MX Hardware Manual

5/21/2018 MX Hardware Manual

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PUBLICATION #890023-02-02

RediStart Solid State StarterHardware Manual for

RBX / RCX PowerStack

The Leader In

Solid State Motor Control

Technology

2004 Benshaw Inc. All Rights Reserved


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ii

TRADEMARK NOTICE

Benshaw and are registered trademarks of Benshaw Incorporated.Modbus is a registered trademark of Schneider Electric.UL is a trademark of Underwriters Laboratories, Incorporated


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SAFETY PRECAUTIONS

iii

W RNIN

1. This starter contains hazardous voltage that can cause electric shock

resulting in personal injury or loss of life.

2. Before servicing, be sure all AC power is removed from the starter and

the motor has stopped spinning

3. Wait at least 1 minute after turning off the AC power for the bus

capacitor to discharge on the control card.

4. Do not connect or disconnect the wires to or from the starter when

power is applied.

5. Ensure shielded cables are discharged.

W RNIN

1. Service only by qualified personnel.

2. Make sure ground connection is in place.

3. Make certain proper shield installation is in place.


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TABLE OF CONTENTS

iv

1 INTRODUCTION .........................................................................................................................................................1

1.1 USING THIS MANUAL ................................................................................................................................................. 2

1.2 CONTACTING BENSHAW ............................................................................................................................................ 4

1.3 INSPECTION............................................................................................................................................................... 5

1.4 GENERAL OVERVIEW OF A REDUCED VOLTAGE STARTER........................................................................................... 6

2 TECHNICAL INFORMATION....................... ............. ............. ............. .............. ............. ............. .............. ............. ... 72.1 GENERAL INFORMATION............................................................................................................................................ 8

2.2 ENVIRONMENTAL CONDITIONS ..................................................................................................................................8

2.3 ALTITUDE DERATING................................................................................................................................................. 8

2.4 APPROVALS ............................................................................................................................................................... 82.5 CERTIFICATE OF COMPLIANCE ....................................................................................................................................8

2.6 MX CONTROL BOARD ...............................................................................................................................................9

2.6.1 Terminal Points, Functions and Ratings ............ .............. .............. ............. .............. ............. ............. ............. ... 9

2.6.2 Terminal Block Rating ............. .............. .............. ............. .............. .............. ............. ............. ............. ............ 10

2.6.3 Connectors, Functions and Ratings ............ ............. ............. .............. ............. ............. ............. ............. .......... 10

2.6.4 Measurements, Accuracy and Ratings................... ............. .............. .............. ............. .............. ............ ............ 10

2.6.5 CT Ratios............ ............. .............. ............. ............. ............. ............. .............. .............. ............. .............. ....... 11

2.6.6 List of Motor Protection Features................. .............. ............. .............. .............. ............. ............. ............. ..... 11

2.6.7 Solid State Motor Overload.............. .............. ............. .............. ............. .............. ............. ............. ............. ..... 122.7 POWER SECTION...................................................................................................................................................... 13

2.7.1 Horse power Starter Rating....... ............. ............. .............. ............. ............. ............. ............... ............. ............ 132.7.2 Power Stack Input Ratings with Protection Requirements for Integral Bypass ............. ............... .............. ......... 17

2.7.3 Power Stack Input Ratings with Protection Requirements for Separate Bypass...... .............. .............. ............. ... 18

2.7.4 Power Stack Input Ratings with Protection Requirements for RC No Bypass .............. .............. .............. ........... 19

2.8 DIMENSIONS............................................................................................................................................................ 20

2.8.1 RB Chassis with Integral Bypass ............ .............. .............. ............. .............. ............. ............. ............. ............ 20

2.8.2 RC Chassis with no Bypass................. ............. .............. ............. .............. .............. ............. ............. ............. ... 30

2.9 KEYPAD/DISPLAY OPTIONS ..................................................................................................................................... 33

2.9.1 LCD Keypad .................................................................................................................................................... 33

3 INSTALLATION................. .............. ............. ............. ............. ............. .............. ............. .............. ............. ............. ... 35

3.1 SITE PREPARATION.................................................................................................................................................. 363.2 INSTALLATION PRECAUTIONS .................................................................................................................................. 36

3.3 INSTALLATION PROCEDURES.................................................................................................................................... 373.3.1 Installation Procedures............. .............. .............. ............. .............. ............. .............. ............ ............. ............ 37

3.3.2 Wiring Practices .............. ............. ............. ............. ............. .............. ............. ............. ............. ............. .......... 373.3.3 Basic Control Wiring Drawing .............. ............. .............. .............. ............. .............. ............ ............. ............. . 39

3.3.4 Control Board Layout ............. .............. ............. ............. ............. ............. .............. .............. ............. ............. . 40

3.4 POWER AND CONTROL DRAWINGS FOR BYPASSED ANDNON BYPASSED POWER STACKS ............................................ 41

3.4.1 CT Ratio Scaling.... .............. ............. ............. .............. ............. .............. ............. ............ .............. ............. ..... 58

3.4.2 Configuring the Analog Input ............. ............. .............. .............. ............. .............. ............. ............. ............. ... 60

3.4.3 Configuring the Analog Output..................... ............. .............. .............. ............. .............. ........... .............. ....... 60

3.5 RBX, POWER STACK, INTEGRAL BYPASS OR SEPARATE........................................................................................... 61

3.5.1 Introduction..................................................................................................................................................... 61

3.5.2 Motor Connections................ ............. ............. .............. ............. .............. ............. .............. ............. ............. ... 613.5.3 Application Consideration between Line Connected and Inside Delta Connected Soft Starter...... ............... ....... 62

3.5.4 Motor Lead Length..................... ............. .............. ............. ............. .............. ............. ............. .............. ........... 63

3.5.5 Bypass Contactor.... .............. ............. .............. ............. ............. .............. ............. .............. ............. ............. ... 633.5.6 Incoming Line.. ............. .............. ............. ............. .............. ............. .............. ............ ............. .............. ........... 63

3.5.7 Use of Electro-Mechanical Brakes.................... .............. ............. .............. .............. ............. ............ ............. ... 64

3.6 POWER WIRING ....................................................................................................................................................... 64

3.6.1 Compression Lugs............ ............. ............. ............. .............. ............. ............. ............. ............. ............. .......... 64

3.6.2 Recommended Wire Gauges............. .............. ............. .............. .............. ............. .............. ............ ............. ..... 64

3.6.3 CT Mounting.............. ............. ............. ............. ............. .............. ............. ............. ............... ............. ............. . 65

3.6.4 Torque Requirements for Power Wiring Terminations ............. .............. .............. ............. .............. ............. ..... 66


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TABLE OF CONTENTS

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3.6.5 Meggering a Motor ............. ............. .............. ............. .............. ............. .............. ............ .............. ............. ..... 66

3.6.6 High Pot Testing............ .............. ............. .............. ............. .............. ............. ............. ............. .............. ......... 66

3.7 MOUNTING CONSIDERATIONS .................................................................................................................................. 67

3.7.1 Bypassed Starters............. .............. ............. ............. ............. ............. .............. .............. ............. .............. ....... 67

3.7.2 Non-Bypassed Starters (with out bypass) ............. .............. ............. .............. .............. ............. ............. ............ 67

3.8 ENCLOSED PRODUCT ............................................................................................................................................... 67

3.8.1 Packaged by Benshaw Inc. ............. ............. .............. .............. ............. .............. .............. ........... .............. ....... 67

3.9 PREVENTIVE MAINTENANCE .................................................................................................................................... 673.9.1 General Information............. ............. ............. .............. ............. .............. ............. ............ .............. ............. ..... 67

3.9.2 Preventive Maintenance............. ............. ............. .............. ............. .............. ............. ............. ............. ............ 673.10 OPTIONS ................................................................................................................................................................. 68

3.10.1 Remote LCD Keypad/Display; MX-1M-RKP-00, MX-2M-RKP-00 ............ ............. .............. ............. ............. ... 68

3.10.2 Single Phase Soft Starter............. ............. .............. .............. ............. .............. .............. ............ ............. .......... 70

4 KEYPAD OPERATION.................... ............. .............. ............. ............. ............. ............. .............. ............. ............. ... 73

4.1 INTRODUCTION........................................................................................................................................................ 74

4.2 STANDARD KEYPAD AND DISPLAY ........................................................................................................................... 74

4.2.1 Special Messages Displayed...... ............. ............. ............. .............. ............. ............. ............... ............. ............ 74

4.2.2 Viewing and Changing Parameters for the Standard Keypad .............. ............. ............. ............. ............. .......... 75

4.2.3 Display Output for the Standard Keypad ............ ............. .............. ............. ............. .............. ............. .............. 75

4.2.4 Quick Meters ............. .............. ............. ............. .............. ............. .............. ............. ............. ............. .............. 764.2.5 Restoring Factory Parameter Settings ............. .............. ............. .............. ............. .............. ............. ............. ... 774.2.6 Resetting a Fault....... ............. ............. .............. ............. ............. ............. ............. .............. ............. ............. ... 77

4.2.7 Emergency Thermal Reset............ .............. ............. .............. ............. .............. ............. ............ .............. ......... 77

5 TROUBLESHOOTING .............................................................................................................................................. 79

5.1 THE TROUBLESHOOTING SECTING IS DIVIDED INTO 3 SECTIONS.................................................................................. 80

5.2 MX CONTROL; GENERAL TROUBLESHOOTING.......................................................................................................... 80

5.2.1 Motor does not start, no output to motor........... ............. .............. .............. ............. .............. ............ ............. ... 80

5.2.2 During starting, motor rotates but does not reach full speed ............. .............. .............. .............. ............ .......... 81

5.2.3 Acceleration not operating as desired............. ............. .............. .............. ............. .............. ............ ............. ..... 815.2.4 Deceleration not operating as desired ............. .............. ............. .............. ............. .............. ............. ............. ... 82

5.2.5 Motor stops unexpectedly while running.............. .............. ............. .............. ............. .............. ............. ............ 82

5.2.6 Metering incorrect ............ .............. ............. .............. ............. .............. ............. ............ .............. ............. ....... 835.2.7 Other Situations............ .............. ............. .............. ............. ............. .............. ............ ............. .............. ........... 845.3 FAULT CODE TROUBLESHOOTINGTABLE ................................................................................................................. 85

5.4 SCR TESTING.......................................................................................................................................................... 92

5.5 SCR REPLACEMENT ................................................................................................................................................ 93

Typical Stack Assembly...... ............. ............. ............. .............. ............. ............. ............. .............. ............. .............. ....... 93

5.5.2 SCR CLAMP PARTS............... .............. ............. .............. ............. .............. ............. ............. ............. .............. 93

5.5.3 SCR Clamp......................................................................................................................................................94

5.5.4 SCR Removal .............. ............. .............. ............. .............. ............. ............. .............. ............ ............. .............. 94

5.5.5 SCR INSTALLATION............. ............. .............. ............. .............. ............. ............. ............. ............. ............. ... 945.5.6 Tightening Clamp....................... ............. .............. ............. ............. .............. ............. ............. .............. ........... 94

5.5.7 Testing SCR..................................................................................................................................................... 94

6 APPENDICES ............................................................................................................................................................. 95

LIST OF TABLES................................................................................................................................................................. 96

LIST OF FIGURES................................................................................................................................................................ 97

APPENDIX A CE MARK................................................................................................................................................... 98APPENDIX B FAULT CODES ............................................................................................................................................. 99

APPENDIX C ALARM CODES.......................................................................................................................................... 100

APPENDIX D SPARE PARTS............................................................................................................................................ 102


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TABLE OF CONTENTS

vi


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1 Introduction


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1 INTRODUCTION

Using This Manual

2

1.1 Using this manual

Layout

This manual is divided into 6 sections. Each section contains topics related to the section.

The sections are as follows:

1. Introduction2. Technical Information3. Installation

4. Keypad Operation5. Troubleshooting6. Appendices

Symbols

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

Warning:Electrical Hazard that could result in injury or death.

Cautionthat could result in damage to the starter.

Highlightmarking an important point in the documentation.


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1 INTRODUCTION

Using This Manual

3

General Information

Benshaw offers its customers the following:

Start-up services

On-site training services

Technical support

Detailed documentation

Replacement parts

NOTE: Information about products and services is available by contacting Benshaw refer to Contacting Benshaw on page 4..

Start-Up Services

Benshaw technical field support personnel are available to do startup and conduct on-site training on the starter operations andtroubleshooting.

On-Site Training Services

Benshaw technical field support personnel are available to conduct on-site training on the operations and troubleshooting.

Technical Support

Benshaw technical support personnel are available (at no charge) to answer customer questions and provide technical support over

the telephone. For more information about contacting technical support personnel, refer to Contacting Benshaw on page 4.

Documentation

Benshaw provides all customers with:

Parameter Configuration Manual, Publication # 890023-01-xx

Hardware Manual, Publication # 890023-02-xx

Quick Start Reference Guide for LED Display, Publication # 890023-03-xx

Quick Start Reference Guide for LCD Display, Publication # 890023-04-xx

On-line Documentation

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

Replacement Parts

Spare and replacement parts can be purchased from Benshaw.

Publication History

Refer to the Revision History in the appendices.


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1 INTRODUCTION

Contacting Benshaw

4

1.2 Contacting Benshaw

Information about Benshaw products and services is available by contacting Benshaw at one of the following offices:

Benshaw Inc. Corporate Headquarters1659 E. Sutter RoadGlenshaw, PA 15116United States of AmericaPhone: (412) 487-8235Fax: (412) 487-4201

Benshaw Canada Controls Inc.550 Bright Street EastListowel, Ontario N4W 3W3CanadaPhone: (519) 291-5112Fax: (519) 291-2595

Benshaw West14715 North 78thWay, Suite 600Scottsdale, AZ 85260United States of AmericaPhone: (480) 905-0601Fax: (480) 905-0757

E-Mail: [email protected]

[email protected]

Technical support for MX Control Series is available at no charge by contacting Benshaws customer service department at one ofthe above telephone numbers. A service technician is available Monday through Friday from 8:00 a.m. to 5:00 p.m. EST.

NOTE:

An on-call technician is available after normal business hours and on weekends by calling Benshaw and following the recordedinstructions.

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

System Voltage

FLA of motor attached to Benshaw product

A brief description of the application


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1 INTRODUCTION

Interpreting Model Numbers

5

1.3 Inspection

Before storing or installing the RediStart starter with MX control, thoroughly inspect the device for possible shipping damage.Upon receipt:

Remove the starter from its package and inspect exterior for shipping damage. If damage is apparent, notify the shipping agent

and your sales representative.

Open the enclosure and inspect the starter for any apparent damage or foreign objects. 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 applicationhas been purchased.

The starter numbering system for a chassis is:

R __ __ __ __ __ __ __ A __ __ __

EnclosuresC = Open Chassis

Amp Rating, (0 999A )

Family of RediStart StarterB = BypassC = Continuos

Type of ControlM = Micro II ControlX = MX Control

Type of Bypass

0 = None (only available with RC)1 = Integrated2 = Separate, Definite Purpose (Only with 1000V Starter)3 = Separate, ATL IEC AC3 Rated4 = Separate, ATL NEMA Rated (AC4)

Fault LevelS = StandardH = Hi h

Frame Size

Example of the model Number: RBX-1S-361A-14C

A RediStart starter with bypass, MX control, Integrated Bypass, Standard Fault, 361 Amp unit, Frame 14, open Chassis


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1 INTRODUCTION

General Overview

6

1.4 General Overview of a Reduced Voltage Starter

The RediStart MX motor starter is a microprocessor-controlled starter for single or three-phase induction motors. The starter can becustom designed for specific applications. A few of the features are:

Solid state design.

Reduced voltage starting and soft stopping.

Closed-loop motor current control, power control, torque control.

Programmable motor protection.

Programmable operating parameters.

Programmable metering.

Each starter can operate within applied line voltage and frequency values of 100VAC to 600VAC (optional 1000VAC) and 23 to72Hz.

The starter can be programmed for any motor FLA and all of the common motor service factors. It enables operators to control bothmotor acceleration and deceleration. It can also protect the motor and its load from damage that could be caused by incorrect phaserotation, normally caused by wiring changes after startup.

The starter continually monitors the current being supplied to each phase of motor. This protects the motor from overheating or fromexcess current. The starter will automatically stop the motor if the Phase to Phase line current is not within acceptable configurableranges or if the current is lost in a line.

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


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7

2 Technical Information


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2 TECHNICAL INFORMATION

Technical Specifications

8

2.1 General Information

The physical specifications of the starter vary depending upon its configuration. The selectable motor current determinesthe configuration and its specific application requirements.

This document covers the control electronics and several power sections:

MX control board

RB Power Stack with Bypass, Integral and Separate

RC Power Stacks, Continues operation, NO bypass

2.2 Environmental Conditions

Table 1 Environmental Ratings

Operating Temperatures 0C to +50C (32F to 122F)

Storage Temperatures -20C to +70C (-4F to 155F)

Maximum heatsink temperatures 90C (194F), during a start

Humidity 0% to 95% non condensingAltitude 1000m (3300ft) without derating

Maximum Vibration 5.9m/s2(19.2ft/s2) [0.6G]

Cooling Natural convection RB, Forced Air RC

2.3 Altitude Derating

Benshaws starters are capable of operating at altitudes up to 3,300 feet (1000 meters) without requiring altitude derating.Table 2 provides the derating percentage to be considered when using a starter above 3,300 feet (1000 meters).

Table 2 Altitude Derating

Altitude Percent Derating (Amps)

3300 Feet 1006 meters 0.0%

4300 Feet 1311 meters 3.0%5300 Feet 1615 meters 6.0%

6300 Feet 1920 meters 9.0%

7300 Feet 2225 meters 12.0%

8300 Feet 2530 meters 15.0%

9300 Feet 2835 meters 18.0%

For derating above 10,000 feet consult Benshaw Inc.

2.4 Approvals

MX control UL, cUL Recognized

RB__ power stacks & Controls UL, cUL Listed

RC__ power stacks & Controls UL, cUL Listed

2.5 Certificate of compliance

CE Mark


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9

2.6 MX Control Board

2.6.1 Terminal Points, Functions and Ratings

Refer to section 3.3.4 on page 40 for terminal placement.

Table 3 Terminals

Function Terminal Number Description

TB1

Control Power Input N, neutralL, lineG, ground

96 144V AC input45VA current requirementsLine Frequency, 23 to 72Hz

Relay Output R1 NC1: Normally ClosedRC1:CommonNO1:Normally Open

Relay Output, SPDT form C5 Amp, 125VAC, resistive1 Amp, 125VAC, 0.4PF100VA Inrush

Relay Output R2 & R3 NC2, RC2, NO2NC3, RC3, NO3

Relay Output, SPDT form C16 Amp, 250VAC, resistive8 Amp, 250VAC, 0.4PF2000VA Inrush

TB2

Digital Inputs

Start & DI1

Start, DI1, S/DI1 Com 120V AC digital input, 2500V optical isolation, 4mA cur. draw

Off = 0 to 35 VAC, On = 60 to 120VAC

Digital InputsDI2 & DI3

DI2, DI3,DI2/DI3 Com

120V AC digital input, 2500V optical isolation, 4mA cur. drawOff = 0 to 35 VAC, On = 60 to 120V AC

Serial Comm. (Slave) SA-, SB+, SCOM,SHLD

Modbus slave serial communication port.RS485 interface, SHLD is chassis groundData Rates; 19.2k baud maximum Modbus RTU2500V Optical Isolation

Serial Comm MA-, MB+, MCOM,

SHLD

Factory Use Only, not isolated

TB12

Analog Output AOUT, COM, SHLD Voltage or Current Output, selectable by JP1Voltage; 0-10VDC (20mA Maximum),

Current; 0-20mA, Software scalable, 500ohm load max.Accuracy 1.5% Full ScaleUpdate rate: 25msec.

TB13

Analog Input AIN+, ANI-, SHLD Voltage or Current Input, selectable by JP3Voltage; 0-10VDC, 1 Meg. impedance

Current; 0-20mA, 499 ohm impedance, Software scalable,Accuracy 3% of full scale

Reference Supply AIN PWR 10V DC (4 mA Maximum) Reference Source

Jumpers

JP1 Analog Output Voltage output when installed, Current loop removed

JP3 Analog Input Current input when installed, Voltage input removed

JP0, JP2,JD3 Factory Use Only


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10

2.6.2 Terminal Block Rating

2.6.2.1 Wire Gauge

The terminals can support a quantity of one- 14 AWG wire or two-16 AWG wires, with two-22 AWG being thesmallest.

2.6.2.2 Wire Strip Length

The strip length should be 5/16

2.6.2.3 Torque rating

The terminals on the control board have a torque rating of 3.5-inch lb. or 0.4nm. This MUST be followed or damagewill occur to the terminals.

2.6.3 Connectors, Functions and Ratings

Table 4 - Connectors

Connectors Description

Aux Power TB0 120V AC, 5 amps, Aux. Connector for control voltage

Current Transformers(CT)Connection

TB3 CT connection for CT1, CT2 and CT3Molex Connector: #39-01-2065Molex Connector Pins: #39-00-0090 crimp,

SCR Connection TB4 Cathode and Gate for SCR # 1






Molex Connector for gates: #39-01-3028

Molex Connector pins: #39-00-0056 crimp,Remote Display Conn 3 Remote Display or Option Board Interface

TB10, Conn 4 Factory Use Only

2.6.4 Measurements, Accuracy and Ratings

Table 5 Accuracy

Internal Measurements

CT Inputs Conversion; True RMS, Sampling @ 1.562kHz

Line Voltage Inputs Conversion; True RMS,Range; 100VAC to 600VAC 10%

MeteringCurrentVoltage

WattsVolts-Amps

VarsWatt-Hours

PFLine Frequency

Ground FaultRun Time

Analog InputAnalog Output

0 40,000 Amps 3%0 660 Volts 3%

0 9,999 MW 5%0 9,999 MVA 5%0 9,999 Mvar 5%0 10,000 MWh 5%

-0.01 to +0.01 (Lag & Lead) 5%23 72 Hz 0.1 Hz5 100% FLA 5% (Machine Protection) 3 seconds per 24 hour periodAccuracy 3% of full scaleAccuracy 1.5% of full scaleNote: Percent accuracys are percent of full scale of the given ranges, Current = Motor FLA FullRange, Voltage = 660V, Watts/Volts-Amps/Watt-Hours = Motor & Voltage range


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11

2.6.5 CT Ratios

Table 6 CT Ratios

CT Ratio Minimum FLA (A rms) Maximum FLA (A rms)

72 (4 wraps 288.1) 2 1696 (3 wraps 288:1) 3 21

144 (2 wraps 288:1) 4 32

288 8 64

864 24 190

1320 (2 wraps 2640) 37 290

2640 73 590

2880 73 640

3900 105 870

5760 160 1280

8000 223 1800

14400 Mult. CT-CT

Combinations

400 3200

28800 Mult. CT-CT

Combinations

800 6400

2.6.6 List of Motor Protection Features

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

ANSI 86 Overload lockout

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

ANSI 50 - Instantaneous electronic overcurrent trip

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

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

ANSI 51G Ground fault detection (Off or 5 to 100%)

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

ANSI 59 / 27 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 47 - Phase rotation (selectable ABC, CBA, Insensitive, or Single Phase) ANSI 81 Over / Under Frequency

ANSI 74 Alarm relay output available

Single Phase Protection

Shorted SCR detection


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12

2.6.7 Solid State Motor Overload

The MX control has an advanced I2t electronic motor overload (OL) protection function. For optimal motor protectionthe MX control has forty standard NEMA style overload curves (in steps of one) available for use. Separate overloadscan be programmed, one for acceleration and another for normal running operation. The overloads can be individually,the same or completely disabled if necessary. The MX motor overload function also implements a NEMA based current

imbalance overload compensation, user adjustable hot and cold motor compensation and user adjustable exponentialmotor cooling. For more detailed information, please refer to Section 7 of the software manual, Solid State MotorOverload Protection.

Figure 1 Common Motor Overload Curves

CommonlyUsed Overload Curves

1

10

100

1000

10000

100 150 200 250 300 350 400 450 500 550 600 650 700 750 800

Current %(FLA)

Seconds

to

Trip

Class40

Class5

Class10

Class 20

Class15

Class 30

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.

Note: Refer to Theory of Operation section in the software manual for more motor overload details and a larger

graph.

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

calculator.


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13

2.7 Power Section

2.7.1 Horse power Starter Rating

Each model number can be rated for different classes of operation. For example, a starter can operate a:300HP motor for a class 10 start (350% for 30 seconds)

Or200HP for a class 20 start (500% for 30 sec)

Or

150HP motor for a class 30 start (600% for 30 seconds)Or

450HP motor when connected to the inside delta of a motor for a class 10 start (350% for 30 seconds

Table 7 Class 10 (Standard Duty) Horsepower Ratings

CLASS 10 (350% current for 30 seconds, 115% Continuous)

HORSEPOWER RATINGMODEL NUMBER NOMINAL

AMPS 200-208V 230-240V 380-400V 440-480V 575-600V

RBX-1-S-027A-11C 27 7.5 10 15 20 25RBX-1-S-040A-11C 40 10 15 25 30 40

RBX-1-S-052A-12C 52 15 20 30 40 50

RBX-1-S-065A-12C 65 20 25 40 50 60

RBX-1-S-077A-13C 77 25 30 60 75

RBX-1-S-096A-13C 96 30 40 50 75 100

RBX-1-S-125A-14C 125 40 50 75 100 125

RBX-1-S-156A-14C 156 50 60 125 150

RBX-1-S-180A-14C 180 60 75 100 150 200

RBX-1-S-180A-15C

RBX-1-S-240A-15C 240 75 100 150 200 250

RBX-1-S-302A-15C 302 100 125 250 300

RBX-1-S-361A-16C 361 125 150 200 300 400RBX-1-S-414A-17C 414 150 250 350

RBX-1-S-477A-17C 477 200 300 400 500

RBX-1-S-515A-17C 515 200 450

RBX-1-S-590A-18C 590 250 350 500 600

RBX-1-S-720A-19C 720 250 300 400 600 700

RBX-1-S-838A-20C 838 300 350 500 700 800

NOTE: For Inside delta ratings refer to Table 10, Table 11and Table 12


20/110



14

Table 8 Class 20 (Heavy Duty) Horsepower Ratings

CLASS 20 (500% current for 30 seconds, 125% Continuous)


AMPS 200-208V 230-240V 380-400V 440-480V 575-600VRBX-1-S-027A-11C 24 7.5 10 15 20 25

RBX-1-S-040A-11C 40 10 15 25 30 40

RBX-1-S-052A-12C 52 15 20 30 40 50

RBX-1-S-065A-12C

RBX-1-S-077A-13C

RBX-1-S-096A-13C 96 30 40 50 75 100

RBX-1-S-125A-14C 125 40 50 75 100 125

RBX-1-S-156A-14C

RBX-1-S-180A-14C

RBX-1-S-180A-15C 204 60 75 100 150 200

RBX-1-S-240A-15C 215 125

RBX-1-S-302A-15C

RBX-1-S-361A-16C 252 75 100 150 200 250

RBX-1-S-414A-17C 372 125 150 200 300 400

RBX-1-S-477A-17C

RBX-1-S-515A-17C

RBX-1-S-590A-18C 551 200 200 300 450 500

RBX-1-S-720A-19C 623 200 250 350 500 600

RBX-1-S-838A-20C


21/110



15

Table 9 Class 30 (Severe Duty) Horsepower Ratings

CLASS 30 (600% current for 30 seconds 125% Continuous)


AMPS 200-208V 230-240V 380-400V 440-480V 575-600VRBX-1-S-027A-11C 24 5 7.5 10 15 20

RBX-1-S-040A-11C 40 10 10 20 30 40

RBX-1-S-052A-12C 45 15 25

RBX-1-S-065A-12C

RBX-1-S-077A-13C

RBX-1-S-096A-13C 77 25 30 40 60 75

RBX-1-S-125A-14C 105 30 40 60 75 100

RBX-1-S-156A-14C

RBX-1-S-180A-14C

RBX-1-S-180A-15C 180 50 60 100 125 150

RBX-1-S-240A-15C

RBX-1-S-302A-15C

RBX-1-S-361A-16C 210 60 75 125 150 200

RBX-1-S-414A-17C 310 100 125 150 250 300

RBX-1-S-477A-17C

RBX-1-S-515A-17C

RBX-1-S-590A-18C 515 150 200 300 450 500

RBX-1-S-720A-19C

RBX-1-S-838A-20C


22/110



16

Table 10 Inside Delta Class 10 (Standard Duty) Horsepower Ratings

INSIDE DELTA CLASS 10 (350% start for 30 seconds 115% Continuous)


AMPS 200-208V 220-240V 380-415V 440-480V 575-600VRBX-1-S-027A-11C

RBX-1-S-040A-11C

RBX-1-S-052A-12C

RBX-1-S-065A-12C

RBX-1-S-077A-13C

RBX-1-S-096A-13C

RBX-1-S-125A-14C 180 60 75 100 150 200

RBX-1-S-156A-14C 240 75 100 150 200 250

RBX-1-S-180A-14C

RBX-1-S-180A-15C

RBX-1-S-240A-15C 361 125 150 200 300 400

RBX-1-S-302A-15C 414 150 250 350

RBX-1-S-361A-16C 515 200 450

RBX-1-S-414A-17C 590 250 350 500 600

RBX-1-S-477A-17C 720 250 300 400 600 700

RBX-1-S-515A-17C 800 500

RBX-1-S-590A-18C 838 300 350 700 800

RBX-1-S-720A-19C 1116 700 900

RBX-1-S-838A-20C 1300 400 500 800 1000 1200

Model Number VARequirements

Minimum VATransformer Size

Model Number VARequirements

Minimum VATransformer Size

RBX-1-S-027A-11C 140 175 RBX-1-S-240A-15C 750 938RBX-1-S-040A-11C 140 175 RBX-1-S-302A-15C 750 938

RBX-1-S-052A-12C 140 175 RBX-1-S-361A-16C 1365 1706

RBX-1-S-065A-12C 265 331 RBX-1-S-414A-17C 1365 1706

RBX-1-S-077A-13C 265 331 RBX-1-S-477A-17C 1365 1706

RBX-1-S-096A-13C 265 331 RBX-1-S-515A-17C 1365 1706

RBX-1-S-125A-14C 330 413 RBX-1-S-590A-18C 1365 1706

RBX-1-S-156A-14C 750 938 RBX-1-S-720A-19C 1365 1706

RBX-1-S-180A-14C 750 938 RBX-1-S-838A-20C 750 938

RBX-1-S-180A-15C 750 938

Note: If Micro II controller is used, add 20 VA to the VA requirements.


23/110


24/110


25/110

2TECHNICALINFORMATION

Techni

calSpecifications

2.7.4

PowerStackInputRatin

gswithProtectionRequirementsforRCNoBypass

Table1

3PowerRatingswithNoBypass

Model

Nominal

125%

Unit

FuseProtectedRating

CurrentLimitingCircuitBreakerProtectedRating

RunningWatt

Number

Current(A)

Curre

nt

Withstand

Connection

Type

AllowableFuse

Maximum

Short

Catalog

Trip

Short

Loss,After

FaultRating

(kA)

PowerBlock1

PowerBlock1

Class

Fuse

Current(A)

Circ

uit

Rating

Number

Plug

C

ircuit

Rating

Bypassed(W)5

RC___

014A11C

14

17.5

42

PowerBlock1

PowerBlock1

J/600VACT/RK1

2030

100

kA

50k

A

CED63B

50A

42kA

RC___

021A11C

21

26.2

5

42

PowerBlock1

PowerBlock1

J/600VACT/RK1

3545

100

kA

50k

A

CED63B

50A

42kA

RC___

027A11C

27

33.7

5

42

PowerBlock1

PowerBlock1

J/600VACT/RK1

4060

100

kA

50k

A

CED63B

60A

42kA

RC___

040A11C

40

50

42

PowerBlock1

PowerBlock1

J/600VACT/RK1

60100

100

kA

50k

A

CED63B

60A

42Ka

RC___

052A12C

52

65

42

PowerBlock2

PowerBlock1

J/600VACT/RK1

60100

100

kA

50k

A

CED63B

100A

42kA

RC___

065A12C

65

81

42

PowerBlock2

PowerBlock1

J/600VACT/RK1

225

100

kA

CED63B

100A

42kA

RC___

077A13C

77

96

42

PowerBlock1

PowerBlock1

J/600VACT/RK1

225

100

kA

CED63B

125A

42kA

RC___

096A13C

96

120

42

PowerBlock1

PowerBlock1

J/600VACT/RK1

225

100

kA

CFD63B

225A

42kA

RC___

125A14C

125

155

42

BusTab4

BusTab4

J/600VACT/RK1

350

100

kA

CFD63B

225A

42kA

RC___

156A14C

156

195

42

BusTab4

BusTab4

J/600VACT/RK1

400

100

kA

CFD63B

225A

65kA

RC___

180A15C

180

2225

42

BusTab4

BusTab4

J/600VACT/RK1

400

100

kA

CFD63B

250A

65kA

RC___

240A15C

240

300

42

BusTab4

BusTab4

J/600VACT/RK1

600

100

kA

CFD63B

400A

65kA

RC___

302A15C

302

377

42

BusTab4

BusTab4

J/600VACT/RK1

800

100

kA

CFD63B

400A

65kA

RC___

361A16C

361

421

42

BusTab4

BusTab4

J/600VACT/RK1

800

100

kA

CJD63B

CLD63b

400A

600A

65kA

RC___

477A17C

477

596

42

BusTab4

BusTab4

J/600VACT/RK1

800

100

kA

CJD63B

CLD63b

400A

600A

65kA

RC___

590A18C

590

737

42

BusTab4

BusTab4

L

1400

100

kA

CND63B

CND63b

800A

1200a

85kA

RC___

720A18C

720

900

42

BusTab4

BusTab4

L

1600

100

kA

CND63B

CND63b

800A

1200A

85kA

RC___

840A19C

840

1050

85

BusTab4

BusTab4

L

1600

100

kA

CND63B

CND63b

800A

1200A

85kA

RC___

960A19C

960

1200

85

BusTab4

BusTab4

L

1600

2000

100

kA

50k

A

HPD63F160

12001600A

85kA

RC___

12KA19C

1200

1440

85

BusTab4

BusTab4

L

1600

2000

100

kA

50k

A

HPD63F160

12001600A

85kA


26/110


Mechanical Drawings

20

2.8 Dimensions

2.8.1 RB Chassis with Integral Bypass

Figure 2 - Dimensions for 2 to 65 Amp RB_1 Starter

Amp Frame

Size

A

in (mm)

B

in (mm)

C (w/MX)

in (mm)

C (w/MII)

in (mm)

D

in (mm)

E

in (mm)

F

in (mm)

G

in (mm)Weightlbs (kg)

2 40 11 14.00

(355.60)

10.00

(254.00)

6.91

(175.51)

7.85

(199.4)

8.75

(222.25)

12.50

(317.45)

0.79

(20.06)

0.75

(19.10)

14

(6.4)

52 65 12 14.00

(355.60)

10.00

(254.00)

6.91

(175.51)

8.60

(218.44)

8.75

(222.25)

12.50

(317.45)

0.79

(20.06)

0.75

(19.10)

17

(7.7)

Mounting Holes: Slot: 0.31 x 0.84 (7.87 x 21.33) Bottom : 0.31 (7.87)

MXCard


27/110


Mechanical Drawings

21


Amp Frame

Size

A

in (mm)

B

in (mm)

C (w/MX)

in (mm)

C (w/MII)

in (mm)

D

in (mm)

E

in (mm)

F

in (mm)

G

in (mm)Weightlbs (kg)

77 96 13 15.00

(381.00)

10.00

(254.00)

7.66

(194.56)

8.60

(218.44)

8.75

(222.25)

14.50

(317.45)

0.79

(20.06)

0.75

(19.10)

18

(8.2)Mounting Holes: Slot: 0.31 x 0.84 (7.87 x 21.33) Bottom : 0.31 (7.87)

MXCard


28/110


Mechanical Drawings

22


Amp FrameSize

A

in (mm)

Bin (mm)

C (w/MX)in (mm)

C (w/MII)in (mm)

Din (mm)

Ein (mm)

Fin (mm)

Gin (mm)

H J Wlb

125

180

14

14

19.80(205.92)

21.55

(547.4)

12.27

(311.8)

8.91

(226.3)

9.4

(238.7)

17.00

(431.8)

3.88

(98.5)

4.00

(101.5)

3.88

(98.5)

1.00

(25.4)

.75

(19.1) (

1801302

15 22.00

(558.8)

12.27

(311.8)

9.16

(232.6)

9.65

(245.1)

18.50

(469.9

3.88

(98.5)

4.00

(101.5)

3.88

(98.5)

1.00

(25.4)

.75

(19.1) (

361 16 23.87

(606.2)

12.90

(327.6)

9.16

(232.6)

9.65

(245.1)

20.25

(514.4)

4.03

(102.4)

4.31

(109.5)

4.03

(102.4)

1.00

(25.4)

.75

(19.1) (

Mounting Holes: Keyhole: 0.31 x 0.63 (7.87 x 15.88) Bottom : 0.31 (7.87)

MXCard


29/110


Mechanical Drawings

23


Amp FrameSize

A

in (mm)

Bin (mm)

C (w/MX)in (mm)

C (w/MII)in (mm)

Din (mm)

Ein (mm)

Fin (mm)

Gin (mm)

Weightlbs (kg)

414 515 17 28.29

(718.5)

18.5

(269.9)

11.33

(287.8)

11.83

(300.5)

27.25

(692.2)

25.25

(641.4)

3.25

(82.6)

6.00

(152.4)

151

(68.5)590 18 28.29

(718.5)

18.5

(269.9)

11.33

(287.8)

11.83

(300.5)

27.25

(692.2)

25.25

(641.4)

3.25

(82.6)

6.00

(152.4)

159

(72.1)

720 19 29.34

(745.23)

18.5

(269.9)

11.33

(287.8)

11.83

(300.5)

29.00

(736.6)

27.00

(685.8)

3.25

(82.6)

6.00

(152.4)

159

(72.1)

MXC

ard


30/110


Mechanical Drawings

24

Figure 6 - Dimensions for 838 Amp RB_1 Starter

Amp FrameSize

A

in (mm)

Bin (mm)

C (w/MX)in (mm)

C (w/MII)in (mm)

Din (mm)

Ein (mm)

Fin (mm)

Gin (mm)

Weightlbs (kg)

838 20 27.75

(704.9)

26.60

(675.6)

12.90

(327.5)

13.39

(340.1)

24.50

(622.3)

22.50

(571.5)

4.60

(116.8)

8.70

(221.0)

160

(72.6)

MXCard


31/110


Mechanical Drawings

25

Figure 7 - 2 to 65 Amp Dimensions with ATL Bypass (AC3 or AC4/NEMA rating)

Amp FrameSize

A

in (mm)

Bin (mm)

C (w/MX)in (mm)

C (w/MII)in (mm)

Din (mm)

Ein (mm)

Fin (mm)

Gin (mm)

2 27

(AC3)

11 14.00

(355.60)

10.00

(254.00)

6.91

(175.51)

7.85

(199.4)

8.75

(222.25)

12.50

(317.45)

0.79

(20.06)

0.75

(19.10)

28 65(AC3)

12 14.00(355.60)

10.00(254.00)

6.91(175.51)

8.60(218.44)

8.75(222.25)

12.50(317.45)

0.79(20.06)

0.75(19.10)

2 - 40

(AC4)

12 14.00

(355.60)

10.00

(254.00)

6.91

(175.51)

8.60

(218.44)

8.75

(222.25)

12.50

(317.45)

0.79

(20.06)

0.75

(19.10)

Mounting Holes: Slot: 0.31 x 0.84 (7.87 x 21.33) Bottom : 0.31 (7.87)

MXCard


32/110


Mechanical Drawings

26

Figure 8 - 66 to 77 Amp Dimensions with ATL Bypass (AC3 rating)

Amp FrameSize

A

in (mm)

Bin (mm)

C (w/MX)in (mm)

C (w/MII)in (mm)

Din (mm)

Ein (mm)

Fin (mm)

Gin (mm)

66 - 77

(AC3)

13 15.00

(381.00)

10.00

(254.00)

7.66

(194.56)

8.60

(218.44)

8.75

(222.25)

14.50

(317.45)

0.79

(20.06)

0.75


MXCard


33/110


Mechanical Drawings

27

Figure 9 - 78 to 96 Amp Chassis Dimensions for use with separate ATL Bypass

Amp FrameSize

A

in (mm)

Bin (mm)

C (w/MX)in (mm)

C (w/MII)in (mm)

Din (mm)

Ein (mm)

Fin (mm)

Gin (mm)

78 - 96 13 15.00

(381.00)

10.00

(254.00)

7.66

(194.56)

8.60

(218.44)

8.75

(222.25)

14.50

(317.45)

0.79

(20.06)

0.75


Add 6 to width for ATL bypass (AC3 or AC4/ NEMA) contactor

MXCard


34/110


Mechanical Drawings

28

Figure 10 - 97 to 361 Amp Chassis Dimensions for use with Separate Bypass (ATL)

Amp FrameSize

A

in (mm)

Bin (mm)

C (w/MX)

in (mm)

C (w/MII)

in (mm)D

in (mm)E

in (mm)F

in (mm)G

in (mm)H J

125 180 14 14.75

(374.7)

11.91

(302.5)

9.91

(251.7)

10.85

(275.5)

11.00

(279.4)

3.88

(98.5)

4.00

(101.5)

3.88

(98.5)

.75

(19.1)

.75

(19.180 302 15 18.75

(476.3)

12.16

(308.8)

10.16

(258.0)

11.10

(281.8)

14.31

(363.5)

3.88

(98.5)

4.00

(101.5)

3.88

(98.5)

1.00

(25.4)

.75

(19.

361 16 17.8

(452.1)

12.22

(310.4)

10.16

(258.0)

11.10

(281.8)

16.00

(406.4)

4.05

(102.9)

4.31

(109.5)

3.85

(97.8)

1.00

(25.4)

1.00

(25.4

The contactor and control relays for ATL operation are NOT included in the above dimensions

MXCard


35/110


Mechanical Drawings

29

Figure 11 - 362 to 840 Chassis Dimensions for use with Separate Bypass (ATL)

Amp FrameSize

A

in (mm)

Bin (mm)

C (w/MX)in (mm)

C (w/MII)in (mm)

Din (mm)

Ein (mm)

Fin (mm)

Gin (mm)

414 515 17 20.00

(508.0)

21.50

(546.1)

10.89

(276.7)

11.83

(300.5)

21.38

(543.2)

19.39

(492.4)

3.75

(95.3)

7.00

(177.8)

590 18 20.00

(508.0)

21.50

(546.1)

10.89

(276.7)

11.83

(300.5)

21.38

(543.2)

19.39

(492.4)

3.75

(95.3)

7.00

(177.8)

720 19 20.00

(508.0)

21.50

(546.1)

10.89

(276.7)

11.83

(300.5)

21.38

(543.2)

19.39

(492.4)

3.75

(95.3)

7.00

(177.8)

838 20 22.25

(565.2)

26.60

(675.6)

12.46

(316.4)

13.49

(340.2)

17.00

(431.8)

15.00

(381.0)

4.60

(116.8)

8.70

(221.0)

The contactor and control relays for ATL operation are NOT included in the above dimensions

MXCard


36/110


Mechanical Drawings

30

2.8.2 RC Chassis with no Bypass

Figure 12 - 2 to 124 Amp Dimensions for Continuous Operation Chassis

Amp FrameSize

Ain (mm)

Bin (mm)

C (w/MX)in (mm)

C (w/MII)in (mm)

Din (mm)

Ein (mm)

Fin (mm)

Gin (mm)

2-52 31 14.00

(355.6)

9.87

(250.7)

7.63

(193.8)

8.61

(218.7)

.25

(6.35)

3.38

(85.9)

4.69

(119.1)

1.31

(33.3)

53-77 32 18.00

(457.2)

9.99

(254)

9.58

(243.3)

10.52

(260.4)

.25

(6.35)

4.38

(111.25)

4.75

(120.65)

1.31

(33.3)

78 -124 33 27.00

(685.8)

10.00

(254)

9.58

(243.3)

10.52

(260.4)

.25

(6.35)

6.63

(168.4)

4.75

(120.65)

1.31

(33.3)

MX Card

MXCard


37/110


Mechanical Drawings

31


Amp Frame

Size

A

in (mm)

B

in (mm)

C (w/MX)

in (mm)

C (w/MII)

in (mm)D

in (mm)

E

in (mm)

F

in (mm)

G

in (mm)

125 180 34 19.00

(482.6)

17.25

(438.2)

11.77

(298.9)

12.77

(324.4)

16.46

(418.0)

14.00

(355.6)

2.88

(73.2)

5.75

(146.0)181 477 35 27.67

(702.8)

17.25

(438.2)

10.86

(275.8)

11.80

(299.7)

24.27

(616.5)

21.75

(552.45)

2.88

(73.2)

5.75

(146.0)

MXCard


38/110


Mechanical Drawings

32


Amp FrameSize

A

in (mm)

Bin (mm)

C (w/MX)

in (mm)

C (w/MII)

in (mm)D

in (mm)E

in (mm)F

in (mm)G

in (mm)

478 - 838 36 35.32

(897.2)

20.25

(514.4)

11.77

(299.0)

12.71

(322.8)

31.52

(800.6)

29.00

(736.6)

3.25

(82.6)

6.88

(174.6)

MXCard


39/110


Mechanical Drawings

33

2.9 Keypad/Display Options

The MX control has one of two types of keypads, either LED display or LCD display. As standard, LED display is permanentlymounted on the control board. The LCD keypad is optional and is mounted remotely from the control board.

2.9.1 LCD Keypad

The LCD keypad is remotely mounted from the MX control board. The cable connecting the display can be 1 or 2 meters in length(39 or 78 inches).

The display comes with a bezel for improved appearance and a higher enclosure rating. When the display is mounted in the bezel the

service rating is NEMA 4.

Figure 15 - Keypad Mounting Dimensions without Bezel


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Figure 16 - Keypad Bezel Mounting Dimensions Bezel


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Control Board Layout

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3.1 Site Preparation

General Information

Before the starter can be installed, the installation site must be prepared. The customer is responsible for:

Providing the correct power source.

Providing the correct power protection.

Selecting the control mechanism.

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 themodel, the power cables can range from a single #14 AWG conductor to four 750 MCM cables. (Consult local and national codesfor selecting wire size)

Site Requirements

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

Mounting

The starter must be mounted so the heat sink fins are vertically oriented in an area that does not experience excessive shock orvibration. All models require airway passages around the heat sink. During normal operation the heat sink may reach 194 degrees

Fahrenheit (90 degrees Centigrade). Do not install the starter in direct contact with any materials that cannot withstand thesetemperatures.

3.2 Installation Precautions

General Information

Installation of some models may require halting production during installation. If applicable, ensure that the starter is installed whenproduction 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 (PFC) 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 seriousdamage to the starter that will not be covered by the starter warranty. The capacitors must be connected to the line sideof the starter. The up-to-speed (UTS) contact can be used to energize the capacitors after the motor has reached fullspeed.


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37

Safety Precautions

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 36).

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.

Consult Table 11, Table 12 and Table 13 Power Ratings for the fault rating.

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 have 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. Toreduce the risk of electrical shock, current carrying parts and other components of the starter should be inspected andreplaced if damaged.

3.3 Installation Procedures

3.3.1 Installation Procedures

To begin installation:

Read and follow all of the installation safety precautions.

Procure the necessary installation tools and any supplies. Ensure the site has sufficient lighting for safe installation.

Move the starter to the installation site. Ensure that the starter is positioned so that the cabinet door has ample clearance, andall of the controls are accessible.

If the starter is to be wall mounted:

Mount the starter on the applicable surface using the appropriate hardware.

NOTE: Moving some models may require more than one individual or lifting equipment (e.g., forklift or crane).

NOTE: The RB/RC Power Chassis is built with all Metric Hardware.

3.3.2 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 betweenmetallic 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 degrees angle.

Different wire groups should be run in separate conduits.


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Good wiring practice also requires separation of control circuit wiring from all power wiring. Since power delivered from the

starter contains high frequencies while starting and may cause interference with other equipment, do not run control wires inthe same conduit or raceway with power or motor wiring.

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

3.3.2.1 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.

3.3.2.2 Considerations for Control and Power Wiring

Control wiring refers to wires connected to the control terminal strip that normally carry 24 to 115V and Power wiring refers to theline and load connections made to terminals L1/R, L2/S, L3/T, and T1/U, T2/V, T3/W respectively. Select power wiring as follows:

Use only UL or CSA recognized wire. Wire voltage rating must be a minimum of 300V for 230VAC systems and 600V (Class 1 wire) for 460VAC and 600VAC

systems.

Use a line disconnect in conjunction with fuses on the incoming power lines.

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.

Wire must be made of copper and rated 60/75C for units 124 Amps and below. Larger amp units may use copper or

aluminum wire. Refer to NEC table 310-16 or local codes for proper wire selection.

3.3.2.3 EMC Installation Guidelines

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

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

Enclosure 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 Refer toWiring Practices on page 37.

Filtering To comply with Conducted Voltage Limits, a high voltage (1000V or greater) 0.33 uF capacitorshould be connected from each input line to ground at the point where the line enters the cabinet.


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3.3.3 Basic Control Wiring Drawing

Digital inputs DI1, DI2, DI3 and relay outputs R1, R2, R3 are pre-programmed. This wiring diagram illustrates a 3-wire start/stopcontrol by programming DI1 as a stop input. 2-wire start/stop control can be implemented by just using the start input. Refer tosections 5 & 6 for configuring the Digital and Analog input and output in software.

Figure 17 Basic Wiring Diagram


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3.3.4 Control Board Layout

Figure 18 Control Board Layout

START

DI 1

S/DICOMDI2DI3

DI2/D3COM

NO1

RC1NC1

NO2

RC2

NC2

NC3

RC3

NO3

BIPC 300050-00-01SN

Gnd

120VControl

Relay OutputR1, R2, R3

Digital InputsStart, DI1,DI2, DI3

ModbusSerial Port

SCR 6

CT Input

LED Display &Keypad

Analog Output& Config Jumper

CT BurdenSelector Switch

Analog

Input& ConfigJumper

SCR 3

SCR 5

SCR 1

SCR 4

SCR 2

SerialNumber

120VControl

CPU Heart Beat LEDSerial Com LEDs

ShieldGround

TerminatingResistor

ResetButton

Conn 3Conn 2


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3.4 Power and Control drawings for Bypassed and Non Bypassed Power Stacks

The following figures illustrate the power and control drawings for the different power stacks.

SGH 700135 00 Sheet 1 of 2 Master Power Schematic RBX, 0 96 A

SGH 700135 00 Sheet 2 of 2 Master Control Schematic RBX, 0 96 A

SGH 700135 01 Sheet 1 of 2 Master Power Schematic RBX, 97 - 361A

SGH 700135 01 Sheet 2 of 2 Master Control Schematic RBX, 97 - 361A





SGH 700135 07 Sheet 1 of 2 Master Power Schematic RBX w/ATL Separate Bypass, 0 96 A

SGH 700135 07 Sheet 2 of 2 Master Control Schematic RBX w/ATL Separate Bypass, 0 96 A

SGH 700135 08 Sheet 1 of 2 Master Power Schematic RBX w/ATL Separate Bypass, 97A 838 A

SGH 700135 08 Sheet 2 of 2 Master Control Schematic RBX w/ATL Separate Bypass, 97A 838 A

SGH 700135 09 Sheet 1 of 2 Master Power Schematic RBC, 3 - 124A

SGH 700135 09 Sheet 2 of 2 Master Control Schematic RBC, 3 - 124A

SGH 700135 10 Sheet 1 of 2 Master Power Schematic RBC, 125 - 838A

SGH 700135 10 Sheet 2 of 2 Master Control Schematic RBC, 125 - 838A


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Figure 19 Power Schematic for RBX Integral Bypass Power Stack, 3 Amps to 96 Amps


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Figure 20 Control Schematic for RBX Integral Bypass Power Stack, 3 Amps to 96 Amps


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Figure 23 Power Schematic for RBX Integral Bypass Power Stack, 362 Amps to 720 amps


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Figure 24 Control Schematic for RBX Integral Bypass Power Stack, 362 Amps to 720 amps


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Figure 27 Power Schematic for RBX with ATL Separate Bypass 3 96 Amp


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Figure 28 Control Schematic for RBX with ATL Separate Bypass 3 to 96 Amp


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Figure 29 Power Schematic for RBX with ATL Separate Bypass 97 Amps and up


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Figure 30 Control Schematic for RBX with ATL Separate Bypass 97 Amp and up


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Figure 31 Power Schematic for RCX No Bypass 3 to 124 Amp


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Figure 32 Control Schematic for RCX with No Bypass 3 to 124 Amp


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Figure 33 Power Schematic for RCX with No Bypass 125 to 840 Amp


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Figure 34 Power Schematic for RCX with No Bypass 125 to 840 Amp


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3.4.1 CT Ratio Scaling

The motor current signal scaling is set according to the motor size and the application specified when the starter is ordered. To ensureaccurate operation, the motor current signal must be correctly scaled for the motor (and its application) being controlled by thestarter. Motor current signal scaling may have to be changed if:

Motor size has been changed from the original specification.

Motor load has been changed from the original application.

Motor current signal scaling is accomplished by verifying the current transformer ratio as supplied with the starter and then selectingthe correct DIP switch setting from the chart on the following page for the current transformer ratio. The DIP switches are:

Figure 35 CT Inputs and CT switches

ON in the RIGHT position

OFF in the LEFT position

Refer to Figure 18 Control Board Layout foractual location of switches

NOTE: The applicable ratio is stamped on each CT. Adjust the DIP switches only when there is no current being supplied to themotor, or the switches could be damaged.

NOTE: See CT Ratio Parameters FUN 03, P68

3.4.1.1 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 andTruTorque 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.

The CT can be placed either before or after the starter. In specific applications, like Inside Delta and a starter with a DC brake, theCTs must be before the starter.

CT1 must be on Line L1 (R), CT2 must be on Line L2 (S), CT3 must be on Line L3 (T).

3.4.1.2 Confirm Switch Settings

To verify or change the motor current signal scaling:

Compare the CT ratio stamped on each CT to the CT ratio listed on the wiring diagram supplied with the starter to ensure the

correct CTs are installed.

Inspect the control card to ensure that the DIP switches are in the correct positions for the applicable CT ratio and the motor

full-load Amps (FLA).

CT Input, White wire (+)

CT Input Black wire (-)


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Table 14 CT Ratios and Burden Switch Settings

CT Ratio MinimumFLA (A rms)

MaximumFLA (A rms)

Switch 6Position 1

Switch 6Position 2

2 3 Off Off

3 4 Off On4 9 On Off

72

(4 wraps288:1)

9 16 On On

3 4 Off Off

4 5 Off On

5 12 On Off

96(3 wraps288:1)

12 21 On On

4 7 Off Off

7 8 Off On

8 18 On Off

144(2 wraps288:1)

18 32 On On

8 14 Off Off

14 16 Off On

16 32 On Off

288

36 64 On On24 42 Off Off

42 50 Off On

50 108 On Off

864

108 190 On On

37 64 Off Off

64 76 Off On

76 165 On Off

1320(2 wraps

2640)

165 290 On On

73 128 Off Off

128 151 Off On

151 330 On Off

2640

330 590 On On

73 140 Off Off

140 165 Off On

165 361 On Off

2880

361 640 On On

105 190 Off Off

190 225 Off On

225 490 On Off

3900

490 870 On On

160 280 Off Off

280 330 Off On

330 720 On Off

5760

720 1280 On On

223 390 Off Off

390 465 Off On

465 1000 On Off

8000

1000 1800 On On

400 700 Off Off

700 840 Off On

840 1800 On Off

14400Mult.

CT-CTCombinations 1800 3200 On On

800 1400 Off Off

1400 1680 Off On

1680 3600 On Off

28800Mult.

CT-CTCombinations 3600 6400 On On


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3.4.2 Configuring the Analog Input

The analog input can be configured for Voltage or Current loop. The input is shipped in the Current Loop configuration unlessspecified in a custom configuration. Next to the analog input terminal block is JP3. When the jumper is installed, the input is currentloop. When removed, it is a voltage input. The control is shipped with the jumper JP3 installed.

NOTE: The analog output common also serves as the analog input common.

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

3.4.3 Configuring the Analog Output

The analog output can be configured for Voltage or Current loop. The output is shipped in the Voltage configuration unless specifiedin a custom configuration. Next to the analog output terminal block is JP1. When the jumper is installed, the output is Voltage. Whenremoved, it is a current loop output. The control is shipped with the jumper installed.

NOTE:The analog output common also serves as the analog input common.

Figure 36 MX Control Board Analog Jumper Placement

Analog Input Jumper

Analog Output Jumper


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3.5 RBX, Power Stack, Integral Bypass or Separate

3.5.1 Introduction

The RBX power stacks combine the SCR and heatsinks with integrated bypass contactors. Two styles of SCR and heatsinks are usedin the RBX product line. The first is the use of an isolated heatsink with dual flat pack SCR modules mounted on the heatsink. Thisstyle is used up to 96A. The second style uses hockey puck SCR devices, which are sandwiched between two pieces of heatsink. Inthis style, the heatsinks are not isolated; in fact they carry the current for the associated phase.

3.5.2 Motor Connections

Illustrated below are two common connections of asynchronous motors that are connected to a solid state motor starter.

3.5.2.1 Line Connected Soft Starter

In Figure 37, the power poles of the soft starter are connected in series with the line. The starter draws line current (L1 ,L2 ,L3 ).

Figure 37 Typical Motor Connection

Motor

L1

L2

L3

T1

T2

T3

5

2

4

6

3

1


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3.5.2.2 Inside Delta Connection

An inside delta soft starter is shown in Figure 38, where the power poles are connected in series with the stator windings of a deltaconnected motor.

Figure 38 Typical Inside Delta Motor Connection

Motor

2

5

3

6

1

4

T6 T3

T4

T1 T5

T2

L3

L2

L1

For an Inside Delta connected motor, the inside windings average SCR current is less than that of the outside average line current bya factor of 1.55 (FLA/1.55). By comparison of Figure 37 and Figure 38, the most obvious advantage of the inside delta starter is thereduction of current seen by the soft starter. The soft starter current rating can be downsized by a factor of 1.55, providing significant

savings in cost and size of the starter.

An inside delta soft starter can also be considered for motors with more than 6 leads, including 12 lead dual voltage motors.

NEMA and IEC use different nomenclature for motor terminal markings, for 3 and 6 leaded motors.

NEMA labels motors leads, 1,2,3,4,5,6,

IEC labels motor leads, U1, V1, W1, U2, V2, W2

3.5.3 Application Consideration between Line Connected and Inside Delta Connected Soft Starter

There are differences between a line connected soft starter as shown in Figure 37 and the inside delta connected soft starter as shownin Figure 38.

By observation of Figure 38, access to all six stator-winding terminals is required for an inside delta application. In the lineconnected soft starter of Figure 37, access to only three leads of the stator windings of the motor is required. For a 12-lead motor, all12 stator terminals must be accessible.

One failed SCR on any phase of the inside delta soft starter will result in a single-phase condition. A in line contact or shunt tripcircuit breaker is recommended to protect the motor. A programmable relay can be configured as a shunt trip relay and can be used totrip the breaker. When certain faults occur, the shunt trip relay energizes. Refer to Appendix B for those faults that cause a shunt trip

The SCR control for an inside delta application is different than the SCR control for a standard soft starter. The starter type(parameter FUN 07 or P64) needs to be properly set so that the SCRs are gated correctly.


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If a circuit breaker is the only means to disconnect the soft starter and motor from the line, then one leg of the motor leads in theinside delta soft starter is always electrically live when the circuit breaker is closed. This requires caution to ensure these leads of themotor are not exposed to personnel.

3.5.4 Motor Lead Length

The standard starter can operate a motor with a maximum of 2000 feet of properly sized cable between the T leads of the starter

and that of the motor. For wire runs greater than 2000 feet contact Benshaw Inc. for application assistance. If shielded cable is used,consult factory for recommended length.

3.5.5 Bypass Contactor

3.5.5.1 Integral Bypass

The RBX power stack has an integrated contactor that is used to bypass the SCR once the motor is up to speed. The contactor is sizedto handle the current of the motor while running, but is NOT sized to start or stop the motor, this is the function of the solid statestarter. The bypass contactor is used to reduce the heat that would be generated if the SCRs were not bypassed. While bypassed, the

SCRs continue to file even though the contactor is bypassing SCR.

3.5.5.2 Separate Bypass

In some starters, the contactor is sized to accommodate a full line start. This variation is typically used as a backup, if for somereason the solid state starter cannot start the motor.

Benshaw Inc. offers bypass contactor ratings from AC1/definite purpose for bypassing the SCRs to NEMA rating used for fullvoltage starting and plugging.

3.5.6 Incoming Line

3.5.6.1 Recommended Incoming Line Protection

Circuit Breaker, Refer to Table 11 & Table 12

Fuses Refer to Table 11 & Table 12

Input Line Requirements

The input line source needs to be an adequate source to start the motor, generally 2 times the rating of the motors FLA. (This may notapply in some cases such as being connected to a generator).

The starter may not work correctly when connected to corner grounded delta or split T (wild leg) connections. Consult factory whenthis type of source is to be used.

3.5.6.2 Use of Power Factor Capacitors

Power factor correction capacitors and surge capacitors CAN NOT be connected between the starter and the motor. These devicescan damage the SCRs during ramping. These devices appear like a short circuit to the SCR when it turns on, which causes a di/dtlevel greater than the SCR can handle. If used, power factor correction capacitors or surge capacitors must be connected ahead of thestarter 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.

NOTE: If the motor manufacturer supplies surge capacitors they should be removed before starting


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3.5.7 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 isapplied to the brake during a start so it will properly release. A programmable relay can be set to a run and then used to pull-in acontactor to power the brake whenever the starter is providing power to the motor.

3.6 Power Wiring

Thread the power and motor cables through the correct connector plate opening. Strip away the motor cable insulation and apply anti-oxidation paste to the conductors, if applicable.

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)

3.6.1 Compression Lugs

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

Table 15 Single Hole Compression Lugs

Wire Size Part # Wire Size Part #

1/0 BLU-1/0S20 500 MCM BLU-050S2

2/0 BLU-2/0S4 600 MCM BLU-060S1

3/0 BLU-3/0S1 650 MCM BLU-065S5

4/0 BLU-4/0S1 750 MCM BLU-075S

250 MCM BLU-025S 800 MCM BLU-080S

3

Documents

MX Hardware Manual