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BENSHAW RediStart EXEXMVRMX3 Series, User Manual

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BENSHAW RediStart EXEXMVRMX3 Series User Manual Download Page 156

146

7 - THEORY OF OPERATION

Summary of Contents for RediStart EXEXMVRMX3 Series

Page 1: ...er Distributor Card BIPC 300007 02 2006 Benshaw Inc 890034 06 00 Solid State Starter Control RediStart TM User Manual MVRMX36 Models 10KV to 13 8KVAC Benshaw retains the right to change specifications...

Page 2: ......

Page 3: ...result with an unexpected fault or damage to the starter For best results on operating the RediStart MX3 starter carefully read this manual and all warning labels attached to the starter before insta...

Page 4: ...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 materia...

Page 5: ...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 1...

Page 6: ...otor 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 Locat...

Page 7: ...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...

Page 8: ...ied 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...

Page 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 BI...

Page 10: ......

Page 11: ...1 Introduction 1...

Page 12: ...ODUCTION 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 per...

Page 13: ...diagram All drawings are produced in AutoCAD format The drawings are available on standard CD DVD or via e mail by contacting Benshaw On Line Documentation All RediStart EXMVRMX3 documentation is avai...

Page 14: ...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 p...

Page 15: ...usable Example of Model Number CFMVRMX36 3500 13 8KV 1 A Combination Fusable RediStart starter with MV MX control 13 800 Volts 3500 Horse Power NEMA 1 Enclosure 3 Voltage 1 Nema 1 3R Nema 3R 12 Nema 1...

Page 16: ...unt 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 Un...

Page 17: ...2 Technical Specifications 7...

Page 18: ...250VA 750VA Relay 2 R2 TB2 NO2 Normally Open Contact RC2 Common Contact NC2 Normally Closed Contact Relay Output SPDT form C NO Contact resistive NC Contact resistive 5A at 250VAC 3A at 250VAC 5A at 1...

Page 19: ...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 J15 1 CT input 2 CT input Zero Sequence Ground Fault CT Typ...

Page 20: ...l 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 outpu...

Page 21: ...tion and user adjustable exponential motor cooling 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...

Page 22: ...commended Lead Resistance Less than 16W per lead Shorted Lead Detection 60W Open Lead Detection 260W RTD Sensing Current 10 mA DC RTD Sensing Voltage 10V DC maximum Range 0 to 200 C 32 to 392 F Resolu...

Page 23: ...2 2 7 Optional Zero Sequence Ground Fault CT The Benshaw BICT 2000 1 6 CT has the following excitation curve 13 2 TECHNICAL SPECIFICATIONS Figure 3 BICT2000 1 6 Excitation Curve...

Page 24: ...RMX3 Unit 2 3 Sample RediStart EXMVRMX3 Unit 14 2 TECHNICAL SPECIFICATIONS z NOTE This is only a sample diagram drawing for component identification purposes Component locations may change to meet end...

Page 25: ...h Range 1 1 1972 to 1 1 2107 with automatic leap year compensation Approvals 2 7 Approvals MX3 Control Card Set is UL cUL Recognized Certificate of Compliance 2 8 Certificate of Compliance CE Mark see...

Page 26: ...NOTES 16 2 TECHNICAL SPECIFICATIONS z NOTE This is only a sample diagram drawing for component identification purposes Component locations may change to meet end users specifications...

Page 27: ...3 Installation 17...

Page 28: ...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...

Page 29: ...ipment Use of the product in domestic environments may cause radio interference in which case the installer may need to use additional mitigation methods Enclosure Install the product in a grounded me...

Page 30: ...actor 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...

Page 31: ...g 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 10 000 to 13 8...

Page 32: ...Typical Wiring Schematics 3 5 Typical Wiring Schematics 3 5 1 EXMVRMX3 Power Wiring Schematic 22 3 INSTALLATION Figure 6 EXMVRMX3 Power Wiring Schematic...

Page 33: ...e provided by the user 3 6 3 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...

Page 34: ...650 73 4 325 36 7 400 203 50 5 6 825 93 2 375 36 7 500 253 50 5 6 825 93 2 375 42 4 600 750 304 380 50 5 6 1000 113 0 375 42 4 800 1000 406 508 50 5 6 1100 124 3 500 56 5 1250 2000 635 1010 1100 124...

Page 35: ...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 on...

Page 36: ...eving tubing extending a minimum of 8 past both sides of the CT 26 3 INSTALLATION GROUND ON STARTER POWER CABLE TO MOTOR GROUND WIRE DOES NOT PASS THROUGH CT CORE BALANCE CT SECONDARY CONNECTION TO J1...

Page 37: ...nalog Output P60 62 I O 13 15 Analog Voltage Current Selector Switch SW1 Part Serial Reset Parameter Down Up Enter Software Part 120 VAC Stack In Benshaw Only Stack Control 4x7 LED Display TB5 TB4 TB3...

Page 38: ...EXMVRMX3 I O Card Layout 3 9 EXMVRMX3 I O Card Layout 28 3 INSTALLATION Figure 11 EXMVRMX3 I O Card Layout...

Page 39: ...istor J6 Digital Inputs DI4 to DI8 J3 Relay Outputs R4 to R6 J1 Remote RTD Module s RJ45 Socket J10 Phase CTs J8 LINE Voltage Divider Card J9 LINE PTs J13 LOAD Voltage Divider Card J14 LOAD PTs S1 to...

Page 40: ...ed 7 NO3 Relay 3 normally open 8 RC3 Relay 3 common 9 NC3 Relay 3 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...

Page 41: ...7 5 DI8 Digital input 8 6 Com 120VAC neutral See Also Digital Input Configuration I O 01 08 on page 90 31 3 INSTALLATION 120VAC LIVE 120VAC NEUTRAL 120VAC LIVE 120VAC NEUTRAL START DI1 DI2 DI3 120VAC...

Page 42: ...lower on page 145 3 11 5 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 configuratio...

Page 43: ...e between 1 and 5 seconds Maximum cold resistance of PTC chain 1500 Ohms An example of the thermistor wiring is shown below in Figure 19 See Also Motor PTC Trip Time PFN 27 on page 86 3 11 8 RTD Modul...

Page 44: ...a small display as P N KPMX3SLCD and large display as P N KPMX3LLCD 3 12 1 Remote Display The LCD keypad is mounted remotely from the MX3 Control via a straight through display cable which connects be...

Page 45: ...ce Torque requirements are 0 7 NM or 6 195 in lbs Plug the cable into the display connector on the MX3 card See Figure 10 Control Card Layout on page 27 for the connector location Route the cable thro...

Page 46: ...ected to the EXMVRMX3 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 modul...

Page 47: ...37 3 INSTALLATION REMOTE RTD MODULE Figure 23 Remote RTD Module Wiring Temperature 100W Pt DIN 43760 o C o F 100W Pt o C o F 100 212 138 50 50 58 80 13 110 230 142 29 40 40 84 27 120 248 146 06 30 22...

Page 48: ......

Page 49: ...4 Keypad Operation 39...

Page 50: ...starter status information 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 St...

Page 51: ...s 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 dig...

Page 52: ...ndicate 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...

Page 53: ...ating motor Kick Starter is applying kick current to the motor Accel Starter is accelerating the load Kick 2 Starter is applying kick current to the motor in Ramp 2 Accel 2 Starter is accelerating the...

Page 54: ...kWatt Hours 0 999 MWatt Hours 0 9999 Starts 0 65535 RS Gnd Cur motor FLA 44 4 KEYPAD OPERATION Current I2 0 0A I1 0 0 I3 0 0A Run Days xxxx Run Hours xx xx Voltage V2 0V V1 0 V3 0V Analog In 0 1 Anal...

Page 55: ...starter Examples of events include a start a stop an overload alarm or a fault The event recorder stores the last 99 events Press MENU until you get to the E01 parameter Pressing UP or DOWN will scro...

Page 56: ...the next restart when PFN 20 is programmed The starts per hour lockout displays the time until the next start is allowed when PFN 22 is programmed The motor PTC lockout is displayed when the motor th...

Page 57: ...Motor FLA QST 01 Press ENTER key once the cursor starts to flash in the one s place Press LEFT key once the cursor flashes in the ten s place Press UP arrow to increase the value for a value of 30 pre...

Page 58: ...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 O10 15 Relay Outputs zNOTE You must consult the...

Page 59: ...5 Parameter Groups 49...

Page 60: ...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 di...

Page 61: ...13 Kick Lvl 1 Kick Level 1 Off 100 to 800 FLA Off 68 CFN 12 P14 Kick Time 1 Kick Time 1 0 1 to 10 0 Seconds 1 0 69 CFN 13 P25 Kick Lvl 2 Kick Level 2 Off 100 to 800 FLA Off 69 CFN 14 P26 Kick Time 2 K...

Page 62: ...72 82 PFN 15 Undr Frq Lvl Under Frequency Trip Level 23 71 Hz 23 82 PFN 16 Frq Trip Time Frequency Trip Time 0 1 90 0 Seconds 0 1 83 PFN 17 PF Lead Lvl PF Lead Trip Level Off 0 80 lag to 0 01 lead Off...

Page 63: ...Out Braking Overcurrent Cool Fan Ctl Undercurrent PORT OL Alarm Tach Loss Shunt FS Fault FS 91 I O 11 P53 R2 Config Relay Output 2 Configuration Off I O 12 P54 R3 Config Relay Output 3 Configuration...

Page 64: ...Group RTD 13 RTD11 Group RTD11 Group RTD 14 RTD12 Group RTD12 Group RTD 15 RTD13 Group RTD13 Group RTD 16 RTD14 Group RTD14 Group RTD 17 RTD15 Group RTD15 Group RTD 18 RTD16 Group RTD16 Group RTD 19...

Page 65: ...Ave Current 101 FUN 02 Meter 2 Meter 2 Ave Volts FUN 03 P78 CT Ratio CT Ratio 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 5 288 1 102 FU...

Page 66: ...247 1 107 FUN 17 P69 Com Baud rate Communication Baud Rate 1200 2400 4800 9600 19200 bps 19200 107 FUN 18 P68 Com Timeout Communication Timeout Off 1 to 120 Seconds Off 107 FUN 19 P71 Com Parity Comm...

Page 67: ...6 Parameter Description 57...

Page 68: ...ssing ENTER you can jump directly to any parameter within that group Motor FLA QST 01 LCD Display Range 1 6400 Amps RMS Default 10A Description The Motor FLA parameter configures the motor full load a...

Page 69: ...d 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 setti...

Page 70: ...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...

Page 71: ...3 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 R...

Page 72: ...nds Default 20 sec Description The Up To Speed Time parameter sets the maximum acceleration time to full speed that the motor can take A stalled motor condition is detected if the motor does not get u...

Page 73: ...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...

Page 74: ...tion 7 3 1 Current Ramp Settings Ramps and Times on page 123 Initial Current 1 CFN 03 LCD Display Range 50 600 of FLA Default 100 Description The Initial Current 1 parameter is set as a percentage of...

Page 75: ...2 CFN 05 LCD Display Range 0 300 seconds Default 15 seconds Description The Ramp Time 2 parameter sets the time it takes for the starter to allow the current to go from the initial current to the maxi...

Page 76: ...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 redu...

Page 77: ...art 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 p...

Page 78: ...Kick Level 1 CFN 11 LCD Display Range Off 100 800 of FLA Default Off Description The Kick Level 1 parameter sets the current level that precedes any ramp when a start is first commanded The kick curr...

Page 79: ...FN 13 LCD Display Range Off 100 800 of FLA Default Off Description The Kick Level 2 parameter sets the current level that precedes any ramp when a start is first commanded when the second ramp is acti...

Page 80: ...n 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...

Page 81: ...he 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...

Page 82: ...g 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...

Page 83: ...See Also Motor Running Overload Class parameter QST 03 on page 59 Stop Mode parameter CFN 15 on page 70 DC Brake Level parameter CFN 20 on page 72 DC Brake Delay parameter CFN 22 on page 73 Controlled...

Page 84: ...rate 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...

Page 85: ...rt 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 re...

Page 86: ...se Control mode A relay can be programmed to change state when an over current alarm condition is detected See Also Over Current Time parameter PFN 02 on page 76 Auto Reset parameter PFN 23 on page 84...

Page 87: ...e in the Phase Control mode A relay can be programmed to change state when an under current alarm condition is detected See Also Under Current Time parameter PFN 04 on page 77 Auto Reset parameter PFN...

Page 88: ...t 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 Iav...

Page 89: ...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 Thi...

Page 90: ...recognizes a ground fault condition it will shut down the motor and display a fault F38 Ground Fault If a programmable relay I O 10 15 is set to Ground Fault the starter energizes the relay when the...

Page 91: ...elow 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 protecti...

Page 92: ...ore 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 See Also Under Frequency Trip Level PF...

Page 93: ...Trip Level PFN 18 on page 83 Power Factor Trip Time PFN 19 on page 83 PF Lag Trip Level PFN 18 LCD Display Range Off 0 01 lag to 0 80 lead Default Off Description The amount of power factor lag befor...

Page 94: ...RT restart Starts per Hour PFN 22 LCD Display Range Off 1 6 Default Off Description The Starts per Hour parameter will set the number of allowed starts in one hour If the starter has been stopped and...

Page 95: ...e 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...

Page 96: ...ttings 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 s...

Page 97: ...114 Motor Running Overload Class PFN 30 LCD Display Range Off 1 40 Default 10 Description The Motor Running Overload Class parameter sets the class for starting and running if the parameter is set to...

Page 98: ...eter PFN 28 on page 86 Motor Running Overload Class parameter PFN 30 on page 87 Motor Starting Overload Class parameter PFN 29 on page 87 Motor Overload Cooling Time parameter PFN 32 on page 88 Relay...

Page 99: ...ting is prevented and the starter is locked out until the accumulated motor overload content has cooled below the programmed Motor OL Lockout Level See Also Theory of Operation section 7 1 Solid State...

Page 100: ...et Emergency Motor Overload content reset After an OL trip has occurred Reset when input asserted 120V applied Local Remote Local Remote control source Selects whether the Local Source parameter or th...

Page 101: ...d when faulted Running Running starter running voltage applied to motor UTS Up to Speed motor up to speed or transition to for Wye Delta Operation Alarm Alarm any alarm condition present Ready Ready s...

Page 102: ...r 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...

Page 103: ...t 100 Description The analog input can be scaled using the Analog Input Span parameter Examples For a 0 10V input or 0 20mA input a 100 Analog Input Span setting results in a 0 input reading with a 0V...

Page 104: ...3 Analog Output Function I O 21 LCD Display Range LCD Description Off Off Disabled Default 0 200 Curr Based on per cycle RMS values 0 800 Curr Based on per cycle RMS values 0 150 Volt Based on per cyc...

Page 105: ...lso Analog Output Offset parameter I O 23 on page 95 Analog Output Offset I O 23 LCD Display Range 0 99 Default 0 Description The analog output signal can be offset using the Analog Output Offset para...

Page 106: ...ee Also Relay Output Configuration parameters I O 10 15 on page 91 Bypass Feedback Time I O 25 LCD Display Range 0 1 5 0 seconds Default 2 0 Description The starter contains a built in dedicated bypas...

Page 107: ...gh while control power is applied and a start will occur if the Start input is high when a fault is reset Description The Auto Start Selection parameter determines whether or not a transition from low...

Page 108: ...ring metering group Other RTD acts independently Description 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...

Page 109: ...to Other z NOTE Consult motor manufacturer Stator Trip Level RTD 22 LCD Display Range 1 200 o C Default 200 o C Description This parameter sets the stator trip temperature when a trip will occur Faul...

Page 110: ...rmal 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 c...

Page 111: ...ion See Also RTD Biasing OL group in section 7 1 7 on page 118 Jump to Parameter FUN 00 LCD Display Description By changing the value of this parameter and pressing ENTER you can jump directly to any...

Page 112: ...ers are displayed on the two lines of the main display screen CT Ratio FUN 03 LCD Display Range 72 1 96 1 144 1 288 1 864 1 2640 1 3900 1 5760 1 8000 1 14400 1 28800 1 50 5 150 5 250 5 800 5 2000 5 50...

Page 113: ...celeration 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 moto...

Page 114: ...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 Enab...

Page 115: ...er 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 curre...

Page 116: ...e 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 Tachomet...

Page 117: ...n Byte Framing parameter FUN 19 on page 108 Communication Baud Rate FUN 17 LCD Display Range 1200 2400 4800 9600 19200 bps Default 19200 Description The Communication Baud Rate parameter sets the baud...

Page 118: ...ersion 2 The software version is also displayed on power up Miscellaneous Commands FUN 22 LCD Display Range LCD Description None No commands Default Reset RT Reset Run Time Meter Reset kWh Reset kWh M...

Page 119: ...ld 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...

Page 120: ...establish password protection after it has been cleared the password must be entered again Fault Log FL1 9 LCD Display Range FL1 FL9 Description When a fault occurs the fault number is logged in non...

Page 121: ...ay the time of the event on the bottom line of the screen See below Pressing ENTER for a 3rd time will display the date of the event on the bottom line of the screen See below Pressing ENTER again ret...

Page 122: ...NOTES 112 6 PARAMETER DESCRIPTION...

Page 123: ...7 Theory of Operation 113...

Page 124: ...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 PF...

Page 125: ...ondition is present to warn of an impending motor overload fault Overload Trip The MX3 starter trips when the motor overload content reaches 100 protecting the motor from damage The starter first perf...

Page 126: ...pecifications and is shown in Figure 28 7 1 5 Harmonic Compensation The MX3 motor overload calculation automatically compensates for the additional motor heating that can result from the presence of h...

Page 127: ...e 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 PF...

Page 128: ...as Max Level RTD29 BiasOL RTD MidBiasTemp MaxBiasTemp MidBiasTemp max _ _ _ _ 99 9 hot cold ratio hot cold ratio RTD Bias Max Level RTD29 Max measured stator RTD temp BiasOL 99 9 The RTD Biasing level...

Page 129: ...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 Ov...

Page 130: ...reduced in an exponential manner When the motor is stopped the motor overload cools as shown in the following Figure 31 120 7 THEORY OF OPERATION t e e CoolingTim 5 Stopped en Content wh OL Content O...

Page 131: ...ool 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 7 1 12 Emergency Motor Overload Reset...

Page 132: ...factor is not sufficient to start the motor 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 i...

Page 133: ...range of 50 to 175 Maximum Current 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 cur...

Page 134: ...conds 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 interv...

Page 135: ...t 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 re...

Page 136: ...If this value is set too low a No Current at Run fault may occur Maximum Power This parameter sets the final or maximum power level that the motor produces at the end of the acceleration ramp For a l...

Page 137: ...oft 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...

Page 138: ...r 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 Tacho...

Page 139: ...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 129 7 THEORY OF OPERATION Ramp Select De energ...

Page 140: ...r 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 130 7 THEORY OF OPERATION Ramp Prof...

Page 141: ...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 Ending Level...

Page 142: ...ng 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 increa...

Page 143: ...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 speci...

Page 144: ...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...

Page 145: ...D BIPC 300034 01 1 2 3 4 5 C1 C2 C3 2 1 J2 J3 RELAY OUTPUTS R G CPU 5V PWR PHASE 2 STACK OT PHASE 3 STACK OT PHASE 1 STACK OT LS3 LS1 LS2 SCR 3A SCR 3E SCR 3F SCR 3B SCR 3C SCR 3D ISO18 ISO17 ISO16 IS...

Page 146: ...gh 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...

Page 147: ...as well as the freewheel current The sensor is connected to the analog input of the MX3 card along with a burden resistor The analog input must be set to be a 0 10V voltage input for correct operatio...

Page 148: ...rse 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 m...

Page 149: ...e 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...

Page 150: ...IN LV COMPARTMENT START THREE WIRE CONTROL STOP TWO WIRE CONTROL SHOWN WITH DISCONNECT OPEN DISCONNECT AUXILIARY CONTACT MOTOR CONTACTOR COIL ALARM RUN START ENTER MENU RJ45 LCD DISPLAY KEYPAD DISPLAY...

Page 151: ...liminates 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 A...

Page 152: ...ed I O Schematics 7 9 Simplified I O Schematics 142 7 THEORY OF OPERATION Figure 44 Digital Input Simplified Schematic Figure 45 Analog Input Simplified Schematic Figure 46 Analog Output Simplified Sc...

Page 153: ...mber 9842 and Alpha Wire part number 6412 7 10 4 Terminating Resistors The MX3 does not have a terminating resistor for the end of the trunk line If a terminating resistor is required the resistor mus...

Page 154: ...twork If the starter is the end device in the network a 120W 1 4W terminating resistor may be required Please refer to Figure 48 for wire and termination practices 144 7 THEORY OF OPERATION B A COM TB...

Page 155: ...NOTES 145 7 THEORY OF OPERATION...

Page 156: ...146 7 THEORY OF OPERATION...

Page 157: ...8 Troubleshooting Maintenance 147...

Page 158: ...ntenance 8 2 Preventative Maintenance 8 2 1 General Information Preventative maintenance performed on a regular basis will help ensure that the starter continues to operate reliably and safely The fre...

Page 159: ...5V Power for I O card On when power is applied J1 Green Modbus RX receive Flash twice per second when receiving J1 Red Modbus TX transmit Flash twice per second when sending Gate Driver Card BIPC 3000...

Page 160: ...rt EXMVRMX3 Gate Driver Card ATTENTION The Fiber Optic cables can be damaged if struck or bent sharply The edge of the printed circuit board should be held to prevent damage 150 8 TROUBLESHOOTING MAIN...

Page 161: ...rimary and secondary fuses Correct as needed Check wiring to Distributor Cards and correct as needed OT Switch wiring to Gate Driver Card bad Check wiring at TB3 on Gate Driver Card and correct as nee...

Page 162: ...urrent Motor FLA QST01 is incorrect Review Motor FLA set point CT ratio FUN03 is incorrect Review CT ratio set point Condition Cause Solution Motor accelerates too quickly Ramp time 1 QST08 too short...

Page 163: ...he deceleration cycle Water hammer still occurs at end of cycle Decel End Level CFN17 set too high Decrease Decel End Level until water hammer is eliminated Decel Time CFN18 too short If possible incr...

Page 164: ...ually steady and that there are not mechanical issues Other equipment on same power feed causing power fluctuations and or distortion Fix cause of power fluctuations and or distortion Voltage Metering...

Page 165: ...an wiring problem Check fan wiring Fan failure Replace fan Analog Output not functioning properly Voltage Current output switch SW1 2 not set correctly Set SW1 2 to give correct output Wiring problem...

Page 166: ...ce factor setting QST 02 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 i...

Page 167: ...rly connected to the MX3 control card F15 Input power not three phase Single phase power has been detected when the starter is expecting three phase power Verify that input power is three phase Correc...

Page 168: ...um voltage systems verify wiring of the voltage feedback measurement circuit Check Gate and Cathode connections to MX3 card F28 No Line No input voltage was detected for longer than the Inline Configu...

Page 169: ...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 MX3 control card F39 No Current at Run Motor current we...

Page 170: ...tarting 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 sou...

Page 171: ...ypad This fault normally occurs if the remote keypad is disconnected while the MX3 control card is powered up Verify that the remote keypad cable has not been damaged and that its connectors are firml...

Page 172: ...the MX3 control card being used Consult factory for more details Fault can also occur if the MX3 control has detected an internal software problem Consult factory F95 CPU Error Parameter EEPROM Checks...

Page 173: ...s 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 av...

Page 174: ...he ohmmeter tests z NOTE Figure 49 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 If all values are greater th...

Page 175: ...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...

Page 176: ...gs 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 cl...

Page 177: ...er of electrical joint compound EJC Place the SCR s onto the dowel pins refer to Figure 52 for proper SCR position The SCR symbol has a triangle that points to the cathode Assemble the insulator cups...

Page 178: ...ly 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 ve...

Page 179: ...es not light up check and verify the 24 VAC Transformer T3 If the transformer is functional then the gate power distributor card has failed 169 8 TROUBLESHOOTING MAINTENANCE Figure 54 Fiber Optic Driv...

Page 180: ...ithin 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 NO...

Page 181: ...ess ENTER pushbutton to move to the next BIST step z NOTE If the SCR gate indicators do not light in the proper sequence during this test then consult Benshaw Do not attempt to operate the starter as...

Page 182: ...VRMX3 registers an event 195 BIST Passed in the event recorder and automatically resets the system 8 9 11 BIST Test Cancelled If for any reason during the test the disconnect is closed power is applie...

Page 183: ...ipment 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 dissip...

Page 184: ...an 10 feet and behind a metal barrier Keep test times to a minimum Power Pole To remove a SCR assembly perform the follow steps Ensure that the main disconnect is open and the grounding blades are sea...

Page 185: ...NOTES 175 8 TROUBLESHOOTING MAINTENANCE...

Page 186: ......

Page 187: ...Appendices 177...

Page 188: ...aded 106 System Stop Commanded 181 Time Set Changed 107 System Stop Complete 182 User Passcode Enabled 183 User Passcode Disabled 110 Motor OL Warning 184 Factory Control Password Accessed 111 Motor O...

Page 189: ...sts when the MX3 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 time...

Page 190: ...l a valid tachometer feedback signal is detected or the fault delay timer has expired When the delay expires a Fault 53 shall occur A60 External Alarm on DI 1 Input This alarm shall exist if DI 1 is p...

Page 191: ...ne L3 L1 Y N Y F24 High Line L1 L2 Y N Y F25 High Line L2 L3 Y N Y F26 High Line L3 L1 Y N Y F27 Phase Loss N N Y F28 No Line N N Y F29 PORT Timeout N N Y F30 Instantaneous over current I O C N Y N F3...

Page 192: ...Communication Fault Y N N F82 Modbus Timeout Fault Y N Y F84 MX to I O Card Communication Fault N N N F85 I O Card Software version Fault N N N F86 I O Card Current Offset Error N N N F87 I O Card Err...

Page 193: ...ng BIRI 100009 00 3 or 1meter 6 or 2meter 3 Cooling Fans 4 6 4 Current Transformers CTs CT 100001 01 CT 100003 01 CT 100005 01 CT 100011 01 CT 100024 01 CT 100034 01 CT 100108 01 Ground Fault 2000 1 1...

Page 194: ...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 residen...

Page 195: ...4 DI 4 Bit 5 DI 5 Bit 6 DI 6 Bit 7 DI 7 Bit 8 DI 8 30023 40023 Alarm Status 1 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...

Page 196: ...e Voltage Vrms 30036 40036 L1 L2 Voltage Vrms 30037 40037 L2 L3 Voltage Vrms 30038 40038 L3 L1 Voltage Vrms 30039 40039 Motor Overload 30040 40040 Power Factor 99 to 100 in 16 bit two s compliment sig...

Page 197: ...the sixteen 16 bits represents an RTD A 1 indicates the RTD is enabled Bit 0 represents RTD 1 Bit 15 represents RTD 16 30080 40080 RTDs Assigned as Stator Bit Mask Each of the sixteen 16 bits represe...

Page 198: ...115 Ramp Time 1 0 300 Sec 30116 40116 Initial Motor Current 2 50 600 FLA 30117 40117 Maximum Motor Current 2 100 800 FLA 30118 40118 Ramp Time 2 0 300 Sec 30119 40119 UTS Time 1 900 Sec 30120 40120 In...

Page 199: ...7 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 30137 40137 Slow Speed Current Level 10 400 FLA 30138 40138 Slow Speed Time Limit Enab...

Page 200: ...Input Phase Sensitivity 0 Ins 1 ABC 2 CBA 3 SPH 30145 40145 Motor Rated Power Factor 1 100 30146 40146 Overcurrent Enable 0 Disabled 1 Enabled 30147 40147 Overcurrent Level 50 800 FLA 30148 40148 Over...

Page 201: ...ed 30169 40169 DI 1 Configuration 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 Sour...

Page 202: ...e 0 Disabled 1 Enabled 30185 40185 Inline Delay Time 10 100 100 mSec 30186 40186 Bypass Feedback Time 1 50 100 mSec 30187 40187 Keypad Stop 0 Disabled 1 Enabled 30188 40188 Modbus Timeout Enable 0 Dis...

Page 203: ...und Current 30 Hottest Stator RTD Temperature 31 Hottest Bearing RTD Temperature 32 Hottest Other RTD Temperature 33 Hottest RTD Temperature 30197 40197 LCD Display Meter 1 1 Ave Current 2 L1 Current...

Page 204: ...urrent Imbalance Delay Time 1 900 100 mSec 30231 40231 Zero Sequence Ground Fault Trip Enable 0 Disabled 1 Enabled 30232 40232 Zero Sequence Ground Fault Trip Level 10 250 100 mArms 30233 40233 Ground...

Page 205: ...65 DI7 Configuration 30266 40266 DI8 Configuration 30267 40267 R4 Configuration Same as R1 through R3 configuration in register 30172 40172 30268 40268 R5 Configuration 30269 40269 R6 Configuration 30...

Page 206: ...line voltage that is present between lines 2 and 3 when a fault occurs Vrms 30671 40671 to 30679 40679 L3 L1 Voltages The line voltage that is present between lines 3 and 1 when a fault occurs Vrms 3...

Page 207: ...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...

Page 208: ...her 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 198 APPENDI...

Page 209: ...e 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 SR...

Page 210: ...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 ModBUS A registered based mult...

Page 211: ...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 Status The condition at a particular time of any nume...

Page 212: ...e 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 T...

Page 213: ...203 APPENDIX H 3 YEAR WARRANTY...

Page 214: ...00 FLA Off 68 CFN 12 P14 Kick Time 1 Kick Time 1 0 1 to 10 0 Seconds 1 0 69 CFN 13 P25 Kick Lvl 2 Kick Level 2 Off 100 to 800 FLA Off 69 CFN 14 P26 Kick Time 2 Kick Time 2 0 1 to 10 0 Seconds 1 0 69 C...

Page 215: ...ult Trip Time 0 1 90 0 Seconds 3 0 80 PFN 10 P38 Over Vlt Lvl Over Voltage Trip Level Off 1 40 Off 81 PFN 11 P39 Undr Vlt Lvl Under Voltage Trip Level Off 1 40 Off 81 PFN 12 P40 Vlt Trip Time Over Und...

Page 216: ...Digital Input 5 Configuration Off I O 06 DI 6 Config Digital Input 6 Configuration Off I O 07 DI 7 Config Digital Input 7 Configuration Off I O 08 DI 8 Config Digital Input 8 Configuration Off I O 09...

Page 217: ...bled Power Fault Power and Fault Disabled 97 RTD Group Group Display Parameter Setting Range Units Default Page Setting RTD 00 Jump Code Jump to Parameter 1 29 1 97 RTD 01 RTD Mod1 Addr RTD Module 1 A...

Page 218: ...00 o C 155 101 Function Group Number LED Display Parameter Setting Range Units Default Page Setting FUN 00 Jump Code Jump to parameter 1 to 24 1 101 FUN 01 P71 Meter 1 Meter 1 Ave Current L1 Current L...

Page 219: ...Seconds Off 105 FUN 12 PORT Recover P O R T Recovery Method Voltage Ramp Fast Recover Current Ramp Curr Ramp 2 Ramp Select Tach Ramp Fast Recover 106 FUN 13 Tach FS Lvl Tachometer Full Speed Voltage...

Page 220: ...m dd yy 12h 109 FUN 24 Time Time Present Time 109 FUN 25 Date Date Present Date 109 FUN 26 Passcode Passcode Off 110 Fault Group Group Fault Number Fault Description Starter State I1 I2 I3 V1 V2 V3 kW...

Page 221: ...Publication History Revision Date ECO 00 12 15 06 Initial Release...

Page 222: ...BENSHAW 615 Alpha Drive Pittsburgh PA 15238 Phone 412 968 0100 Fax 412 968 5415 BENSHAW Canada 550 Bright Street Listowel Ontario N4W 3W3 Phone 519 291 5112 Fax 519 291 2595...

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