST 07) parameter setting.

Start Mode (CFN 01) on page 63.

Ramp Time 1 (QST 08 / CFN 02) on page 64.

Maximum Current 1 (QST 07 / CFN 04) on page 65.

Kick Level 1 (CFN 11) on page 68.

Kick Time 1 (CFN 12) on page 69.

Theory of Operation section 7.3.1, Current Ramp Settings, Ramps and Times on page 123.

Maximum Current 1 QST 07

QST: Max Cur 1

07 600 %

100 – 800 % of FLA (Default: 600%)

The Maximum Current 1 parameter is set as a percentage of the Motor FLA (QST 01) parameter setting. This parameter performs two functions. It sets the current level for the end of the ramp profile, as well as the maximum current that is allowed to reach the motor after the ramp is completed.

If the ramp time expires before the motor has reached full speed, the starter holds the current at the maximum current level until either the UTS timer expires, the motor reaches full speed, or the overload trips.

Typically, the maximum current is set to 600% unless the power system or load dictates the setting of a lower maximum current.

Up To Speed Time (QST 09) on page 62.



Initial Current 1 (QST 06 / CFN 03) on page 64.




61


LCD Display

Range

Description

See Also

LCD Display

Range

Description

See Also

Ramp Time 1 QST 08

QST: Ramp Time 1

08 15 sec

0 – 300 seconds (Default: 15 seconds)

The Ramp Time 1 parameter is the time it takes for the starter to allow the current, voltage, torque or power

(depending on the start mode) to go from its initial to the maximum value. To make the motor accelerate faster, decrease the ramp time. To make the motor accelerate slower, increase the ramp time.

A typical ramp time setting is from 15 to 30 seconds.

If the ramp time expires before the motor reaches full speed, the starter maintains the maximum current level until either the motor reaches full speed, the UTS timer expires, or the motor thermal overload trips.

z NOTE: Setting the ramp time to a specific value does not necessarily mean that the motor will take this time to accelerate to full speed. The motor and load may achieve full speed before the ramp time expires if the application does not require the set ramp time and maximum current to reach full speed. Alternatively, the motor and load may take longer than the set ramp time to achieve full speed.








Up To Speed Time QST 09

QST: UTS Time

09 20 sec

1 – 300 seconds (Default: 20 sec)

The Up To Speed Time parameter sets the maximum acceleration time to full speed that the motor can take. A stalled motor condition is detected if the motor does not get up-to-speed before the up-to-speed timer expires.

The motor is considered up-to-speed once the current stabilizes below 175 percent of the FLA value and the ramp time expires.

z NOTE: During normal acceleration ramps, the up-to-speed timer has to be greater than the sum of the highest ramp time in use and the kick time. The up-to-speed timer does not automatically change to be greater than the ramp time. If a ramp time greater than the up-to-speed timer is set, the starter will declare an up-to-speed fault every time a start is attempted.

z NOTE: When the Start Mode (CFN 01) parameter is set to "Voltage Ramp", the UTS timer acts as an acceleration kick. When the UTS timer expires, full voltage is applied to the motor. This feature can be used to reduce motor oscillations if they occur near the end of an open loop voltage ramp start.

z NOTE: When the Starter Type (FUN 07) parameter is set to "Wye-Delta", the UTS timer is used as the transition timer. When the UTS timer expires, the transition from Wye starting mode to Delta running mode takes place if it has not already occurred.

Fault Code 01 - Up to Speed Fault is declared when a stalled motor condition is detected.



Ramp Time 2 (CFN 05) on page 65.



62

LCD Display

Description:

LCD Display

Range

Description

See Also


Starter Type (FUN 07) on page 103.

Application section 7.7, Wye-Delta on page 140.

Theory of Operation section 7.3, Acceleration Control on page 123.

Jump to Parameter CFN 00

CFN: Jump Code

00 1


Start Mode CFN 01

CFN: Start Mode

01 Current Ramp

LCD

Voltage Ramp

Current Ramp

TT Ramp

Power Ramp

Tach Ramp

Description

Open Loop Voltage acceleration ramp.

Current control acceleration ramp. (Default)

TruTorque control acceleration ramp.

Power (kW) control acceleration ramp.

Tachometer control acceleration ramp.

The Start Mode parameter allows the selection of the optimal starting ramp profile based on the application.

The closed loop current control acceleration ramp is ideal for starting most general-purpose motor applications. Ex: crushers, ball mills, reciprocating compressors, saws, centrifuges, and most other applications.

The closed loop trutorque control acceleration ramp is suitable for applications that require a minimum of torque transients during starting or for consistently loaded applications that require a reduction of torque surges during starting. Ex: centrifugal pumps, fans, and belt driven equipment.

The closed loop power control acceleration ramp is ideal for starting applications using a generator or other limited capacity source.

In addition to the basic motor and starter setup variables, the following needs to be done to use the tachometer feedback control ramp:

•

Connect a tachometer with appropriate DC output voltage and correct polarity to the MX

3 input (TB5-2(+input), TB5-3(-input)).

power card

•

The Start Mode (CFN 01) is to be selected as "Tach Ramp".

•

Program Tachometer Full Speed Voltage (FUN 13, see page 106).

•

Program Tachometer Loss Time (FUN 14, see page 106).

•

Program Tachometer Loss Action (FUN 15, see page 106).

•

Set the Initial Current Level (CFN 03, see page 64) to the desired current limit.

•

Set the Maximum Current Level (CFN 04, see page 65) to the desired maximum current limit.

Initial Voltage/Torque/Power (CFN 08) on page 66.

Maximum Torque/Power (CFN 09) on page 67.

Acceleration Ramp Profile (CFN 10) on page 67.


63


LCD Display

Range

Description

See Also

LCD Display

Range

Description

See Also

Ramp Time 1 CFN 02

CFN: Ramp Time 1

02 15 sec


The Ramp Time 1 parameter is the time it takes for the starter to allow the current, voltage, torque or power

(depending on the start mode) to go from its initial to the maximum value. To make the motor accelerate faster, decrease the ramp time. To make the motor accelerate slower, increase the ramp time.

A typical ramp time setting is from 15 to 30 seconds.

If the ramp time expires before the motor reaches full speed, the starter maintains the maximum current level until either the motor reaches full speed, the UTS timer expires, or the motor thermal overload trips.

z NOTE: Setting the ramp time to a specific value does not necessarily mean that the motor will take this time to accelerate to full speed. The motor and load may achieve full speed before the ramp time expires if the application does not require the set ramp time and maximum current to reach full speed. Alternatively, the motor and load may take longer than the set ramp time to achieve full speed.








Initial Current 1 CFN 03

CFN: Init Cur 1

03 100 %

50 – 600 % of FLA (Default: 100%)

The Initial Current 1 parameter is set as a percentage of the Motor FLA (QST 01) parameter setting. The

Initial Current 1 parameter sets the current that is initially supplied to the motor when a start is commanded.

The initial current should be set to the level that allows the motor to begin rotating within a couple of seconds of receiving a start command.

To adjust the initial current setting, give the starter a run command. Observe the motor to see how long it takes before it begins rotating and then stop the unit. For every second that the motor doesn’t rotate, increase the initial current by 20%. Typical loads require an initial current in the range of 50% to 175%.

If the motor does not rotate within a few seconds after a start command, the initial current should be increased.

If the motor takes off too quickly after a start command, the initial current should be decreased.

The Initial Current 1 parameter must be set to a value that is lower than the Maximum Current 1 (QST

07/CFN 04) parameter setting.







64

LCD Display

Range

Description

See Also

LCD Display

Range

Description

See Also

LCD Display

Range

Description

See Also


Maximum Current 1 CFN 04

CFN: Max Cur 1

04 600 %

100 – 800 % of FLA (Default: 600%)

The Maximum Current 1 parameter is set as a percentage of the Motor FLA (QST 01) parameter setting and 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.

If the ramp time expires before the motor has reached full speed, the starter holds the current at the maximum current level until either the UTS timer expires, the motor reaches full speed, or the overload trips.

Typically, the maximum current is set to 600% unless the power system or load dictates the setting of a lower maximum current.








Ramp Time 2 CFN 05

CFN: Ramp Time 2

05 15 sec


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 (QST 08 / CFN

02) for description of operation.



Theory of Operation section 7.3.1, Current Ramp Settings, Ramp and Times on page 123.

Theory of Operation section 7.3.6, Dual Acceleration Ramp Control on page 128.

Initial Current 2 CFN 06

CFN: Init Cur 2

06 100 %

50 – 600 % of FLA (Default: 100%)

The Initial Current 2 parameter is set as a percentage of the Motor FLA (QST 01) parameter setting when the second ramp is active. Refer to the Initial Current 1 (CFN 03) parameter for description of operation.

Initial Current 1 (CFN 03) on page 64.




65


LCD Display

Range

Description

See Also

LCD Display

Range

Description

See Also

Maximum Current 2 CFN 07

CFN: Max Cur 2

07 600 %

100 – 800 % of FLA (Default: 600%)

The Maximum Current 2 parameter is set as a percentage of the Motor FLA (QST 01) parameter setting, when the second ramp is active. Refer to the Maximum Current 1 (CFN 04) on page 65 parameter for description of operation.

Maximum Current 1 (CFN 04) on page 65.




Initial Voltage/Torque/Power CFN 08

CFN: Init V/T/P

08 25 %

1 – 100 % of Voltage/Torque/Power (Default: 25%)

Start Mode (CFN 01) 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. If the motor does not start rotating within a few seconds after a start is commanded, increase this parameter.

Start Mode (CFN 01) set to Current Control Acceleration:

Not used when the Start Mode parameter is set to Current control acceleration. Refer to the Initial Current 1

(QST 06/CFN 03) parameter to set the initial current level.

Start Mode (CFN 01) set to TruTorque Control Acceleration:

This parameter sets the initial torque level that the motor produces at the beginning of the starting ramp profile. A typical value is 10% to 20%. If the motor starts too quickly or the initial torque level is too high, reduce this parameter. If the motor does not start rotating within a few seconds after a start is commanded, increase this parameter. If the value is set too low a “No Current at Run” fault may occur during acceleration.

z NOTE: It is important that the Rated Power Factor (FUN 06) parameter is set properly so that the actual initial torque level is the value desired.

Start Mode (CFN 01) set to (kW) Power Control Acceleration:

This parameter sets the initial motor power (KW) level that will be achieved at the beginning of the starting ramp profile. A typical value is 10% to 30%. If the motor starts too quickly or the initial power level is too high, reduce this parameter. If the motor does not start rotating within a few seconds after a start is commanded, increase this parameter. If the value is set too low a “No Current at Run” fault may occur during acceleration.

z NOTE: It is important that the Rated Power Factor (FUN 06) parameter is set properly so that the actual initial power level is the value desired.


Ramp Time 1 (CFN 02) on page 64.

Initial Current 1 (CFN 03 / QST 06) on page 64.

Maximum Torque/Power (CFN 09) on page 66.

Rated Power Factor (FUN 06) on page 103.


66

LCD Display

Range

Description

See Also

LCD Display

Range

Description


Maximum Torque/Power CFN 09

CFN: Max T/P

09 105 %

10 – 325 % of Torque/Power (Default: 105%)

Start Mode (CFN 01) set to Open Loop Voltage Acceleration:

Not used when the Start Mode (CFN 01) parameter is set to open-loop voltage acceleration. When in open loop voltage acceleration mode, the final voltage ramp value is always 100% or full voltage.

Start Mode (CFN 01) set to Current Control Acceleration:

Not used when the Start Mode (CFN 01) parameter is set to current control acceleration mode. Refer to the

Maximum Current 1 (CFN 04) parameter to set the maximum current level.

Start Mode (CFN 01) set to TruTorque Control Acceleration:

This parameter sets the final or maximum torque level that the motor produces at the end of the acceleration ramp time. For a loaded motor, the maximum torque value initially should be set to 100% or greater. If the maximum torque value is set too low, the motor may not produce enough torque to reach full speed and may stall. On lightly loaded motors, this parameter may be reduced below 100% to produce smoother starts.

z NOTE: It is important that the Rated Power Factor (FUN 06) parameter is set properly so that the desired maximum torque level is achieved.

Start Mode (CFN 01) set to Power Control Acceleration:

This parameter sets the final or maximum power (KW) consumption level that will be achieved at the end of the ramp time. For a loaded motor, the maximum power value initially should be set to 100% or greater. If the maximum power level is set too low, the motor may not produce enough torque to reach full speed and may stall. On lightly loaded motors, this parameter may be reduced below 100% to provide for smoother starts.

z NOTE: It is important that the Rated Power Factor (FUN 06) parameter is set properly so that the actual maximum power level is achieved.


Ramp Time 1 (CFN 02 / QST 08) on page 64.


Initial Voltage/Torque/Power (CFN 08) on page 66.

Initial Current 1 (CFN 03) on page 64.



Acceleration Ramp Profile CFN 10

CFN: Accel Prof

10 Linear

Linear, Square, S-Curve (Default: Linear)

Linear – The linear profile linearly increases the control reference (voltage, current, torque, power, speed) from the initial acceleration ramp value to the final acceleration ramp value. The linear profile is the default profile and is recommended for most acceleration and deceleration situations.

Linear

67


Squared – The squared profile increases the control reference (voltage, current, torque, power, speed) in a squared manner. A squared acceleration profile can be useful when using TruTorque control on a load with a squared torque characteristic (such as pumps, and fans). A squared torque profile can provide a more linear speed profile during acceleration and deceleration.

Squared

S–Curve – The S-curve profile slowly increases the control reference’s rate of change at the beginning of the ramp profile and an slowly decreases the rate of change of the reference at the end of the ramp profile. This profile can be useful when using closed loop tach control to smooth the starting and ending of the acceleration profile. It can also be useful with other types of control methods that require extra smooth starts.

S-Curve

See Also

LCD Display

Range

Description

See Also


Kick Level 1 CFN 11

CFN: Kick Lvl 1

11 Off

Off, 100 – 800% of FLA (Default: Off)

The Kick Level 1 parameter sets the current level that precedes any ramp when a start is first commanded.

The kick current is only useful on motor loads that are hard to get rotating but then are much easier to move once they are rotating. An example of a load that is hard to get rotating is a ball mill. The ball mill requires a high torque to get it to rotate the first quarter turn (90°). Once the ball mill is past 90°of rotation, the material inside begins tumbling and it is easier to turn.

The kick level is usually set to a low value and then the kick time is adjusted to get the motor rotating. If the kick time is set to more than 2.0 seconds without the motor rotating, increase the kick current by 100% and re-adjust the kick time.

Start Mode on (CFN 01) on page 63.

Kick Time 1 on (CFN 12) on page 68.

Theory of Operation section 7.3.2, Programming A Kick Current on page 124.

68

LCD Display

Range

Description

See Also

LCD Display

Range

Description

LCD Display

Range

Description

See Also


Kick Time 1 CFN 12

CFN: Kick Time 1

12 1.0 sec

0.1 – 10.0 seconds (Default: 1.0 sec)

The Kick Time 1 parameter sets the length of time that the kick current level is applied to the motor.

The kick time adjustment should begin at 0.5 seconds and be adjusted by 0.1 or 0.2 second intervals until the motor begins rotating. If the kick time is adjusted above 2.0 seconds without the motor rotating, start over with a higher kick current setting.

z NOTE: The kick time adds to the total start time and must be accounted for when setting the UTS time.

Up To Speed (QST 09) on page 62




Kick Level 2 CFN 13

CFN: Kick Lvl 2

13 Off

Off, 100 – 800% of FLA (Default: Off)

The Kick Level 2 parameter sets the current level that precedes any ramp when a start is first commanded when the second ramp is active. Refer to the Kick Level 1 (CFN 11) parameter on page 68 for description of operation.

Kick Time 2 CFN 14

CFN: Kick Time 2

14 1.0 sec


The Kick Time 2 parameter sets the length of time that the kick current level is applied to the motor when the second ramp is active. Refer to the Kick Time 1 (CFN 12) parameter on page 69 for description of operation.


Digital Input Configuration (I/O 01 - 08) on page 90.



69


LCD Display

Range

Description

See Also

LCD Display

Range

Description

Stop Mode CFN 15

CFN: Stop Mode

15 Coast

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. The bypass contactor is opened before the SCRs stop gating to reduce wear on the contactor contacts.

Voltage Decel: In this mode, the starter linearly phases-back the SCRs based on the parameters Decel Begin

Level (CFN 16), Decel End Level (CFN 17), and Decel Time (CFN 18).

TruTorque Decel: In this mode, the starter linearly reduces the motor torque based on the parameters Decel

End Level (CFN 17)and Decel Time (CFN 18).

DC Brake: In this mode the starter provides D.C. injection for frictionless braking of a three phase motor.

z NOTE: The MVRMX

3 stops the motor when any fault occurs. Depending on the application, it may be desirable for the motor to be stopped in a controlled manner (Voltage Decel, TT Decel or D.C. Braking) instead of being allowed to coast to a stop when this occurs. This may be achieved by setting the Controlled

Fault Stop (PFN 25) parameter to "On". Be aware however that not all fault conditions allow for a controlled fault stop.

Decel Begin Level (CFN 16) on page 70.

Decel End Level (CFN 17) on page 71.

Decel Time (CFN 18) on page 71.

Deceleration Ramp Profile (CFN 19) on page 72.

DC Brake Level (CFN 20) on page 72.

DC Brake Time (CFN 21) on page 73.

DC Brake Delay (CFN 22) on page 73.

Controlled Fault Stop Enable (PFN 25) on page 85.

Digital Input Configuration (I/O 01 - 08) on page 90.

Relay Output Configuration (I/O 10 - 15) on page 91.

Theory of Operation, Deceleration Control on page 131.

Theory of Operation, Braking Controls on page 133.

Decel Begin Level CFN 16

CFN: Decel Begin

16 40 %

1 – 100 % of phase angle firing (Default: 40%)

Stop Mode (CFN 15) 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. The deceleration beginning level is not a precise percentage of actual line voltage, but defines a point on the

S-curve deceleration profile.

A typical voltage decel begin level setting is between 30% and 40%. If the motor initially surges (oscillates) when a stop is commanded, decrease this parameter value. If there is a sudden drop in motor speed when a stop is commanded, increase this parameter value.

Stop Mode (CFN 15) set to TruTorque Deceleration:

Not used when the Stop Mode parameter is set to "TruTorque Decel". The TruTorque beginning deceleration level is automatically calculated based on the motor load at the time the stop command is given.

70

See Also

LCD Display

Range

Description

See Also

LCD Display

Range

Description


z NOTE: It is important that the Rated Power Factor (FUN 06) parameter is set properly so that the actual deceleration torque levels are the levels desired.

Stop Mode (CFN 15) on page 70.





Theory of Operation section 7.4, Deceleration Control on page 131.

Decel End Level CFN 17

CFN: Decel End

17 20 %

1 – 99 % of phase angle firing (Default: 20%)

Stop Mode (CFN 15) set to Voltage Deceleration:

The voltage deceleration profile utilizes an open loop S-curve voltage ramp profile. The Decel End Level parameter sets the ending voltage level for the voltage deceleration ramp profile. The deceleration ending level is not a precise percentage of actual line voltage, but defines an ending point on the S-curve deceleration profile.

A typical voltage decel end level setting is between 10% and 20%. If the motor stops rotating before the deceleration time has expired, increase this parameter value. If the motor is still rotating when the deceleration time has expired, decrease this parameter value. If the value is set too low a “No Current at Run” fault may occur during deceleration.

z NOTE: The deceleration end level cannot be set greater than the decel begin level.

Stop Mode (CFN 15) set to TruTorque Deceleration:

The Decel End Level parameter sets the ending torque level for the TruTorque deceleration ramp profile.

A typical TruTorque decel end level setting is between 10% and 20%. If the motor stops rotating before the deceleration time has expired, increase this parameter value. If the motor is still rotating when the deceleration time has expired, decrease this parameter value.






Decel Time CFN 18

CFN: Decel Time

18 15 sec

1 – 180 seconds (Default: 15 sec)

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. In voltage decel mode, this time sets the time to ramp from the initial decel level to the final decel level.

z NOTE: If the motor is not up to speed when a stop is commanded, the voltage decel profile begins at the lower of either the decel begin level setting or at the motor voltage level when the stop is commanded.

Although the profile may be adjusted, the deceleration time remains the same.

In the TruTorque deceleration mode, the decel time sets the time between when a stop is commanded and when the decel end torque level is applied.

71


See Also

LCD Display

Range

Description

See Also

LCD Display

Range

Description

If the motor stops rotating before the decel time expires, decrease the Decel Time (CFN 18) parameter. If the motor is still rotating when the decel time expires, increase the Decel Time (CFN 18) parameter.

A typical decel time is 20 to 40 seconds.

z NOTE: Depending on the motor load and the Decel parameter settings, the motor may or may not be fully stopped at the end of the deceleration time.

Refer to section 7.4, Deceleration Control on page 131.




Controlled Fault Stop (PFN 25) on page 85.


Decel Ramp Profile CFN 19

CFN: Decel Prof

19 Linear

Linear, Squared, S-Curve (Default: Linear)

See Accel Prof (CFN 10) on page 67 for details.


DC Brake Level CFN 20

CFN: Brake Level

20 25 %

10 – 100 % of available brake torque (Default: 25%)

When the Stop Mode (CFN 15) is set to "DC brake", the DC Brake Level parameter sets the level of DC current applied to the motor during braking. The desired brake level is determined by the combination of the system inertia, system friction, and the desired braking time. If the motor is braking too fast the level should be reduced. If the motor is not braking fast enough the level should be increased. Refer to Nema MG1, Parts

12 and 20 for maximum load inertias. A PTC Thermistor or RTD MUST be installed to protect the motor.

DC Brake Function Programming Steps:

1. The DC Brake function may be enabled by setting the Stop Mode (CFN 15) parameter to "DC Brake".

2. Once this function is enabled, a relay output configuration (I/O 10 - 15) must be used to control the DC brake contactor or 7th SCR gate drive card during braking. It is recommended to use Relay R3 - (I/O12) because it is a higher rated relay.

z NOTE: Standard duty braking

- For load inertias less than 6 x motor inertia

Heavy duty braking

- For NEMA MG1 parts 12 and 20 maximum load inertias z NOTE: When DC injection braking is utilized, discretion must be used when setting up the DC Brake

Level. Motor heating during DC braking is similar to motor heating during starting. Even though the Motor

OL is active (if not set to "Off") during DC injection braking, excessive motor heating could still result if the load inertia is large or the brake level is set too high. Caution must be used to assure that the motor has the thermal capacity to handle braking the desired load in the desired period of time without excessive heating.

z NOTE: Consult motor manufacturer for high inertia applications.

72

LCD Display

Range

Description

See Also

LCD Display

Range

See Also

LCD Display

Range

Description

See Also


z NOTE: Not to be used as an emergency stop. When motor braking is required even during a power outage an electromechanical brake must be used.

Stop Mode parameter (CFN 15) on page 70.

DC Brake Time parameter (CFN 21) on page 73.

DC Brake Delay parameter (CFN 22) on page 73.

Controlled Fault Stop Enable parameter (PFN 25) on page 85.

Digital Input parameters (I/O 01 - 08) on page 90.

Theory of Operation section 7.1, Solid State Motor Overload Protection, on page 114.

Theory of Operation section 7.5.1, DC Injection Braking Control, on page 134.

DC Brake Time CFN 21

CFN: Brake Time

21 5 sec

1 – 180 Seconds (Default: 5)

When the Stop Mode (CFN 15) parameter is set to "DC brake", the DC Brake Time parameter sets the time that DC current is applied to the motor. The required brake time is determined by the combination of the system inertia, system friction, and the desired braking level. If the motor is still rotating faster than desired at the end of the brake time increase the brake time if possible. If the motor stops before the desired brake time has expired decrease the brake time to minimize unnecessary motor heating.

Motor Running Overload Class parameter (QST 03) on page 59.


DC Brake Level parameter (CFN 20) on page 72.

DC Brake Delay parameter (CFN 22) on page 73.



DC Brake Delay CFN 22

CFN: Brake Delay

22 0.2 sec

0.1 – 3.0 Seconds (Default: 0.2)

When the Stop Mode (CFN 15) 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. If a large surge of current is detected when DC braking is first engaged increase the delay time. If the delay before the braking action begins is too long then decrease the delay time. In general, low horsepower motors can utilize shorter delays while large horsepower motor may require longer delays.


DC Brake Level parameter (CFN 20) on page 72.

DC Brake Time parameter (CFN 21) on page 73.


Preset Slow Speed CFN 23

CFN: SSpd Speed

23 Off

Off, 1.0 – 40.0 % (Default: Off)

73


Description

See Also

LCD Display

Range

Description

See Also

LCD Display

Range

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 idle will initiate slow speed operation.

z NOTE: When the motor is operating at slow speeds its cooling capacity can be greatly reduced. Therefore, the running time of the motor at a given current level is dependant on the motor’s thermal capacity. Although the Motor OL is active (if not set to "Off") during slow speed operation, it is recommended that the motor temperature be monitored when slow speed is used for long periods of time.

Slow Speed Current Level parameter (CFN 24) on page 74.

Slow Speed Time Limit parameter (CFN 25) on page 74.


Digital Input Configuration parameters (I/O 01 - 08) on page 90.

Relay Output Configuration parameter (I/O 10 - 15) on page 91.

Theory of Operation section 7.6, Slow Speed Operation on page 138.

Preset Slow Speed Current Level CFN 24

CFN: SSpd Curr

24 100 %

10 – 400 % FLA (Default: 100 %)

The Preset Slow Speed Current Level parameter selects the level of current applied to the motor during slow speed operation. The parameter is set as a percentage of motor full load amps (FLA). This value should be set to the lowest possible current level that will properly operate the motor.

z NOTE: When the motor is operating at slow speeds its cooling capacity can be greatly reduced. Therefore, the running time of the motor at a given current level is dependant on the motor’s thermal capacity. Although the Motor OL is active (if not set to "Off") during slow speed operation, it is recommended that the motor temperature be monitored when slow speed is used for long periods of time.

Motor Running Overload Class parameter (QST 03) on page 59.

Slow Speed Time Limit parameter (CFN 25) on page 74.


Theory of Operation section 7.6 , Slow Speed Operation on page 138.

Slow Speed Time Limit CFN 25

CFN: SSpd Timer

25 10 sec

Off, 1 – 900 Seconds (Default: 10 sec)

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.

z NOTE: The Slow Speed Time Limit includes the time used for the Slow Speed Kick Time (CFN27) parameter if kick is enabled.

z NOTE: The Slow Speed Time Limit resets when the motor is stopped. Therefore, this timer does not prevent the operator from stopping slow speed operation and re-starting the motor, which can result in the operation time of the motor being exceeded.

z NOTE: When the motor is operating at slow speeds, its cooling capacity can be greatly reduced.

Therefore, the running time of the motor at a given current level is dependant on the motor’s thermal capacity.

74

See Also

LCD Display

Range

Description

See Also

See Also

LCD Display

Range

Description


Although the Motor OL is active (if not set to "Off") during slow speed operation it is recommended that the motor temperature be monitored if slow speed is used for long periods of time.

Motor Running Overload Class (QST 03) parameter on page 59.

Slow Speed Current Level (CFN 24) parameter on page 74.

Motor PTC Trip Time (PFN 27) parameter on page 86.

Theory of Operation section 7.6, Slow Speed Operation on page 138.

Slow Speed Kick Level CFN 26

CFN: SSpd Kick Cu

26 Off

Off, 100 – 800 % FLA (Default: Off)

The Slow Speed Kick Level sets the short-term current level that is applied to the motor to accelerate the motor for slow speed operation. If set to "Off" the Slow Speed Kick feature is disabled. Slow speed kick can be used to “break loose” difficult to start loads while keeping the normal slow speed current level at a lower level.

This parameter should be set to a midrange value and then the Slow Speed Kick Time (CFN 27) parameter should be increased in 0.1 second intervals until the kick is applied long enough to start the motor rotating. If the motor does not start rotating then increase the Slow Speed Kick Level and begin adjusting the kick time from 1.0 seconds again.

If the motor initially accelerates too fast then reduce the Slow Speed Kick Level and/or reduce the Slow Speed

Kick Time (CFN 27).

Kick Level 1 parameter (CFN 11) on page 67.

Slow Speed Kick Time parameter (CFN 27) on page 75.


Theory of Operations section 7.6, Slow Speed Operation on page 138.

Slow Speed Kick Time CFN 27

CFN: SSpd Kick T

27 1.0 sec


The Slow Speed Kick Time parameter sets the length of time that the Slow Speed Kick Current Level (CFN

24) is applied to the motor at the beginning of slow speed operation. After the Slow Speed Kick Level (CFN

26) is set, the Slow Speed Kick Time should be adjusted so that the motor starts rotating when a slow speed command is given.

If the motor initially accelerates too fast then reduce the Slow Speed Kick Level (CFN 26) and/or reduce the

Slow Speed Kick Time.

Preset Slow Speed (CFN 23) on page 73.

Slow Speed Kick Level parameter (CFN 26) on page 75.


Theory of Operations section 7.6, Slow Speed Operation on page 138.

75


LCD Display

Description

LCD Display

Range

Description

See Also

LCD Display

Range

Description

Jump to Parameter PFN 00

PFN: Jump Code

00 1


Over Current Trip Level PFN 01

PFN: Over Cur Lvl

01 Off

Off, 50 – 800 % of FLA (Default: Off)

If the MX

3 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. The over current timer starts a delay time.

If the over current still exists when the delay timer expires, the starter Over Current Trips (F31) any relay programmed as fault relay changes state.

The Over Current Trip is only active in the UTS state, Energy Saver state, Current follower or while in the

Phase Control mode.

A relay can be programmed to change state when an over current alarm condition is detected.

Alarm

Condition

Fault

Trip

Over Cur Level

PFN 01

Motor FLA

QST 01

% Current

Time

Over Current Trip

Delay Time

PFN 02

Over Current Time parameter (PFN 02) on page 76.

Auto Reset parameter (PFN 23) on page 84.


Relay Output Configuration parameters (I/O 10 - 15) on page 91.

Over Current Trip Delay Time PFN 02

PFN: Over Cur Tim

02 0.1

sec

Off, 0.1 – 90.0 seconds (Default: 0.1 sec)

The Over Current Time parameter sets the period of time that the motor current must be greater than the Over

Current Level (PFN 01) parameter before an over current fault and trip occurs.

If "Off" is selected, the over current timer does not operate and the starter does not trip. It energizes any relay

76

See Also

LCD Display

Range

Description

See Also

See Also

LCD Display

Range

Description


set to Over current until the current drops or the starter trips on an overload.

A shear pin function can be implemented by setting the delay to its minimum value.

Over Current Level parameter (PFN 01) on page 76.




Under Current Trip Level PFN 03

PFN: Undr Cur Lvl

03 Off

Off, 5 – 100 % of FLA (Default: Off)

If the MX

3 detects a one cycle, average current that is less than the level defined, an under current alarm condition exists and any relays programmed as alarm will energize. The under current timer starts a delay time. If the under current still exists when the delay time expires, the starter Under Current Trips (F34) and any relay programmed as fault relay changes state.

The Under Current Trip is only active in the UTS state, Energy Saver state, Current follower or while in the

Phase Control mode.

A relay can be programmed to change state when an under current alarm condition is detected.

Alarm

Condition

Fault

Trip

% Current

Motor FLA

QST 01

Under Cur Level

PFN 03

Time

Under Current Trip

Delay Time

PFN 04

Under Current Time parameter (PFN 04) on page 77.




Under Current Trip Delay Time PFN 04

PFN: Undr Cur Tim

04 0.1

sec

Off, 0.1 – 90.0 seconds (Default: 0.1 sec)

The Under Current Time parameter sets the period of time that the motor current must be less than the Under

Current Level (PFN 03) parameter before an under current fault and trip occurs.

If "Off" is selected, the under current timer does not operate and the starter does not trip. It energizes any relay set to undercurrent until the current rises.

Under Current Level parameter (PFN 03) on page 77.




77


LCD Display

Range

Description

See Also

LCD Display

Range

Current Imbalance Trip Level PFN 05

PFN: Cur Imbl Lvl

05 15 %

Off, 5 – 40 % (Default: 15 %)

The Current Imbalance Level parameter sets the imbalance that is allowed before the starter shuts down. The current imbalance must exist for the Current Imbalance Delay Trip Time (PFN 06) before a fault occurs.

At average currents less than or equal to full load current (FLA), the current imbalance is calculated as the percentage difference between the phase current that has the maximum deviation from the average current

(Imax) and the FLA current.

The equation for the current imbalance if running at current <=FLA:

%

imbalance

=

(

Iave

-

I max

)

FLA

´

100 %

At average currents greater than full load current (FLA), the current imbalance for each phase is calculated as the percentage difference between the phase current that has the maximum deviation from the average current

(Imax) and the average current (Iave).

The equation for the current imbalance if running at current > FLA:

%

imbalance

=

(

Iave

-

Im ax

)

Iave

´

100 %

If the highest calculated current imbalance is greater than the current imbalance level for the Current

Imbalance Delay Trip Time (PFN 06), the starter shuts down the motor and declares a Fault 37 (Current

Imbalance).

Alarm

Condition

Fault

Trip

% Imbalance

Current Imbl Lvl

PFN 05

Time

Current Imbalance

Trip Time

PFN 06

Current Imbalance Trip Time (PFN 06) on page 78.



Current Imbalance Trip Time

PFN: Cur Imbl Tim

06 10.0 sec


PFN 06

78

Description

See Also

LCD Display

Range

Description

See Also


The Imbalance Delay parameter sets the time that the current imbalance must be greater than the Percent

Imbalance (PFN 05) parameter before a trip will occur.

Current Imbalance Trip Level (PFN 05) on page 78.

Residual Ground Fault Trip Level PFN 07

PFN: Resid GF Lvl

07 Off

Off, 5 – 100 % FLA (Default: Off)

The Residual Ground Fault 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.

Ground Fault Trip: The MVRMX

3 will trip with a ground fault indication if:

- No other fault currently exists.

- Ground fault current is equal to or greater than the GF Trip Level for a time period greater than the GF Trip Delay (PFN 09).

Once the starter recognizes a ground fault condition, it shuts down the motor and declares a Fault 38 (Ground

Fault).

% FLA

Alarm

Condition

Fault

Trip

Residual Gnd Fault

Level

PFN 07

Time

Ground Fault

Trip Time

PFN 09

If a programmable relay (I/O 01 - 08) is set to "Ground Fault", the starter energizes the relay when the condition exists.

A typical value for the ground fault current setting is 10% to 20% of the full load amps of the motor.

z NOTE: This type of protection is meant to provide machine ground fault protection only. It is not meant to provide human ground fault protection.

z NOTE: The MVRMX

3 residual ground fault protection function is meant to detect ground faults on solidly grounded systems. Use on a high impedance or floating ground power system may impair the usefulness of the MVRMX

3 residual ground fault detection feature.

z NOTE: Due to uneven CT saturation effects and motor and power system variations, there may be small values of residual ground fault currents measured by the MVRMX

3 during normal operation.

Ground Fault Trip Time parameter (PFN 09) on page 80.




79


LCD Display

Range

Description

See Also

LCD Display

Range

Description

See Also

Zero Sequence Ground Fault Trip Level PFN 08

PFN: ZS GF Lvl

08 Off

Off, 1.0 – 25.0 amps (Default: Off)

The Zero Sequence Ground Fault parameter sets a ground fault current trip or alarm level that can be used to protect the system from a ground fault condition. In isolated or high impedance-grounded systems, core-balanced current sensors are typically used to detect low level ground faults caused by insulation breakdowns or entry of foreign objects. Detection of such ground faults can be used to interrupt the system to prevent further damage, or to alert the appropriate personnel to perform timely maintenance.

Ground Fault Trip: The MVRMX

3 will trip with a ground fault indication if:

- No other fault currently exists.

- Ground fault current is equal to or greater than the GF Trip Level for a time period greater than the GF Trip Delay (PFN 09).

Once the starter recognizes a ground fault condition, it will shut down the motor and display a fault

F38-Ground Fault.

Amps

Alarm

Condition

Fault

Trip

Zero Sequence Gnd

Fault Level

PFN 08

Time

Ground Fault

Trip Time

PFN 09

If a programmable relay (I/O 10 - 15) is set to "Ground Fault", the starter energizes the relay when the condition exists.

z NOTE: The MVRMX 3 zero sequence ground fault detection consists of installing a Cat. No

BICT-2000/1-6 (50: 0.025 amps) core balance current transformer to terminal J15 Gnd Flt located on the I/O card.

Ground Fault Trip Time (PFN 09) on page 80.


Controlled Fault Stop (PFN 25) on page 85.

Relay Outputs (I/O 10 - 15) on page 91.

Ground Fault Trip Time PFN 09

PFN: Gnd Flt Time

09 3.0

sec

0.1 – 90.0 seconds (Default: 3.0)

The Ground Fault Trip Time parameter can be set from 0.1 to 90.0 seconds in 0.1 second intervals.

Residual Ground Fault Trip Level (PFN 07) on page 79.

Zero Sequence Ground Fault Trip Level (PFN 08) on page 80.

80

See Also

LCD Display

Range

Description

See Also

See Also

LCD Display

Range

Description

LCD Display

Range

Description


Over Voltage Trip Level PFN 10

PFN: Over Vlt Lvl

10 Off

Off, 1 – 40 % (Default: Off)

If the MVRMX

3 detects a one cycle input phase voltage that is above the over voltage level, the over/under voltage alarm is shown and the voltage trip timer begins counting. The delay time must expire before the starter faults.

z NOTE: For the over voltage protection to operate correctly, the Rated Voltage parameter (FUN 05) must be set correctly.

z NOTE: The voltage level is only checked when the starter is running.

Under Voltage Level parameter (PFN 11) on page 81.

Voltage Trip Time parameter (PFN 12) on page 81.



Rated Voltage parameter (FUN 05) on page 103.

Under Voltage Trip Level PFN 11

PFN: Undr Vlt Lvl

11 Off

Off, 1 – 40 % (Default: Off)

If the MVRMX

3 detects a one cycle input phase voltage that is below the under voltage level, the over/under voltage alarm is shown and the voltage trip timer begins counting. The delay time must expire before the starter faults.

z NOTE: For the under voltage protection to operate correctly, the Rated Voltage parameter (FUN 05) must be set correctly.

z NOTE: The voltage level is only checked when the starter is running.

Over Voltage Level parameter (PFN 10) on page 81.




Rated Voltage parameter (FUN 05) on page 103.

Over/Under Voltage Trip Delay Time PFN 12

PFN: Vlt Trip Tim

12 0.1

sec

0.1 – 90.0 seconds (Default: 0.1)

The Voltage Trip Time parameter sets the period of time that either an over voltage or under voltage condition must exist before a fault occurs.





81


LCD Display

Range

Description

LCD Display

Range

Description

See Also

LCD Display

Range

Description

See Also

Phase Loss Trip Time PFN 13

PFN: Ph Loss Time

13 0.2 sec

0.1 – 5.0 seconds (Default: 0.2)

The Phase Detect Delay parameter sets the delay time on Fault #27: "Phase Loss." This fault detects a loss of proper phase timing even when the phasing remains valid; example: loss of line when the motor back generates a voltage. This allows a much faster detection than low line or no current at run faults.

Over Frequency Trip Level PFN 14

PFN: Over Frq Lvl

14 72 Hz

24 – 72 Hz (Default: 72)

The Over Frequency Trip Level parameter sets the highest line frequency that the starter will operate on.

When operating on line power, the default setting will usually suffice. If the application is speed sensitive, or the line power is suspect, the Over Frequency Trip Level parameter can be set to the highest acceptable frequency. When operating on generator power, the Over Frequency Trip Level parameter should be set to the highest acceptable frequency. This will ensure that a generator problem will not cause unnecessarily large fluctuations in the speed of the motor.

The frequency must be above the over frequency trip level setting for the Frequency Trip Time (PFN 16) parameter before the starter will recognize a high frequency condition. Once a high frequency condition exists, the starter will shut down and display a Fault #13, "High Freq Trip."

Under Frequency Trip Level (PFN 15) on page 82.

Frequency Trip Time (PFN 16) on page 83.

Under Frequency Trip Level PFN 15

PFN: Undr Frq Lvl

15 23 Hz

23 – 71 Hz (Default: 23)

The Under Frequency Trip Level parameter sets the lowest line frequency that the starter will operate on.

When operating on line power, the default setting will usually suffice. If the application is speed sensitive, or the line power is suspect, the Under Frequency parameter can be set to the lowest acceptable frequency.

When operating on generator power, the Under Frequency parameter should be set to the lowest acceptable frequency. This will ensure that a generator problem will not cause unnecessarily large fluctuations in the speed of the motor.

The frequency must be below the under frequency setting for the Frequency Trip Time (PFN 16) parameter before the starter will recognize an under frequency condition. Once an under frequency condition exists, the starter will shut down and display a Fault #12, "Low Freq Trip."

Over Frequency Trip Level (PFN 14) on page 82.

Frequency Trip Time (PFN 16) on page 83.

82

Range

Description

See Also

LCD Display

Range

Description

See Also

LCD Display

Range

Description

See Also

LCD Display

Range

Description

See Also

LCD Display


Frequency Trip Time PFN 16

PFN: Frq Trip Tim

16 0. 1 sec

0.1 – 90.0 seconds (Default: 0.1)

The Frequency Trip Time parameter sets the time that the line frequency must go above the Over Frequency

Trip Level (PFN 14) or below the Under Frequency Trip Level (PFN 15) parameter before a high or low frequency fault will occur.

Over Frequency Level (PFN 14) on page 82.

Under Frequency Level (PFN 15) on page 82.

PF Lead Trip Level PFN 17

PFN: PF Lead Lvl

17 Off

Off, - 0.80 lag to +0.01 lead (Default: Off)

The amount of power factor lead before the specified PF Trip Time (PFN 19) fault will occur.

Power Factor Lag Trip Level (PFN 18) on page 83.

Power Factor Trip Time (PFN 19) on page 83.

PF Lag Trip Level PFN 18

PFN: PF Lag Lvl

18 Off

Off, - 0.01 lag to +0.80 lead (Default: Off)

The amount of power factor lag before the specified PF Trip Time (PFN 19) fault will occur.

Power Factor Lead Trip Level (PFN 17) on page 83.

Power Factor Trip Time (PFN 19) on page 83.

PF Trip Time PFN 19

PFN: PF Trip Time

19 10.0 sec

0.1 – 90.0 seconds (Default: 10.0)

The amount of time that the power factor lead level (PFN 17) or lag level (PFN 18) conditions must exist beyond the window (PFN 19) before a trip will occur.

Power Factor Lead Trip Level (PFN 17) on page 83.

Power Factor Lag Trip Level (PFN 18) on page 83.

83


LCD Display

Range

Description

LCD Display

Range

Description

LCD Display

Range

Description

LCD Display

Range

Description

Backspin Timer PFN 20

PFN: Backspin Tim

20 Off

Off, 1 – 180 minutes (Default: Off)

The Backspin Timer parameter sets the minimum time between a stop and the next allowed start. If the starter is stopped and a time has been set, the starter will display a backspin lockout and the time until the next allowed start in the bottom right of the display.

Time Between Starts PFN 21

PFN: Time Btw St

21 Off

Off, 1 – 180 minutes (Default: Off)

The Time Between Starts parameter sets the minimum allowed time between starts. Once a start command has been given, the next start cannot be performed until this time has expired. If the starter is stopped and the time between starts has yet to expire, the starter will display a time btw starts lockout and the time until the next start is allowed in the bottom left of the display.

z NOTE: The TBS timer is not activated by a PORT restart.

Starts per Hour PFN 22

PFN: Starts/Hour

22 Off

Off, 1 – 6 (Default: Off)

The Starts per Hour parameter will set the number of allowed starts in one hour. If the starter has been stopped and the number of starts given in the last hour has exceeded this setting, the starter will display a starts per hour lockout and the time until the next start is allowed in the bottom right of the display.

z NOTE: The Starts/Hour counter does not increment on a PORT restart.

Auto Fault Reset Time PFN 23

PFN: Auto Reset

23 Off

Off, 1 – 900 seconds (Default: Off)

The Auto Reset parameter sets the time delay before the starter will automatically reset a fault. For the list of faults that may be auto reset, refer to Appendix B - Fault Codes on page 183.

z NOTE: A start command needs to be initiated once the timer resets the fault.

z NOTE: If the Auto Reset feature is used, CAUTION must be exercised to assure that any restart occurs in a safe manner.

84

See Also

LCD Display

Range

Description

See Also

LCD Display

Range

Description

See Also

LCD Display

Range

Description


Appendix C - Fault Codes on page 183.

Auto Fault Reset Count Limit parameter (PFN 24) on page 85.

Auto Fault Reset Count Limit PFN 24

PFN: Auto Rst Lim

24 Off

Off, 1 – 10 (Default: Off)

The Auto Reset Limit parameter sets the number of times that an auto fault reset may be performed. Once the number of auto reset counts have been exceeded, the starter will lockout until a manual fault reset is performed.

If less than the maximum number of auto resets occur and the starter does not fault for 15 minutes after the last auto fault reset occurred, the counter will be set back to zero. The auto reset counter is also set back to zero when a manual fault reset occurs.


Auto Reset Limit parameter (PFN 23) on page 84.

Controlled Fault Stop Enable PFN 25

PFN: Ctrl Flt En

25 On

Off / On (Default: On)

A Controlled Fault Stop Enable can occur if this parameter is "On". The controlled stop will occur before the starter trips. During a controlled fault stop, the action selected by the Stop Mode ( ) parameter is performed before the starter is tripped. This prevents the occurrence of water hammer etc. in sensitive systems when a less than fatal fault occurs.

z NOTE: All relays except the UTS relay are held in their present state until the stop mode action has been completed.

z NOTE: Only certain faults can initiate a controlled fault stop. Some faults are considered too critical and cause the starter to stop immediately regardless of the Controlled Fault Stop Enable parameter.

Refer to Appendix C - Fault Codes to determine if a fault may perform a controlled stop.



Speed Switch Trip Time PFN 26

PFN: Speed Sw Tim

26 Off


When using the zero speed stall protection, the starter will start monitoring the zero speed input as soon as a run command is given and will recognize a stalled motor if the zero speed time has elapsed before the zero speed signal is removed. The zero speed input requires a high or low signal to indicate the zero speed condition.

Fault Code #04 - Speed Switch Timer will be displayed when a stalled motor condition is detected.

85


See Also

LCD Display

Range

Description

LCD Display

Range

Description

See Also

Digital Inputs (I/O 01 - 08) on page 90.

Motor PTC Trip Time PFN 27

PFN: M PTC Time

27 Off


The soft starter has the capability to monitor a PTC (Positive Temperature Coefficient) thermistor signal from the motor. The thermistors will provide a second level of thermal protection for the motor. There is no PTC input required when set to "Off".

z NOTE: A motor PTC Fault #F05 occurs if resistance exceeds 3.5K ohm (+/- 300 ohms). The starter is locked out until the resistance drops below 1.65K ohm (+/- 150 ohms).

z NOTE: Open terminals will give an F05 fault immediately if this parameter is not set to "Off".

The input is designed for DIN44081 and DIN44082 standard thermistors.

Independent Starting/Running Overload PFN 28

PFN: Indep S/R OL

28 Off

Off / On (Default: Off)

If “Off”

When this parameter is “Off” the overload defined by the Motor Running Overload Class parameter (QST 03) is active in all states.

If “On”

When this parameter is “On”, the starting and running overloads are separate with each having their own settings. The starting overload class is used during motor acceleration and acceleration kick. The running overload class is used during all other modes of operation.

If both the running overload and the starting overload classes are set to "Off", then the existing accumulated motor OL% is erased and no motor overload is calculated in any state.

If the starting overload class is set to "Off" and the running overload class is set to "On", then the I

2 t motor overload does NOT accumulate during acceleration kick and acceleration ramping states. However, the existing accumulated OL% remains during starting and the hot/cold motor compensation is still active. The

OL% is capped at 99% during starting.

Although there is really no reason to do so, the starting overload class could be set to "On" and the running overload class set to "Off".

Motor Starting Overload Class parameter (PFN 29) on page 87.

Motor Running Overload Class parameter (PFN 30) on page 87.

Motor Overload Hot/Cold Ratio parameter (PFN 31) on page 88.

Motor Overload Cooling Time parameter (PFN 32) on page 88.

Theory of Operation section 7.1.9, Separate Starting and Running Motor Overload Settings on page 119.

86

LCD Display

Range

Description

See Also

LCD Display:

Range

Description

See Also


Motor Starting Overload Class PFN 29

PFN: Starting OL

29 10

Off, 1 – 40 (Default: 10)

The Motor Starting Overload Class parameter sets the class of the electronic overload when starting. The starter stores the thermal overload value as a percentage value between 0 and 100%, with 0% representing a

“cold” overload and 100% representing a tripped overload.

The starting overload class is active during Kicking and Ramping when the Independent Starting/Running

Overload parameter is set to “On”.

When the Motor Starting Overload Class parameter is set to "Off", the electronic overload is disabled while starting the motor.

z NOTE: Care must be taken not to damage the motor when turning the starting overload class off or setting to a high value.

z NOTE: Consult motor manufacturer data to determine the correct motor OL settings.

Independent Starting/Running Overload parameter (PFN 28) on page 86.




Relay Output Configuration parameters (I/O 10-15) on page 91.


Motor Running Overload Class PFN 30

PFN: Running OL

30 10

Off, 1– 40 (Default: 10)

The Motor Running Overload Class parameter sets the class for starting and running if the parameter is set to

"Off". If separate starting versus running overload classes are desired, set the parameter to "On".

The Motor Running Overload Class parameter sets the class of the electronic overload when up to speed and stopping. The starter stores the thermal overload value as a percentage value between 0 and 100%, with 0% representing a “cold” overload and 100% representing a tripped overload. See section 7.1, for the overload trip time versus current curves.

When the parameter is set to "Off", the electronic overload is disabled when up to speed and a separate motor overload protection device must be supplied.

z NOTE: Care must be taken not to damage the motor when turning the running overload class off or setting a high value.

z NOTE: Consult motor manufacturer data to determine the correct motor overload settings.





Relay Output Configuration parameter (I/O 10-15) on page 91.


87


LCD Display

Range

Description

See Also

LCD Display

Range

Description

Motor Overload Hot/Cold Ratio PFN 31

PFN: OL H/C Ratio

31 60 %

0 – 99 % (Default: 60)

The Motor Overload Hot/Cold Ratio parameter defines the steady state overload content (OL ss

) that is reached when the motor is running with a current less than full load current (FLA) * Service Factor (SF). This provides for accurate motor overload protection during a “warm” start.

The steady state overload content is calculated by the following formula.

OL ss

=

OL H/C Ratio

´

Current

´

FLA

1

Current Imbalance Derate Factor

The rise or fall time for the overload to reach this steady state is defined by the Motor Overload Cooling Time

(PFN 32) parameter.

The default value of 60% for Motor Overload Hot/Cold Ratio parameter is typical for most motors. A more accurate value can be derived from the hot and cold locked rotor times that are available from most motor manufacturers using the following formula.

OL H/C Ratio

=

ç

è

1

Max Hot Lo

Max cked

Cold Locked

Rotor

Rotor

Time

Time

ø

÷

ö x 100%

z NOTE: Consult motor manufacturer data to determine the correct motor overload settings.






Theory of Operation section 7.1.6, Hot/Cold Motor Overload Compensation on page 116.

Motor Overload Cooling Time PFN 32

PFN: OL Cool Tim

32 30.0 min

1.0 – 999.9 minutes (Default: 30.0)

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.

Refer to the following equation:

OL Content

=

OL Content wh en Stopped *

5

e

CoolingTim e t

So, a motor with a set cooling time of 30 minutes (1800 sec) with 100% accumulated OL content cools to

<1% OL content in 30 minutes.

z NOTE: Consult motor manufacturer data to determine the correct motor cooling time.

88

See Also

LCD Display

Range

Description

See Also

LCD Display

Range

Description

See Also

LCD Display

Range

Description






Theory of Operation section 7.1.10, Motor Cooling While Stopped on page 120.

Theory of Operation section 7.1.11, Motor Cooling While Running on page 121.

Motor OL Alarm Level PFN 33

PFN: OL Alarm Lvl

33 90 %

1 – 100 % (Default: 90)

An overload alarm condition is declared when the accumulated motor overload content reaches the programmed OL Alarm Level. An output relay can be programmed to change state when a motor overload alarm condition is present to warn of an impending motor overload fault.



Motor OL Lockout Level PFN 34

PFN: OL Lock Lvl

34 15 %

1 – 99 % (Default: 15)

After tripping on an overload, restarting is prevented and the starter is "locked out" until the accumulated motor overload content has cooled below the programmed Motor OL Lockout Level.


Motor OL Auto Lockout Level PFN 35

PFN: OL Lock Calc

35 Off

Off, Auto (Default: Off)

The MX

3 has the capability to automatically calculate a motor OL lockout release level. This level shall be calculated so that the OL lockout is cleared when there is enough OL content available to start the motor without tripping the OL. This prevents the motor from being started if the O/L will trip during the start.

The value shall be calculated based on OL content used for the past four (4) successful motor starts. A factor of 1.25 shall be applied as a safety margin.

Example:

The OL content used for the past 4 starts were 30%, 29%, 30%, 27%

Average OL content used is 29% (using integer math).

Multiply result by 1.25 -> 36%

The new calculated motor OL lockout release level will be 100% - 36% -> 64%

The starting OL% content shall be latched when a start command is given. A value for OL content used

89


See Also

during a start shall only be added to the list if the motor start fully completes the start (i.e. the starter reaches up to speed).

z NOTE: This feature should not be used on systems where the starting load varies greatly from start to start.

Motor OL Lockout Level (PFN 34) on page 89.

Theory of Operation 7.1, Solid State Motor Overload Protection on page 114.

Jump to Parameter I/O 00

LCD Display

Description

I/O: Jump Code

00 1


Digital Input Configuration I/O 01 - I/O 08

LCD Display

Range

Description

I/O: DI 1 Config

01 Stop

I/O: DI 4 Config

04 Off

I/O: DI 7 Config

07 Off

I/O: DI 2 Config

02 Off

I/O: DI 5 Config

05 Off

I/O: DI 8 Config

08 Off

I/O: DI 3 Config

03 Off

I/O: DI 6 Config

06 Off

LCD

Off

Stop

Fault High

Fault Low

Fault Reset

Disconnect

Inline Cnfrm

Bypass Cnfrm

E OL Reset

Local/Remote

Heat Disable

Heat Enable

Ramp Select

Slow Spd Fwd

Slow Spd Rev

Brake Disabl

Brake Enabl

Speed Sw NO

Speed Sw NC

Description

Off, Not Assigned, Input has no function. (Default DI02 -DI08)

Stop Command for 3-wire control. (Default DI 1)

Fault High, Fault when input is asserted, 120V applied. See (I/O 09) on page 91.

Fault Low, Fault when input is de-asserted, 0V applied. See (I/O 09) on page 91.

Reset when input asserted, 120V applied.

Disconnect switch monitor.

Inline contactor feedback.

Bypass/2M, bypass contactor feedback, 2M contactor feedback in full voltage or Wye-delta.

Emergency Motor Overload content reset. After an OL trip has occurred. Reset when input asserted, 120V applied.

Local/Remote control source, Selects whether the Local Source parameter or the Remote Source parameter is the control source.

Local Source is selected when input is de-asserted, 0V applied.

Remote Source selected when input asserted, 120V applied.

Heater disabled when input asserted, 120V applied.

Heater enabled when input asserted, 120V applied.

Ramp 2 is enabled when input asserted, 120V applied.

Operate starter in slow speed forward mode.

Operate starter in slow speed reverse mode.

Disable DC injection braking.

Enable DC injection braking.

Speed Switch Normally Open, 0V applied. See (PFN 26) on page 85.

Speed Switch Normally Closed, 120V applied. See (PFN 26) on page 85.

I/O 01-03 parameters configure which features are performed by the DI 01 to DI 03 terminals.

I/O 04-08 parameters configure which features are performed by the DI 04 to DI 08 terminals.

90

See Also

LCD Display

Range

Description:

See Also

LCD Display

Range



Remote Source parameter (QST 05) on page 60.

Bypass Feedback Time parameter (I/O 25) on page 96.

Heater Level parameter (FUN 08) on page 104.

Theory of Operation section 7.1.12, Emergency Motor Overload Reset on page 121.


Theory of Operation section 7.7, Wye-Delta Operation on page 140.

Theory of Operation section 7.9, Start/Stop Control with a Hand/Off/Auto Selector Switch on page 144.

Digital Fault Input Trip Time I/O 09

I/O: Din Trp Time

09 0.1 sec

0.1 – 90.0 Seconds (Default: 0.1 Sec)

The Digital Fault Input Trip Time parameter sets the length of time the digital input must be high or low before a trip occurs. This delay time only functions for fault high and fault low.

Digital Input Configuration parameter on page 90.

Relay Output Configuration I/O 10 - 15

I/O: R1 Config

10 Fault FS

I/O: R4 Config

13 Off

I/O: R2 Config

11 Off

I/O: R5 Config

14 Off

I/O: R3 Config

12 Off

I/O: R6 Config

15 Off

LCD

Off

Fault FS

Fault NFS

Running

UTS

Alarm

Ready

Locked Out

OverCurrent

UnderCurrent

OL Alarm

Shunt FS

Shunt NFS

Ground Fault

Energy Saver

Heating

Slow Spd

Slow Spd Fwd

Slow Spd Rev

Braking

Cool Fan Ctl

PORT

Tach Loss

Description

Off, Not Assigned. May be controlled over Modbus (Default: R - 2, 3, 4, 5, 6)

Faulted – Fail Safe operation. Energized when no faults present, de-energized when faulted. (Default: R1)

Faulted– Non Fail Safe operation. Energized when faulted.

Running, starter running, voltage applied to motor.

Up to Speed, motor up to speed or transition to for Wye/Delta Operation.

Alarm, any alarm condition present.

Ready, starter ready for start command.

Locked Out.

Over Current Alarm, over current condition detected.

Under Current Alarm, under current condition detected.

Overload Alarm.

Shunt Trip Relay – Fail Safe operation, energized when no shunt trip, fault present, de-energized on shunt trip fault.

Shunt Trip Relay – Non Fail Safe operation, de-energized when no shunt trip fault present, energized on shunt trip fault.

A Ground Fault trip has occurred.

Operating in Energy Saver Mode.

Motor Heating, starter applying heating pulses to motor.

Starter operating in slow speed mode.

Starter operating in slow speed forward mode.

Starter operating in slow speed reverse mode.

Starter is applying DC brake current to motor.

Heatsink fan control.

Energized when the starter is in the Power Outage Ride Through mode.

Energized when the starter has faulted on a Tachometer Loss of Signal Fault.

91


Description

See Also

LCD Display

Range

Description

See Also

LCD Display

Range

Description

Parameters I/O 10-12 configure which functions are performed by the R1 to R3 relays located on MX

3 card.

Parameters I/O 13-15 configure which functions are performed by the R4 to R6 relays located on I/O card.

Up To Speed Time parameter (QST 09) on page 62.

Over Current Level parameter (PFN 01) on page 76.

Under Current Level parameter (PFN 03) on page 77.

Residual Ground Fault Level parameter (PFN 07) on page 79.

Inline Configuration parameter (I/O 24) on page 96.

Heater Level parameter (FUN 08) on page 104.

Energy Saver parameter (FUN 09) on page 106.

Theory of Operation section 7.1 , Motor Overload Operation on page 114.


Theory of Operation section 7.8, Across The Line (Full Voltage Starter) on page 143.


Analog Input Trip Type I/O 16

I/O: Ain Trp Type

16 Off

LCD

Off

Low Level

High Level

Description

Off, Disabled. (Default)

Low, Fault if input signal below preset trip level.

High, Fault if input signal above preset trip level.

The analog input is the reference input for a starter configured as a Phase Controller or Current Follower. In addition, the Analog Input Trip parameter allows the user to set a "High" or "Low" comparator based on the analog input. If the type is set to "Low", then a fault occurs if the analog input level is below the trip level for longer than the trip delay time. If the type is set to "High", then a fault occurs if the analog input level is above the trip level for longer than the trip delay time. This function is only active when the motor is running.

This feature can be used in conjunction with using the analog input as a reference for a control mode in order to detect an open 4-20mA loop providing the reference. Set the Analog Input Trip Type parameter to"Low" and set the Analog Trip Level parameter to a value less than (<) 20%.

Analog Input Trip Level parameter (I/O 17) on page 92.

Analog Input Trip Time/Level parameter (I/O 18) on page 93.

Analog Input Span parameter (I/O 19) on page 93.

Analog Input Offset parameter (I/O 20) on page 94.

Starter Type parameter (FUN 07) on page 103.

Analog Input Trip Level I/O 17

I/O: Ain Trp Lvl

17 50 %

0 – 100 % (Default: 50)

The Analog Input Trip Level parameter sets the analog input trip or fault level.

This feature can be used to detect an open 4-20mA loop by setting the Analog Input Trip Type (I/O 16) parameter to "Low" and setting the Analog Input Trip Level (I/O 17) 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. Therefore, if the trip level is set to 10% and the Analog Input Trip Type parameter is set to "Low", a fault occurs when the analog input signal level is less than (<) 1V or 2mA regardless of what the

Analog Input and Analog Input Span parameters values are set to.

92

See Also

LCD Display

Range

Description

See Also

LCD Display

Range

Description

See Also


Analog Input Trip Type parameter (I/O 16) on page 92.



Analog Input Trip Delay Time I/O 18

I/O: Ain Trp Tim

18 0.1

sec

0.1 – 90.0 seconds (Default: 0.1)

The Analog Input Trip Time parameter sets the length of time the analog input trip level (I/O17) must be exceeded before a trip occurs.

Analog Input Trip Type parameter (I/O 16) on page 92.




Analog Input Span I/O 19

I/O: Ain Span

19 100 %

1 – 100 % (Default: 100)

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.

For a 0-5V input, a 50% Analog Input Span setting results in a 0% input reading with a 0V input and a 100% input reading with a 5V input.

For a 4-20mA input, a 80% Analog Input Span setting and a 20% Analog Input Offset setting results in a 0% input reading at 4mA and a 100% input reading at 20mA.

z NOTE: Input signal readings are clamped at a 100% maximum.

Example: 4ma = 0% input, 20ma = 100% input

Analog Input

Reading %

100%

0%

20% Ain

Offset

2V / 4mA

Ain Span = 80%

Input Signal

10V / 20mA


Analog Input Trip Time parameter (I/O 18) on page 93.

93


LCD Display

Range

Description

See Also

LCD Display

Range

Description

See Also



Analog Input Offset I/O 20

I/O: Ain Offset

20 0 %

0 – 99 % (Default: 0)

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.

z NOTE: For a 4-20mA input, set the Analog Input Span to 80 % and the Analog Input Offset to 20 %.

z NOTE: The measured input reading is clamped at 0 % minimum.


Analog Input Trip Time parameter (I/O 18) on page 93.



Analog Output Function I/O 21

I/O: Aout Fctn

21 Off

LCD

Off

0 – 200% Curr

0 – 800% Curr

0 – 150% Volt

0 – 150% OL

0 – 10 kW

0 – 100 kW

0 – 1 MW

0 – 10 MW

0 – 100% Ain

0 – 100% Firing

Calibration

Description

Off, Disabled (Default)

Based on per cycle RMS values



Motor Thermal Overload

Based on filtered V and I values




The output value takes into account the inputs span and offset settings

Output Voltage to Motor, based on SCR firing angle

Calibration, full (100%) output

The Analog Output Function parameter selects the function of the analog output. The available analog output function selections and output scaling are shown below. The analog output is updated every 25msec.

Analog Output Span parameter (I/O 22) on page 95.

Analog Output Offset parameter (I/O 23) on page 95.

94

See Also

LCD Display

Range

Description

See Also

LCD Display

Range

Description


Analog Output Span I/O 22

I/O: Aout Span

22 100 %

1 – 125 % (Default: 100)

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.

z NOTE: For a 4-20mA output, set the Analog Output Span to 80% and the Analog Output Offset to 20%.

z NOTE: The output does not exceed 100% (10V or 20mA).

Example: 0% output => 4mA, 100% output => 20ma

10V /

20mA

Analog

Output

2V / 4mA

0 V / 0mA

Selected Output value = 0%

Aout Span =

80%

Selected Output value = 100%

Aout Offset

= 20%

Analog Output Offset parameter (I/O 23) on page 95.

Analog Output Offset I/O 23

I/O: Aout Offset

23 0 %

0 – 99 % (Default: 0)

The analog output signal can be offset using the Analog Output Offset parameter. A 50% offset outputs a

50% output (5V in the 10V case) when 0% is commanded. If the selected variable requests 100% output, the span should be reduced to (100 minus offset) so that a 100% output request causes a 100% output voltage (x% offset + (100-x)%span)=100%.

z NOTE: For a 4-20mA output, set the Analog Output Span to 80% and the Analog Output Offset to 20%.

Analog Output Span parameter (I/O 22) on page 95.

95


LCD Display

Range

Description

See Also

LCD Display

Range

Description

See Also

LCD Display

Range

Description

Inline Configuration I/O 24

I/O: Inline Confg

24 3.0

sec

Off, 0 – 10.0 seconds (Default: 3.0)

The Inline Configuration parameter controls the behavior of the No Line warning, No Line fault, and the

Ready relay function.

If the Inline Configuration parameter is set to "Off", then the MX

3 assumes that there is no Inline contactor and that line voltage should be present while stopped. If no line is detected, then a No Line alarm condition exists and the ready condition does not exist. If a start is commanded, then a No Line fault is declared.

If the Inline Configuration parameter is set to a time delay, then the MX

3 assumes that there is an Inline contactor and that line voltage need not be present while stopped. If no line is detected, then the No Line alarm condition does not exist and the ready condition does exist. If a start is commanded and there is no detected line voltage for the time period defined by this parameter, then a “noL” (No Line) fault is declared.

In order to control an inline contactor, program a relay as a Run relay.

z NOTE: This fault is different than over/under voltage since it detects the presence of NO line.


Bypass Feedback Time I/O 25

I/O: Bpas Fbk Tim

25 2.0

sec

0.1 – 5.0 seconds (Default: 2.0)

The starter contains a built in dedicated bypass feedback input that is enabled when the dedicated stack relay is factory programmed to "bypass". The programmable inputs DI 1, DI 2, DI 3, DI4, DI5, DI6, DI7 or DI8 may also be used to monitor an auxiliary contact from the bypass contactor(s) or in the case of a wye-delta starter the 2M contactor. The digital input is expected to be in the same state as the UTS relay. If it is not, the

MX

3 trips on Fault 48 (Bypass Fault).

The Bypass Confirmation input must be different from the UTS relay for the time period specified by this parameter before a fault is declared. There is no alarm associated with this fault.

Digital Input Configuration parameters (I/O 01-08) on page 90.


Keypad Stop Disable I/O 26

I/O: Keypad Stop

26 Enabled

LCD

Disabled

Enabled

Description

Keypad Stop does not stop the starter

Keypad Stop does stop the starter (Default)

If “Disabled”

When this parameter is set to "Disabled", the keypad Stop button is de-activated. This should be done with caution, as the [STOP] will not stop the starter.

96

See Also

LCD Display

Range

Description

LCD Display

Description

LCD Display

Range

Description


If the keypad is selected as local or remote control sources, the [STOP] key cannot be disabled.

If “Enabled”

When this parameter is set to "Enabled", the keypad stop button is enabled and stops the starter regardless of the selected control source (keypad, terminal or serial).



Auto Start Selection I/O 27

I/O: Auto Start

27 Disabled

LCD

Disabled

Power

Fault

Power, Fault

Description

When Disabled, the Start input must always transition from low to high for a start to occur. (Default)

When set to Power, a start will occur if the Start input is high while control power is applied.

When set to Fault, a start will occur if the Start input is high when a fault is reset.

When set to Power and Fault, a start will occur if the Start input is high while control power is applied, and a start will occur if the Start input is high when a fault is reset.

The Auto Start Selection parameter determines whether or not a transition from low to high is required on the

Start input for a start to occur after either a power up or a fault reset. This applies to lockout conditions being cleared as well. The behavior for a lockout clearing is the same as for a fault being reset.

Jump to Parameter RTD 00

RTD: Jump Code

00 1


RTD Module #1 Address RTD 01

RTD: RTDMod1 Addr

01 Off

Off, 16 to 23 (Default Off)

The module #1 address parameter has to be set to the Modbus address of the first RTD module attached to the soft-starter. The address of the RTD module can be verified by checking the rotary switch on the top of the

RTD module.

97


LCD Display

Range

Description

LCD Display

Range

Description

LCD Display

Range

Description

LCD Display

Range

RTD Module #2 Address RTD 02

RTD: RTDMod2 Addr

02 Off

Off, 16 to 23 (Default Off)

The module #2 address parameter has to be set to the Modbus address of the second RTD module attached to the soft-starter. The address of the RTD module can be verified by checking the rotary switch on the top of the RTD module. Ensure that module #2 is not set to the same address as module #1.

RTD Group RTD 03 - RTD 18

RTD: RTD 1 Group

03 Off

RTD: RTD ? Group

??

Off

LCD

Off

Stator

Bearing

Other

(? = RTD number)

(?? = menu index number)

Description

RTD channel not read.

RTD included in Stator metering group.

RTD included in Bearing metering group.

RTD acts independently.

Each of the 16 available RTD input channels has a parameter to assign that RTD channel to a grouping.

z NOTE: RTD 1 – 8 is on module 1.

RTD 9 – 16 is on module 2.

Stator Alarm Level RTD 19

RTD: Stator Alrm

19 200 C

1 – 200 o

C (Default 200

o

C)

The Stator Alarm Level parameter selects its Alarm temperature level. When an RTD in this group reaches

Alarm level an alarm condition will be declared. This parameter sets the alarm level for any RTD set to

"Stator".

z NOTE: Consult motor manufacturer.

Bearing Alarm Level RTD 20

RTD: Bearing Alrm

20 200 C

1 – 200 o

C (Default 200

o

C)

98

Description

LCD Display

Range

Description

LCD Display

Range

Description

LCD Display

Range

Description

LCD Display

Range

Description


The Bearing Alarm Level parameter selects its Alarm temperature level. When an RTD in this group reaches


"Bearing".

z NOTE: Consult Motor Manufacturer.

Other Alarm Level RTD 21

RTD: Other Alrm

21 200 C

1 – 200 o

C (Default 200

o

C)

The Other Alarm Level parameter selects its Alarm temperature level. When an RTD in this group reaches


"Other".


Stator Trip Level RTD 22

RTD: Stator Trip

22 200 C

1 – 200 o

C (Default 200

o

C)

This parameter sets the stator trip temperature when a trip will occur. Fault delay time is 1 second.

Bearing Trip Level RTD 23

RTD: Bearing Trip

23 200 C

1 – 200 o

C (Default 200

o

C)

This parameter sets the bearing trip temperature when a trip will occur. Fault delay time is 1 second.


Other Trip Level RTD 24

RTD: Other Trip

24 200 C

1 – 200

°C (Default 200

o

C)

This parameter sets the other trip temperature when a trip will occur. Fault delay time is 1 second.

99


LCD Display

Range

Description

LCD Display

Range

Description

See Also

LCD Display

Range

RTD Voting RTD 25

RTD: RTD Voting

25 Disabled

Disabled, Enabled (Default: Disabled)

RTD Trip voting can be enabled for extra reliability in the event of a RTD malfunction. When RTD voting is enabled, two (2) RTDs in one assigned group will need to exceed their trip temperature before a fault is declared.

z NOTE: If there is only one RTD assigned to a group the RTD voting will be disabled.

RTD Motor OL Biasing RTD 26

RTD: RTD Biasing

26 Off

Off, On (Default: Off)

When RTDs are present, active, and assigned to the stator group and when RTD biasing is enabled the stator

RTD measurements will effect the motor OL content. RTD biasing works together with the I

2 t thermal model of the motor. In the RTD biasing case a three point approximation of motor overload capacity based on the highest measured stator RTD temperature is used. If the RTD motor overload capacity calculation exceeds the I

2 t based calculation then the RTD biasing value will be used. If the I

2 t value is higher then the I

2 t value will be used.

RTD Bias Curve

RTD BiasMax

60

50

40

30

20

10

0

100

90

80

70

50

RTD BiasMid

RTD BiasMin

0 50 100 150

Maximum RTD Temperature (C)

200 250

Hot/Cold Ratio

Setpoints

RTD27 = Bias Minimum Level Setpoint

RTD28 = Bias Midpoint Level Setpoint

RTD29 = Bias Maximum Level Setpoint

RTD Biasing OL group in section 7.1.7, on page 118.

RTD Bias Minimum Level

RTD: RTD Bias Min

27 40 C

0 – 198 o

C (Default: 40

o

C)

RTD 27

100

Description

See Also

LCD Display

Range

Description

See Also

LCD Display

Range

Description

See Also

LCD Display

Description

LCD Display

Range


Typically set to ambient conditions (40

°C)

RTD Biasing OL group in section 7.1.7 on page 118.

RTD Bias Midpoint Level

RTD: RTD Bias Mid

28 130 C

1 – 199

°C (Default: 130

o

C)

Typically set at the rated motor running temperature.

z NOTE: Consult motor manufacturer for information.


RTD Bias Maximum Level

RTD 28

RTD 29

RTD: RTD Bias Max

29 155 C

105 – 200

° C (Default: 155

o

C)

The stator insulation maximum temperature rating.

z NOTE: Consult motor manufacturer for information.


Jump to Parameter FUN 00

FUN: Jump Code

00 1


Meter FUN 01, 02

FUN: Meter 1

01 Ave Current

LCD

Status

Ave Current

L1 Current

L2 Current

L3 Current

Curr Imbal

Ground Fault

Ave Volts

L1-L2 Volts

FUN:

02

Meter 2

Ave Volts

Description

Running State.

Average current. (Default: Meter 1)

Current in phase 1.

Current in phase 2.

Current in phase 3.

Current Imbalance %.

Residual Ground Fault % FLA.

Average Voltage L-L RMS. (Default: Meter 2)

Voltage in, L1 to L2 RMS.

101


Description

LCD Display

Range

Description

LCD Display

Range

Description

L2-L3 Volts

L3-L1 Volts

Overload

Power Factor

Watts

VA vars kW hours

MW hours

Phase Order

Line Freq

Analog In

Analog Out

Run Days

Run Hours

Starts

TruTorque %

Power %

Pk accel Curr

Last Start T

Zero Seq GF

Stator Temp

Bearing Temp

Other Temp

All Temp



Thermal overload in %.

Motor power factor.

Motor real power consumed.

Motor apparent power consumed.

Motor reactive power consumed.

Kilo-watt-hour used by the motor, wraps at 1,000.

Mega-watt-hour used by the motor, wraps at 10,000.

Phase Rotation.

Line Frequency.

Analog Input %.

Analog Output %.

Running time in days, wraps at 2,730 days.

Running time in Hours and Minutes, wraps at 24:00.

Number of Starts, wraps at 65,536.

TruTorque %.

Power %.

Peak starting current.

Last starting duration.

Zero sequence ground fault.

Highest Stator temperature.

Highest Bearing temperature.

Highest Other temperature.

Highest of all temperatures.

Parameters FUN 01 and FUN 02 configure which meters are displayed on the two lines of the main display screen.

CT Ratio FUN 03

FUN: CT Ratio

03 50:5

72:1, 96:1, 144:1, 288:1, 864:1, 2640:1, 3900:1, 5760:1, 8000:1, 14400:1, 28800:1, 50:5, 150:5, 250:5, 800:5,

2000:5, 5000:5 (Default: 288:1)

The CT Ratio parameter must be set to match the CTs (current transformers) supplied with the starter. This allows the starter to properly calculate the current supplied to the motor.

z NOTE: It is very important that the CT ratio is set correctly. Otherwise, many starter functions will not operate correctly.

Input Phase Sensitivity FUN 04

FUN: Phase Order

04 Insensitive

LCD

Insensitive

ABC

CBA

Single phase

Description

Runs with any three phase sequence. (Default)

Only runs with ABC phase sequence.

Only runs with CBA phase sequence.

Single Phase.

The Phase Order parameter sets the phase sensitivity of the starter. This can be used to protect the motor from a possible change in the incoming phase sequence. If the incoming phase sequence does not match the set phase rotation, the starter displays an alarm while stopped and faults if a start is attempted.

102

LCD Display

Range

Description

See Also

LCD Display

Range

Description

See Also

LCD Display

Range


Rated RMS Voltage FUN 05

FUN: Rated Volts

05 2200 Vlt

100, 110, 120, 200, 208, 220, 230, 240, 350, 380, 400, 415, 440, 460, 480, 500, 525, 575, 600, 660, 690, 800,

1000, 1140, 2200, 2300, 2400, 3300, 4160, 4600, 4800, 6000, 6600, 6900, 10.00K, 11.00K, 11.50K, 12.00K,

12.47K, 13.20K, 13.80K (Default: 480)

The Rated Voltage parameter sets the line voltage that is used when the starter performs Over and Under line voltage calculations. This value is the supply voltage, NOT the motor utilization voltage.

z NOTE: Settings above 1140V are for medium voltage applications.

z NOTE: Rated Voltage must be set properly for the starter to operate properly.




Meter parameter (FUN 01, FUN 02) on page 101.

Motor Rated Power Factor FUN 06

FUN: Motor PF

06 –0.92

-0.01 lag to 1.00 unity (Default: –0.92)

The Motor Rated Power Factor parameter sets the motor power factor value that is used by the MX

3 starter for

TruTorque and Power control calculations and metering calculations.

If TruTorque or Power acceleration and/or deceleration control is used, it is very important to properly set this parameter to the motor's full load rated power factor (usually available on the motor nameplate or from the motor manufacturer). For a typical induction motor, this value is between 0.80 and 0.95.

If the motor rated power factor is not available from either the motor nameplate or the motor manufacturer, the value can be obtained by viewing the power factor meter.

With the motor running at full name plate current, view the power factor meter by pressing the [UP] arrow key until the Motor PF meter is displayed using the LCD display.

The meter value can be entered into the Rated Power Factor parameter.

Meter parameters (FUN 01, FUN 02) on page 101.

Theory of Operation section 7.3.3, TruTorque Acceleration Control Settings and Times on page 124.

Theory of Operation section 7.3.4, Power Control Acceleration Settings and Times on page 126.

Starter Type FUN 07

FUN: Starter Type

07 Normal

LCD

Normal

Inside Delta

Wye-Delta

Phase Ctl

Description

Normal Reduced Voltage Soft Starter RVSS. (Default)

Inside Delta, RVSS. - Consult Factory

Wye Delta.

Open Loop Phase control using external analog input reference. - Consult Factory

103


Description

See Also

LCD Display

Range

Description

Curr Follow

ATL

Closed Loop Current follower using external analog input reference. - Consult Factory

Across the line (Full Voltage).

The MX

3 has been designed to be the controller for many control applications; Solid State Starter, both

Normal (outside Delta) and Inside Delta, and electro mechanical starters, Wye Delta, Across the line full voltage starter, Phase Control/Voltage Follower, Current Follower. In each case, the MX

3 is providing the motor protection and the necessary control for these applications.

Input Phase Sensitivity parameter (FUN 04) on page 102.


Heater Level FUN 08

FUN: Heater Level

08 Off

Off, 1 – 40% FLA (Default: Off)

The Heater Level parameter sets the level of D.C. current that reaches the motor when the motor winding heater/anti-windmilling brake is enabled. The motor winding heater/anti-windmilling brake can be used to heat a motor in order to prevent internal condensation or it can be used to prevent a motor from rotating.

z NOTE: The motor can still slowly creep when the anti-windmilling brake is being used. If the motor has to be held without rotating, a mechanical means of holding the motor must be used.

The motor winding heater/anti-windmilling brake operation may be controlled by a digital input and by a heater disable bit in the starter control Modbus register. There are two methods of using the digital inputs, either the input is an enable or disable.

Enabled: When the DI 1, 2, 3, 4, 5, 6, 7, 8 inputs are programmed as Heat Enable Inputs, the input may be used to control when heating/anti-windmilling is applied. The Heater Level parameter must be set, the starter stopped and this input must be high for heating to occur.

Disabled: When the DI 1,2, 3, 4, 5, 6, 7, 8 inputs are programmed as Heat Disable Inputs, the input may be used to control when heating/anti-windmilling is applied. The Heater / Anti-Windmill Level parameter must be set and this input must be low for heating to occur.

If no digital inputs are programmed as heater enabled or disabled and HEATER LEVEL is programmed greater than 0, the heater is applied at all times when the motor is stopped.

The level of D.C. current applied to the motor during this operation needs to be monitored to ensure that the motor is not overheated. The current level should be set as low as possible and then slowly increased over a long period of time. While this is being done, the temperature of the motor should be monitored to ensure it is not overheating.

The motor should be labeled as being live even when not rotating.

The heater feature should not be used to dry out a wet motor.

z NOTE: When this function is "On", all of the other parameters cannot be programmed until this parameter is turned "Off".

104

LCD Display

Range

Description

LCD Display

Range

Description

LCD Display

Range

Description


Energy Saver FUN 09

FUN: Energy Saver

09 Off

On – Off (Default: Off) *THIS FUNCTION IS NOT AVAILABLE FOR MEDIUM VOLTAGE*

The Energy Saver parameter lowers the voltage applied to a lightly loaded motor. It continues to lower the voltage until it finds the point where the current reaches its lowest stable level and then regulates the voltage around this point. If the load on the motor increases, the starter immediately returns the output of the starter to full voltage.

z NOTE: This function does not operate if a bypass contactor is used.

z NOTE: In general, Energy Saver can save approximately 1000 watts per 100 HP. Consult Benshaw for further detail.

P.O.R.T. Fault Time FUN 10

FUN: PORT Flt Time

10 Off

Off, 0.1 – 90.0 seconds (Default: Off)

The purpose of PORT is to not fault when all line power has been lost and to wait for a predetermined amount of time for power to return. There is the capability to hold the bypass contactor (if present) in for a given amount of time. Then when power returns, PORT shall perform a controlled restart of the motor to prevent current and/or torque spikes from occurring. The starter will enter PORT when the line voltage drops below the undervoltage trip level if enabled, or 30% below rated voltage when undervoltage protection is not enabled.

z NOTE: For PORT to operate it is assumed that an UPS (Uninterruptible Power Supply) will supply the

MX

3 control power. Also the MX

3 run command needs to be held active during the power outage otherwise the MX

3 will perform a normal stop.

P.O.R.T. Bypass Hold Time FUN 11

FUN: PORT Byp Tim

11 Off

Off, 0.1 – 5.0 seconds (Default: Off)

When a power outage event is detected and the PORT bypass hold timer is enabled, the starter will hold the

Bypass contactor in for a user selectable amount of time. When the time expires the starter shall open the bypass.

105


LCD Display

Range

Description

LCD Display

Range

Description

LCD Display

Range

Description

LCD Display

Range

P.O.R.T. Recovery Method FUN 12

FUN: PORT Recover

12 Fast Recover

LCD

Fast Recover

Current Ramp

Current Ramp 2

Ramp Select

Tach Ramp

Description

Current acceleration ramp from 100% FLA -> 800% FLA with a ramp time of 1 second. (Default)

Current acceleration ramp using the Ramp#1 user parameter settings.

Current acceleration ramp using the Ramp#2 user parameter settings.

Current acceleration ramp using the appropriate current ramp selected by the RAMP Select digital input.

Speed controlled acceleration ramp. Ramp starts at motor speed measured at start of recovery and accelerates motor at same slope

(acceleration rate) as a normal tachometer start from zero speed would do.

The PORT Recovery parameter sets how the starter will re-accelerate the motor when power returns.

Tachometer Full Speed Voltage FUN 13

FUN: Tach FS Lvl

13 5.00 Vlt

1.00 – 10.00 V in 0.01 volt increments (Default: 5.00V)

The Tachometer Full Speed Voltage parameter sets the tachometer input voltage at full speed. This value should be set at full (unloaded) motor speed.

Ex. A tachometer rated at 0.0033 volts-per-rpm is mounted on a 4-pole 1800 rpm motor. Therefore, the FS

Volts should be set to: 0.0033 * 1800 = 5.94 volts.

Tachometer Loss Time FUN 14

FUN: Tach Los Tim

14 1.5

sec

0.1 – 90.0 seconds (Default: 1.5)

The Tachometer Loss Time is the allowable time the starter will operate when a tachometer signal is lost. If the signal is lost, the starter will perform the action set by the Tach Loss Action parameter.

z NOTE: Nuisance tachometer loss faults at start can be prevented by setting the initial current parameter to a value that allows the motor to begin rotating soon after a start is commanded.

Tachometer Loss Action FUN 15

FUN: Tach Los Act

15 Fault

LCD

Fault

Current Acceleration

Description

The starter will shutdown and indicate a tachometer loss fault.

If the tachometer signal is lost the starter will fault. However the start mode parameter will be set to Current control acceleration so that when the fault is reset the starter will start in current control mode.

106

LCD Display

Range

Description

See Also

LCD Display

Range

Description

See Also

Description

LCD Display

Range

Description

See Also


TruTorque Accel

KW (Power)

If the tachometer signal is lost the starter will fault. However the start mode parameter will be set to TruTorque control acceleration so that when the fault is reset the starter will start in Current control mode.

If the tachometer signal is lost the starter will fault. However the start mode parameter will be set to KW (Power) so that when the fault is reset the starter will start in Current control mode.

If the tachometer detects the feedback signal is not valid one of the above actions will be taken depending on the value of the Tach Loss Action user parameter.

Communication Address FUN 16

FUN: Com Drop #

16 1

1 – 247 (Default: 1)

The Communication Address parameter sets the starter’s address for Modbus communications.





Communication Byte Framing parameter (FUN 19) on page 108.

Communication Baud Rate FUN 17

FUN: Com Baudrate

17 19200

1200, 2400, 4800, 9600, 19200 bps (Default: 19200)

The Communication Baud Rate parameter sets the baud rate for Modbus communications.





Communication Byte Framing parameter (FUN 19) on page 108.

Communication Timeout FUN 18

FUN: Com Timeout

18 Off


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.







107


LCD Display

Range

Description

See Also

LCD Display

Description

LCD Display

Description

LCD Display

Range

Communication Byte Framing FUN 19

FUN: Com Parity

19 Even, 1 Stop

Even, 1 Stop (Default)

Odd, 1 Stop

None, 1 Stop

None, 2 Stop

The Communication Byte Framing parameter sets both the parity and number of stop bits.




Software Version 1 FUN 20

FUN: Software 1

20 810023-02-01

This parameter shows the software version 1.

The software version is also displayed on power up.

Software Version 2 FUN 21

FUN: Software 2

21 810024-01-01

This parameter shows the software version 2.

The software version is also displayed on power up.

Miscellaneous Commands

FUN: Misc Command

22 None

LCD

None

Reset RT

Reset kWh

Reflash Mode

Store Parms

Load Parms

Factory Rst

Std BIST

Powered BIST

Description

No commands (Default)

Reset Run Time Meter

Reset kWh/MWh Meters

Activate Reflash Mode

The current parameter values are stored in non-volatile memory

All parameter are retrieved from non-volatile memory

All parameters are restored to the factory defaults

Built In Self Test with no line voltage applied to the starter.

Built In Self Test with line voltage applied to the starter.

z NOTE: Powered BIST not available on medium voltage starters.

FUN 22

108

Description

LCD Display

Range

Description

LCD Display

Description

See Also

LCD Display

Description

See Also


The Miscellaneous Commands parameter is used to issue various commands to the MX

3 starter.

The Reset Run Time command resets the user run time meters back to zero (0).

The Reset kWh command resets the accumulated kilowatt-hour and megawatt-hour meters back to zero (0).

The Reflash Mode command puts the MX

3 be entered if the MX

3 into a reflash program memory mode. The reflash mode can only starter is idle. When the reflash mode is entered, the MX

3 waits to be programmed.

The onboard LED display shows “FLSH”. The remote display is disabled after entering reflash mode. The

MX

3 does not operate normally until reflash mode is exited. Reflash mode may be exited by cycling control power.

The Store Parameters command allows the user to copy the parameters into non-volatile memory as a backup.

If changes are being made, store the old set of parameters before any changes are made. If the new settings do not work, the old parameter values can be loaded back into memory.

The Load Parameters command loads the stored parameters into active memory.

The Factory Reset command restores all parameters to the factory defaults. The default values can be found in chapter 5.

The standard BIST command will put the starter into the unpowered BIST test. See section 8.9 on page 171.

z NOTE: The powered BIST test is only offered in the Low Voltage systems.

Time and Date Format FUN 23

FUN: T/D Format

23 mm/dd/yy 12h

LCD

mm/dd/yy 12h mm/dd/yy 24h yy/mm/dd 12h yy/mm/dd 24h dd/mm/yy 12h dd/mm/yy 24h

Description

month/day/year 12 hour month/day/year 24 hour year/month/day 12 hour year/month/day 24 hour day/month/year 12 hour day/month/year 24 hour

Sets the date display format and 12 hour or 24 hour time display.

z NOTE: The system clock does not recognize daylight savings time.

Time

FUN: Time

24 present time

Sets the present time.

Time and Date parameter (FUN 23) on page 109.

Date

FUN: Date

25 present date

Sets the present date.

Time and Date parameter (FUN 23) on page 109.

FUN 24

FUN 25

109


LCD Display

Description

LCD Display

Range

Description

See Also

Range

Description

See Also

LCD Display

Passcode FUN 26

FUN: Passcode

26 Off

The MX

3 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.

Viewing the Passcode parameter indicates whether or not the parameters are locked. If they are locked, the

Passcode parameter displays "On". If they are not locked, the Passcode parameter displays "Off".

To lock the parameters, press the [ENTER] key while viewing the Passcode parameter. This allows entry of a

4-digit number. Press the [UP] or [DOWN] keys and [ENTER] for each of the four digits. After entering the fourth digit, the number is stored as the passcode and the parameters are locked.

Once parameters are locked, the same 4-digit number must be re-entered into the Passcode parameter in order to unlock them. Any other 4-digit number entered will be ignored.

z NOTE: To re-establish password protection after it has been cleared, the password must be entered again.

Fault Log FL1 - 9

FL1: Last Fault #

Fault Name

FL1 – FL9

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.

Pressing [ENTER] toggles through the Starter data recorded at the time of the fault. See section 4.4.5 for more information.


Event Recorder E01 - E99

E01 – E99

An event is anything that changes the present state of the starter. Some examples of events would be an operation fault, a Start command, or a Stop command. The event recorder stores the last 99 events. When an event occurs, the event number is logged in non-volatile memory. The most recent event is in E01 and the oldest event is in E99.

Appendix A – Event Codes on page 180.

Appendix C – Fault Codes on page 183.

The first screen displayed in the event recorder gives the starter state on the second line of the screen. See below;

E01: Event #??

Stop Complete

110

See Also


Pressing [ENTER] will now display the starter state at the time of the event on the bottom line of the screen.

See below;

E01: Event #??

Fault

Pressing [ENTER] for a 2nd time will display the time of the event on the bottom line of the screen. See below;

E01: Event #??

hh:mm:ss

Pressing [ENTER] for a 3rd time will display the date of the event on the bottom line of the screen. See below;

E01: Event #??

mm/dd/yy

Pressing [ENTER] again returns to the first display screen.

Appendix A - Event Codes on page 180.

111


NOTES:

112

7 Theory of Operation

113

7 - THEORY OF OPERATION

Motor Overload

7.1

7.1.1

Solid State Motor Overload Protection

Overview

The MX

3 contains an advanced I

2 t electronic motor overload (OL) protection function. For optimal motor protection, the MX

3 has forty standard NEMA style overload curves (in steps of one) available for use. Separate overload classes can be programmed for acceleration and for normal running operation and individually or completely disabled if necessary. The MX

3 motor overload function also implements a NEMA based current imbalance overload compensation, adjustable hot and cold motor compensation, and adjustable exponential motor cooling.

CAUTION: If the MVRMX

3 motor overload protection is disabled during any mode of operation, external motor overload protection must be provided to prevent motor damage and/or the risk of fire in the case of a motor overload.

7.1.2

Setting Up The MX

3

Motor Overload

Motor overload protection is easily configured through seven parameters (please refer to the descriptions of each parameter in section 6 of this manual for additional parameter information):

1.

Motor FLA (QST 01)

2.

Motor Service Factor (QST 02)

3.

Motor Running Overload Class (QST 03)

4.

Motor Starting Overload Class (PFN 29)

5.

Independent Starting/Running Overload (PFN 28)

6.

Motor Overload Hot/Cold Ratio (PFN 31)

7.

Motor Overload Cooling Time (PFN 32)

The Motor FLA and Service Factor parameter settings define the motor overload "pickup" point. For example, if the motor service factor is set to 1.00, the motor overload begins accumulating or incrementing when the measured motor current is >100% FLA (100% *

1.00). The overload will NOT trip if the motor current is <100%. If the motor service factor is set to 1.15, the overload starts accumulating content when the motor current >115% FLA (100% * 1.15). The overload will NOT trip if the measured motor current is

<115% of rated FLA.

The available overload classes are based on the trip time when operating at 600% of rated motor current. For example, a Class 10 overload trips in 10 seconds when the motor is operating at 600% rated current; a Class 20 overload trips in 20 seconds when the motor is operating at 600% rated current.

The equation for the MX

3 standard overload curves after the "pick-up" point has been reached is:

Time to Trip (seconds)

=

æ

ç

Measured

35 seconds * Class

Current *

Current Imbal

Motor FLA

1

Derate Factor

ö

÷

2

-

1

114


Figure 30: Commonly Used Overload Curves

10000

1000

100

10

1

100 150 200 250 300 350 400 450

Current % (FLA)

500 550 600 650 700 750 800

Class 40

Class 35

Class 30

Class 25

Class 20

Class 15

Class 10

Class 5

7.1.3

Visit the web at www.benshaw.com for an automated overload calculator.

Motor Overload Operation

Overload Heating

When the motor is operating in the overloaded condition (motor current greater than FLAxSF), the motor overload content accumulates based on the starter’s operating mode at a rate established by the overload protection class chosen. The accumulated overload content can be viewed on the display or over the communications network.

Overload Alarm

An overload alarm condition is declared when the accumulated motor overload content reaches the Motor OL Alarm Level (PFN 33).

An output relay can be programmed to change state when a motor overload alarm condition is present to warn of an impending motor overload fault.

Overload Trip

The MX

3 starter trips when the motor overload content reaches 100%, protecting the motor from damage. The starter first performs the defined deceleration or DC braking profile before stopping the motor if the controlled fault stop feature of the MX

3 is enabled. The motor overload trip time accuracy is ± 0.2 seconds or ± 3% of total trip time.

Overload Start Lockout

After tripping on an overload, restarting is prevented and the starter is “locked out” until the accumulated motor overload content has cooled below the Motor OL Lockout Level (PFN 34).

115


7.1.4

Current Imbalance / Negative Sequence Current Compensation

The MX

3 motor overload calculations automatically compensate for the additional motor heating which results from the presence of unbalanced phase currents. There can be significant negative sequence currents present in the motor when a current imbalance is present,. These negative sequence currents have a rotation opposite the motor rotation and are typically at two times the line frequency.

Due to the negative sequence currents opposite rotation and higher frequency, these currents can cause a significant increase in rotor heating.

The overload curves provided by a motor manufacturer are based on balanced motor operation. Therefore, if a current imbalance is present, the MX

3 motor overload compensates for the additional heating effect by accumulating overload content faster and tripping sooner to protect the motor. The current imbalance compensation also adjusts the Hot / Cold motor protection as described below in section 7.1.6 . The MX

3 derating factor is based on NEMA MG-1 14.35 specifications and is shown in Figure 31.

Figure 31: Overload Derating for Current Imbalance

MX Motor OL derating vs. current imbalance

1

0.95

0.9

0.85

0.8

0.75

0 5 10 15

Current imbalance %

20 25 30

7.1.5

7.1.6

Harmonic Compensation

The MX

3 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.

Hot / Cold Motor Overload Compensation

If a motor has been in operation for some time, it will have heated up to some point. Therefore, there is typically less overload content available in the case where a motor is restarted immediately after it has been running when compared to the situation where a motor has been allowed to cool down before restarting. The MX

3 provides adjustable hot motor overload compensation to fully protect the motor in these cases.

If the hot and cold maximum locked rotor times are provided, the MX

3

Hot/Cold Ratio parameter value can be calculated as follows:

OL H/C Ratio

=

ç

1

Max Hot Locked Rotor Time

Max Cold Locked Rotor Time x 100 %

116


If no motor information is available, a Hot/Cold ratio value of 60% is usually a good starting point.

The MX

3 adjusts the actual motor overload content based on the programmed Hot/Cold Ratio set point and the present running current of the motor so that the accumulated motor overload content accurately tracks the thermal condition of the motor. If the motor current is constant, the overload content eventually reaches a steady state value. This value is derived as follows:

OL

ss

=

OL H/C Ratio

´

Current

FLA

´

Current

1

Imbalance Derate Factor

The running OL content is also adjusted based on the derating factor due to the presence of any current imbalances and or harmonics.

If the existing motor overload content is less than the calculated running OL content, the motor overload exponentially increases the overload content until the appropriate running overload content level is achieved. If the existing motor overload content is greater than the calculated running OL content level, the overload exponentially cools down or decreases to the appropriate running overload content level. The rate of the running motor overload heating or cooling is controlled by the Motor Overload Cooling Time (PFN 32) parameter.

The following diagram illustrates how the current and the Motor Overload Hot/Cold Ratio (PFN 31) parameter determine the steady state overload content. It assumes there is no current imbalance.

Figure 32: Motor Overload H/C 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/C Ratio is set at 30%. It is assumed that the motor has been running for some time and the motor overload content has reached a steady state value of 30% (30% H/C Ratio x 100% FLA = 30%).

At time T1, the motor current drops to 50%FLA. The motor overload content exponentially cools to a new steady state value of 15%

(30% H/C Ratio x 50% FLA = 15%).

At time T2, the OL H/C Ratio is set to 80%. The motor overload content exponentially rises to a new steady state value of 40% (80%

H/C Ratio x 50% FLA = 40%).

At time T3 the motor current rises back up to 100%FLA. The motor overload content exponentially rises to a new steady state value of

80% (80% H/C Ratio x 100% FLA= 80%).

117


7.1.7

RTD Overload Biasing

The RTD biasing calculates a motor thermal value based on the highest stator RTD measurement. The motor thermal overload content is set to this calculated value, if this calculated value is higher than the motor thermal overload content. The RTD biasing is calculated as follows:

Max measured stator RTD temp < RTD Bias Min Level (RTD27)

BiasOL%

= 0

RTD Bias Min Level (RTD27) < Max measured stator RTD temp < RTD Bias Mid Point Level (RTD28)

BiasOL

%

=

RTD

max

-

MinBiasTemp

MidBiasTemp

-

MinBiasTemp

RTD Bias Mid Point Level (RTD28) < Max measured stator RTD temp < RTD Bias Max Level (RTD29)

BiasOL

%

=

é

RTD

max

-

MidBiasTemp

ëê

MaxBiasTemp

-

MidBiasTemp

´ ( . % -

_ )

ù

ûú

+

RTD Bias Max Level (RTD29) < Max measured stator RTD temp

_

BiasOL%

The RTD Biasing levels are generally set by using the motor data as follows:

RTD Bias Min Level (RTD27): This parameter is typically programmed to the ambient temperature rating of the motor.

RTD Bias Mid Level (RTD28): This parameter is typically programmed to the temperature rise rating of the motor.

RTD Bias Max Level (RTD29): This parameter is typically programmed to insulation rating of the motor.

Figure 33: RTD Bias Curve

RTD Bias Curve

RTD BiasMax

50

40

70

60

10

0

30

20

100

90

80

50

RTD BiasMid

RTD BiasMin

0 50 100 150

Maximum RTD Temperature (C)

200 250

Hot/Cold Ratio

118


7.1.8

7.1.9

Overload Auto Lockout

This feature prevents an overload trip during the motor start due to insufficient thermal capacity. It will automatically calculate the overload content required to start the motor. It will lockout the starter if there is not enough overload content available. The release value calculated is based on OL content used for the past four (4) successful motor starts. A factor of 1.25 is applied as a safety margin.

Example:

The OL content used for the past 4 starts were 30%, 29%, 30%, 27%.

step 1 (30+29+30+27) / 4 = 29% step 2 step 3

29% * 1.25 = 36%.

100% - 36% = 64% Therefore 64% is the calculated OL Lockout release level.

Separate Starting and Running Motor Overload Settings

If desired, separate overload classes can be programmed for use during starting and during running. The motor overload protection may also be disabled during starting or during normal running. In order to enable separate overload settings the Independent

Starting/Running Overload (PFN 28) parameter needs to be set to "On" to allow independent overload operation. Once set to "On", the individual Motor Starting Overload Class (PFN 29) and Motor Running Overload Class (PFN 30) parameters can be set to either "Off" or the desired overload class settings.

The Motor Starting Overload Class (PFN 29) parameter value is used for the motor overload calculations when the starter is starting the motor (kick mode, acceleration, and running before up-to-speed has been declared). Once the motor has reached full speed and during deceleration or braking, the Motor Running Overload Class (PFN 29) is used for the motor overload calculations. As the motor protection curves shift from the acceleration curve to the running curve, the accumulated overload content is retained to provide a seamless transition from one mode of operation to the other.

Disabling the Starting OL function or using a higher OL class for the Starting OL can be useful on extremely high inertial loads such as large centrifuges or high friction loads that require very long starting periods.

z NOTE: When the Independent Starting/Running Overload (PFN 28) parameter is set to "Off", the running OL is used at all times.

z NOTE: When one or the other overload is disabled, the Hot/Cold motor compensation is still active. Therefore the motor overload content may still slowly increase or decrease depending on the measured motor current. However if the motor overload is disabled in one of the operating modes, the motor overload content is limited in that mode to a maximum of 99%. Therefore, a motor overload trip can not occur.

CAUTION: When both overloads are disabled, the accumulated overload content is set to zero (0%) and the starter does not provide any motor overload protection. External motor overload protection must be provided to prevent motor damage and/or the risk of fire in the case of a motor overload.

119


7.1.10

Motor Cooling While Stopped

The Motor Overload Cooling Time (PFN 32) parameter is used to adjust the cooling rate of the motor overload. When the motor is stopped and cooling, the accumulated motor overload content is reduced in an exponential manner.

OL Content

=

OL Content wh en Stopped *

e

5

CoolingTim e t

When the motor is stopped, the motor overload cools as shown in the following Figure 34.

Figure 34: Motor Cooling While Stopped Curves

MX Motor OL Cooling, Motor Stopped

100

90

60

50

80

70

40

30

3 30min

20

10

12 min

20 min

15 min

0

0 200 400 600 800 1000

Time (sec)

1200 1400 1600 1800 2000

120


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

180

280

360

400/440

500

Larger frames

Cooling Time

30 min

60 min

90 min

120 min

180 min

Consult

Manufacturer

For motors less than 300hp, another approximation based on allowable motor starts per hour can also be used to set an initial value of the

Motor Overload Cooling Time (PFN 32) parameter:

Motor Cooling Time (minutes)

»

60

Starts minutes per hour

z NOTE: The Motor Overload Cooling Time (PFN 32) parameter is defined as the time that it takes for the motor to cool from 100% overload content to less than 1% overload content. Sometimes a motor manufacturer may provide a cooling time constant (t or tau) value. In these cases, the Motor Overload Cooling Time (PFN 32) parameter should be set to five (5) times the specified time constant value.

7.1.11

Motor Cooling While Running

When the motor is running, the Motor Overload Cooling Time (PFN 32) parameter and the Motor Overload Hot/Cold Ratio (PFN 31) parameter settings control the motor OL content. If the motor overload content is above the steady state OL running level (See section

7.1.6, Hot / Cold Motor Overload Compensation for more details) the motor OL exponentially cools to the appropriate steady state OL level. When the motor is running, the cooling time is adjusted based on the measured current level and current imbalance level at which the motor is operating.

Cooling Time Running

=

Cooling Time Stopped *

Measured Running

Motor FLA

Current

*

1

Current Imbalance Derate Factor

7.1.12

In all cases, the running motor cooling time is shorter (motor will cool faster) than when the motor is stopped. The faster cooling results because it is assumed that when a motor is running, cooling air is being applied to the motor.

Emergency Motor Overload Reset

The MX

3 has an emergency motor overload reset feature that allows the user to override the overload starter lockout. This resets the motor overload content to 0%. It does not reset the overload fault.

To perform an emergency overload reset, simultaneously press the [RESET] and [DOWN] buttons on the keypad. An emergency overload reset may also be performed by applying 120 Volts to a digital input that is configured as an emergency overload reset input or by setting the emergency overload reset bit in the starter control Modbus register.

CAUTION: This feature should only be used in an emergency. Before an emergency reset is performed the cause of the motor overload should be investigated to ensure that the motor is capable of restarting without causing undesired motor or load damage. When the emergency motor overload reset is used, the accumulated motor overload content is reset back to zero (0%). Therefore, the MX

3 motor protection functions may not be able to fully protect the motor from damage during a restart after performing an emergency motor overload reset.

121


7.2

Motor Service Factor

Motor Service Factor

General

The Motor Service Factor (QST 02) 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. Check with other local electrical codes for their requirements.

The National Electrical Code, article 430 Part C, allows for different overload multiplier factors depending on the motor and operating conditions. NEC section 430-32 outlines the allowable service factor for different motors as follows:

Motor Overload Multiplier

Service factor 1.15 or more

Motor temp. rise 40°C or less

All others

1.25

1.25

1.15

NEC section 430-34 permits further modifications if the service factor is not sufficient to start the motor:

Motor Overload Multiplier

Service factor 1.15 or more

Motor temp. rise 40°C or less

All others

1.40

1.40

1.30

Although the NEC does not address the effect of the ambient temperature of the motor location, guidance can be derived by examining NEC limits. If the motor is operating in an ambient temperature that is less than

40°C, then the overload multiplier can be increased while still protecting the motor from exceeding its maximum designed temperature. The following curve gives the ambient temperature versus the correction factor.

122

Example: If a motor operates at 0°C, then a 1.36 correction factor could be applied to the overload multiplier.

This could give a theoretical overload multiplier of 1.36 x 1.25 or 1.70. The highest legal NEC approved value of overload multiplier is 1.40, so this could be used.


Acceleration Control

7.3

7.3.1

General

Acceleration Control

Current Ramp Settings, Ramps and Times

The current ramp sets how the motor accelerates. The current ramp is a linear increase in current from the initial setting to the maximum setting. The ramp time sets the speed of this linear current increase. The following figure shows the relationships of these different ramp settings.

Figure 35: Current Ramp

Initial Current

Maximum Current

Current

Max

Current

Start command

Kick

Current

Initial

Current

Motor FLA

Time

Kick Time Ramp Time

Up To Speed Timer

The initial current should be set to the level that allows the motor to begin rotating within a couple of seconds of receiving a start command.

To adjust the initial current setting, give the starter a run command. Observe the motor to see how long it takes before it begins rotating and then stop the unit. For every second that the motor doesn't rotate, increase the initial current by 20%. Typical loads require an initial current in the range of 50% to 175%.

For most applications, the maximum current can be left at 600%. This ensures that enough current is applied to the motor to accelerate it to full speed.

The maximum current can also be set to a lower current limit. This is usually done to limit the voltage drop on the power system or to limit the torque the motor produces to help prevent damage to the driven load.

z NOTE: The motor may achieve full speed at any time during the current ramp. This means that the maximum current setting may not be reached. Therefore, the maximum current setting is the most current that could ever reach the motor, and not necessarily the maximum current that reaches the motor.

z NOTE: When setting a current limit, the motor must be monitored to ensure that the current is high enough to allow the motor to reach full speed under worst case load conditions.

123


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.

z NOTE: Setting the ramp time to a specific value does not necessarily mean that the motor will take this time to accelerate to full speed. The motor and load may achieve full speed before the ramp time expires if the application does not require the set ramp time and maximum current to reach full speed. Alternatively, the motor and load may take longer than the set ramp time to achieve full speed.

7.3.2

General

Programming A Kick Current

The kick current sets a constant current level that is applied to the motor before the ramp begins. The kick current is only useful on motor loads that are hard to get rotating but then are much easier to move once they are rotating. An example of a load that is hard to get rotating is a ball mill. The ball mill requires a high torque to get it to rotate the first quarter turn (90°). Once the ball mill is past 90° of rotation, the material inside begins tumbling and it is easier to turn.

Kick Level

The kick current parameter is usually set to a low value and then the kick time is adjusted to get the motor rotating. If the kick time is set to more than 2.0 seconds without the motor rotating, increase the kick current by 100% and re-adjust the kick time.

Kick Time

The kick time adjustment should begin at 0.5 seconds and be adjusted by 0.1 or 0.2 second intervals until the motor begins rotating. If the kick time is adjusted above 2.0 seconds without the motor rotating, start over with a higher kick current setting.

7.3.3

General

TruTorque Acceleration Control Settings and Times

TruTorque acceleration control is a closed loop torque based control. The primary purpose of TruTorque acceleration control is to smoothly start motors and to reduce the torque surge that can occur as an AC induction motor comes up to speed. This torque surge can be a problem in applications such as pumps and belt driven systems. In pumping applications, this torque surge can result in a pressure peak as the motor comes up to speed. In most situations this small pressure peak is not a problem. However in selected cases, even a small pressure rise can be highly undesirable. In belt driven applications, TruTorque can prevent the slipping of belts as the motor reaches full speed.

Figure 36: TruTorque Ramp

Motor

Torque

Max Torque

Motor Running

Torque

Start command

Optional Kick

Current

Initial Torque

Time

Kick Time Ramp Time

Up To Speed Timer

TruTorque acceleration control can be very useful for a variety of applications. However it is best used to start centrifugal pumps, fans, and other variable torque applications. TruTorque generally should not be used in applications where the starting load varies greatly during the start such as with a reciprocating compressor, where the starting load is very low, or where the starting load varies greatly from one start to another.

TruTorque control is not recommended for the starting of AC synchronous motors.

124

Initial Torque

Maximum Torque

Ramp Time


This parameter (CFN 08) sets the initial torque level that the motor produces at the beginning of the starting ramp profile. A typical value is 10% to 20%. If the motor starts too quickly or the initial motor torque is too high, reduce this parameter. If the motor does not start rotating within a few seconds after a start is commanded, increase this parameter. If the value is set too low a "No Current at Run" fault may occur.

This parameter (CFN 09)sets the final or maximum torque level that the motor produces at the end of the acceleration ramp time. For a loaded motor, the maximum torque value initially should be set to 100% or greater. If the maximum torque value is set too low, the motor may not produce enough torque to reach full speed and may stall. On lightly loaded motors, this parameter may be reduced below 100% to produce smoother starts.

If the motor can be started by using the default TruTorque acceleration parameter values or another ramp profile, the Maximum Torque level can be determined more precisely so that the motor comes up to speed in approximately the preset ramp time. In this case, while the motor is running fully loaded, display the

TruTorque percent (TT%) meter on the display. Record the value displayed. The Maximum Torque level should then be set to the recorded full load value of TT% plus an additional 10%. Restart the motor with this value to verify correct operation.

z NOTE: When setting the Maximum Torque value, the motor must be monitored to ensure that the torque level is high enough to allow the motor to reach full speed under worst-case load conditions.

z NOTE: Depending on loading, the motor many achieve full speed at any time during the TruTorque ramp.

This means that the Maximum Torque level many never be achieved. Therefore, the maximum torque level is the maximum TruTorque level that is permitted. However the motor torque may not necessarily reach this value during all starts.

When in TruTorque acceleration mode, the ramp time setting is the time it takes for the torque to go from the initial torque setting to the maximum torque setting. To make the motor accelerate faster, decrease the ramp time. To make the motor accelerate slower, increase the ramp time.

If the ramp time expires before the motor reaches full speed, the starter maintains the Maximum Torque level until either the motor reaches full speed, UTS timer expires, or the motor thermal overload protection trips.

z NOTE: Setting the ramp time to a specific value does not necessarily mean that the motor takes that exact amount of time to accelerate to full speed. The motor and load may achieve full speed before the ramp time expires if the load does not require the set ramp time or set torque level to reach full speed. Alternately, the motor and load may take longer than the set ramp time to achieve full speed depending on the parameter settings and load level.

125


7.3.4

General

Power Control Acceleration Settings and Times

Power control is a closed loop power based acceleration control. The primary purpose of Power controlled acceleration is to control and limit the power (kW) drawn from the power system and to reduce the power surge that may occur as an AC induction motor comes up to speed. This power surge can be a problem in applications that are operated on generators or other limited or "soft" power systems. Power control also reduces the torque surge that can also occur as an AC induction motor comes up to speed.

Figure 37: Power Ramp

Motor Input

Power

Max Power

Motor Running

Power Level

Start command

Optional Kick

Current

Initial Power

Initial Power

Maximum Power

Time

Kick Time Ramp Time

Up To Speed Timer

Power control acceleration can be very useful for a variety of applications. Power control generally should not be used in applications where the starting load varies greatly during the start such as with a reciprocating compressor. Power control is not recommended for starting of AC synchronous motors.

This parameter sets the initial power level that the motor draws at the beginning of the starting ramp profile.

A typical value is usually 10% to 30%. If the motor starts too quickly or the initial power level is too high, reduce this parameter. If the motor does not start rotating within a few seconds after a start is commanded, increase this parameter. If this value is set too low a "No Current at Run" fault may occur.

This parameter sets the final or maximum power level that the motor produces at the end of the acceleration ramp. For a loaded motor, the maximum power level initially should be set to 100% or greater. If the maximum power level value is set too low, the motor may not produce enough torque to reach full speed and may stall. On lightly loaded motors, this parameter may be reduced below 100% to produce smoother starts.

If the motor can be started by using the default Power acceleration parameter values or the Current control ramp, the Maximum Power level can be determined more precisely so that the motor comes up to speed in approximately the preset ramp time. In this case, while the motor is running fully loaded, display the Power percent (KW%) meter on the display. Record the value displayed. The Maximum Power level should then be set to the recorded full load value of KW% plus an additional 5% to 10%. Restart the motor with this value to verify correct operation.

z NOTE: When setting the Maximum Power level, the motor must be monitored to ensure that the starting power is high enough to allow the motor to reach full speed under worst case load conditions.

126


Ramp Time

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.

When in Power acceleration mode, the ramp time setting is the time it takes for the power to go from the initial power setting to the maximum power setting. To make the motor accelerate faster, decrease the ramp time. To make the motor accelerate slower, increase the ramp time.

If the ramp time expires before the motor reaches full speed, the starter maintains the Maximum Power level until either the motor reaches full speed, the UTS timer expires, or the motor thermal overload protection trips.

z NOTE: Setting the ramp time to a specific value does not necessarily mean that the motor takes that exact amount of time to accelerate to full speed. The motor and load may achieve full speed before the ramp time expires if the load does not require the set ramp time or set power level to reach full speed. Alternately, the motor and load may take longer than the set ramp time to achieve full speed depending on the parameter settings and load level.

7.3.5

General

Open Loop Voltage Ramps and Times

The open loop voltage ramp provides soft starting of a motor by increasing the voltage applied to motor from the Initial Voltage setting to full (100%) line voltage. The ramp time sets the speed at which the voltage is increased. Because this is an open loop control profile, the motor current during starting tends to be reduced; however, the current is not limited to any particular level. This starting mode (old), is not commonly used except in special circumstances. In most applications, the use of one of the other closed loop starting profiles is recommended.

Figure 38: Voltage Ramp

Voltage

Full Voltage

Start command

Optional Kick

Current

Initial Voltage

Time

Kick Time Ramp Time

Initial Voltage

Ramp Time

This parameter sets the initial voltage level that is applied to the motor. To adjust the starting voltage level, give the starter a run command and observe the motor operation. If the motor starts too quickly reduce the initial voltage level. If the motor does not start rotating immediately or starts too slowly then increase the initial voltage level until the motor just starts to rotate when a start command is given. If the initial voltage level is set too low, a Fault 39 - No Current at Run may occur. In this case increase the initial voltage level to permit more current to initially flow to the motor.

The ramp time setting is the time that it takes for the applied voltage to go from the initial voltage level to the full voltage (100%) level. To make the motor accelerate faster, decrease the ramp time. To make the motor accelerate slower, increase the ramp time.

127


UTS Timer

When the start mode is set to open-loop voltage ramp acceleration, the UTS Timer acts as an acceleration kick. When the UTS timer expires, full voltage is applied to the motor. This feature can be used to reduce motor surging that may occur near the end of an open loop voltage ramp start. If a surge occurs near the end of the ramp, set the UTS timer to expire at this time and restart the motor. If the surge still occurs, set the UTS time to a lower time until the surging subsides. If motor surging continues to be a problem, it is recommended that one of the other standard MX

3 closed-loop starting profiles be used.

Figure 39: Effect of UTS Timer on Voltage Ramp

Voltage

Full Voltage

Start command

Optional Kick

Current

Initial Voltage

Time

Kick Time

UTS Time

Ramp

Time

7.3.6

General

Dual Acceleration Ramp Control

Two independent current ramps and kick currents may be programmed. The use of two different starting profiles can be very useful with applications that have varying starting loads such as conveyors that can start either loaded or unloaded.

The Current Ramp 1 profile is programmed using the parameters Initial Current 1, Maximum Current 1, and

Ramp Time 1. The Current Ramp 2 is programmed using the parameters Initial Current 2, Maximum Current

2, and Ramp Time 2. Kick Current 1 profile is programmed using the parameters Kick Level 1 and Kick Time

1. Kick Current 2 profile is programmed using the parameters Kick Level 2 and Kick Time 2.

7.3.7

Description

Tachometer Ramp Selection

The Tachometer control ramp profile provides a method to linearly ramp the speed of the system. When this control mode is selected, the starter uses a tachometer to provide speed feedback to the starter. This mode is commonly used on conveyor belt applications where a smooth controlled start is necessary under various load conditions to prevent belt breakage, lifting, or excessive stretching. The Tachometer controller consists of an inner PID current loop and an outer PI speed control loop.

z NOTE: The maximum current limit will override the speed control loop if necessary. If the Maximum

Current level is not set high enough or the load is too great, the MX

3 starter will limit the motor current to this maximum level. When current limiting occurs, the speed profile will no longer be linear and the motor(s) will take longer to accelerate to full speed. Therefore, if current limiting is undesirable, this parameter must be set higher than the peak starting current during a linear speed ramp start.

Tachometer Requirements

In addition to the basic motor and starter setup variables, the following needs to done to use the tachometer feedback control ramp:

1.

Connect a tachometer with appropriate DC output voltage and correct polarity to the MX

3 input (TB5-2 (+ positive) & TB5-3 (- negative)).

power card

2.

The tachometer feedback Start Mode (CFN 01) is selectable as “Tach Ramp” from the Starter Modes menu.

3.

Program the appropriate variables in the Tachometer Setup menu.

FUN 13- Tachometer Full Speed Voltage on page 106.

FUN 14- Tachometer Loss Time on page 106.

FUN 15- Tachometer Loss Action on page 106.

4.

Set the Initial Current (QST 06/CFN 03) level to the desired starting current on page 64.

5.

Set the Maximum Current (QST 07/CFN 04) level to the desired maximum current limit on page 65.

128


Acceleration Ramp Selection

Current Ramp 2 and Kick Current 2 starting profiles are selected by programming a digital input to the Ramp

Select function and then energizing that input by applying 120 Volts to it. When a digital input is programmed to Ramp Select, but de-energized, Current Ramp 1 and Kick Current 1 are selected. When no digital inputs are programmed to the Ramp Select function the Ramp 1 profile is used.

The Ramp Select input only affects the starting profile when using a current ramp profile and during a kick.

The Ramp Select input does not affect the TruTorque ramp, Power ramp, or the Voltage ramp profile (unless kicking is enabled at the beginning of those ramps).

The following table summarizes which parameters affect the starting profile when a digital input is programmed to the Ramp Select function and that input is either energized or de-energized.

Ramp Modes

Current Ramp

TruTorque Ramp

Power (KW) Ramp

Voltage Ramp

Tachometer Ramp

Ramp Select De-energized

Initial Current 1

Maximum Current 1

Ramp Time 1

Kick Level 1

Kick Time 1



Ramp Time 1

Kick Level 1

Kick Time 1



Ramp Time 1

Kick Level 1

Kick Time 1


Ramp Time 1

Kick Level 1

Kick Time 1

Initial Current 1

Maximum Current 1

Ramp Time 1

Kick Level 1

Kick Time 1

Ramp Select Energized

Initial Current 2

Maximum Current 2

Ramp Time 2

Kick Level 2

Kick Time 2

Kick Level 2

Kick Time 2

Kick Level 2

Kick Time 2

Kick Level 2

Kick Time 2

Initial Current 2

Maximum Current 2

Ramp Time 2

Kick Level 2

Kick Time 2

129


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.

Figure 40: Changing Ramps During Acceleration Example

Ramp Profile 1

Kick Level 1

Maximum Current 1

Initial Current 1

Ramp Time 1

Ramp Profile 2

Kick Time 1

Maximum Current

2

Kick Level 2

Initial Current 2

Kick Time 2

Ramp Time 2

Ramp Select Changed During Start

Ramp 1 Selected

Ramp Time 2

Ramp 2 Selected

130


Deceleration Control

7.4

7.4.1

Overview

Deceleration Control

Voltage Control Deceleration

The deceleration control on the MX

3 uses an open loop voltage ramp. The MX

3 ramps the voltage down to decelerate the motor. The curve shows the motor voltage versus the decel setting.

Figure 41: Motor Voltage Versus Decel Level

Beginning Level

Ending Level

Decel Time

This sets the starting voltage of the deceleration ramp. Most motors require the voltage to drop to around 60% or lower before any significant deceleration is observed. Therefore, a good first setting for this parameter is

35%.

To adjust this parameter, it is necessary to observe the motor operation as soon as a stop is commanded. If the motor hunts (speed oscillations) at the beginning of the deceleration, then lower the parameter by 5%. If the motor has a big drop in speed as soon as a stop is commanded, then raise the parameter by 5%.

Some motors are very sensitive to the adjustment of this parameter. If a 5% adjustment changes the motor from hunting to dropping in speed, then a smaller change of 1% or 2% may be necessary.

This sets the final voltage for the deceleration ramp. In most cases, this parameter can be set to 10% and the decel time can be used to adjust the deceleration rate. If the motor is coming to a stop too quickly or if the starter continues to apply current to the motor after the motor has stopped, this parameter can be increased in

5% increments to fix this.

The decel time sets how quickly the motor decelerates. Usually a time of 30 seconds is a good starting point.

To make the motor take longer to decelerate, increase this parameter or to make the motor decelerate quicker, decrease this parameter.

z NOTE: Deceleration control provides a smoother stop. However, the motor will take longer to stop than if it was just allowed to coast to stop.

131


7.4.2

Overview

TruTorque Deceleration

TruTorque deceleration control is a closed loop deceleration control. This allows TruTorque deceleration to be more consistent in cases of changing line voltage levels and varying motor load conditions. TruTorque deceleration is best suited to pumping and compressor applications where pressure surges, such as water hammer, must be eliminated. The MX

3 linearly reduces the motor's torque to smoothly decelerate the motor and load. TruTorque deceleration is very easy to use with only two parameters to set.

Figure 42: TruTorque Deceleration

Motor

Torque

Stop command

Motor Torque

Before Stop

Command

Ending Level

Decel Time

End Torque

Level

Time

Decel Time

The Decel End Level parameter sets the ending torque level for the TruTorque deceleration ramp profile.

A typical TruTorque decel end level setting is between 10% and 20%. If the motor stops rotating before the deceleration time has expired, increase this parameter value. If the motor is still rotating when the deceleration time has expired, decrease this parameter value.

The decel time sets the ramp time between the motor torque level when stop was commanded and the decel end torque level.

If the motor stops rotating before the decel time has expired, decrease the decel time parameter. If the motor is still rotating when the decel time expires, increase the decel time parameter.

132


Braking Controls

7.5

Overview

Braking Controls

When the Stop Mode parameter is set to DC Brake, the MX

3 friction braking of a three-phase motor. The MX

3 starter provides DC injection braking for fast and starter applies a controlled DC current to the motor in order to induce a stationary magnetic field that then exerts a braking torque on the motor's rotating rotor. The braking current level and braking time required depends on the motor characteristics, the load inertia, and the friction in the system.

The MX

3 starter supports two different levels of DC injection braking:

1. Standard Duty Brake - For less than 6 x motor inertia.

2. Heavy Duty Brake - For NEMA specified inertia and two motor current feedback methods: a) Standard Current Transformers (CTs) b) Optional Hall Effect Current Sensor (LEM)

The optional Hall Effect Current sensor can be used when a more precise measurement of braking current is necessary. This can occur if the DC injection braking is applied when the source supply has a very high short circuit capability (very stiff) or in special instances when more precise braking current control is required.

The appropriate brake type and feedback method is preset from the factory. Please consult Benshaw for more information if changes need to be made.

Maximum Load Inertia

350

400

450

500

600

700

800

150

200

250

300

HP

75

100

125

3600

315

349

381

443

503

560

172

210

246

281

71

92

113

133

The following table shows maximum load inertia, NEMA MG1 parts 12 and 20. It is recommended a thermistor or RTD be installed to protect the motor from overheating.

1800

338

441

542

640

831

1017

1197

1373

1546

1714

1880

2202

2514

2815

1200

904

1181

1452

1719

2238

2744

3239

3723

4199

4666

5130

6030

-

-

Speed - RPM

900

Inertia (lb-ft2)

1814

2372

2919

3456

4508

5540

6540

7530

8500

9460

-

-

-

-

720

3111

4070

5010

5940

7750

9530

11270

-

-

-

-

-

-

-

600

4831

6320

7790

9230

12060

14830

-

-

-

-

-

-

-

-

514

-

-

-

-

-

-

-

-

-

-

7010

9180

11310

-

133


7.5.1

DC Injection Braking, Standard Duty

The MX

3

Standard Duty Braking allows up to approximately 250% FLA current to be applied to the motor. The MX

3

Standard Duty package consists of an extra braking contactor that shorts motor terminals 2 and 3 together while braking, as DC current is applied by the

MX

3 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). The three contacts must be paralleled.

7.5.2

DC Injection Braking, Heavy Duty

The MX

3

Heavy Duty Braking allows up to 400% FLA current to be applied to the motor for maximum braking performance. The MX

3

Heavy Duty braking package includes a freewheel current path between phases 1 and 3 that consists of a fuse and a 7 th

SCR with gating card. In combination with the applied DC current from the MX

3 starter, the freewheeling current path greatly enhances available braking torque. When Braking, the stop must be counted as another motor start when looking at the motor starts per hour limit.

z NOTE: Semi-Conductor Fuse and 7th SCR supplied by Benshaw.

7.5.3

Braking Output Relay

To utilize DC injection braking, one of the user output Relays needs to be programmed as a Braking relay. (Refer to the Relay Output

Configuration parameters on page 91 for more information). The output of a Braking relay is needed to control the contactor and/or 7 th

SCR gating control card used during braking.

z NOTE: Verify that the correct output relay is programmed to Braking and that the wiring of this relay is correct. Damage to the starter can result if the braking relay is not programmed and/or wired properly.

7.5.4

Stand Alone Overload Relay for emergency ATL (Across The Line) Operation

Due to the currents being drawn on Line 1 and Line 3 for braking, this stand alone overload relay will cause nuisance current imbalance trips. For a solution consult factory.

134


7.5.5

DC Injection Brake Wiring Example

Figure 43: DC Injection Brake Wiring Example

L1

3Ø50/60Hz.

2200-6900 VAC

L2

L3

GROUND BUS

TB6

R3

TB3

R2

TB1

R1

R6

R5

R4

TB7 TB4 TB2 TB5

5A CT

CT1

5A CT

CT2

5A CT

CT3

IL

SCRs

PHASE 1 SCR STACK

PHASE 2 SCR STACK

PHASE 3 SCR STACK

BP

TO 120VAC

LOCATED IN LOW VOLTAGE SECTION

BRAKING

CONTACTOR COIL

INLINE

CONTACTOR COIL

TWO WIRE CONTROL

THREE WIRE CONTROL

STOP

START


1 2 3 4 5 6

G

N

N

L LIVE

L LIVE

1

2

1(L)

2(N)

J1

J4

J8

LINE VOLTAGE

SENSING DIVIDER

TB1

120 VAC

CARD

INPUT POWER

1 C1 2

R1

3 C2 4

J10

5A CT

INPUT

LED1

R

POWER

LED8

G

CPU

BIPC-300055-02

MX³ CARD

R2

TB2

RELAY

OUTPUTS

R3

R4

R5

J3

RELAY

OUTPUTS

R6

LED1

CPU

G

LED3

R

5V PWR

BIPC-300034-01

MVIO CARD

5 C3 6

1 2

GND FLT

SCR 1A

J15

2000:1

SCR 1B

SCR 1C

GFCT INPUT

SCR 1D

SCR 1E

SCR 1F

PHASE 1 STACK OT

ISO1

ISO2

ISO3

ISO4

ISO5

ISO6

LS1

SCR 2A

SCR 2B

SCR 2C

SCR 2D

SCR 2E

SCR 2F

PHASE 2 STACK OT

ISO7

ISO8

ISO9

ISO10

ISO11

ISO12

LS2

SCR 3A

SCR 3B

SCR 3C

SCR 3D

SCR 3E

SCR 3F

PHASE 3 STACK OT

ISO13

ISO14

ISO15

ISO16

ISO17

ISO18

LS3

LEDS IN CONNECTOR

G R

RX TX

J1

RJ45

TB5

ANALOG

INPUT +10V

MAX

AIN

POWER

AIN+

AIN-

COM

1

2

3

4

TB5

ANALOG

OUTPUT

AOUT 5

COM 6

SHIELD 7

1

2

STAT

FBK

J2

LED2

G

RS485

RX

LED3

R

RS485

TX

TB4

MODBUS

SLAVE

B+ 1

A2

COM 3 1 START

2 DI1

3 DI2

TB3

OPTO

INPUTS

4 DI3

5 COM

1 DI4

2 DI5

3 DI6

4 DI7

5 DI8

6 COM

J6

PROGRAMMABLE

DIGITAL

INPUTS

MEDIUM VOLTAGE

MX³ CARD ASSEMBLY

BIPC-450100-01

CONSISTS OF BIPC-300055-02 (TOP)

& BIPC-300034-01 (BOTTOM)

U24

SW2

RESET

SW3

PARAM

SW4

DOWN

SW5

UP

SW6

ENTER

J7

MOT

PTC

J2

RJ45

1

MOUNTED IN LOW VOLTAGE DOOR

2

DISPLAY CABLE

RJ45

KPMX3LLCD

KEYPAD/DISPLAY CARD

R STOP

LCD DISPLAY A

G

ALARM

RUN

STOP

RESET

START MENU

ENTER

J5

(BYPASS

CONFIRM)

3

4

(BYPASS

COIL)

5

6

1

2

BYPASS

CONTACTOR COIL

DB

HEAVY DUTY BRAKE

T1

T2

T3

3Ø50/60Hz.

2200-6900 VAC

135


7.5.6

DC Brake Timing

The MX

3

DC injection brake timing is shown below:

Figure 44: DC Injection Brake Timing

DC Brake

Delay Time

DC Brake

Time

Delay after

DC Brake

Brake Relay On

Brake Relay Off

DC Injection On

DC Injection Off

Braking Relay Energized

Starter SCRs On, DC Current Applied time

Stop

Commanded

Delay to allow contactor to close before applying DC current

DC Brake

Time

Expired

Braking Relay opens after a delay to allow residual DC current to decay

After the DC Brake Time has expired, the Braking Relay is held energized to allow the DC current to decay before opening the freewheel path. This delay prevents a contactor (if used) from having to open significant DC current which greatly prolongs the life of the contactor. This delay time is based on motor FLA, the larger the motor the longer the delay time. The delay after DC brake time is approximately:

Motor FLA

10 A

100 A

500 A

1000 A

Delay after DC Brake Time

0.4 seconds

0.8 seconds

2.3 seconds

4.3 seconds

Motor Overload Calculations During DC Injection Braking

During DC braking the MX

3

Solid State Motor Overload Protection is fully active. During braking the Running Motor overload setting is used. The MX

3 adjusts the overload calculations based on whether Standard Duty or Heavy Duty braking is used. The overload calculations are also adjusted based on whether the standard Current Transformers (CTs) are used for current feedback or if the optional

Hall Effect Current sensor is used for current feedback.

z NOTE: Discretion must be used when DC injection braking. Motor heating during DC injection braking is similar to motor heating during starting. Although the Motor OL is active (if it has not been intentionally disabled), excessive rotor heating could still result if the load inertia is very large, braking level is high, or the brake time is set too long. Caution must be used to assure that the motor has the thermal capacity to brake the desired load in the desired period of time without excessive heating.

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.

136


7.5.8

Once DC Braking is stopped due to a digital input state change, no further DC braking will take place and the starter will return to the idle state.

Use of Optional Hall Effect Current Sensor

The Hall Effect Current Sensor should be located on Phase 1 of the motor output wiring. The sensor should be located so that the sensor measures both the applied DC current from the starter as well as the freewheel current. The sensor is connected to the analog input of the

MX

3 card along with a burden resistor. The analog input must be set to be a 0-10V voltage input for correct operation. The sensor scaling and burden resistance are factory selected. Please consult factory if changes to either the sensor scaling or burden resistance is required.

z NOTE: Hall effect current sensor must be used when load inertia exceeds motor manufactures recommended specifications.

z NOTE: Hall effect current sensor must be protected with high voltage sleeving.

137


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.

Brake Time:

Brake Delay:

The DC Brake Time parameter sets the time that DC current is applied to the motor. The desired brake time is determined by the combination of the system inertia, system friction, and the desired braking level. If the motor is still rotating faster than desired at the end of the brake time increase the brake time if possible. If the motor stops before the desired brake time has expired decrease the brake time to minimize unnecessary motor heating.

The DC Brake Delay Time is the time delay between when a stop is commanded and the DC braking current is applied to the motor. This delay allows the residual magnetic field and motor counter EMF to decay before applying the DC braking current. If a large surge of current is detected when DC braking is first engaged increase the delay time. If the delay before the braking action begins is too long then decrease the delay time.

In general, low horsepower motors can utilize shorter delays while large horsepower motor may require longer delays.

7.6

Slow Speed Cyclo Converter

Slow Speed Cyclo Converter

The MX

3

Soft Starter implements a patented Slow Speed algorithm that can be used to rotate a three-phase AC motor, with control of the stator current, at speeds less than the rated synchronous speed of the motor. The algorithm is used with a standard three-phase six-switch

SCR based soft starter. The advantages of the MX

3 starter algorithm over other "jogging" techniques are that: the low speed motor rotation is done without any additional hardware such as additional mechanical contactors and/or extra SCRs, the peak phase currents are reduced compared with other jogging techniques, motor heating is minimized, and higher shaft torque can be generated.

7.6.1

Operation

Slow speed forward and reverse operation is achieved by energizing a digital input that has been programmed to either Slow Speed

Forward or Slow Speed Reverse (refer to the Digital Input Configuration parameters on page 90 for more information). The active control source (Local Source or Remote Source) must be set to terminal. Slow Speed Start/Stop control is not available from the LCD keypad. The starter must be in the idle state in order to enter slow speed operation.

Relay outputs can be programmed to energize during slow speed operation (refer to the Relay Output Configuration parameters on page

91 for more information). This feature can be used to disable mechanical brakes or energize clutches during slow speed operation.

Motor Overload Calculations During Slow Speed Operation

During Slow Speed Operation the MX

3

Solid State Motor Overload Protection is fully active. During slow speed operation the Running

Motor overload setting is used.

z NOTE: When the motor is operating at slow speeds its cooling capacity can be greatly reduced. Therefore the running time of the motor at a given current level is dependant on the motor's thermal capacity. Although the Motor OL is active (if it has not been intentionally disabled) during slow speed operation it is recommended that the motor temperature be monitored if slow speed is used for long periods of time.

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). This value should be set to the lowest possible current level that will properly operate the motor.

Slow Speed Time Limit:

The Slow Speed Time Limits parameter sets the amount of time that continuous operation of slow speed may take place. When this parameter is set to "Off" the timer is disabled. This parameter can be used to limit the amount of continuous slow speed operation to protect the motor and/or load.

z NOTE: The Slow Speed Time Limit includes the time used for the Slow Speed Kick if kick is enabled.

z NOTE: The Slow Speed Time Limit resets when the motor is stopped. This timer does not prevent the

138

Slow Speed Kick Level:

Slow Speed Kick Time:


operator from stopping and re-starting the motor which can result in the slow speed operation time of the motor being exceeded.

The Slow Speed Kick Level sets the short-term current level that is applied to the motor to accelerate the motor for slow speed operation. The Slow Speed Kick feature is disabled if it is set to off. Slow Speed Kick can be used to "break loose" difficult to start loads while keeping the operating slow speed current level lower.

This parameter should be set to a midrange value and then the Slow Speed Kick Time should be increased in

0.1 second intervals until the kick is applied long enough to start the motor rotating. If the motor does not start rotating with the set Slow Speed Kick Level increase the level and begin adjusting the kick time from 1.0

seconds again.


Kick Time.

The Slow Speed Kick Time parameter sets the length of time that the Slow Speed Kick current level is applied to the motor at the beginning of slow speed operation. After the Slow Speed Kick Level is set, the Slow

Speed Kick Time should be adjusted so that the motor starts rotating when a slow speed command is given.


Kick Time.

139


7.7

Wye Delta Starter

Wye Delta Starter

When the Starter Type parameter is set to Wye-Delta, the MX

3 starter. When in Wye-Delta mode, all MX

3 is configured to operate an electro mechanical Wye-Delta (Star-Delta) motor and starter protective functions except bad SCR detection and power stack overload, are available to provide full motor and starter protection.

A typical closed transition Wye-Delta starter schematic is shown in the following figure.

Figure 45: Wye Delta Motor Connection to the MVRMX

3

2M

T6

T4

T5

1S 2S

T4 T2

T1

T6 T3

T5

1M

L1

3Ø50/60Hz.

2200-6900 VAC

L2

L3

GROUND BUS

TB6 TB3 TB1

R3 R2 R1

R6

R5

R4

TB7 TB4 TB2 TB5

5A CT

CT1

5A CT

CT2

5A CT

CT3

T1

T2

T3

TO 120VAC


TWO WIRE CONTROL

THREE WIRE CONTROL

STOP

START


1 2

3 4 5 6

G

N

N

L LIVE

L LIVE

1

2

1(L)

2(N)

J1

J4

J8

LINE VOLTAGE

SENSING DIVIDER

CARD

TB1

120 VAC

INPUT POWER

1 C1 2

R1

3 C2 4

J10

5A CT

INPUT

LED1

R

POWER

LED8

G

CPU

BIPC-300055-02

MX³ CARD

R2

TB2

RELAY

OUTPUTS

R3

R4

R5

J3

RELAY

OUTPUTS

R6

LED1

CPU

G

LED3

R

5V PWR

BIPC-300034-01

MVIO CARD

5 C3 6

1 2

GND FLT

SCR 1A

SCR 1B

J15

2000:1

GFCT INPUT

SCR 1C

SCR 1D

SCR 1E

SCR 1F

PHASE 1 STACK OT

ISO1

ISO2

ISO3

ISO4

ISO5

ISO6

LS1

SCR 2A

SCR 2B

SCR 2C

ISO7

ISO8

ISO9

SCR 2D

SCR 2E

ISO10

ISO11

SCR 2F

PHASE 2 STACK OT

ISO12

LS2

SCR 3A

SCR 3B

SCR 3C

ISO13

ISO14

SCR 3D

SCR 3E

ISO15

ISO16

SCR 3F

PHASE 3 STACK OT

ISO17

ISO18

LS3

LEDS IN CONNECTOR

RX

G

TX

R

J1

RJ45

TB5

ANALOG

INPUT +10V

MAX

AIN

POWER

AIN+

AIN-

COM

1

2

3

4

AOUT 5

TB5

ANALOG

OUTPUT

COM 6

SHIELD 7

1

STAT

2

FBK

J2

LED2

G

RS485

RX

LED3

R

RS485

TX

TB4

MODBUS

SLAVE

B+ 1

A2

COM 3 1 START

2 DI1

3 DI2

4 DI3

TB3

OPTO

INPUTS

5 COM

1 DI4

2 DI5

3 DI6

4 DI7

5 DI8

6 COM

J6

PROGRAMMABLE

DIGITAL

INPUTS

MEDIUM VOLTAGE

MX³ CARD ASSEMBLY

BIPC-450100-01



U24

SW2

RESET

SW3

PARAM

SW4

DOWN

SW5

UP

SW6

ENTER

J7

J2

RJ45

MOT

PTC

1


2

DISPLAY CABLE

RJ45

KPMX3LLCD

KEYPAD/DISPLAY CARD

LCD DISPLAY

R

A

G

STOP

ALARM

RUN

STOP

RESET

START MENU

ENTER

J5

(BYPASS

3

CONFIRM)

4

(BYPASS

5

COIL)

6

1

2

140


The MX

3 utilizes an intelligent Wye to Delta transition algorithm. During starting, if the measured motor current drops below 85% of

FLA and more than 25% of the Up To Speed timer setting has elapsed, then a Wye to Delta transition occurs. The intelligent transition algorithm prevents unnecessarily long motor starts which reduces motor heating. If a Wye to Delta transition has not already occurred, a transition always occurs when the complete Up To Speed Time expires.

The MX

3 can operate two configurations of Wye-Delta starters, open transition and closed transition. An open transition starter momentarily disconnects the motor from the input line during the transition from Wye to Delta operating mode. A closed transition starter uses resistors that are inserted during the transition so that the motor is never completely disconnected from the input line. The presence of the resistors in a closed transition starter smooths the transition. A typical closed transition Wye-Delta starter schematic is shown in Figure 45 on page 140.

The closed transition resistors generally are sized to be in the circuit for a short period of time. To protect the resistors from over heating, one input should be programmed as a Bypass/2M contact feedback input and the Bypass/2M confirm parameter must be set.

For the Wye-Delta starter mode to operate properly one output relay needs to be programmed to the RUN output function and another output relay needs to be programmed to the UTS output function. (Refer to the Relay Output Configuration parameters on page 91 for more information).

Based on the typical closed transition schematic shown in Figure 45, when a start command is given, the starter enters the Wye starting mode by energizing the relay programmed as RUN.

The transition to Wye (Starting) mode occurs as follows:

1.

2.

3.

Start command is given to the starter.

The RUN relay is energized which energizes the 1S contactor.

When the 1S contactor pulls in, the 1M contactor is energized.

The MX

3 starter remains in the Wye mode until either:

1.

2.

3.

The start command is removed.

The Up To Speed Time expires.

4.

The measured motor current is less than 85% of FLA and more than 25% of the Up To Speed Timer setting has elapsed.

A fault occurs.

When the Up To Speed Time expires, the starter changes from Wye starting mode to the Delta or normal running mode by energizing the relay programmed as UTS. In Delta mode, the RUN and UTS relays are both energized and the motor is connected in the normal running Delta configuration.

The transition to Delta (Run) mode occurs as follows:

1.

The UTS relay is energized which energizes the 2S contactor.

2.

3.

4.

When the 2S contactor pulls in, resistors are inserted in the circuit and the 1S contactor is de-energized.

When the 1S contactor drops out the 2M contactor is energized.

When the 2M contactor is pulled in, feedback can be sent to the MX

3 transition sequence to Delta is complete.

control card to confirm that the

The starter remains in the Delta or running mode until the start command is removed or a fault occurs.

Usually the MX

3 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 may occur only after the Up To Speed Time has expired. In order to reduce the current surge during the transition from Wye to Delta mode, the Up To Speed Time parameter should be adjusted so that the transition occurs as close to full speed as possible within the constraints of the load. If the Up To Speed Time is set too short, a large current and torque surge may occur during the transition. If the Up To Speed Time is set too long, the motor may not have sufficient torque to continue accelerating when in Wye mode and may stop accelerating at a low speed until the transition to Delta mode occurs. If this occurs, the start is unnecessarily prolonged and motor heating is increased.

141


A typical closed transition Wye-Delta starting current profile is shown in Figure 46.

Figure 46: Wye Delta Profile

Wye-Delta Closed Transition Current Profile

600%

500%

% Full

Load

Motor

Current

400%

300%

200%

100%

0%

100%

% speed

Transition from Wye to Delta mode

A digital input can be programmed as a 2M contactor feedback input. This input provides verification that the 2M contactor has fully closed preventing operation when the transition resistors are still connected in the motor circuit. The use of this feedback is recommended to prevent the overheating of the transition resistors if the 2M contactor does not close properly. The 2M confirmation trip time can be adjusted by modifying the Bypass Feedback Time parameter.

z NOTE: When in Wye-Delta mode, the acceleration ramp, kick, and deceleration settings have no effect on motor operation.

z NOTE: When in Wye-Delta mode, the SCR gate outputs are disabled.

142


7.8

Across The Line Starter

Across The Line (Full Voltage Starter)

When the Starter Type parameter is set to ATL, the MX

3 is configured to operate an electro mechanical full voltage or across-the-line

(ATL) starter.

In the ATL configuration, the MX

3 assumes that the motor contactor (1M) is directly controlled by a digital output relay that is programmed for the RUN function. Therefore, when a start command is given, the RUN programmed relay energizes the motor contactor, which applies power to the motor. When the MX

3 determines that the motor is at full speed, the up-to-speed (UTS) condition is indicated by energizing the UTS programmed relays. When configured as an ATL starter, all MX

3 motor and starter protective functions, except bad SCR detection and power stack overload, are available to provide full motor and starter protection.

L1

Figure 47: A Typical ATL Starter Schematic with the MVRMX

3

CT4 - GFCT

ZERO SEQUENCE

GROUND FAULT CT

(OPTIONAL)

M

T1

5A CT

CT1

3Ø50/60Hz.

2200-6900 VAC

L2

5A CT

T2

CT2

3Ø50/60Hz.

2200-6900 VAC

L3 T3

5A CT

CT3

BIPC-450100-01

DI3

GROUND BUS

4160VAC

120VAC

TX1

TB6

R3

TB3 TB1

R2 R1

R6

R5

R4

TB7 TB4 TB2

TB5

TEST PLUG

TO 120VAC

NORMAL TEST

X

X

X

X

MOUNTED IN

LV COMPARTMENT

MOTOR

CONTACTOR

COIL

TWO WIRE CONTROL

THREE WIRE CONTROL

STOP

START

DISCONNECT AUXILIARY CONTACT

(SHOWN WITH DISCONNECT OPEN)



G

N

N

L LIVE

L LIVE

1(L)

2(N)

J1

1

2

J4

1 2 3 4 5 6

J8

LINE VOLTAGE

SENSING DIVIDER

TB1

CARD

120 VAC

INPUT POWER

1 C1 2

R1

3 C2 4

J10

5A CT

INPUT

LED1

R

POWER

LED8

G

CPU

BIPC-300055-02

MX³ CARD

R2

TB2

RELAY

OUTPUTS

R3

R4

R5

R6

J3

RELAY

OUTPUTS

LED1

G

CPU

LED3

R

5V PWR

BIPC-300034-01

MVIO CARD

5 C3 6

1 2

GND FLT

SCR 1A ISO1

J15

2000:1

GFCT INPUT

SCR 1B

SCR 1C

ISO2

ISO3

ISO4 SCR 1D

SCR 1E

SCR 1F

PHASE 1 STACK OT

ISO5

ISO6

LS1

SCR 2A

SCR 2B

SCR 2C

ISO7

ISO8

SCR 2D

SCR 2E

ISO9

ISO10

ISO11

SCR 2F

PHASE 2 STACK OT

ISO12

LS2

SCR 3A

SCR 3B

ISO13

ISO14

SCR 3C

SCR 3D

ISO15

ISO16

SCR 3E ISO17

SCR 3F

PHASE 3 STACK OT

ISO18

LS3

LEDS IN CONNECTOR

G R

RX TX

J1

RJ45

TB5

ANALOG

INPUT +10V

MAX

AIN

POWER

1

AIN+ 2

AIN3

COM 4

AOUT 5

TB5

ANALOG

OUTPUT

COM 6

SHIELD 7

1

2

STAT

FBK

J2

1 START

LED2

G

RS485

RX

LED3

R

RS485

TX

TB4

MODBUS

SLAVE

B+ 1

A2

COM 3

2 DI1

3 DI2

4 DI3

TB3

OPTO

INPUTS

5 COM

1 DI4

2 DI5

3 DI6

4 DI7

5 DI8

6 COM

J6

PROGRAMMABLE

DIGITAL

INPUTS

MEDIUM VOLTAGE

MX³ CARD ASSEMBLY

BIPC-450100-01



U24

SW2

RESET

SW3

PARAM

SW4

DOWN

SW5

UP

SW6

ENTER

J7

J2

RJ45

MOT

PTC

1

2

RJ45

DISPLAY CABLE


KPMX3LLCD

KEYPAD/DISPLAY CARD

R STOP

LCD DISPLAY A

G

ALARM

RUN

STOP

RESET

START MENU

ENTER

1

J5

2

(BYPASS

CONFIRM)

3

4

(BYPASS

COIL)

5

6 z NOTE: When in ATL mode, the acceleration ramp, kick, and deceleration parameter settings have no effect on motor operation.

z NOTE: When in ATL mode, the SCR gate outputs are disabled.

143


7.9

Start/Stop Control with a Hand/Off/Auto Selector Switch

Start/Stop Control with a Hand/Off/Auto Selector Switch

Often times, a switch is desired to select between local or “Hand” mode and remote or “Auto” mode. In most cases, local control is performed as 3-wire logic with a normally open, momentary contact Start pushbutton and a normally closed, momentary contact Stop pushbutton, while remote control is performed as 2-wire logic with a “Run Command” contact provided by a PLC.

The MX

3 can perform both 2-wire start/stop logic and 3-wire start/stop logic. With 2-wire logic, the starter starts when a run command is applied to the Start input. It continues to run until the run command is removed from the Start input. With 3-wire logic, the starter starts when a start command is momentarily applied to the Start input and continues to run until an input programmed as a Stop input goes low.

The MX

3 automatically determines whether to use 2-wire logic or 3-wire logic by the presence of a high level on a Stop input. If there is an input programmed as a Stop input, and that input is high when the Start input goes high, then 3-wire start/stop logic is used.

Otherwise, 2-wire start/stop logic is used. This feature eliminates the need for external logic relays often used to “seal in” the momentary

Start and Stop pushbuttons, creating a 2-wire logic signal. The key is to have the Stop input be high when the Hand/Off/Auto switch is in the Hand position, but be low when the switch is in the Auto position. The following wiring diagram illustrates a possible implementation. In this example, DI 1 on the MX

3 is programmed as a Stop input.

Figure 48: Example of Start/Stop with a Hand/Off/Auto Selector Switch

OFF

120VAC LIVE

START

STOP

TB2

SELECTOR

SWITCH

120VAC NEUTRAL

When the Hand/Off/Auto selector switch is in the Hand position, current flows to the Stop push button contact and to the Stop input on the MX

3

. If the Stop is not pressed and the Start push button is pressed the starter starts. This is a typical 3-wire control. The seal for the Start push button input is accomplished in software. When the stop is pressed, the starter stops.

When the Hand/Off/Auto selector switch is in the Auto position, current flows to the user supplied run contact, but the Stop input remains low. When the user supplied run contact closes, and the stop input is low (no power applied) the starter is in 2-wire control.

CAUTION: It is important that the Stop push button be wired in front of the Start push button, otherwise the starter could be started when the Stop bush button is pressed and the Start button is pressed.

144


Simplified I/O Schematics

7.10

Simplified I/O Schematics

Figure 49: Digital Input Simplified Schematic

Figure 50: Analog Input Simplified Schematic

Figure 51: Analog Output Simplified Schematic

145


Remote Modbus Communications

7.11

Remote Modbus Communications

The MX

3 starter provides Modbus RTU to support remote communication.

The communication interface is RS-485, and allows up to 247 slaves to be connected to one master (with repeaters when the number of drops exceeds 31). Please refer to Figures 52 and 53 for connection diagrams.

7.11.1

7.11.2

7.11.3

7.11.4

7.11.5

7.11.6

Supported Commands

The MX

3 supports the following Modbus commands:

•

Read Holding Registers (03 hex)

•

Read Input Registers (04 hex)

•

Preset Single Register (06 hex)

•

Preset Multiple Registers (10 hex)

Up to 64 registers may be read or written with a single command.

Modbus Register Addresses

The Modbus specification defines holding registers to begin at 40001 and input registers to begin at 30001. Holding registers may be read and written. Input registers may only be read.

In the MX

3

, the register maps are identical for both the holding registers and the input registers. For example, the Motor FLA (QST 01) parameter is available both in holding register 40101 and in input register 30101. This is why the register addresses in the Modbus

Register Map are listed with both numbers (e.g. 30101/40101).

Cable Specifications

Good quality twisted, shielded communications cable should be used when connecting to the Modbus port on the MX

3

. The cable should contain two twisted pairs and have an overall shield. Use one pair of conductors for the A(-) and B(+) signals. Use the other pair of conductors for the Common signal. The cable should adhere to the following specifications.

•

Conductors: 2 twisted pair

•

Impedance: 100 Ohm to 120 Ohm

•

Capacitance: 16 pF/ft or less

•

Shield: Overall shield or individual pair shields

Examples of cables that meet these specifications are Belden part number 9842 and Alpha Wire part number 6412.

Terminating Resistors

The MX

3 does not have a terminating resistor for the end of the trunk line. If a terminating resistor is required, the resistor must be wired to the terminal block.

The purpose of terminating resistors is to eliminate signal reflections that can occur at the end of a network trunk line. In general, terminating resistors are not needed unless the bit rate is very high, or the network is very long. In fact, terminating resistors place a large load on the network and may reduce the number of drops that may be placed on the network.

The maximum baudrate of 19,200 supported by the MX

3 is not high enough to warrant a terminating resistor unless the network is extremely long (3,000 feet or more). A terminating resistor should only be installed on the MX

3 if signal reflection is known to be a problem and only if the MX

3 is at the end of the network. Terminating resistors should never be installed on nodes that are not at the end of the network.

Grounding

RS-485 buses with isolated nodes are most immune to noise when the bus is not connected to earth ground at any point. If electrical codes require that the bus be connected to earth ground, then the Common signal should be connected to earth ground at one point and one point only. If the Common signal is connected to earth ground at more than one point, then significant currents can flow through the

Common signal when earth ground potentials are different at those points. This can cause damage to devices attached to the bus.

Shielding

The shield should be continuous from one end of the trunk to the other. The shield must be tied to the RS-485 Common signal at one point and one point only. If the shield is not tied to Common at any point or is tied to Common at more than one point, then its effectiveness at eliminating noise is greatly reduced.

146


7.11.7

Wiring

Figure 52 shows the wiring of TB4 to a Modbus-485 Network. If the starter is the end device in the network, a 120

W, 1/4W terminating resistor may be required. Please refer to Figure 53 for wire and termination practices.

Figure 52: TB4 Connector

TB4

B+

A-

COM

Figure 53: Modbus Network Wiring Example

147


NOTES:

148

8

Troubleshooting

& Maintenance

149

8 - TROUBLESHOOTING & MAINTENANCE

8.1



For safety of maintenance personal as well as others who might be exposed to electrical hazards associated with maintenance activities, the safety related work practices of NFPA 70E, Part II, should always be followed when working on electrical equipment. Maintenance personnel must be trained in the safety practices, procedures, and requirements that pertain to their respective job assignments.

WARNING: To avoid shock hazard, disconnect main before working on controller/starter, motor or control devices such as start/stop pushbuttons. Procedures which require parts of the equipment to be energized during troubleshooting, testing, etc, must be performed by properly qualified personnel, using appropriate work practices and precautionary measures as specified in NFPA70, Part II.

CAUTION: Disconnect the controller/starter from the motor before measuring insulation resistance (IR) or the motor windings.

Voltages used for insulation resistance testing can cause failure of SCR's. Do not make any measurements on the controller with an IR tester (megger).

z NOTE: Blades against ground bar (in circular picture).

Preventative Maintenance

8.2

8.2.1



Preventative maintenance performed on a regular basis will help ensure that the starter continues to operate reliably and safely. The frequency of preventative maintenance depends upon the type of maintenance and the installation site’s environment.

z NOTE: A trained technician should always perform preventative maintenance.

8.2.2


During Commissioning:

•

Torque all power connections during commissioning. This includes factory wired equipment.

•

Check all of the control wiring in the package for loose connections.

•

If fans are installed, ensure proper operation

One month after the starter has been put in operation:

•

Re-torque all power connections during the month. This includes factory wired equipment.

•

Inspect the cooling fans after two weeks to ensure proper operation.

After the first month of operation:

•

Re-torque all power connections every year.

•

Clean any accumulated dust from the starter using a clean source of compressed air or a vacuum cleaner.

•

Inspect the cooling fans every three months to ensure proper operation.

•

Clean or replace any air vent filters on the starter every three months.

z NOTE: If mechanical vibrations are present at the installation site, inspect the electrical connections more frequently.

150


8.3

LED Diagnostics

LED Diagnostics

There are several LEDs located on the MVRMX

3

Refer to the circuit card layouts for LED locations.

circuit cards. These LEDs can be used to help troubleshoot problems with the starter.

CARD

MX

3

Assembly

BIPC-450100-01-01

Gate Driver Card

BIPC-300047-01

Remote

RTD Module

SPR-100P

DC Power Supply

LED # Description

LED1 (Red) CPU Power

LED8 (Green) CPU heart beat

LED1 (Green) I/O CPU heart beat

LED3 (Red) 5V Power for I/O card

J1 (Green)

J1 (Red)

LED1 (Red)

LED2 (Green)

LED3 (Green)

Modbus RX (receive)

Modbus TX (transmit)

Card power supply is sending power to the 6 isolated gate drive circuits

–6 isolated gate drive circuits are receiving power

–Input DC voltage to the card power supply is acceptable

–Stack thermal switch is closed

–Gate drive circuit for SCR A has power

–Stack thermal switch is closed

LED4 (Green)

LED5 (Green)

Gate drive circuits for SCR B & C have power

Gate drive circuits for SCR D & E have power

LED6 (Green) Gate drive circuit for SCR F has power

LED7 (Red) SCR gate A is Firing

LED8 (Red)

LED9 (Red)

SCR gate B is Firing

SCR gate C is Firing

LED10 (Red) SCR gate D is Firing

LED11 (Red) SCR gate E is Firing

LED12 (Red) SCR gate F is Firing

OPTIONAL RTD Modules

TX (Red) Transmit Data

RX (Green) Receive Data

Status (Green) Operation

DC ON (Green) DC voltage is On

INDICATION

On when power is applied.

Flash once per second.


On when power is applied.

Flash twice per second when receiving.

Flash twice per second when sending.

On if control voltage is present.(located behind transformer)

On if card is OK.

On if voltage is present.




On when SCR is being fired.






Flash once per second when card is transmitting data.

Flash twice per second when card is receiving data.


Stays on when RTD module has power.

z NOTE: The SCR Gate Firing LEDs (RED / LED 7, 8, 9, 10, 11, 12) are always turned off expect during the BIST test and start up.

151


RediStart MVRMX

3

Gate Driver Card

LED Gate A (LED 7-Red)

12V Healthy / Status (LED 2-Green)

Gate (white leads)

Cathode (red leads)

Gate Power OK (LED 3-Green)

Gate (white leads)

Cathode (red leads)

Gate B (LED 8-Red)

Gate C (LED 9-Red)


Gate D (LED 10-Red)

Gate E (LED 11-Red)


Gate F (LED 12-Red)


Power On (LED 1-Red)

ATTENTION: The Fiber Optic cables can be damaged if struck or bent sharply. The edge of the printed circuit board should be held to prevent damage.

152


8.4

General Troubleshooting Charts

General Troubleshooting Charts

The following troubleshooting charts can be used to help solve many of the common issues that may occur.

8.4.1

Stack Overtemp Lockout

Stack Overtemp

Lockout

Condition

Display screen displays what is shown above.

Cause

Factory Reset in (FUN 22) was entered.

Display screen displays what is shown above plus (Green / LED3) on driver card is NOT lit.

Display screen displays what is shown above plus any of the (Green / LED 3,

4, 5, 6) are NOT lit.

Fiber Optic connections (FS1, FS2 or

FS3) are not connected on the bottom of the I/O board or to each gate driver card.

J3 connection (Stack OT) on the upper right hand corner of any 3 gate driver cards is bad.

Fiber Optic connections are bad.

Solution

Enter the equipment specified rated voltage in Rated Voltage (FUN05).

Enter the value of the CTs supplied with the MVRMX

3 into the CT Ratio parameter

(FUN 03).

Set DI #2 - (I/O02) to "inline confirm".

Set DI #3 - (I/O03) to "disconnect".

Set Relay #3 - (I/O12) to "running".

Reconnect the Fiber optics.

Reconnect the two wires into the J3 connection.

Check Power Supply

Check for damaged fiber optic cables.

Check for bad connections.

8.4.2

Motor does not start, no output to motor

Condition

Display Blank, CPU Heartbeat LED on

MX

3 board not blinking.

Fault Displayed.

Cause

Control voltage absent.

MX

3 control board problem.

Fault Occurred.

Start command given but nothing happens.

Start/Stop control input problems.

Control Source parameters (QST 04 - 05) not set correctly.

NOL or No Line is displayed and a start command is given, it will fault in F28.

No line voltage has been detected by the

MX

3 when a start command is given.

Solution

Check for proper control voltage input.

Verify fuses and wiring.

Consult factory.

See fault code troubleshooting table for more details.

Verify that the start/stop wiring and start input voltage levels are correct.

Verify that the parameters are set correctly.

Check input supply for inline contactor, open disconnects, open fuses, open circuit breakers, or disconnected wiring.

Verify that the SCR gate wires are properly connected to the MX

3 control board.

On medium voltage systems, verify wiring of the voltage feedback measurement circuit.


153


8.4.3

During starting, motor rotates but does not reach full speed

Condition

Fault Displayed.

Display shows Accel or Run.

Motor Hums before turning.

Cause

Fault Occurred.

Maximum Motor Current setting

(QST07) set too low.

Motor loading too high and/or current not dropping below 175% FLA indicating that the motor has not come up to speed.

Motor FLA (QST01) or CT ratio

(FUN03) parameter set incorrectly.

Abnormally low line voltage.

A mechanical or supplemental brake is still engaged.

Initial current (QST06) to low.

Motor FLA (QST01) is incorrect

CT ratio (FUN03) is incorrect

Solution


Review acceleration ramp settings.

Reduce load on motor during starting.

Verify that Motor FLA and CT ratio parameters are set correctly.

Fix cause of low line voltage.

Verify that any external brakes are disengaged.

Increase initial current.

Review Motor FLA set point.

Review CT ratio set point.

8.4.4

Starter not accelerating as desired

Condition

Motor accelerates too quickly.

Motor accelerates too slowly.

Cause

Ramp time 1 (QST08) too short.

Initial current (QST06) set too high.

Maximum current (QST07) set too high.

Kick start current (CFN11) too high.

Kick start time (CFN12) too long.



Starter Type parameter (FUN07) set incorrectly.

Maximum Motor Current setting (QST07) set too low.

Motor loading too high.



Abnormally low line voltage.

Ramp time to long.

Solution

Increase ramp time.

Decrease Initial current.

Decrease Maximum current.

Decrease or turn off Kick current.

Decrease Kick time.


Verify that Starter Type parameter is set correctly.

Review acceleration ramp settings.

Reduce load on motor during starting.


Fix cause of low line voltage.

Decrease ramp time.

154


8.4.5

Starter not decelerating as desired

Condition

Motor stops too quickly.

Cause

Decel Time (CFN18) set too short.

Decel Begin and End Levels (CFN16 and

CFN17) set improperly.

Decel time seems correct but motor surges

(oscillates) at beginning of deceleration cycle.

Decel Begin Level (CFN16) set too high.

Decel time seems correct but motor stops before end of deceleration cycle.

Decel End Level (CFN17) set too low.

Decel End Level (CFN17) set too high.

Water hammer still occurs at end of cycle.

Decel Time (CFN18) too short.

Motor speed drops sharply before decel.

Decel Begin Level (CFN16) too low.

Solution

Increase Decel Time.

Increase Decel Begin and/or Decel

End levels.

Decrease Decel Begin Level until surging is eliminated.

Increase Decel End Level until motor just stops at the end of the deceleration cycle.

Decrease Decel End Level until water hammer is eliminated.

If possible, increase Decel Time to decelerate system more gently.

Increase the Decel Begin Level until drop in speed is eliminated.

8.4.6

Motor stops unexpectedly while running

Condition

Fault Displayed.

Cause

Fault Occurred.

Ready Displayed.

Start command lost.

Display Blank, Heartbeat LED on MX

3 card not blinking.

Control voltage absent.

MX

3 control card problem.

Solution


Verify start command input signal is present or serial communications start command is present.

Check any permissive that may be wired into the run command (Start/Stop)

Check for proper control voltage input.

Verify wiring and fuses.

Consult factory.

155


8.4.7

Metering incorrect

Condition Cause

CTs installed or wired incorrectly.

Power Metering not reading correctly.

PF Meter not reading correctly.

CT ratio parameter (FUN03) set incorrectly.


Energy Saver active.

Loose connections.

Motor Current or Voltage meters fluctuating with steady load.

SCR fault.

Voltage Metering not reading correctly.

Load actually is not steady.

Other equipment on same power feed causing power fluctuations and/or distortion.

In medium voltage systems, Rated

Voltage parameter (FUN05) set incorrectly.


Current Metering not reading correctly.



Residual Ground Fault Current Metering not reading correctly.


Zero Sequence GF Metering not reading correctly.

CT installed or wired incorrectly.

Solution

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

Verify that the CT ratio parameter is set correctly.

Verify correct CT wiring and verify that the CTs are installed with all the White dots towards the input line side.

Turn off Energy Saver if not desired.

Shut off all power and check all connections.

Verify that the SCRs gate leads are connected properly and the SCRs are ok.

Verify that the load is actually steady and that there are not mechanical issues.

Fix cause of power fluctuations and/or distortion.

Verify that Rated Voltage parameter is set correctly.

Verify that the CT ratio (FUN03) parameter is set correctly.

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

Verify that the CT ratio parameter is set correctly.

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

Verify CT installation.

156


8.4.8

Other Situations

Condition

Motor Rotates in Wrong Direction.

Erratic Operation.

Motor Overheats.

Starter cooling fans do not operate.

(When Present)

Analog Output not functioning properly.

Remote Keypad does not operate correctly.

Cannot change parameters.

Cause

Phasing incorrect.

Loose connections.

Motor overloaded.

Too many starts per hour.

High ambient temperature.

Acceleration time too long.

Incorrect motor OL settings.

Motor cooling obstructed/damaged.

Fan power supply lost.

Fan wiring problem.

Fan failure.

Voltage/Current output switch (SW1-2) not set correctly.

Wiring problem.

Analog Output Function parameter

( I/O21) set incorrectly.

Analog Output Offset and/or Span parameters (I/O23 and I/O22) set incorrectly.

Load on analog output too high.

Ground loop or noise problems.

Keypad cable not plugged in properly or cable is damaged.

Remote display damaged.

Passcode is set.

Starter is running.

Modbus is overriding.

Heater Level (FUN08) is set to "On".

Solution

If input phasing correct, exchange any two output wires.

If input phasing incorrect, exchange any two input wires.

Shut off all power and check all connections.

Reduce motor load.

Allow for adequate motor cooling between starts. Set Hot/Cold ratio higher or lengthen cooling time.

Reduce ambient temperature or provide for better cooling. Set OL class lower to compensate for ambient temperature.

Reduce starting load and/or review acceleration ramp settings.

Review and correct if necessary motor OL settings.

Remove cooling air obstructions. Check motor cooling fan.

Verify fan power supply, check fuses.

Check fan wiring.

Replace fan

Set SW1-2 to give correct output.

Verify output wiring.

Verify that the Analog Output Function parameter is set correctly.

Verify that the Analog Output Span and

Offset parameters are set correctly.

Verify load on analog output meets the

MX

3 analog output specifications.

Verify correct grounding of analog output connection to prevent noise and/or ground loops from affecting output.

Verify that the remote keypad cable has not been damaged and that it is properly seated at both the keypad and the MX

3 control card.

Replace remote display.

Clear Passcode.

Stop Starter.

Stop communications.

Turn Heater Level (FUN08) "Off".

157


8.5

Fault Code Table

Fault Code Table

The following is a list of possible faults that can be generated by the MX starter control.

Fault Code

F01

F02

F03

F04

F05

F06

F07

F08

Description

UTS Time Limit Expired

Detailed Description of Fault / Possible Solutions

Motor did not achieve full speed before the UTS timer (QST 09) expired.

Check motor for jammed or overloaded condition.

Verify that the combined kick time (CFN 12) and acceleration ramp time

(QST 08) is shorter than the UTS timer (QST 09) setting.

Evaluate acceleration ramp settings. The acceleration ramp settings may be too low to permit the motor to start and achieve full speed. If so, revise acceleration ramp settings to provide more motor torque during starting.

Evaluate UTS timer setting and, if acceptable, increase UTS timer setting

(QST 09).

Check motor for mechanical failure, jammed, or overloaded condition.

Verify the motor thermal overload parameter settings (QST 03 and PFN 28 to

PFN 35,) and motor service factor setting (QST 02).

Motor OL

Verify that the motor FLA (QST 01) and CT ratio (FUN 03) settings are correct.

If motor OL trip occurs during starting, review acceleration ramp profile settings.

Verify that there is not an input line power quality problem or excessive line distortion present.

Verify that PF caps, if installed, are ahead of CTs.

Reset overload when content falls below Motor OL Lockout Level (PFN 34).

Slow Speed Timer

Speed Switch Time Limit Expired

Increase Slow Speed Timer (CFN 25).

Increase Speed Switch Time (PFN 26).

Accelerate motor faster.

Motor PTC Overtemperature

Verify PTC thermistor specifications.

Allow motor to cool, this will reset motor PTC thermistors.

Check motor cooling fan.

Clean debris off of motor.

Reduce Overload.

Reduce high ambient.

Verify Stator RTD specifications.

Allow motor to cool.

Stator RTD Overtemperature

Bearing RTD Overtemperature

Other RTD Overtemperature

Check motor cooling fan.

Clean debris off of motor.

Reduce Overload.


Verify Bearing RTD specifications.

Replace bearings.

Reduce load on bearings.


Reduce high vibrations.

Verify Other RTD specifications

Reduce load.


158


Fault Code

F10

F11

F12

F13

F14

F15

F21

F22

F23

Description

Phase Rotation Error, not ABC

Phase Rotation Error, not CBA

Low Line Frequency

High Line Frequency

Input power not single phase

Input power not three phase

Low Line L1-L2

Low Line L2-L3

Low Line L3-L1


Input phase rotation is not ABC and Input Phase Sensitivity parameter (FUN 04) is set to ABC only.

Verify correct phase rotation of input power. Correct wiring if necessary.

Verify correct setting of Input Phase Sensitivity parameter (FUN 04).

Input phase rotation is not CBA and Input Phase Sensitivity parameter (FUN 04) is set to CBA only.

Verify correct phase rotation of input power. Correct wiring if necessary.

Verify correct setting of Input Phase Sensitivity parameter (FUN 04).

Line frequency below Under Freq Trip (PFN 15).

Verify input line frequency.

If operating on a generator, check generator speed governor for malfunctions.

Check input supply for open fuses or open connections.

Line power quality problem / excessive line distortion.

Line frequency above Over Freq Trip (PFN 14).

Verify input line frequency.

If operating on a generator, check generator speed governor for malfunctions.

Line power quality problem / excessive line distortion.

Three-phase power has been detected when the starter is expecting single-phase power.

Verify that input power is single phase.

Verify that single-phase power is connected to the L1 and L2 inputs. Correct wiring if necessary.


3 control card.

Single-phase power has been detected when the starter is expecting three-phase power.

Verify that input power is three phase. Correct wiring if necessary.


3 control card.


Low voltage below the Under voltage Trip Level parameter setting (PFN 11) was detected for longer than the Over/Under Voltage Trip delay time (PFN 12).

Verify that the actual input voltage level is correct.

Verify that the Rated Voltage parameter (FUN 05) is set correctly.


On medium voltage systems, verify wiring of the voltage measurement circuit.











159


Fault Code

F24

F25

F26

F27

F28

F29

F30

F31

F34

Description

High Line L1-L2

High Line L2-L3

High Line L3-L1

Phase Loss

No Line

PORT Timeout

I.O.C.

(Instantaneous Over current)

Over current

Undercurrent


High voltage above the Over voltage Trip Level parameter setting (PFN 10) was detected for longer than the Over/Under Voltage Trip delay time (PFN 12).



Line power quality problems/ excessive line distortions.









The MX

3 has detected the loss of one or more input or output phases when the starter was running. Can also be caused by line power dropouts.

Check input supply for open fuses.

Check power supply wiring for open or intermittent connections.

Check motor wiring for open or intermittent connections.


Check Gate and Cathode connections to MX

3 card.

No input voltage was detected for longer than the Inline Configuration time delay parameter setting ( I/O 24) when a start command was given to the starter.

If an inline contactor is being used, verify that the setting of the Inline

Configuration time delay parameter (I/O 24) allows enough time for the inline contactor to completely close.

Check input supply for open disconnects, open fuses, open circuit breakers or disconnected wiring.


3 control card.


PORT fault timer timed out before line power returned.

Extend PORT fault time parameter (FUN 10) if possible.

During operation, the MX

3 phases.

detected a very high level of current in one or more

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.


Motor current exceeded the Over Current Trip Level setting (PFN 01) for longer than the Over Current Trip Delay Time setting (PFN 02).

Check motor for a jammed or an overload condition.

Motor current dropped under the Under Current Trip Level setting (PFN 03) for longer than the Under Current Trip Delay time setting (PFN 04).

Check system for cause of under current condition.

160


Fault Code Description

F35 Power Factor Leading

F36 Power Factor Lagging

F37

F38

F39

F40

F41

F46

Current Imbalance

Ground Fault

No Current at Run

Shorted / Open SCR

Current at Stop

Disconnect Open


The motor power factor went above the PF leading trip level.

Verify loading of motor.

On synchronous motors, verify field supply current.

The motor power factor went below the PF lagging trip level.

Verify loading of motor.

On synchronous motors, verify field supply current.

A current imbalance larger than the Current Imbalance Trip Level parameter setting (PFN 05) was present for longer than the Curr Imbal Trip Time (PFN 06).

Check motor wiring for cause of imbalance. (Verify dual voltage and 6 lead motors for correct wiring configuration).

Check for large input voltage imbalances that can result in large current imbalances.

Check motor for internal problems.

Ground current above the Ground Fault Trip level setting (PFN 07 / PFN 08) has been detected for longer than the delay time (PFN 09) setting.

Check motor wiring for ground faults.

Check motor for ground faults.

Megger motor and cabling (disconnect from starter before testing).


Verify that the CTs are installed with all the White dots towards the input line.

In Single phase applications, verify that only two CTs are being used; that they are installed with all the White dots or Xs in the correct direction; and that the CTs are connected to the L1 and L3 CT inputs on the MX

3 control card.

Motor current went below 10% of FLA while the starter was running.

Verify Motor Connections.

Verify the CT wiring to the MX

3 control card.


Check if load is still connected to starter.

Check if motor may have been driven by the load (a regeneration condition).

Check Gate and Cathode connections to MX

3 for loose connections.

Check for inline contactor or disconnect.

A shorted or open SCR condition has been detected.

Verify that all SCR gate leads wires are properly connected at the SCR devices and the MX

3 control card.

Check all SCRs with ohmmeter for shorts.

Verify that the Input Phase Sensitivity parameter setting (FUN 04) is correct.

Verify that the Starter Type parameter setting (FUN 07) is correct.

Verify the motor wiring. (Verify dual voltage motors for correct wiring configuration).

Motor current was detected while the starter was not running.

Examine starter for shorted SCRs.

Examine bypass contactor (if present) to verify that it is open when starter is stopped.


A signal on the disconnect digital input (I/O 01 - I/O 08) was not present when a start was commanded.

Verify that disconnect feedback wiring is correct.

Verify that disconnect is not faulty.

161


Fault Code

F47

F48

F49

F50

F51

F53

F54

F55

F56

Description

Stack Protection Fault (stack thermal overload)

Bypass /2M Contactor Fault

Inline Contactor Fault

Control Power Low

Current Sensor Offset Error

Tachometer Signal Loss

BIST Fault

BIST CT Fault

RTD Open or Shorted


The MX

3 condition.

electronic power stack OL protection has detected an overload

Check motor for jammed or overloaded condition.

Verify that the CT ratio (FUN 03) is correct.

Motor load exceeds power stack rating. Consult factory

A digital input has been programmed as a Bypass/2M Contactor Feedback input and an incorrect bypass feedback has been detected for longer than the Bypass

Confirm time parameter setting (I/O 25).

Verify that the bypass/2M contactor coil and feedback wiring is correct.

Verify that the relay connected to the bypass/2M contactor(s) is programmed as the UTS function (I/O 10 - I/O 15).

Verify that the bypass/2M contactor power supply is present (J4).

Verify that the appropriate Digital Input Configuration parameter (I/O 01 -08) has been programmed correctly.

Verify that the bypass contactor(s) are not damaged or faulty.

The in-line contactor did not close.

Check wiring to coil of contactor.

Check feedback wiring from auxiliary contactor to digital input (I/O 01 - 08).

Check in-line fault delay (I/O 24).

Low control power (below 90V) has been detected while running.

Verify that the control power input level is correct, especially during starting when there may be significant line voltage drop.

Check control power transformer tap setting (if available).

Check control power transformer fuses (if present).

Check wiring between control power source and starter.

Indicates that the MX

3 control card self-diagnostics have detected a problem with one or more of the current sensor inputs.

Verify that the motor FLA (QST 01) and CT ratio (FUN 03) 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.

No tachometer signal detected during start or run.

Verify tachometer wiring and level of signal.

Verify tachometer Full Speed Voltage (FUN 13) setting.

Extend Tachometer Loss Time (FUN 14) to allow time for motor to start turning.

Increase Initial Current to make sure motor starts turning immediately after the start command is given.

The Build In Self Test was cancelled.

The disconnect (if present) was closed during standard BIST testing.

Line voltage and/or phase current was detected during standard BIST testing.

During powered BIST testing the disconnect was opened during testing.

During powered BIST testing line voltage was lost during testing.

During powered BIST testing the starter detected that one or more CTs are located on the incorrect phases or one or more CT's polarities are reversed.

Verify CT wiring, positioning and direction.

An open or shorted RTD was detected.

Verify the condition and wiring of the RTD.

162


F63

F64

F65

F66

Fault Code

F60

F61

F62

F67

F71

F80

F81

F82

F84

F85

F86

Description

External Fault on DI#1 Input

External Fault on DI#2 Input

External Fault on DI#3 input







DI # 01 - 08 (I/O 01 - 08) has been programmed as a fault type digital input and the input indicates a fault condition is present.

Analog Input Level Fault Trip.

RTD Module Communications

Fault

Keypad Communication Fault

Modbus Timeout Fault

MX

3 to I/O Card Communication

Fault (Interboard fault)

I/O Card SW version Fault

I/O Card Current Offset Error

Increase Digital Fault Input Trip Time (I/O 09).

Based on the Analog Input parameter settings, the analog input level has either exceeded or dropped below the Analog Input Trip Level setting ( I/O 17) for longer than the Analog Input Trip Delay time (I/O 18).

Measure value of analog input to verify correct reading.

Verify settings of all Analog Input parameters ( I/O 16 - I/O 20 ).

Verify correct positioning of input switch (SW1-1) (Voltage or Current) on the

MX

3 control card.

Verify correct grounding of analog input connection to prevent noise or ground loops from affecting input.

Communications with the RTD module(s) has been lost.

Verify RS-485 wiring between RTD module(s) and MX

3 card set.

Verify RTD module 24VDC power supply.

Verify that the RTD module(s) are set to the same address as the MX

3 address parameters RTD 01 and RTD 02.

module

Indicates that communication has been lost with the remote keypad.

(This fault normally occurs if the remote keypad is disconnected while the MX

3 control card is powered up.

Verify that the remote keypad cable has not been damaged and that its connectors are firmly seated at both the keypad and the MX

3 control card.

Route keypad cables away from high power and/or high noise areas to reduce possible electrical noise pickup.

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 (FUN 18) defined time.

Verify communication parameter settings ( FUN 16 - FUN 19).

Check wiring between the remote network and the MX

3 control card.

Examine remote system for cause of communication loss.

Communication between the two MX

3 cards has been lost.

Verify that both cards are mounted together and that the mounting hardware is not loose.

Verify that no foreign matter is located between the two boards.

Consult factory if fault persists.

Typically occurs when attempting to run a version of application software that is incompatible with the bottom I/O card. Verify that the software is a correct version for the I/O card being used. Consult factory for more details.

Indicates that the I/O card self-diagnostics have detected a problem with the zero sequence ground fault input.

If no zero sequence ground fault CT is connected to input, verify that parameters

ZS GF Lvl (PFN 08) is turned "Off".

Verify that no current is flowing through the zero sequence ground fault CT.

Consult factory is fault persists.

163


Fault Code

F87

F88

F89

F90

F91

F94

F95

F96

F97

F98

F99

Description

I/O Card Error

I/O Card Error

I/O Card SW Watchdog

I/O Card Error

I/O Card Program EPROM

Checksum


I/O card has detected a problem with the Real Time Clock operation. Consult factory.

I/O card has detected an internal CPU problem. Consult factory.

I/O card has detected an internal software problem. Consult factory.



CPU Error – SW Fault

Typically occurs when attempting to run a version of control software that is incompatible with the MX

3 control card hardware being used. Verify that the software is a correct version for the MX

3 control card being used. Consult factory for more details.

Fault can also occur if the MX

3

Consult factory.

control has detected an internal software problem.

The MX

3 found the non-volatile parameter values to be corrupted. Typically occurs when the MX

3 is re-flashed with new software.

CPU Error – Parameter EEPROM

Checksum Fault

CPU Error – Program EPROM

Checksum Fault

Perform a Factory Parameter reset and then properly set all parameters before resuming normal operation.

CPU Error

If fault persists after performing a Factory Parameter reset, consult factory.

The MX

3 has detected an internal CPU problem. Consult factory.

CPU Error – SW Watchdog Fault The MX

3 has detected an internal software problem. Consult factory.

CPU Error The MX

3 has detected an internal CPU problem. Consult factory.

The non-volatile program memory has been corrupted.

Consult factory. Control software must be reloaded in to the MX

3 before normal operation can resume.

control card

164


8.6

Minimum Safety Practices

Minimum Safety Practices

Before performing any tests on electrical equipment make certain all PPE (Personal Protective Equipment) is worn. Check with your

Health and Safety co-ordinator or for more information see (www.NFPA.ORG) Electrical Safety in the workplace.

Open the disconnect switch and perform lockout and tag procedures. After opening the switch and before opening door, use the viewing window to ensure that all three Load Break Interrupter Switch blades are open and resting on the ground bar. Use a flashlight if necessary (see picture).

There are several interlocks on the switches. They are for personal and/or equipment protection. Under no circumstances should they be made inoperative when the switch is in service. To do so could cause bodily injury, death and/or property damage.

Prior to commencing any testing procedures, ensure that the designated five minute wait period has passed, then discharge any power factor correction capacitors if present. The wait time allows the charge in the capacitors to dissipate.

Inspect the LV section first, using a voltage sniffer to verify that all voltage has been successfully removed or discharged.

Next, conduct the same tests within the MV section.

A smell test is then needed to detect a scent of burning or any visual trace of burn damage to the system.

Follow all grounding procedures set forth by the health and safety co-ordinator. If no such procedures are available contact NFPA 70E for the proper procedure.

Never energize a switch without the arc chutes and barriers installed in place.

For more details refer to Powercon PIF or Micro-Rupter Load Break Interrupter Switch Instruction Book with the switch model number supplied with the starter.

H

DANGER

HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH

•

Only qualified personnel familiar with medium voltage equipment are to perform work described in this set of instructions.

•

Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See NFPA 70E.

•

Turn off all power before working on or inside equipment.

•

Use a properly rated voltage sensing device to confirm that the power is off.

•

Before performing visual inspections, tests, or maintenance on the equipment, disconnect all sources of electric power.

Assume that circuits are live until they have been completely de-energized, tested, and tagged. Pay particular attention to the design of the power system. Consider all sources of power, including the possibility of backfeeding.

•

Replace all devices, doors, and covers before turning on power to this equipment.

Failure to follow these instructions will result in death or serious injury.

165


8.7

Ohm Meter Testing

Ohm Meter Testing

A few reasons for an SCR Test Procedure would be if the starter is receiving shorted SCR trips, current imbalance trips, or ground fault trips - basically the SCR is not turning on properly. If any cards have been replaced, it is also recommended to do a BIST test (see BIST testing). A ohmmeter will be needed to perform the following tests. For accurate results, it is important to use the same ohmmeter throughout the tests and for each SCR in the starter. If all ohm readings are within specified limits, then the SCRs can be considered good and this procedure completed.

8.7.1

8.7.2

Fuse Tests

Perform ohmmeter resistance across both power and control fuses. Verify fuses for continuity.

Shorted SCR Test

This will test the anode to cathode integrity of the SCR. Use the following table and figure to place the ohmmeter probes. You should not need to remove components to perform the ohmmeter tests.

z NOTE: Figure 54 is the heat sinks that are underneath the 3 separate cards. Place the leads of the ohmmeter on the heat sinks behind the gate driver card.

Figure 54: Heat sinks

1

2

3

4

5

6

166

Test

From position 1 to position 2



Table 17: Ohmmeter Position

Ohm Meter Reading

Greater than 50 k

W

Less than 50 k

W

Greater than 50 k

W

Less than 50 k

W

Greater than 50 k

W

Less than 50 k

W

Results

Pass

Fail

Pass

Fail

Pass

Fail

Value

z NOTE: All three test functions only apply to a 4160V system. If testing a 2400V system, test only against position 1 versus 2 and 4 versus 5.

If all values are greater than 50K ohms, proceed to the SCR Gate to Cathode Test. If an SCR measures less than 50K ohms but not 0 ohms, the SCR still may be good. Contact Benshaw for further assistance. If any of the recorded values are 0 ohms then one or more of the SCRs in that phase has failed. An ohmmeter can only determine failed devices; an SCR tester is required to verify proper operation of the device.


8.7.3

z NOTE: If at any time during this procedure it is necessary to remove any of the red and white SCR gate leads from the firing card, care must be taken to insure that these leads are reconnected to the terminal they were removed from.

Alternative Shorted SCR Test

This will test the anode to cathode integrity of the SCR. Measure the resistance between sets of red (cathode) leads on the right hand side of the firing card. The measured value should be greater than 50K ohms. Abnormally high or low values may indicate a failed SCR. To perform the SCR test, attach the ohmmeter to cathodes (red leads) of the SCR in the patterns shown below.

Figure 55

Meter Testing

With your ohmmeter, test each SCR cathode (red to red wire). Perform this test on SCRs labeled

A-B,C-D,E-F.

8.7.4

A and B

Pair

C and D

Pair

E and F

Pair

Test

Table 18


Greater than 50 k

W

Less than 50 k

W

Greater than 50 k

W

Less than 50 k

W

Greater than 50 k

W

Less than 50 k

W

Pass

Fail

Pass

Fail

Pass

Fail

Value

z NOTE: The E and F test only applies to tests on 4160V systems.

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

SCRs in that phase has failed. An ohmmeter can only determine failed devices; an SCR tester is required to verify proper operation of the device.

Shorted SCR Found

If a shorted SCR was found during the Shorted SCR Test, all of the circuit boards and the jumper bars on the phase will need to be removed in order to test each individual SCR to find the one that has shorted. Refer to Figure 54 on page 166 and table 19 to place the ohmmeter cables.

Table 19: Ohmmeter Position for Shorted SCR

Test








Greater than 50 k

W

Less than 50 k

W

Greater than 50 k

W

Less than 50 k

W

Greater than 50 k

W

Less than 50 k

W

Greater than 50 k

W

Less than 50 k

W

Greater than 50 k

W

Less than 50 k

W

Greater than 50 k

W

Less than 50 k

W

Results

Pass

Fail

Pass

Fail

Pass

Fail

Pass

Fail

Pass

Fail

Pass

Fail

Value

167


8.7.5

SCR Gate to Cathode Test

To perform the gate to cathode test, attach the ohmmeter to SCRs like in the picture shown below to measure the resistance between the red and white SCR gate leads.

Figure 56: SCR Gate Test

Test

Table 20: Ohmmeter Position for SCR Gate Test

Gate to cathode for each SCR


8

W to 50 W

Less than 8

W or more than 50 W

Pass

Fail

Results

If an SCR measures less than 8 ohms but not 0 ohms, the SCR still may be good. If any of the recorded values are 0 ohms then that SCR has failed. An ohmmeter can only determine failed devices; an SCR tester is required to verify proper operation of the device.

z NOTE: If at any time during this procedure it is necessary to remove any of the red and white SCR gate leads from the firing card, care must be taken to insure that these leads are reconnected to the terminal they were removed from.

z NOTE: If at any time these resistance readings are outside of the above specified values consult factory.

168


8.8

8.8.1

SCR Replacement

SCR Replacement

Card Removal

Before the SCRs can be removed, the PC boards and Lexan

ä or glastic must first be removed. If unsure of any wiring connections to the card, write down location of wires on drawings.

Next, remove the snubbers (refer to Figure 57).

Figure 57: Lexan

ä/Glastic & Card Assembly

8.8.2

SCR Clamp

The SCR clamp pictured below is typical of the clamp used on all SCRs. The larger SCRs have two spring washer stacks and pressure indicating washers. These SCR clamps are precision clamps that allows easy installation to the proper SCR clamping pressure. They have a pressure indicator(s) that will become loose once the proper pressure is reached.

Figure 58: Clamp Assembly

169


ATTENTION: The Fiber Optic cables can be damaged if struck or bent sharply. The edge of the printed circuits board should be held to prevent damage. Special equipment is required for working on the fiber optic portion of the starter. Please contact Benshaw for service in this area.

8.8.3

8.8.4

SCR Removal

To remove the SCR from heatsink, loosen the two bolts at each end of the clamp body. The SCR has a dowel pin centering it in the heat sink so the two bolts have to be loosened enough to allow it to clear this pin. DO NOT loosen the nut on indicator washer. This will

change the clamping pressure of the clamp and the clamp will be rendered defective.

SCR Installation

To install an SCR, use Benshaw approved SCR's. Coat the faces of the SCR's to be installed with a thin layer of electrical joint compound (EJC). Place the SCR's onto the dowel pins (refer to Figure 59 for proper SCR position). The SCR symbol has a triangle that points to the cathode. Assemble the insulator cups, washers and bolts as shown in the clamp diagram. Finger tighten the bolts until they are snug, ensuring that the bolts are evenly tightened and the clamp body is parallel to the heat sink. Tighten each bolt in 1/8 turn increments until the pressure indicator(s) can be turned on the bolt. This ensures the proper clamping pressure on the SCR.

Figure 59

8.8.5

8.8.6

z NOTE: For clamps with two washer stacks, it may be necessary to adjust (tighten or loosen) one or both bolts, until both indicators are even, allowing both washers to spin.

Re-Test SCR's

Once the SCR's have been replaced, perform another SCR Test Procedure.

Re-Assemble Unit

When the SCR readings are correct, re-install the PC boards, RC snubber, and Lexan

ä or glastic. Make certain that all wiring is done correctly, and re-install the phase in the unit it was taken from.

170


8.9

8.9.1

Built-In Self Test (BIST)

Built-In Self Test (BIST)


The MVRMX

3 starter has the capability to perform a test sequence to ensure it is operating properly. The test will operate the vacuum contactors and fire the SCR gates so that proper operation can be determined.

The standard BIST tests are designed to be run with no line voltage applied to the starter. When a disconnect switch is used, the disconnect switch must be opened before starting the standard tests. Standard BIST mode can be entered by entering the appropriate value into the Miscellaneous Command user parameter.

CAUTION: In order to prevent backfeeding of voltage through the control power transformer (if used), control power must be carefully applied to the MX

3 control card and contactors so that self testing can occur safely. The user must verify that the applied test control power cannot be fed backwards through the system. “Run/Test” isolation switches, test power plugs, and wiring diagrams are available from Benshaw.

CAUTION: Verify that line voltage is not applied to the line side of the inline contactor before the test is performed. Otherwise the inline test will apply line voltage to the starter and a BIST test fault will occur.

CAUTION: Before starting the Built-In Self Test, ensure that the disconnect is open. This test should not be performed until it has been verified that all three phases of the disconnect are open and the disconnect is locked out.

8.9.2

Test Setup

To perform the BIST, open the control panel door to connect 120VAC to the test plug. Move the Normal/Test switch to the Test Position and verify that the 120VAC control power is present.

Figure 60:

Normal/Test

Switch

8.9.3

Open the medium voltage door and verify the operation of six different LEDs on each of the three gate driver cards. The Power LED

(RED / LED 1) which is behind the red glastic holding the transformer must be verified. The 12 volt healthy LED (GREEN / LED 2) for the fiber optic cable on each of the fiber optic boards must also be illuminated in the upper left corner. The separate gate power LEDs

(GREEN / LED 3, 4, 5, 6) along the middle of the board must be illuminated for verification of power to the gates.

BIST Notes

The display will indicate step by step the activity of the BIST operation throughout the test.

To skip or move to the next activity of the BIST before the predetermined time has elapsed, press the [ENTER] button until the desired activity is present on the display screen.

The normal length of a BIST is 285 seconds. At the completion of the test, the display will briefly read the display below and then return to the home screen.

BIST Mode

Tests completed

171


z NOTE: If the power LED1 (RED) does not light up (behind the transformer), check and verify the 28 VAC Transformer. If the transformer is functional then the gate driver card that does not have all of its SCR indicator lights operating has failed.

Figure 61: Fiber Optic Driver Card Location (BIPC-300047-01)

172


8.9.4

8.9.5

Conducting a BIST

To conduct a BIST Test, follow these steps:

•

Press the [MENU] button six times to scroll to th FUN group.

•

Press the [DOWN] button five times to get to FUN 22.

•

Press the [ENTER] button.

•

Press the [UP] button seven times to set parameter to "Std BIST".

•

Press the [ENTER] button to begin the BIST test.

FUN: Misc Command

22 Std BIST

Begin BIST Test

Once started, the MVRMX

3 will log an event log 193 - "Std BIST Enter" in the event recorder and check the state of the disconnect switch. If the disconnect switch is closed, the MVRMX

3 will display:

Open disconnect to begin BIST

8.9.6

RUN relay and In-line Test

The MVRMX

3 will begin the test sequence by operating the in-line contactor and monitoring the 120VAC feedback for proper operation.

The RUN assigned relays are cycled on and off once and the feedback from an inline contactor is verified. In order to have a valid inline contactor feedback, a digital input (I/O 01 – 08) needs to be set to "Inline Confirm" and the input needs to be wired to an auxiliary contact of the inline contactor. The feedback is checked in both the open and closed state. If the feedback does not match the state of the

RUN relay within the amount of time set by the Inline Config (I/O 24) parameter an “Inline” fault (Fault #49) will occur.

z NOTE: If no digital input is assigned as an Inline Confirm input this test will always pass.

z NOTE: If the Inline Config (I/O 24) parameter on page 96 is set to "Off" this test will be skipped. During the in-line contactor test, the MVRMX

3 will display the following:

BIST Mode

Inline Closed

BIST Mode

Inline Open

8.9.7

UTS relay and Bypass Test

In this test, the dedicated bypass relay (if assigned) and UTS assigned relays are cycled on and off once and the feedback from a bypass contactor is verified. In order to have a valid bypass contactor feedback, the dedicated bypass confirm input and any other inputs set to bypass confirm needs to be wired to an auxiliary contact of the bypass contactor. The feedback is checked in both the open and closed state. If the feedback does not match the state of the UTS relay within the amount of time set by the Bypass Feedback (I/O 25) parameter a “Bypass/2M Fault” (Fault #48) will occur.

z NOTE: If the dedicated bypass relay is set to "fan" and if no digital inputs are assigned as a Bypass Confirm input this test will always pass.

BIST Mode

Bypass Closed

BIST Mode

Bypass Open

173


8.9.8

Sequential SCR Gate Firing

The SCR gate outputs are fired sequentially in this test . This test is used to verify that the fiber optic gate driver cards are properly connected and functional. The gate output LEDs must be monitored during this test to verify proper operation.

When the MX

3 is performing this test it will display the following;

BIST Mode

Gate G ?

On

This display will indicate a gate number from 1 to 6 in the order G6, G3, G5, G2, G4 and G1. The medium voltage starter uses series

SCR strings instead of a single SCR so each gate number indicates a series SCR string being fired in sequence. The firing pattern is shown in the table below. Ensure that the starter steps through this sequence triggering the SCRs in the order shown below .

5

6

3

4

Step

1

2

Display

G6

G3

G5

G2

G4

G1

Table 21: Gate Firing Sequence

Gates Fired

Phase 1 - B, D, F

Phase 1 - A, C, E

Phase 2 - B, D, F

Phase 2 - A, C, E

Phase 3 - B, D, F

Phase 3 - A, C, E

Watch the sequence of the gate LEDs while this test is operating. If the SCR gates are fired out of sequence than check the fiber optics for improper installation.

Press [ENTER] pushbutton to move to the next BIST step.

z NOTE: The gate firing sequence shown above is a three phase pattern illustrating the firing procedure of a 4160V system. If operating a 2400V system the sequence will not include the gate testing of the E and F positions.

z NOTE: If the SCR gate indicators do not light in the proper sequence during this test then consult Benshaw. Do not attempt to operate the starter as SCR damage will occur.

8.9.9

All SCR Gates Firing

The SCR gate outputs are all fired in this test. This test allows easy measurement of the gate voltages. The gate voltages can be measured with a DC voltage meter or with an oscilloscope. The voltages should be between 0.5VDC and 2VDC when measured with a DC voltage meter. Connect the positive lead to the white gate wire and the negative lead to the red gate wire to measure the gate waveform with an oscilloscope. Use 2 volts per division and a 2 millisecond time scale. See the figure below for a sample voltage measurement using an oscilloscope.

Figure 62: Gate voltage of a proper SCR

174


8.9.10

8.9.11

During this test the display will show the following.

BIST Mode

All gates on

Press [ENTER] pushbutton to complete BIST procedure.

z NOTE: If the LED gate indicators (RED / LED 7, 8, 9, 10, 11, 12) do not all light during this test then consult Benshaw. Do not attempt to operate the starter as SCR damage will occur.

Resetting System

After the completion of the BIST Test the MVRMX

3 resets the system.

registers an event #195 -" BIST Passed" in the event recorder and automatically

BIST Test Cancelled

If, for any reason during the test, the disconnect is closed, power is applied, or the BIST command is removed, the MVRMX

3 the test and log the fault number and name of event that caused the BIST to be cancelled.

will stop

Fault #

Fault Description

High Pot Test

8.10

High Pot Testing

Consult Factory

Vacuum Contactor

8.11

Vacuum Contactor

Consult manual for vacuum contactor.

See also page 176 for more information.

175


Optional RTD Module Troubleshooting

8.12

RTD Module Troubleshooting

If the system includes optional RTD Modules, verify that all three LED indicator lights on the remote RTD units are toggling. There is a

TX (Red) & RX (Green) that will flash when the module is communicating and a Status (Green) light that blinks once per second. The

RTD module connects to the top of the MX

3

I/O card. There should be a Red TX and Green RX blinking in the J1 connection where the two devices connect.

z NOTE: For more details see Remote RTD Module Manual Pub. # 890010-00-X.

Figure 63: RTD Module (SPR-100P)

Remote

RTD Module

SPR-100P

TX (Red)

RX (Green)

Status (Green)

Transmit Data

Receive Data

Operation

Flashes when module is transmitting data.

Flashes when module is receiving data.

On when module measures RTD.

Maintenance

8.13

VACUUM contactor and Power Pole assembly Maintenance

General:

During the life of the MVRMX

3

, it may be necessary to perform routine maintenance on the unit. The following sections describe how to change a VACUUM contactor and power pole assembly.

Attention:

Servicing energized equipment can be hazardous. Sever injury or death may result from electrical shock or burn due to improper use of the equipment. It is recommended that the equipment is disconnected and a lock out command is enacted prior to any maintenance that is performed. Remember to allow any stored energy in the capacitors to dissipate. If it is necessary to work in the vicinity of energized as well as de-energized equipment, the work practices of NFPA 70E, Electrical Safety Requirements for Employee Workplace, must be followed.

Periodical Inspection:

Benshaw controls require only periodical inspections. These inspections can be visual for physical traces of dust, dirt or visible damage.

Circuit boards should be physically tested to ensure that all the cables are connected properly.

Remember cleaning solvents should not come in contact with circuit or PC boards.

If filters or blowers are used, they should be cleaned or replaced as specified in the NEMA Standards Publication No. ICS 1.1 - 1987

Static:

While performing maintenance on the MVRMX

3

, certain preventative measures must be taken when handling or touching static sensitive components in the enclosure.

Most circuit boards and SCRs can be damaged by Electro-Static Discharge (ESD). If persons make contact with an ESD sensitive component during maintenance, they must be grounded. Grounding should be accomplished with a wrist strap which is connected to an approved ground.

176

ATTENTION:

Maintenance Records:

Vacuum Contactor:

Vacuum Bottles:

Power Pole:

Fans:

Interlocks:

Barriers:

Disconnect Switch:


Using other than factory recommended test equipment and instructions on the controls may result in personal injury and damage or failure of equipment.

Keeping good maintenance records will be helpful in locating possible intermittent problems by pointing to a particular area of recurring trouble within the system.

To remove either of the contactors, perform the following steps:

•

Ensure that the main disconnect is open and the grounding blades are seated.

•

Disconnect all power wire going to the VACUUM contactor poles.

•

If necessary, remove the gray cover on the bottom of the contactor.

•

Remove the control wires from the contactor.

•

Undo the four mounting bolts and remove the contactor.

Replacement of the contactor is the reverse of the removal. Test the contactor before installing to ensure proper operation. A contactor manual is provided with each starter and should be referred to when disassembling and reassembling the contactor. If required contact Benshaw for a manual.

The contacts in a vacuum bottle can not be seen or examined directly. They rely on a vacuum to operate properly and to interrupt current. Wear indicators must not be in the red zone when the contacts initially touch. Operate the contactor manually with a hex wrench to perform this test. Consult contactor manufacturers instruction manual included with the starter for addition maintenance requirements.

zNOTE: High pot testing of vacuum bottles creates radiation. Personnel should be no closer than 10 feet and behind a metal barrier. Keep test times to a minimum.

To remove a SCR power pole, perform the follow steps:

•

Ensure that the main disconnect is open and the grounding blades are seated.

•

Disconnect all power and control wiring going to the phase.

•

Remove the two nuts, one top and one bottom, holding the phase in place.

•

Carefully lift the phase from the enclosure, using caution to avoid damage to the control wiring.

•

Once removed, contact Benshaw to have the phase serviced or exchanged.

The installation of the power pole is the opposite of the removal process. The bypass contactor in the package is horsepower rated and can be used to operate the motor while the power pole is being serviced. If this is the case, ensure that the power wire for the removed phase is completely removed from the unit and that the control wiring is isolated and will not come into contact with any medium voltage to prevent damage to the starter.

Physically testing the fans by rotating and observing the fans for noise or binding will indicate if any failure is evident.

Verify that interlocks functions as intended, and have not been forced, damaged or removed.

Verify that all barriers are in place and securely fastened.

Perform a visual inspection for evidence of damage such as overheating, and do a tightness check. Consult disconnect switch manufacturers instruction manual included with the starter for addition maintenance requirements.

177


NOTES:

178

Appendices

179

APPENDIX A - EVENT CODES

Event Codes

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

117

118

119

110

111

112

113

114

115

116

140

141

Event Number

1 through 99 **

101

102

103

104

105

106

107

Event

Starter Faults

Start Commanded

Slow Speed Commanded

System UTS

Energy Saver Entered

Energy Saver Exited

System Stop Commanded

System Stop Complete

Motor OL Warning

Motor OL Lockout Activated

Motor OL Lockout Expired

Stack OL Warning

Stack OL Lockout Activated

Stack OL Lockout Expired

Emergency OL Reset Performed

RTD Stator Warning

RTD Bearing Warning

RTD Other Warning

Disconnect Opened

Disconnect Closed

Event Number

170

171

172

173

174

192

193

194

195

180

181

182

183

184

185

186

187

188

190

191

Event

PORT Entered due to low voltage

PORT Entered due to low current

PORT Bypass contactor opened

PORT Power returned

PORT Recovery complete

Parameter Defaults Loaded

Time Set / Changed

User Passcode Enabled

User Passcode Disabled

Factory Control Password Accessed

Event Log Cleared

User Run Time Reset

User KWh meters Reset

Reflash Mode Entered

System Powered Up

System Powered Down

Low Control Power Detected when

Stopped

Standard BIST Entered

Powered BIST Entered

BIST Passed

180

APPENDIX B - ALARM CODES

Alarm Codes

The following is a list of all MX

3 alarm codes. The alarm codes correspond to associate fault codes. In general, an alarm indicates a condition that if continued, will result in the associated fault.

Alarm

Code

Description

A02

A05

A06

A07

A08

A10

A11

A12

A13

A14

A15

A21

A22

A23

A24

A25

A26

A27

A28

Motor Overload Alarm

Motor PTC Alarm

Stator RTD Alarm

Bearing RTD Alarm

Other RTD Alarm

Phase Rotation not ABC

Phase Rotation not CBA

Low Line Frequency

High Line Frequency



Low Line L1-L2

Low Line L2-L3

Low Line L3-L1

High Line L1-L2

High Line L2-L3

High Line L3-L1

Phase Loss

No Line

Notes

This occurs when the motor thermal content reaches the

Motor OL Alarm Level (PFN33). The MX

3 trips when it reaches 100%. The alarm continues until the overload trip lockout is reset.

This occurs when the Motor PTC thermistor input indicates that the motor is overheated but before the fault trip time has expired.

This occurs when a RTD assigned to the Stator group reaches its alarm level.

This occurs when a RTD assigned to the Bearing group reaches its alarm level.

This occurs when a RTD assigned to the other group reaches its alarm level.

This alarm exists while the MX

3 is stopped, line voltage is detected and phase sensitivity parameter is set to ABC. If a start is commanded, a Fault 10 occurs.


3 is stopped, line voltage is detected and phase sensitivity parameter is set to CBA. If a start is commanded, a Fault 11 occurs.

This alarm exists when the MX

3 has detected a line frequency below the user defined low line frequency level.

The alarm continues until either the line frequency changes to be in range or the fault delay timer expires.

This alarm exists when the MX

3 has detected a line frequency above the user defined high line frequency level.

The alarm continues until either the line frequency changes to a valid frequency or the fault delay timer expires.


3 is stopped, set to single phase mode, and line voltage is detected that is not single phase. If a start is commanded, a Fault 14 occurs.


3 is stopped, set to a three-phase mode, and single-phase line voltage is detected. If a start is commanded, a Fault 15 occurs.


3 is stopped and low line voltage is detected. If a start is commanded, a Fault 21 may occur.






3 is stopped and high line voltage is detected. If a start is commanded, a Fault 24 may occur.






3 is running and a phase loss condition is detected, but the delay for the fault has not yet expired. When the delay expires, a Fault 27 occurs.


3 needs to be synchronized or is trying to sync to the line and no line is detected.

181

APPENDIX B - ALARM CODES

Alarm

Code

A29

Description

P.O.R.T. Timeout

A31 Over current

A34 Undercurrent

A35

A36

Power Factor Leading

Power Factor Lagging

A37

A64

A65

A66

A67

A71

A60

A61

A62

A63

A38

A47

A53

Current Imbalance

Ground Fault

Stack Overload Alarm


External Alarm on DI 1 Input








Analog Input Level Trip Alarm

Notes


3 is in Power Outage Ride

Through mode and it is waiting for line power to return.

When the PORT fault delay expires a Fault 29 shall occur.


3 is running and the average current is above the defined threshold, but the delay for the fault has not yet expired. When the delay expires, a Fault

31 occurs.


3 is running and the average current is below the defined threshold, but the delay for the fault has not yet expired. When the delay expires, a Fault

34 occurs.


3 is running and the measured PF is leading the defined threshold, but the delay for the fault has not yet expired. When the delay expires, a

Fault 35 occurs.


3 is running and the measured PF is lagging the defined threshold, but the delay for the fault has not yet expired. When the delay expires, a

Fault 36 occurs.


3 is running and a current imbalance above the defined threshold is detected, but the delay for the fault has not yet expired. When the delay expires, a Fault 37 occurs.


3 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%.

This occurs when a non-valid or tachometer input signal is detected. The alarm shall exist until a valid tachometer feedback signal is detected or the fault delay timer has expired. When the delay expires, a Fault 53 shall occur.

This alarm shall exist if DI 1 is programmed as a fault, is in the fault state, but the fault timer has not yet expired.

When the timer expires a Fault 60 shall occur.















This alarm exists if the analog input exceeds the defined threshold, but the delay for the fault has not yet expired.

When the delay expires, a Fault 71 occurs.

182

F56

F60

F61

F62

F63

F51

F53

F54

F55

F47

F48

F49

F50

F39

F40

F41

F46

F35

F36

F37

F38

F29

F30

F31

F34

F25

F26

F27

F28

F21

F22

F23

F24

F12

F13

F14

F15

F07

F08

F10

F11

F03

F04

F05

F06


F00 No fault

F01

F02

UTS Time Limit Expired

Motor Thermal Overload Trip

Slow Speed Time Limit Expired

Speed Switch Time Limit Expired

Motor PTC Overtemperature

Stator RTD Overtemperature

Bearing RTD Overtemperature

Other RTD Overtemperature

Phase Rotation Error, not ABC

Phase Rotation Error, not CBA

Low Line Frequency

High Line Frequency



Low Line L1-L2

Low Line L2-L3

Low Line L3-L1

High Line L1-L2

High Line L2-L3

High Line L3-L1

Phase Loss

No Line

PORT Timeout

Instantaneous over current (I.O.C.)

Overcurrent

Undercurrent

Power Factor Leading

Power Factor Lagging

Current Imbalance

Ground Fault

No Current at Run

Shorted / Open SCR

Current at Stop

Disconnect Fault

Stack Overtemperature / P.S Failure

Bypass/2M Contactor Fault

Inline Contactor Fault

Control Power Low

Current Sensor Offset Error


BIST Fault

BIST CT Fault

RTD Open or Shorted

External Fault on DI 1 Input




APPENDIX C - FAULT CODES

Y

N

N

N

Y

N

Y

N

N

N

Y

Y

N

N

N

N

N

Y

Y

Y

N

N

N

Y

Y

Y

Y

N

N

Y

Y

Y

Y

N

N

N

N

Y

Y

N

N

N

Y

Y

Y

Controlled Fault Stop Shunt Trip Fault

-

Y

Y

N

N

N

N

N

N

N

N

N

N

N

N

N

N

N

N

N

N

N

N

N

N

N

Y

N

N

N

N

N

Y

N

N

N

N

N

Y

N

N

N

N

N

N

N

N

Y

Y

Y

Fault Codes

N

Y

Y

Y

Y

N

N

N

N

Y

N

N

Y

Y

N

N

N

Y

Y

Y

Y

Y

N

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

N

Y

Y

Y

Auto-Reset Allowed

-

Y

Y

183

APPENDIX C - FAULT CODES


F88

F89

F90

F91

F84

F85

F86

F87

F71

F80

F81

F82

F64

F65

F66

F67

F94

F95

F96

F97

F98

F99





Analog Input #1 Level Fault Trip

RTD Module Communication Fault

Keypad Communication Fault

Modbus Timeout Fault

MX to I/O Card Communication Fault

I/O Card Software version Fault

I/O Card Current Offset Error

I/O Card Error

I/O Card Error

I/O Card Software Watchdog

I/O Card Error

I/O Card Program EPROM Checksum Fault

CPU Error – Software fault

CPU Error – Parameter EEPROM Checksum Fault

CPU Error

CPU Error - Software Watchdog

CPU Error

CPU Error – Program EPROM Checksum Fault

N

N

N

N

N

N

N

N

N

N

N

Y

N

N

N

Y

Y

Y

Y

Controlled Fault

Stop

Y

Y

Y

Shunt Trip Fault

N

N

N

N

N

N

N

N

N

N

N

N

N

N

N

N

N

N

Y

Y

N

N

Auto-Reset Allowed

N

N

N

N

N

N

N

N

Y

N

N

Y

Y

Y

Y

Y

N

N

N

N

N

N

184

1)

2)

3)

4)

5)

6)

Description

LCD Display (small)

LCD Display (large)

LCD display cable

Remote RTD Module

Zero Sequence Ground Fault CT

Communication Modules

Part Number

KPMX3SLCD

KPMX3LLCD

RI-100008-00

RI-100009-00

SPR-100P

CT-2000/1-6 (CT100001-01) consult factory

APPENDIX D - SPARE PARTS

Options and Accessories

Size

H=63mm(2.48"), W=101mm(4")

H=77mm(3.03"), W=127mm(5")

3' or 1meter

6' or 2 meter

3)

4)

1)

2)

5)

8)

9)

6)

7)

10)

11)

12)

13)

14)

15)

Description

LCD Display - small

LCD Display - large

LCD display cable

Cooling Fans

Current Transformers (CTs)

Zero Sequence Current Transformer

MX

3

Assembly

DV/DT Board

Gate Drive Board

Medium Voltage Fuses

MV Stack

-Power Pole

-SCRs

-DV/DT

-Fiber Optic

Voltage Transformer

Control Power Transformers

SCRs

Divider Card

Part Number

KPMX3SLCD

KPMX3LLCD short = BIRI-100008-00 long = BIRI-100009-00

CT-100001-01

CT-100003-01

CT-100005-01

CT-100011-01

CT-100024-01

CT-100034-01

CT-100108-01

CT-2000/1-6 (CT100001-01)

PC-450100-01-01

PC-300048-01-02

300047-01 rev 13

R-rated

S-450100-00

S-450101-00

S-450102-00

S-450103-00

S-450104-00

S-450105-00

S-450106-00

Size

H=63mm(2.48"), W=101mm(4")

H=77mm(3.03"), W=127mm(5")

3' or 1meter

6' or 2meter

4" – 6"

Ground Fault, 2000:1

150:5

250:5

800:5

50:5

2000:5

5000:5

Consult Factory

208A, 2.3KV

208A, 5KV

415A, 2.3KV

415A, 5KV

600A, 2.3KV

600A, 5KV

144A, 6.6KV

Consult Factory

Consult Factory

Consult Factory

100032-01

Spare Parts

Quantity

3

3

3

185

APPENDIX E - EU DECLARATION OF CONFORMITY

EU Declaration of Conformity

Product Category:

Product Type:

Model Number:

According to the EMC – Directive 89/336/EEC as Amended by 92/31/EEC and 93/68/EEC

Motor Controller

Reduced Voltage Solid State Motor Controller

CFMVRMX18-3500-4160-1

1 - Nema 1

3R - Nema 3R

12 - Nema 12

Voltage

HP

12 - 2300 Volts

- 2400 Volts

- 3300 Volts

18 - 4160 Volts

- 4800 Volts

- 7200 Volts

3

MV MX Control

Combination Fusable

Example of Model Number: CFMVRMX18-3500-4160-1

A Combination Fusable RediStart starter with MV MX control, 4160 Volts, 3500 Horse Power, NEMA 1 Enclosure.

Manufacturer's Name:

Manufacturer's Address:

Benshaw, Inc.

659 East Sutter Road

Glenshaw, PA 15116

United States of America

The before mentioned products comply with the following EU directives and Standards:

Safety:

UL 347 Standard for Motor Controllers over 1500V devices for starting, stopping, regulating, controlling, or protecting electric motors with ratings of 1.5KV to 7.2KV.

Electromagnetic Compatibility:

EN 61000-6-4 :2001 Emissions Radiated/Conducted

EN 55011/05.98+A1:1999

EN 61000-6-2 :2001 Immunity/Susceptibility which includes:

EN 61000-4-2 Electrostatic Discharge

EN 61000-4-3 Radiated RF

EN 61000-4-4 Electrical Fast Transient/Burst

EN 61000-4-5 Surge

EN 61000-4-6 Injected Currents

EN 61000-4-8 Magnetic

EN 61000-4-11 Voltage Dips

The products referenced above are for the use of control of the speed of AC motors. The use in residential and commercial premises (Class B) requires an optional EMC series filter. Via internal mechanisms and Quality Control, it is verified that these products conform to the requirements of the Directive and applicable standards.

Glenshaw, PA USA - 1 October 2003

Neil Abrams

Quality Control

Manager

186

APPENDIX F - MODBUS REGISTER MAP

Modbus Register Map

Following is the Modbus Register Map. Note that all information may be accessed either through the Input registers (30000 addresses) or through the Holding registers (40000 addresses).

Absolute Register Address Description

30020/40020

30021/40021

30022/40022

30023/40023

30024/40024

Starter Control

Starter Status

Input Status

Alarm Status 1

Alarm Status 2

Range

Bit Mask:

Bit 0: Run/Stop

Bit 1: Fault Reset

Bit 2: Emergency Overload Reset

Bit 3: Local/Remote

Bit 4: Heat Disable

Bit 5: Ramp Select

Bit 10: Relay 6

Bit 11: Relay 5

Bit 12: Relay 4

Bit 13: Relay 3

Bit 14: Relay 2

Bit 15: Relay 1

Bit Mask:

Bit 0: Ready

Bit 1: Running

Bit 2: UTS

Bit 3: Alarm

Bit 4: Fault

Bit 5: Lockout

Bit Mask:

Bit 0: Start

Bit 1: DI 1

Bit 2: DI 2

Bit 3: DI 3

Bit 4: DI 4

Bit 5: DI 5

Bit 6: DI 6

Bit 7: DI 7

Bit 8: DI 8

Bit Mask:

Bit 0: “A OL” – Motor overload

Bit 1: "A 5" – Motor PTC

Bit 2: "A 6" – Stator RTD

Bit 3: "A 7" – Bearing RTD

Bit 4: "A 8" – Other RTD

Bit 5: “A 10” – Phase rotation not ABC

Bit 6: “A 11” – Phase rotation not CBA

Bit 7: “A 12” – Low Line Frequency

Bit 8: “A 13” – High Line Frequency

Bit 9: “A 14” – Phase rotation not 1PH

Bit 10: “A 15” – Phase rotation not 3PH

Bit 11: “A 21” – Low line L1-L2



Bit 14: “A 24” – High line L1-L2



Bit 1: “A 27” – Phase loss

Bit 2: “noL” – No line

Bit 3: “A 29” – PORT Timeout

Bit 4: “A 31” – Overcurrent

Bit 5: “A 34” – Undercurrent

Bit 6: “A 35” – PF Too Leading

Bit 7: “A 36” – PF Too Lagging

Bit 8: “A 37” – Current imbalance

Bit 9: “A 38” – Ground fault

Bit 10: “A 47” – Stack overtemperature

Bit 11: “A 53” – Tach Loss

Bit 12: “A 60” – DI 1

Bit 13: “A 61” – DI 2

Bit 14: “A 62” – DI 3

Bit 15: “A 63” – DI 4

Units

–

–

–

–

–

187


30027/40027

30028/40028

30029/40029

30030/40030

30031/40031

30032/40032

30033/40033

30034/40034

30035/40035

30036/40036

30037/40037

30038/40038

30039/40039

30040/40040

30041/40041

30042/40042

30043/40043

30044/40044

30045/40045

30046/40046

30047/40047

30048/40048

30049/40049

30050/40050

30051/40051

30052/40052

30053/40053

30054/40054

30055/40055

30056/40056

30057/40057

Absolute Register Address

30025/40025

30026/40026

Description

Alarm Status 3

Lockout Status

Present Fault Code

Average Current

L1 Current

L2 Current

L3 Current

Current Imbalance

Residual Ground Fault Current

Zero Sequence Ground Fault Current

Average Voltage

L1-L2 Voltage

L2-L3 Voltage

L3-L1 Voltage

Motor Overload

Power Factor

Watts (lower 16 bits)

Watts (upper 16 bits)

VA (lower 16 bits)

VA (upper 16 bits) vars (lower 16 bits) vars (upper 16 bits) kW hours (lower 16 bits) kW hours (upper16 bits)

Phase Order

Line Frequency

Analog Input %

Analog Output %

Running Time

Running Time

Starts

TruTorque %

Power %

Range

Bit 0: “A 64” – DI 5

Bit 1: “A 65” – DI 6

Bit 2: “A 66” – DI 7

Bit 3: “A 67” – DI 8

Bit 4: “A 71” – Analog Input Trip

Bit 0: Motor overload

Bit 1: Motor PTC

Bit 2: RTD Stator

Bit 3: RTD Bearing

Bit 4: RTD Other

Bit 5: Disconnect open

Bit 6: Stack overtemperature

Bit 7: Control power

Bit 8: RTD Open/Short

Bit 9: Time between starts

Bit 10: Backspin

Bit 11: Starts per hour

Bit 12: RTD Comm Loss

Units

–

–

A rms

A rms

A rms

A rms

0.1 %

% FLA

0.1 Arms

V rms

V rms

V rms

V rms

%

-99 to +100

(in 16-bit two’s compliment signed format)

0.01

(in 32-bit unsigned integer format) W

(in 32-bit unsigned integer format) VA

(in 32-bit two’s compliment signed integer format) var

(in 32-bit unsigned integer format) kWh

0: no line

1: ABC

2: CBA

3: SPH

230 – 720, or 0 if no line

-1000 to +1000

(in 16-bit two’s compliment signed format)

0.1 Hz

0.1 %

0 – 1000

0.1 %

–

0 – 65535

0 – 59 hours minutes

–

%

%

188



30058/40058 Peak Starting Current

30059/40059 Last Starting Duration

30060/40060

30061/40061

30062/40062

Hottest Stator RTD Temperature

Hottest Bearing RTD Temperature

Hottest Other RTD Temperature

30063/40063

30064/40064

30065/30065

RTD 1 Temperature

RTD 2 Temperature

RTD 3 Temperature

30066/40066

30067/40067

30068/40068

30069/40069

30070/40070

30071/40071

30072/40072

30073/40073

30074/40074

30075/40075

30076/40076

30077/40077

30078/40078

30079/40079

30080/40080

30081/40081

30082/40082

30083/40083

30084/40084

30085/40085

30086/40086

30087/40087

30101/40101

30102/40102

30103/40103

30104/40104

RTD 4 Temperature

RTD 5 Temperature

RTD 6 Temperature

RTD 7 Temperature

RTD 8 Temperature

RTD 9 Temperature

RTD 10 Temperature

RTD 11 Temperature

RTD 12 Temperature

RTD 13 Temperature

RTD 14 Temperature

RTD 15 Temperature

RTD 16 Temperature

RTDs Enabled

RTDs Assigned as Stator

RTDs Assigned as Bearing

RTDs Assigned as Other

RTDs with Open Leads

RTDs with Shorted Leads

Remaining Lockout Time

Date/Time (lower 16 bits)

Date/Time (upper 16 bits)

Motor FLA


Independent Start/Run Motor Overloads

Motor Overload Running Enable

Range

0 - 200

0 - 200

0 - 200

0 - 200

0 - 200

0 - 200

0 - 200

0 - 200

0 - 200

0 - 200

0 - 200

0 - 200

0 - 200

0 - 200

0 - 200

0 - 200

0 - 200

0 - 200

0 - 200

Bit Mask:

Each of the sixteen (16) bits represents an

RTD. A 1 indicates the RTD is enabled.

Bit 0 represents RTD 1. Bit 15 represents

RTD 16.

Bit Mask:


RTD. A 1 indicates the RTD is assigned to the stator group.

Bit Mask:


RTD. A 1 indicates the RTD is assigned to the bearing group.

Bit Mask:


RTD. A 1 indicates the RTD is assigned to the other group.

Bit Mask:


RTD. A 1 indicates the RTD has an open lead.

Bit Mask:


RTD. A 1 indicates the RTD has shorted leads.

Units

A rms

0.1 Sec

°C

°C

°C

°C

°C

°C

°C

°C

°C

°C

°C

°C

°C

°C

°C

°C

°C

°C

°C

–

–

–

–

–

–

Sec

(in 32-bit unsigned integer format)

1 – 6400

100 – 199

0: Disabled

1: Enabled

0: Disabled

1: Enabled

Sec

A rms

0.01

–

–

189



30105/40105 Motor Overload Running Class

30106/40106 Motor Overload Starting Enable

30107/40107

30108/40108

30109/40109

30110/40110

30111/40111

Motor Overload Starting Class



Local Source

Remote Source

30112/40112

30113/40113

30114/40114

30115/40115

30116/40116

30117/40117

30118/40118

30119/40119

30120/40120

30121/40121

30122/40122

30123/40123

30124/40124

30125/40125

30126/40126

30127/40127

30128/40128

30129/40129

30130/40130

30131/40131

30132/40132

30133/40133

30134/40134

30135/40135

Start Mode



Ramp Time 1



Ramp Time 2

UTS Time

Initial V/T/P

Max T/P

Stop Mode

Decel Begin Level

Decel End Level

Decel Time

DC Brake Level

DC Brake Time

DC Brake Delay

Kick Enable 1

Kick Current Level 1

Kick Time 1

Kick Enable 2

Kick Current Level 2

Kick Time 2

Slow Speed Enable

Range

1 – 40

0: Disabled

1: Enabled

1 – 40

100 – 1

99 – 1

1 – 180

10 – 100

1 – 180

1 – 30

0: Disabled

1: Enabled

100 – 800

1 – 100

0: Disabled

1: Enabled

100 – 800

1 – 100

0: Disabled

1: Enabled

0 – 99

10 – 9999

0: Keypad

1: Terminal

2: Serial

0: Open Loop Voltage Ramp

1: Closed Loop Current Ramp

2: TruTorque Ramp

3: Power Ramp

4: Tach Ramp

50 – 600

100 – 800

0 – 300

50 – 600

100 – 800

0 – 300

1 – 900

1 – 100

10 – 325

0: Coast

1: Voltage Decel

2: TruTorqu Decel

3: DC Brake

Units

–

–

–

%

0.1 Min

–

–

% FLA

% FLA

Sec

% FLA

% FLA

Sec

Sec

%

%

–

%

%

Sec

%

Sec

100 mSec

–

% FLA

100 mSec

–

% FLA

100 mSec

–

190


30136/40136

30137/40137

30138/40138

30139/40139

30140/40140

30141/40141

30142/40142

Slow Speed


Units


Slow Speed Time Limit Enable

Slow Speed Time Limit

Slow Speed Kick Enable



Range

16: 5.0

17: 5.5

18: 6.2

19: 7.1

20: 8.3

21: 9.1

22: 10.0

23: 11.1

24: 12.5

25: 14.3

26: 16.7

27: 20.0

28: 25.0

29: 33.3

30: 37.5

31: 40.0

0: 1.0

1: 1.5

2: 1.6

3: 1.7

4: 1.9

5: 2.0

6: 2.5

7: 2.6

8: 2.8

9: 2.9

10: 3.1

11: 3.3

12: 3.5

13: 3.8

14: 4.2

15: 4.5

10 – 400

0: Disabled

1: Enabled

1 – 900

0: Disabled

1: Enabled

100 – 800

1 – 100

%

% FLA

–

Sec

–

% FLA

100 mSec

191


30144/40144

30145/40145

30146/40146

30147/40147

30148/40148

30149/40149

30150/40150

30151/40151

30152/40152

30153/40153

30154/40154

30155/40155


30143/40143

Description

Rated RMS Voltage


Motor Rated Power Factor

Overcurrent Enable

Overcurrent Level

Overcurrent Delay Time Enable

Overcurrent Delay Time

Undercurrent Trip Enable

Undercurrent Trip Level

Undercurrent Trip Delay Time Enable

Undercurrent Trip Delay Time

Current Imbalance Trip Enable


1 – 100

0: Disabled

1: Enabled

50 – 800

0: Disabled

1: Enabled

1 – 900

0: Disabled

1: Enabled

5 – 100

0: Disabled

1: Enabled

1 – 900

0: Disabled

1: Enabled

5 – 40

Range

16: 525

17: 575

18: 600

19: 660

20: 690

21: 800

22: 1000

23: 1140

24: 2200

25: 2300

26: 2400

27: 3300

28: 4160

29: 4600

30: 4800

31: 6000

0: 100

1: 110

2: 120

3: 200

4: 208

5: 220

6: 230

7: 240

8: 350

9: 380

10: 400

11: 415

12: 440

13: 460

14: 480

15: 500

32: 6600

33: 6900

34: 10000

35: 11000

36: 11500

37: 12000

38: 12470

39: 13200

40: 13800

0: Ins

1: ABC

2: CBA

3: SPH

192

Units

Vrms

–

–

–

% FLA

–

100 mSec

–

% FLA

–

100 mSec

–

%



30156/40156

30157/40157

Residual Ground Fault Trip Enable

Residual Ground Fault Trip Level

30158/40158

30159/40159

30160/40160

30161/40161

30162/40162

30163/40163

Over Voltage Trip Enable


Under Voltage Trip Enable


Over/Under Voltage Delay Time

Digital Input Trip Delay Time

30164/40164

30165/40165

30166/40166

Auto Fault Reset Enable

Auto Fault Reset Delay Time

Auto Fault Reset Count Enable

30167/40167

30168/40168

30169/40169

30170/40170

Auto Fault Reset Count


DI 1 Configuration

DI 2 Configuration

30171/40171

30172/40172

30173/40173

30174/40174

30175/40175

DI 3 Configuration

R1 Configuration

R2 Configuration

R3 Configuration

Analog Input Trip Enable

Range

0: Disabled

1: Enabled

5 – 100

0: Disabled

1: Enabled

1 – 40

0: Disabled

1: Enabled

1 – 40

1 – 900

1 – 900

0: Disabled

1: Enabled

1 – 900

0: Disabled

1: Enabled

1 – 10

0: Disabled

1: Enabled

0: Off

1: Stop

2: Fault High

3: Fault Low

4: Fault Reset

5: Disconnect

6: Inline Feedback (F49)

7: Bypass / 2M Feedback (F48)

8: Emergency Motor OL Reset

9: Local / Remote Control

Source

10: Heat Disable

11: Heat Enable

12: Ramp Select

13: Slow Speed Forward

14: Slow Speed Reverse

15: DC Brake Disable

16: DC Brake Enable

17: Speed Switch Normally Open

18: Speed Switch Normally Closed

0: Off

1: Fault Fail Safe

2: Fault Non Fail Safe

3: Running

4: Up To Speed

5: Alarm

6: Ready

7: Locked Out

8: Over Current Alarm

9: Under Current Alarm

10: Overload Alarm

11: Shunt Trip Fail Safe

12: Shunt Trip Non Fail Safe

13: Faulted on Ground Fault

14: In Energy Saver Mode

15: Heating

16: Slow Speed

17: Slow Speed Forward

18: Slow Speed Reverse

19: DC Braking

20: Cooling Fan

21: PORT

22: Tach Loss

0: Disabled

1: Enabled

Units

–

% FLA

–

%

–

%

100 mSec

100 mSec

–

Sec

–

–

–

–

–

–

193



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

30181/40181

30182/40182

30183/40183

30184/40184

30185/40185

30186/40186

30187/40187

30188/40188

30189/40189

30190/40190

30191/40191

30192/40192

30193/40193

30194/40194

30195/40195

Analog Output Function

Analog Output Span


Inline Enable

Inline Delay Time

Bypass Feedback Time

Keypad Stop

Modbus Timeout Enable

Modbus Timeout

CT Ratio

Auto Start

Energy Saver Enable

Heater / Anti-Windmill Enable

Heater / Anti-Windmill Level

Starter Type

Range

0: Low – Fault below preset level

1: High – Fault above preset level

0 – 100

1 – 900

1 – 100

0 – 99

0: Off (no output)

1: 0 – 200% Current

2: 0 – 800% Current

3: 0 – 150% Voltage

4: 0 – 150% Overload

5: 0 – 10kW

6: 0 – 100kW

7: 0 – 1MW

8: 0 – 10MW

9: 1 – 100% Analog Input

10: 0 – 100% Firing

11: Calibration (full output)

1 – 125

0 – 99

0: Disabled

1: Enabled

10 – 100

1 – 50

0: Disabled

1: Enabled

0: Disabled

1: Enabled

1 – 120

0: 72:1

1: 96:1

2: 144:1

3: 288:1

4: 864:1

5: 2640:1

6: 3900:1

7 5760:1

8: 8000:1

9: 14400:1

10: 28800:1

11: 50:5

12: 150:5

13: 250:5

14: 800:5

15: 2000:5

16: 5000:5

0: Disabled

1: Start after power applied

2: Start after fault reset

3: Starter after power applied and after fault reset

0: Disabled

1: Enabled

0: Disabled

1: Enabled

1 – 40

0: Normal (Outside Delta)

1: Inside Delta

2: Wye-Delta

3: Phase Controller

4: Current Follower

5: Across the Line (Full Voltage)

Units

%

100 mSec

%

%

%

%

Sec

–

–

–

100 mSec

100 mSec

–

–

–

–

–

–

% FLA

–

194


30196/40196

30197/40197

30198/40198

LED Display Meter

LCD Display Meter 1

LCD Display Meter 2


Range

0: Status

1: Ave Current

2: L1 Current

3: L2 Current

4: L3 Current

5: Current Imbalance %

6: Residual 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 Frequency

20: Analog Input

21: Analog Output

22: Running Days

23: Running Hours

24: Starts

25: TruTorque %

26: Power %

27: Peak Starting Current

28: Last Starting Duration

29: Zero Sequence Ground Current

30: Hottest Stator RTD Temperature

31: Hottest Bearing RTD Temperature

32: Hottest Other RTD Temperature

33: Hottest RTD Temperature

1: Ave Current

2: L1 Current

3: L2 Current

4: L3 Current

5: Current Imbalance %

6: Residual Ground Current

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 Frequency

20: Analog Input

21: Analog Output

22: Running Days

23: Running Hours

24: Starts

25: TruTorque %

26: Power %

27: Peak Starting Current

28: Last Starting Duration

29: Zero Sequence Ground Current

30: Stator RTD Temperature

31: Bearing RTD Temperature

32: Other RTD Temperature

33: Hottest RTD Temperature

Units

–

–

195



30199/40199

30221/40221

30222/40222

30223/40223

30224/40224

30225/40225

30226/40226

30227/40227

30228/40228

30229/40229

30230/40230

30231/40231

30232/40232

30233/40233

30234/40234

30235/40235

30236/40236

30237/40237

30238/40238

30239/40239

30240/40240

30241/40241

30242/40242

30243/40243

30244/40244

30245/40245

30246/40246

30247/40247

30248/40248

30249/40249

Description

Misc. Commands

Acceleration Profile

Deceleration Profile

PORT Bypass Enable

PORT Bypass Delay Time

PORT Recovery Method

Tachometer Full Speed Voltage

Tachometer Loss Delay Time


Time/Date Format

Current Imbalance Delay Time

Zero Sequence Ground Fault Trip Enable

Zero Sequence Ground Fault Trip Level

Ground Fault Delay Time

Phase Loss Delay Time

Over Frequency Trip Level

Under Frequency Trip Level

Over/Under Frequency Delay Time

Power Factor Leading Trip Enable

Power Factor Leading Trip Level

Power Factor Lagging Trip Enable

Power Factor Lagging Trip Level

Power Factor Delay Time

Backspin Timer Enable

Backspin Time

Time Between Starts Enable

Time Between Starts

Starts per Hour Enable

Starts per Hour

Speed Switch Enable

Range

0: None

1: Reset Run Time

2: Reset kWh

3: Enter Reflash Mode

4: Store Parameters

5: Load Parameters

6: Factory Reset

7: Standard BIST

8: Powered BIST

0: Linear

1: Squared

2: S-Curve

0: Disabled

1: Enabled

1 – 50

0: Voltage Ramp

1: Fast Recover

2: Current Ramp

3: Current Ramp 2

4: Ramp Select

5: Tach Ramp

100 – 1000

1 – 900

0: Fault

1: Closed Loop Current Ramp

2: TruTorque Ramp

3: Power Ramp

0: MM/DD/YY, 12 Hour

1: MM/DD/YY, 24 Hour

2: YY/MM/DD, 12 Hour

3: YY/MM/DD, 24 Hour

4: DD/MM/YY, 12 Hour

5: DD/MM/YY, 24 Hour

1 – 900

0: Disabled

1: Enabled

10 – 250

1 – 900

1 – 50

24 – 72

23 – 71

1 – 900

0: Disabled

1: Enabled

80 – 99 =-0.80 to -0.99 lag

100 – 120 =-1.00 to +0.80 lead

0: Disabled

1: Enabled

1 – 99 = -0.01 to -0.99 lag

100 – 120 =1.00 to +0.80 lead

1 – 900

0: Disabled

1: Enabled

1 – 180

0: Disabled

1: Enabled

1 – 180

0: Disabled

1: Enabled

1 – 6

0: Disabled

1: Enabled

196

Units

–

–

–

–

100 mSec

–

10 mV

100 mSec

–

–

–

–

100 mSec

–

Min

–

Min

–

–

–

100 mSec

–

100 mArms

100 mSec

100 mSec

Hz

Hz

100 mSec

–

–


30273/40273

30274/40274

30275/40275

30276/40276

30277/40277

30278/40278

30279/40279

30280/40280

30281/40281

30282/40282

30283/40283

30284/40284

30285/40285

30286/40286

30287/40287

30288/40288

30289/40289

30290/40290

30291/40291

30292/40292

30293/40293

30294/40294

30295/40295


30250/40250

30251/40251

30252/40252

30253/40253

30254/40254

30255/40255

30256/40256

30257/40257

30258/40258

Description

Speed Switch Delay Time

Motor PTC Enable

Motor PTC Delay Time

PORT Trip Enable

PORT Trip Delay Time

Motor Overload Alarm Level

Motor Overload Lockout Level

Motor Overload Auto Lockout Calculation

Motor Overload RTD Biasing Enable

Range

1 – 250

0: Disabled

1: Enabled

1 – 5

0: Disabled

1: Enabled

1 – 900

1 – 100

1 – 99

0: Disabled

1: Enabled

0: Disabled

1: Enabled

0 – 198

1 – 199

105 – 200

30259/40259

30260/40260

30261/40261

30262/40262

30263/40263

30264/40264

30265/40265

30266/40266

30267/40267

30268/40268

30269/40269

Motor Overload RTD Biasing Min

Motor Overload RTD Biasing Mid

Motor Overload RTD Biasing Max

DI4 Configuration

DI5 Configuration

DI6 Configuration

DI7 Configuration

DI8 Configuration

R4 Configuration

R5 Configuration

R6 Configuration

Same as DI 1 through DI 3 configuration in register 30169/40169

Same as R1 through R3 configuration in register 30172/40172

30270/40270 RTD Module 1 Enable

0: Disabled

1: Enabled

30271/40271 RTD Module 1 Address

30272/40272 RTD Module 2 Enable

16 – 23

0: Disabled

1: Enabled

RTD Module 2 Address

RTD 1 Group

RTD 2 Group

RTD 3 Group

RTD 4 Group

RTD 5 Group

RTD 6 Group

RTD 7 Group

RTD 8 Group

RTD 9 Group

RTD 10 Group

RTD 11 Group

RTD 12 Group

RTD 13 Group

RTD 14 Group

RTD 15 Group

RTD 16 Group

RTD Stator Alarm Level

RTD Bearing Alarm Level

RTD Other Alarm Level

RTD Stator Alarm Level

RTD Bearing Trip Level

RTD Other Trip Level

16 – 23

0:

1:

2:

3:

Off

Stator

Bearing

Other

1 – 200

30296/40296 RTD Voting Enable

0: Disabled

1: Enabled o

C o

C o

C o

C

Units

Sec

–

Sec

–

100 mSec

%

%

–

–

–

–

–

–

–

–

–

–

197


30621/40621 to

30629/40629

30631/40631 to

30639/40639

30641.40649

to

30649/40649

30651/40651 to

30659/40659

30661/40661 to

30669/40669

30671/40671 to

30679/40679

30681/40681 to

30689/40689

30691/40691 to

30699/40699

30701/40701 to

30709/40709

30711/40711 to

30719/40719

30801/40801 (newest) to

30899/40899 (oldest)

30901/40901 (newest) to

30999/40999 (oldest)

31001/41001 to

31198/41198


30601/40601 to

30609/40609

30611/40611 to

30619/40619

Description

Fault Code (newest fault) to

Fault Code (oldest fault)

System States: The state that the starter was in when the fault has occurred.

Range

Refer to page 183

0: Initializing

1: Locked Out

2: Faulted

3: Stopped

4: Heating

5: Kicking

6: Ramping

7: Slow Speed

8: Not UTS

9: UTS (up to speed)

10: Phase Control / Current Follower

11: Decelling

12: Braking

13: Wye

14: PORT

15: BIST

16: Shorted SCR Test

17: Open SCR Test

L1 Currents: The current that the load is drawing from Line 1 when the fault has occurred.

L2 Currents: The current that the load is drawing from Line 2 when a fault occurs.

L3 Currents: The current that the load is drawing from Line 3 when a fault occurs.

L1 – L2 Voltages: The line voltage that is present between lines 1 and 2 when a fault occurs.



Kilowatts: The power that the load is drawing when a fault occurs.

Line Periods: The line period

(1/frequency) that is present when a fault occurs.

Run Time Hours: The value of the running time meter when a fault occurs.

Run Time Counts: The value of the running time meter when a fault occurs.

The running counts provides more resolution than the running time hours.

Event Codes: Bit 15 indicates whether a record is an event or fault. A 1 indicates fault and a 0 indicates an event. The remaining 15 bits contain the code.

The system state when the event or fault occurred may be read.

resets to 0 each time the running time hours increments (at 35 999) refer to page 180 refer to address 30611 – 30619

Time and Date Stamp

2 registers= 32 bit unsigned integer / event.

seconds since 01/01/1972 - 01/01/2107

Units

–

–

Arms

Arms

Arms

Vrms

Vrms

Vrms

KW microseconds

Hours

10 counts/sec

198


Starter Control Register:

Bit 0 – Run/Stop

Bit 1 – Fault Reset

Bit 2 –Emergency Overload Reset

Bit 3 –Local/Remote

Bit 4 –Heat Disabled

Bit 5 –Ramp Select

Bit 10 – Relay 6

Bit 11 – Relay 5

Bit 12 – Relay 4

Bit 13 – Relay 3

Bit 14 – Relay 2

Bit 15 – Relay 1

0: Stop

1: Start

0: No action

1: Fault Reset

0: No action

1: Emergency Overload Reset

0: Local

1: Remote

0: Heater Enabled

1: Heater Disabled

0: Ramp 1

1: Ramp 2

0: Energize(d)

1: De-energize(d)

Same as above

Same as above

Same as above

Same as above

Same as above

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 Auto Start parameter (I/O 27).

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.

When the relays are programmed as “Off”, the relay bits may be written in order to control the relays. When the relays are programmed for any function other than “Off” (Fault, Run, UTS for example), then the relay bits may be read to determine the state of the relays.

199


Starter Status Register:

Bit 0 – Ready

Bit 1 – Running

Bit 2 –UTS

Bit 3 –Alarm

Bit 4 –Fault

Bit 5 –Lockout

0: Initializing or

Faulted and decelerating or

Faulted and Braking or

Faulted and Stopped or

Lockout

1: Otherwise

0: Not Running

1: Running

0: Not UTS

1: UTS

0: No alarm conditions

1: 1 or more alarm conditions

0: No Fault Condition

1: Fault Condition

0: Start or Fault Reset not locked out.

1: Start or Fault Reset locked out. Possible causes are:

Overload Lockout State

Watts, VA, vars, and kW hour Registers:

Meter registers present 32 bit meters in two consecutive 16 bit registers. The least significant 16 bits are in the first register followed by the most significant 16 bits in the second register.

Reading the least significant register latches data into the most significant register so that the data remains synchronized between the two.

Parameter Registers:

For those parameters that can be set either to “Off”, or some value within a range (many of the protection parameters, for example) there are two Modbus registers. One is an “enable” register, and the other sets the value within the range.

200

A

AC

Ambient Temperature

American Wire Gauge

Auto Synchronizing

B

Buffer

C

Contactor, Reversing

CPU Board

Cursor

Cycle

D

DeviceNet

Disable

Duty Cycle

DV/DT

E

Enable

F

Fault

Fiber Optic Isolation

G

Gate

Gate Drive Boards

H

I

APPENDIX G - APPLICATION GLOSSARY

Glossary

Alternating Current

Is the temperature of the air, water or a surrounding medium where equipment is operated or stored.

A standard system used for designing the size of electrical conductors. Gauge numbers have an inverse relationship to size; larger numbers have a smaller cross-sectional area. However, a single strand conductor has a larger cross sectional area than a multi strand conductor of the same gauge so that they have the same current carrying specification.

Auto Synchronizing of the gate timing pulses matches each phase firing angle to their respective phases. The soft start actively tracks minor shifts in the line frequency, avoiding nuisance tripping that may happen with conventional gate firing systems.

- In software terms, a register or group of register used for temporary storage of data to compensate for transmission rate differences between the transmitter and receiving device.

- In hardware terms, an isolating circuit used to avoid the reaction of one circuit with another.

A method of reversing motor rotation by the use of two separate contactors, one of which produces rotation in on direction and the other produces rotation in the opposite direction. The contactors are electrically (and mechanically) interlocked so that both cannot be energized at the same time.

This is where the microprocessor. The CPU Board is attached to the main power, and communicates to it and the keypad operator interface via ribbon cables. The CPU determines operating functions, stores user programming and acts on feedback signals for faults, metering and historical data. This board also contains the flash EEPROM and SRAM memory.

The intensified or blinking element in a video display. A means for indication where data entry or editing occurs.

- A sequence of operations that is repeated regularly

- The time it take for one sequence of operations to occur.

A producer / consumer based, high speed multi-node network.

To inhibit logic from being activated.

The relationship between the operation and rest time or repeatable operation at different loads.

The DV/DT boards are used to reduce voltage transients across the stack assemblies.

To allow an action or acceptance of data by applying an appropriate signal to the appropriate input.

Any malfunction that interferes with normal system operation.

Is provided for all signal interfaces between the medium and low voltage systems.

The control element of an SCR (silicon controlled rectifier) commonly referred to as a thyristor. When a small positive voltage is applied to the gate momentarily, the SCR will conduct current (when the anode is positive with respect to the cathode of the SCR). Current conduction will continue even after the gate signal is removed.

Are located directly on the SCR stacks. These boards communicate to the main power board via fiber optic cables. They amplify the gate pulse signals with power from the ring transformer to create two sustained pulse firing of the SCRs. There is one gate drive board for each pair of SCRs in each stack.

201

ModBUS

Mode

N

Normally Closed Contacts

Normally Open Contacts

O

P

Port

Power Factor

Preset Speed

Programmable Controller

Protocol

Q

R

Ramp

Ramp Time


Interface Board

J

Jogging

Jumper

K

Keypad

L

LCD

Locked Rotor Torque

Low Voltage

M

Main Power Board

Medium Voltage

This circuit board take line-side and load-side voltage feedback signals from the voltage feedback board and passes them via pin cables to the processor.

Is a means of accomplishing momentary motor movement by repetitive closure of a circuit using a single push button or contact element.

A short conductor with which you connect two parts.

Is a 2 line x 16 character LCD display with backlighting for low ambient conditions. The display reads out in truncated english and can show multiple data points in each screen.

Liquid crystal display, which is a reflective visual readout device commonly used in digital watches and laptop computers.

The minimum torque that a motor will develop at rest for all angular positions of the rotor with rated voltage applied at rated frequency.

Low Voltage electronics include the keypad operator interface, CPU, main power PC board and are located in isolated low voltage compartments of the enclosure.

This is also referred to as the firing board. It contains the digital I/O relays and interfaces to the terminal for user interface. See "terminal and control". It also controls the sequencing of the isolation and bypass contactors with the SCR firing. This board generates all firing signals for the SCR stacks and receives feedback signals from the fiber optic transmitters. It converts analog levels to digital signals for the CPU. These firing pulses are via fiber optic signals to isolate them from the medium voltage environment.

Control electronics are located in the medium voltage section of the soft start. The main line power must be disconnected before accessing these electronics, which include the TCB (terminal and control board), gate drive, and temp/CT(current transformer) board.

A registered based, multi-point network

A selected method of operation. For example; run

A set of contacts on a relay or switch that are closed when the relay is de-energized or the switch is de-activated. They are open when the relay is energized or the switch is activated

A set of contacts on a relay or switch that are open when the relay is de-energized or the switch is de-activated. They are closed when the relay is energized or the switch is activated.

Power outage ride-through

A measurement of the time phase difference between the voltage and current in an AC circuit. It is represented by the cosine of the angle of this phase difference. Power factor is the ratio of Real Power

(kW) to total kVA or the ratio of actual power (W) to apparent power (volt-amperes).

Refers to one or more speeds at which the drive will operate.

A solid state system that has user-programmable memory for storage of instructions to implement specific functions such as I/O control, logic, timing, counting, report generation, communication, arithmetic, and data file manipulation. A controller consists of a central processor, input/output interface, and memory. A controller is designed as an industrial control system.

A set of conventional governing the format and timing of data between communication devices.

Is the charted path that the torque, current, power, follows will achieving maximum torque.

Is the time it takes for the torque to go from the initial torque, current, power setting to the maximum torque, current, power setting.

202


Transient

U

cUL

V

W

X

Y

Z

Remote I/O

RS-232-C

RS-422

RS-485

RTD

S

Scrolling

Serial

Service Factors

SCR Gate Firing Circuit

Silicon Controlled Rectifier (SCR)

Status

Surge Protection

Sustained Pulse Firing

I/O connected to a processor across a serial link. With a serial link, remote I/O can be located long distances from the processor.

An EIA standard that specifies electrical, mechanical and functional characteristics for serial binary communication circuits in a point-to-point link.

An EIA standard that specifies electrical characteristics of balanced-voltage digital interface circuits in a point-to-point link.

An EIA standard that specifies electrical characteristics of balanced-voltage digital interface circuits in a multi-point link.

Resistance Temperature Detector- is a temperature measurement device, used by passing a low-level current through the RTD and measuring the voltage drop.

The vertical movement of data on a display screen caused by the dropping of one line of display data for each new line added at the opposite end.

Pertaining to time sequential transmission of, storage of, or logic operations on data, using the same facilities for successive parts.

When used on a motor nameplate, a number which indicates how much above the nameplate rating a motor can be loaded with out causing serious degradation (i.e., a motor with 1.15 S-F can produce 15% greater torque than one with 1.0 S-F) to adjust measured loads in an attempt to compensate for conditions which are difficult to measure or define.

The soft start contains a firing circuit that includes several unique features that maximize performance without the need for reactors or field installed devices used in other systems, regardless of conditions.

These features include; Auto Synchronizing, sustained pulse firing, closed loop firing control, transformer isolation and fiber optic isolation.

A solid state switch, sometimes referred to as a thyristor. The SCR has an anode, cathode and control element called the gate. The device provides controlled rectification since it can be turned on at will.

the SCR can rapidly switch large currents at high voltage.

The condition at a particular time of any numerous entities within a system. These conditions may be represented by values in a status line.

The process of absorbing and clipping voltage transients on an incoming AC line or control circuit.

MOVs (Metal Oxide Varistors) and specially designed R-C networks are usually used to accomplish this.

Keeps the firing signal active for 270 electrical degrees, ensuring that the DC gate pulse causes the

SCR to fire even if line noise is present at a critical moment. this provides noise immunity and protects against misfiring, enhancing system reliability.

T

Terminal and Control Board

Toggle

Transformer Isolation

This is the user connection interface board. It is located in the medium voltage section in order to satisfy UL termination requirements but does not actually connect directly to the medium voltage components other than the contactor coils. This board contains the user terminal blocks, out relays

(duplicated), inputs, and control power connections. It also contain additional timed relays for interfacing with power factor correction contactors (if used) and other external devices.

To switch alternately between two possible selections

Prevents the interference from line noise and EMI/RFI signals that may be present. Specially designed

120 V, 3-phase isolation transformers provide potential measurement, firing board power, and gate power systems while isolated from the line voltage. High isolation ring transformers are used to reduce the voltage down to 28 Vac for the sustained pulse firing circuit, providing further isolation for the

SCR gates. Additional magnetic isolation is provided via a separate control power transformer (CPT), which powers the low voltage controls and the CPU.

A momentary deviation in an electrical or mechanical system.

Canadian Underwriters Laboratories (an approval agency)

203

APPENDIX H - 3-YEAR WARRANTY

3-Year Warranty

Benshaw's standard warranty is one (1) year from date of shipment. Benshaw will extend this warranty to three (3) years from date of shipment when done by a supervised start up by a Benshaw Technician. See attached Warranty Statement and Terms of Conditions.

204

APPENDIX H - 3-YEAR WARRANTY

205

APPENDIX I - PARAMETER TABLES

Parameter Table

Following is the parameter table for both the LED and LCD Display. The last column is a convenient place to write down parameter settings.

Quick Start Group

P6

P7

P8

P9

LED LCD

P1 QST 01

P2

P3

P4

QST 02

QST 03

QST 04

P5 QST 05

QST 06

QST 07

QST 08

QST 09

Display

Motor FLA

Motor SF

Running OL

Local Src

Remote Src

Parameter

Motor FLA


Motor Running Overload Class

Local Source

Remote Source

Init Cur 1 Initial Motor Current 1

Max Cur 1 Maximum Motor Current 1

Ramp Time 1 Ramp Time 1

UTS Time UTS Time / Transition Time

Setting Range

1 – 6400

1.00 – 1.99

Off, 1 – 40

Keypad

Terminal

Serial

50 – 600

100 – 800

0 – 300

1 – 900

Units

RMS Amps

%FLA

%FLA

Seconds

Seconds

100

600

15

20

Default

10

1.15

10

Terminal

61

61

62

62

Page Setting

58

58

59

59

60

Control Function Group

Group

CFN 00

CFN 01

LED

P10

Display

Jump Code

Start Mode

Parameter

Jump to Parameter

Start Mode

CFN 02

CFN 03

CFN 04

CFN 05

CFN 06

CFN 07

CFN 08

CFN 09

CFN 10

CFN 11

CFN 12

CFN 13

CFN 14

P13

P14

P25

P26

P22

P23

P11

P12

P8

P6

P7

P24


Init Cur 1 Initial Motor Current 1

Max Cur 1 Maximum Motor Current 1


Init Cur 2

Max Cur 2

Init V/T/P

Max T/P





Accel Prof

Kick Lvl 1

Kick Time 1

Kick Lvl 2

Kick Time 2

Acceleration Ramp Profile

Kick Level 1

Kick Time 1

Kick Level 2

Kick Time 2

CFN 15 P15 Stop Mode Stop Mode

CFN 16

CFN 17

CFN 18

CFN 19

CFN 20

CFN 21

P16

P17

P18

Decel Begin

Decel End

Decel Time

Decel Prof

P19

P20

Brake Level

Brake Time

Decel Begin Level

Decel End Level

Decel Time

Decel Ramp

Profile

DC Brake Level

DC Brake Time

Setting Range

0.1 to 10.0

Coast

Volt Decel

TT Decel

DC Brake

100 to 1

99 to 1

1 to 180

Linear

Squared

S-Curve

10 to 100

1 to 180

1 to 25

Voltage Ramp

Current Ramp

TT Ramp

Power Ramp

Tach Ramp

0 to 300

50 to 600

100 to 800

0 to 300

50 to 600

100 to 800

1 to 100

10 to 325

Linear

Squared

S-Curve

Off, 100 to 800

0.1 to 10.0

Off, 100 to 800

Units

Seconds

%FLA

%FLA

Seconds

%FLA

%FLA

%

%

%FLA

Seconds

%FLA

Seconds

1

Default

Current Ramp

100

600

25

105

15

100

600

15

Linear

Off

1.0

Off

1.0

Coast

%

%

Seconds

%

Seconds

40

20

15

Linear

25

5

Page

63

63

70

71

71

72

72

73

Setting

67

68

69

69

69

65

66

66

67

64

64

65

65

70

206


Group

CFN 22

CFN 23

CFN 24

CFN 25

CFN 26

CFN 27

LED Display

P21 Brake Delay

P27 SSpd Speed

P28 SSpd Curr

P29 SSpd Timer

P30

SSpd Kick

Curr

P31 SSpd Kick T

Parameter

DC Brake Delay

Slow Speed


Slow Speed Timer



Setting Range

0.1 to 3.0

Off, 1 – 40

10 to 400

Off, 1 to 900

Off, 100 to 800

0.1 to 10.0

Units

Seconds

%

% FLA

Seconds

% FLA

Seconds

0.2

Default

Off

100

10

Off

1.0

Page Setting

73

73

74

74

75

75

Protection Function Group

Group LED Display

PFN 00 Jump Code

PFN 01 P32 Over Cur Lvl

PFN 02 P33 Over Cur Time

PFN 03 P34 Undr Cur Lvl

PFN 04 P35 Undr Cur Time

PFN 05 P36 Cur Imbl Lvl

PFN 06 Cur Imbl Time

PFN 07 P37 Resid GF Lvl

PFN 08 ZS GF Lvl

PFN 09 Gnd Flt Time

PFN 10 P38 Over Vlt Lvl

PFN 11 P39 Undr Vlt Lvl

PFN 12 P40 Vlt Trip Time

PFN 13

PFN 14

PFN 15

PFN 16

Ph Loss Time

Over Frq Lvl

Undr Frq Lvl

Frq Trip Time

PFN 17 PF Lead Lvl

PFN 18 PF Lag Lvl

PFN 19

PFN 20

PFN 21

PFN 22

PF Trip Time

Backspin Time

Time Btw St

Starts/Hour

PFN 23 P41 Auto Reset

PFN 24 P42 Auto Rst Lim

PFN 25 P43 Ctrl Flt En

PFN 26 Speed Sw Time

PFN 27 M PTC Time

PFN 28 P44 Indep S/R OL

PFN 29 P45 Starting OL

PFN 30 Running OL

Parameter

Jump to parameter

Over Current Trip Level

Over Current Trip Delay Time

Under Current Trip Level

Under Current Trip Delay Time


Current Imbalance Trip Time

Residual Ground Fault Trip Level

Zero Sequence Ground Fault Trip

Level

Ground Fault Trip Time



Over/Under Voltage Trip Delay

Time

Phase Loss Trip Time

Over Frequency Trip

Under Frequency Trip

Frequency Trip Time

PF Lead Trip Level

PF Lag Trip Level

PF Trip Time

Backspin Timer

Time Between Starts

Starts per Hour

Auto Fault Reset Time

Auto Fault Reset

Count Limit


Speed Switch Trip Time

Motor PTC Trip Time

Independent Starting/Running

Overload

Motor Overload Class Starting


Setting Range

1 - 35

Off, 50 - 800

Off, 0.1 - 90.0

Off, 5 - 100

Off, 0.1 - 90.0

Off, 5 - 40

0.1 - 90

Off, 5 - 100

Off, 1.0 - 25

0.1 - 90.0

Off, 1 - 40

Off, 1 - 40

0.1 - 90.0

0.1 - 5.0

24 - 72

23 - 71

0.1 - 90.0

Off, -0.80 lag to

+0.01 lead

Off, -0.01 lag to

+0.80 lead

0.1 - 90.0

Off, 1 - 180

Off, 1 - 180

Off, 1 - 6

Off, 1 - 900

Off, 1 - 10

Off, On

Off, 1 - 250

Off, 1 - 5

Off, On

Off, 1 - 40

Off, 1 - 40

Units

%FLA

Seconds

%FLA

Seconds

%

Seconds

%FLA

Amps

Seconds

%

%

Seconds

Seconds

Hz

Hz

Seconds

Seconds

Minutes

Minutes

Seconds

Seconds

Seconds

Off

10

10

Off

10.0

Off

Off

Off

Off

Off

On

Off

Off

0.1

0.2

72

23

0.1

3.0

Off

Off

Off

Default Page Setting

0.1

15

10

Off

1

Off

0.1

Off

76

76

76

77

77

78

78

79

Off 80

81

82

82

82

83

80

81

81

83

83

83

84

84

84

84

85

85

85

86

86

87

87

207


Group LED Display

PFN 31 P46 OL H/C Ratio

PFN 32 P47 OL Cool Time

PFN 33

PFN 34

PFN 35

OL Alarm Lvl

OL Lock Lvl

OL Lock Calc

Parameter



Motor OL Alarm Level

Motor OL Lockout Level

Motor OL Auto Lockout Level

Setting Range

0 - 99

1.0 - 999.9

1 - 100

1 - 99

Off, Auto

Units

%

Minutes

%

%

Default Page Setting

60

30

90

15

Off

88

88

89

89

89

I/O Group

Group LED Display Parameter Setting Range

I/O 00

I/O 01

I/O 02

I/O 03

I/O 04

I/O 05

I/O 06

I/O 07

P48

P49

P50

Jump Code

DI 1 Config

DI 2 Config

DI 3 Config

DI 4 Config

DI 5 Config

DI 6 Config

DI 7 Config

Jump to parameter

Digital Input #1

Configuration

Digital Input #2

Configuration

Digital Input #3

Configuration

Digital Input #4

Configuration

Digital Input #5

Configuration

Digital Input #6

Configuration

Digital Input #7

Configuration

1 to 27

Off

Stop

Fault High

Fault Low

Heat Disable

Heat Enable

Ramp Select

Slow Spd Fwd

Fault Reset

Disconnect

E OL Reset

Local/Remote

Slow Spd Rev

Brake Disable

Inline Cnfrm Brake Enable

Bypass Cnfrm Speed Sw NO

Speed Sw NC

I/O 08 DI 8 Config

Digital Input #8

Configuration

I/O 09 P51 Dig Trp Time Digital Fault Input Trip Time 0.1 to 90.0

I/O 10

I/O 11

I/O 12

I/O 13

I/O 14

I/O 15

P52

P53

P54

R1 Config

R2 Config

R3 Config

R4 Config

R5 Config

R6 Config

Relay Output

#1Configuration

Relay Output #2

Configuration

Relay Output #3

Configuration

Relay Output #4

Configuration

Relay Output #5

Configuration

Relay Output #6

Configuration

Off

Fault FS

Fault NFS

Running

UTS

Alarm

Ready

Locked Out

Overcurrent

Undercurrent

OL Alarm

Shunt FS

Shunt NFS

Ground Fault

Energy Saver

Heating

Slow Spd

Slow Spd Fwd

Slow Spd Rev

Braking

Cool Fan Ctl

PORT

Tach Loss

I/O 16

I/O 17

P55

P56

Ain Trp Type

Ain Trp Lvl

Analog Input Trip Type

Off

Low Level

High Level

0 to 100

I/O 18

I/O 19

I/O 20

P57

P58

P59

Ain Trp Tim

Ain Span

Ain Offset

Analog Input Trip Level

Analog Input Trip Delay

Time

Analog Input Span

Analog Input Offset

0.1 to 90.0

1 to 100

0 to 99

Units Default Page Setting

1 90

Stop

Off

Off

Off

Off

Off

Off

90

Seconds

Off

0.1

Fault FS

91

Off

Off

Off

Off

Off

91

Off

%

Seconds

%

%

50

0.1

100

0

92

92

93

93

94

208


Group

I/O 21

LED

P60

Display

Aout Fctn

Parameter

Analog Output

Function

I/O 22 P61 Aout Span

I/O 23 P62 Aout Offset

I/O 24 P63 Inline Confg

I/O 25 P64

Bypas Fbk

Tim

I/O 26 P65 Kpd Stop

Analog Output Span


Inline Configuration

Bypass / 2M Confirm

Keypad Stop Disable

I/O 27 P66 Auto Start Power On Start Selection

Setting Range

Off

0 – 200% Curr

0 – 800% Curr

0 – 150% Volt

0 – 150% OL

0 – 10 kW

0 – 100 kW

0 – 1 MW

0 – 10 MW

0 – 100% Ain

0 – 100% Firing

Calibration

1 to 125

0 to 99

Off, 1.0 to 10.0

0.1 to 5.0

Enabled, Disabled

Disabled

Power

Fault

Power and Fault

RTD Group

Group Display

RTD 00 Jump Code

RTD 01 RTD Mod1 Addr

RTD 02 RTD Mod2 Addr

RTD 03 RTD1 Group

RTD 04 RTD2 Group

RTD 05 RTD3 Group

RTD 06 RTD4 Group

RTD 07 RTD5 Group

RTD 08 RTD6 Group

RTD 09 RTD7 Group

RTD 10 RTD8 Group

RTD 11 RTD9 Group

RTD 12 RTD10 Group

RTD 13 RTD11 Group

RTD 14 RTD12 Group

RTD 15 RTD13 Group

RTD 16 RTD14 Group

RTD 17 RTD15 Group

RTD 18 RTD16 Group

Parameter

Jump to Parameter



RTD1 Group

RTD2 Group

RTD3 Group

RTD4 Group

RTD5 Group

RTD6 Group

RTD7 Group

RTD8 Group

RTD9 Group

RTD10 Group

RTD11 Group

RTD12 Group

RTD13 Group

RTD14 Group

RTD15 Group

RTD16 Group

Setting Range

1 - 29

Off, 16 - 23

Off

Stator

Bearing

Other

Units

%

%

Seconds

Seconds

Off

Default

Off

100

0

3.0

2.0

Enabled

Disabled

Page

98

94

95

95

96

96

96

97

Setting

Units Default

1

Off

Page Setting

97

97

98

209


RTD 19 Stator Alrm

RTD 20 Bearing Alrm

RTD 21 Other Alrm

RTD 22 Stator Trip

RTD 23 Bearing Trip

RTD 24 Other Trip

RTD 25 RTD Voting

RTD 26 RTD Biasing

RTD 27 RTD Bias Min

RTD 28 RTD Bias Mid

RTD 29 RTD Bias Max

Stator Alarm Level

Bearing Alarm Level

Other Alarm Level

Stator Trip Level

Bearing Trip Level

Other Trip Level

RTD Voting

RTD Motor OL Biasing

RTD Bias Minimum Level

RTD Bias Mid Point Level

RTD Bias Maximum Level

Function Group

Number LED

FUN 00

Display

Jump Code

Parameter

Jump to parameter

FUN 01

FUN 02

FUN 03

P71

P78

Meter 1

Meter 2

CT Ratio

Meter 1

Meter 2

CT Ratio

1 - 200

Disabled

Enabled

Off, On

0 - 198

1 - 199

105 - 200 o o o o

C

C

C

C

200

200

200

200

200

200

Disabled

Off

40

130

155

98

98

99

99

99

99

100

100

100

101

101

Setting Range

1 to 24

Ave Current

L1 Current

L2 Current

L3 Current

Curr Imbal

Ground Fault

Ave Volts

L1-L2 Volts

L2-L3 Volts

L3-L1 Volts

Overload

Power Factor

Watts

VA vars kW hours

MW hours

Phase Order

Line Freq

Analog Input

Analog Output

Run Days

Run Hours

Starts

TruTorque %

Power %

Pk Accel Cur

Last Start T

Zero Seq GF

Stator Temp

Bearing Temp

Other Temp

All Temp

72:1, 96:1, 144:1, 288:1,

864:1, 1320:1, 2640:1,

2880:1, 3900:1, 5760:1,

8000:1, 14400:1, 28800:1,

50:5, 150:5, 250:5, 800:5,

2000:5, 5000:5

Units Default

1

Ave

Current

Ave Volts

288:1

Page

101

101

102

Setting

210


Number LED

FUN 04

FUN 05

FUN 06

FUN 07

FUN 08

FUN 13

FUN 14

P73

FUN 09 P72

FUN 10

FUN 11

FUN 12

FUN 15

FUN 16

FUN 17

FUN 18

FUN 19

FUN 20

FUN 21

FUN 22

P77

P76

P75

P74

P70

P69

P68

P71

P80

P67

Display

Phase Order

Rated Volts

Motor PF

Starter Type

Heater Level

Energy Saver

PORT Flt Tim

PORT Byp Tim

PORT Recover

Tach FS Lvl

Tach Los Tim

Tach Los Act

Com Drop #

Com Baud rate

Com Timeout

Com Parity

Software 1

Software 2

Misc Command

Parameter


Rated RMS Voltage

Setting Range

Insensitive

ABC

CBA

Single Phase

100, 110, 120, 200, 208,

220, 230, 240, 350, 380,

400, 415, 440, 460, 480,

500, 525, 575, 600, 660,

690, 1000, 1140, 2200,

2300, 2400, 3300, 4160,

4600, 4800, 6000, 6600,

6900, 10000, 11000,

11500, 12000, 12470,

13200, 13800

Motor Rated Power

Factor

-0.01 (Lag) to 1.00 (Unity)

Starter Type

Heater Level

Energy Saver

P.O.R.T. Fault Time

P.O.R.T. Bypass Hold

Time

Normal

Inside Delta

Wye-Delta

Phase Ctl

Curr Follow

ATL

Off, 1 to 40

Off, On

Off, 0.1 - 90.0

Off, 0.1 - 5.0

P.O.R.T. Recovery

Method

Voltage Ramp

Fast Recover

Current Ramp

Curr Ramp 2

Ramp Select

Tach Ramp

Tachometer Full Speed

Voltage

Miscellaneous

Commands

1.00 - 10.00

Tachometer Loss Time


0.1 - 90.0

Fault

Current

TruTorque

KW

Communication Address 1 to 247

Communication Baud

Rate

1200

2400

4800

9600

19200

Communication

Timeout

Off, 1 to 120

Communications Byte

Framing

Even, 1 Stop Bit

Odd, 1 Stop Bit

None, 1 Stop Bit

None, 2 Stop Bit

Software Part Number 1 Display Only

Software Part Number 2 Display Only

None

Reset RT

Reset kWh

Reflash Mode

Store Parameters

Load Parameters

Factory Reset

Std BIST

Powered BIST

Units

RMS

Voltage

%FLA Off

Seconds Off

Seconds Off

Seconds Off

Volts 5.00

Seconds 1.5

bps

Seconds

Default

Insens.

480

-0.92

Normal

Fast

Recover

Fault

1

19200

Off

Even, 1

Stop

None

Page

102

103

103

103

104

105

105

105

106

106

106

106

107

107

107

108

108

108

108

Setting

211


Number

FUN 23

LED Display

T/D Format

FUN 24

FUN 25

FUN 26

Time

Date

Passcode

Fault Group

FL4

FL5

FL6

FL7

Group

Fault

Number

FL1

FL2

FL3

FL8

FL9

Fault Description

Parameter

Time and Date Format

Setting Range

mm/dd/yy 12h mm/dd/yy 24h yy/mm/dd 12h yy/mm/dd 24h dd/mm/yy 12h dd/mm/yy 24h

Time

Date

Passcode

Starter

State

I1 I2 I3 V1

Units

V2

Default

mm/dd/yy

12h

109

Present

Time

Present

Date

Off

V3 kW

Page

109

109

110

Setting

Hz

Run

Time

Event Group

E_

E_

E_

E_

Group Event/Fault #

E01

E02

E_

E_

E98

E99

Event/Fault Description Condition Time Date

212

Publication History;

Revision

00

Date

12/15/06

ECO#

Initial Release

BENSHAW

ADVANCED CONTROLS & DRIVES

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