RediStart Solid State Starter Hardware Manual for RBX / …manualarchive.ingersollrandproducts.com/manuals/ma… · · 2007-11-15RediStart Solid State Starter Hardware Manual for

PUBLICATION #890023-02-02

RediStart Solid State Starter Hardware Manual for

RBX / RCX PowerStack

The Leader In

Solid State Motor Control Technology

© 2004 Benshaw Inc. All Rights Reserved

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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

SAFETY PRECAUTIONS

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WARNING

1. This starter contains hazardous voltage that can cause electric shock resulting in personal injury or loss of life.

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

3. Wait at least 1 minute after turning off the AC power for the bus capacitor to discharge on the control card.

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

5. Ensure shielded cables are discharged.

WARNING

1. Service only by qualified personnel.

2. Make sure ground connection is in place.

3. Make certain proper shield installation is in place.

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.................................................................................................................................... 7

2.1 GENERAL INFORMATION ............................................................................................................................................ 8 2.2 ENVIRONMENTAL CONDITIONS .................................................................................................................................. 8 2.3 ALTITUDE DERATING................................................................................................................................................. 8 2.4 APPROVALS............................................................................................................................................................... 8 2.5 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.............................................................................................................................. 12

2.7 POWER SECTION...................................................................................................................................................... 13 2.7.1 Horse power Starter Rating.............................................................................................................................. 13 2.7.2 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 .................................................................................................................................................. 36 3.2 INSTALLATION PRECAUTIONS .................................................................................................................................. 36 3.3 INSTALLATION PROCEDURES.................................................................................................................................... 37

3.3.1 Installation Procedures .................................................................................................................................... 37 3.3.2 Wiring Practices .............................................................................................................................................. 37 3.3.3 Basic Control Wiring Drawing ......................................................................................................................... 39 3.3.4 Control Board Layout ...................................................................................................................................... 40

3.4 POWER AND CONTROL DRAWINGS FOR BYPASSED AND NON 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........................................................................................................................................... 61 3.5.3 Application Consideration between Line Connected and Inside Delta Connected Soft Starter............................ 62 3.5.4 Motor Lead Length........................................................................................................................................... 63 3.5.5 Bypass Contactor............................................................................................................................................. 63 3.5.6 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

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 .................................................................................................................................... 67 3.9.1 General Information......................................................................................................................................... 67 3.9.2 Preventive Maintenance ................................................................................................................................... 67

3.10 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 ................................................................................................................................................... 76 4.2.5 Restoring Factory Parameter Settings .............................................................................................................. 77 4.2.6 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............................................................................................................... 81 5.2.4 Deceleration not operating as desired .............................................................................................................. 82 5.2.5 Motor stops unexpectedly while running........................................................................................................... 82 5.2.6 Metering incorrect ........................................................................................................................................... 83 5.2.7 Other Situations ............................................................................................................................................... 84

5.3 FAULT CODE TROUBLESHOOTING TABLE ................................................................................................................. 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....................................................................................................................................... 94 5.5.6 Tightening Clamp............................................................................................................................................. 94 5.5.7 Testing SCR ..................................................................................................................................................... 94

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

LIST OF TABLES................................................................................................................................................................. 96 LIST OF FIGURES................................................................................................................................................................ 97 APPENDIX A – CE MARK................................................................................................................................................... 98 APPENDIX B – FAULT CODES ............................................................................................................................................. 99 APPENDIX C – ALARM CODES.......................................................................................................................................... 100 APPENDIX D – SPARE PARTS............................................................................................................................................ 102

TABLE OF CONTENTS

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1 Introduction

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. Introduction 2. Technical Information 3. Installation 4. Keypad Operation 5. Troubleshooting 6. 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.

Caution that could result in damage to the starter. Highlight marking an important point in the documentation.

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 and troubleshooting.

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.

1 – INTRODUCTION

Contacting Benshaw

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1.2 Contacting Benshaw

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

Benshaw Inc. Corporate Headquarters 1659 E. Sutter Road Glenshaw, PA 15116 United States of America Phone: (412) 487-8235 Fax: (412) 487-4201

Benshaw Canada Controls Inc. 550 Bright Street East Listowel, Ontario N4W 3W3 Canada Phone: (519) 291-5112 Fax: (519) 291-2595

Benshaw West 14715 North 78th Way, Suite 600 Scottsdale, AZ 85260 United States of America Phone: (480) 905-0601 Fax: (480) 905-0757

E-Mail: [email protected]

[email protected]

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

NOTE:

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

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

• Name of Company • Telephone number where the caller can be contacted • Fax number of caller • Benshaw product name • Benshaw model number • Benshaw serial number • Name of product distributor • Approximate date of purchase • System Voltage • FLA of motor attached to Benshaw product • A brief description of the application

1 – INTRODUCTION

Interpreting Model Numbers

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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 application has 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 Bypass0 = 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 = High

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

1 – INTRODUCTION

General Overview

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1.4 General Overview of a Reduced Voltage Starter

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

• Solid state design. • Reduced voltage starting and soft stopping. • Closed-loop motor current control, power control, torque control. • Programmable motor protection. • Programmable operating parameters. • Programmable metering.

Each starter can operate within applied line voltage and frequency values of 100VAC to 600VAC (optional 1000VAC) and 23 to 72Hz.

The starter can be programmed for any motor FLA and all of the common motor service factors. It enables operators to control both motor acceleration and deceleration. It can also protect the motor and its load from damage that could be caused by incorrect phase rotation, 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 from excess current. The starter will automatically stop the motor if the Phase to Phase line current is not within acceptable configurable ranges 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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2 Technical Information

2 – TECHNICAL INFORMATION

Technical Specifications

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2.1 General Information

The physical specifications of the starter vary depending upon its configuration. The selectable motor current determines the 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 0°C to +50°C (32°F to 122°F) Storage Temperatures -20°C to +70°C (-4°F to 155°F) Maximum heatsink temperatures 90°C (194°F), during a start Humidity 0% to 95% non condensing Altitude 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

Benshaw’s 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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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, neutral L, line G, ground

96 – 144V AC input 45VA current requirements Line Frequency, 23 to 72Hz

Relay Output R1 NC1: Normally Closed RC1:Common NO1:Normally Open

Relay Output, SPDT form C 5 Amp, 125VAC, resistive 1 Amp, 125VAC, 0.4PF 100VA Inrush

Relay Output R2 & R3 NC2, RC2, NO2 NC3, RC3, NO3

Relay Output, SPDT form C 16 Amp, 250VAC, resistive 8 Amp, 250VAC, 0.4PF 2000VA 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 Inputs DI2 & DI3

DI2, DI3, DI2/DI3 Com

120V AC digital input, 2500V optical isolation, 4mA cur. draw Off = 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 ground Data Rates; 19.2k baud maximum Modbus RTU 2500V 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 JP1 Voltage; 0-10VDC (20mA Maximum), Current; 0-20mA, Software scalable, 500ohm load max. Accuracy ±1.5% Full Scale Update rate: 25msec.

TB13

Analog Input AIN+, ANI-, SHLD Voltage or Current Input, selectable by JP3 Voltage; 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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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 the smallest.

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 damage will 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 CT3 Molex Connector: #39-01-2065 Molex Connector Pins: #39-00-0090 crimp,

SCR Connection TB4 Cathode and Gate for SCR # 1 SCR Connection TB5 Cathode and Gate for SCR # 4 SCR Connection TB6 Cathode and Gate for SCR # 2 SCR Connection TB7 Cathode and Gate for SCR # 5 SCR Connection TB8 Cathode and Gate for SCR # 3 SCR Connection TB9 Cathode and Gate for SCR # 6 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% Metering

Current Voltage

Watts Volts-Amps

Vars Watt-Hours

PF Line Frequency

Ground Fault Run Time

Analog Input Analog 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 Hz 5 – 100% FLA ± 5% (Machine Protection) ± 3 seconds per 24 hour period Accuracy ± 3% of full scale Accuracy ±1.5% of full scale Note: Percent accuracy’s are percent of full scale of the given ranges, Current = Motor FLA Full Range, Voltage = 660V, Watts/Volts-Amps/Watt-Hours = Motor & Voltage range



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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 16 96 (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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2.6.7 Solid State Motor Overload

The MX control has an advanced I2t electronic motor overload (OL) protection function. For optimal motor protection the MX control has forty standard NEMA style overload curves (in steps of one) available for use. Separate overloads can 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 exponential motor cooling. For more detailed information, please refer to Section 7 of the software manual, Solid State Motor Overload Protection.

Figure 1 – Common Motor Overload Curves

Commonly Used Overload Curves

1

10

100

1000

10000

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

Current % (FLA)

Seco

nds

to T

rip

Class 40

Class 5

Class 10

Class 20Class 15

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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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) Or

200HP 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 RATING MODEL NUMBER NOMINAL

AMPS 200-208V 230-240V 380-400V 440-480V 575-600V RBX-1-S-027A-11C 27 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 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 361 125 150 200 300 400 RBX-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



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Table 8 – Class 20 (Heavy Duty) Horsepower Ratings

CLASS 20 (500% current for 30 seconds, 125% Continuous) HORSEPOWER RATING MODEL NUMBER NOMINAL

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



15

Table 9 – Class 30 (Severe Duty) Horsepower Ratings

CLASS 30 (600% current for 30 seconds 125% Continuous) HORSEPOWER RATING MODEL NUMBER NOMINAL

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



16

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

INSIDE DELTA CLASS 10 (350% start for 30 seconds 115% Continuous) HORSEPOWER RATING MODEL NUMBER NOMINAL

AMPS 200-208V 220-240V 380-415V 440-480V 575-600V RBX-1-S-027A-11C ⎯ ⎯ ⎯ ⎯ ⎯ ⎯ RBX-1-S-040A-11C ⎯ ⎯ ⎯ ⎯ ⎯ ⎯ RBX-1-S-052A-12C ⎯ ⎯ ⎯ ⎯ ⎯ ⎯ RBX-1-S-065A-12C ⎯ ⎯ ⎯ ⎯ ⎯ ⎯ RBX-1-S-077A-13C ⎯ ⎯ ⎯ ⎯ ⎯ ⎯ RBX-1-S-096A-13C ⎯ ⎯ ⎯ ⎯ ⎯ ⎯ RBX-1-S-125A-14C 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 VA Requirements

Minimum VA Transformer Size

Model Number VA Requirements

Minimum VA Transformer Size

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

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0kA

C

JD63

B

CLD

63b

400A

60

0A

65kA

RC

_ _

_590

A18

C

590

737

42

Bus

Tab

4 B

us T

ab4

L 14

00

100k

A

CN

D63

B

CN

D63

b 80

0A

1200

a 85

kA

RC

_ _

_720

A18

C

720

900

42

Bus

Tab

4 B

us T

ab4

L 16

00

100k

A

CN

D63

B

CN

D63

b 80

0A

1200

A

85kA

RC

_ _

_840

A19

C

840

1050

85

B

us T

ab4

Bus

Tab

4 L

1600

10

0kA

C

ND

63B

C

ND

63b

800A

12

00A

85

kA

RC

_ _

_960

A19

C

960

1200

85

B

us T

ab4

Bus

Tab

4 L

1600

20

00

100k

A

50kA

H

PD63

F160

12

00 –

160

0A

85kA

RC

_ _

_12K

A19

C

1200

14

40

85

Bus

Tab

4 B

us T

ab4

L 16

00

2000

10

0kA

50

kA

HPD

63F1

60

1200

– 1

600A

85

kA


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)

Weight lbs (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)

MX

Ca

rd


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)

Weight lbs (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)


MX

Ca

rd


Mechanical Drawings

22


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)

H J Weight lbs (kg)

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)

43

(19.5)

1801– 302

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)

51 (23.1)

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)

56 (25.4)

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

MX

Ca

rd


Mechanical Drawings

23


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)

Weight lbs (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)

MX

Ca

rd


Mechanical Drawings

24

Figure 6 - Dimensions for 838 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)

Weight lbs (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)

MX

Ca

rd


Mechanical Drawings

25

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

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)

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)


MX

Ca

rd


Mechanical Drawings

26

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

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)

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

(19.10)


MX

Ca

rd


Mechanical Drawings

27

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

Amp Frame

Size A

in (mm) B


C (w/MII) in (mm)

D in (mm)

E in (mm)

F in (mm)

G in (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

(19.10)


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

MX

Ca

rd


Mechanical Drawings

28

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

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)

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 (19.1)

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 (19.1)

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

MX

Ca

rd


Mechanical Drawings

29

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

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)

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

MX

Ca

rd


Mechanical Drawings

30

2.8.2 RC Chassis with no Bypass

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

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)

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 M

X C

ard


Mechanical Drawings

31


Amp Frame

Size A

in (mm) B


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)

MX

Ca

rd


Mechanical Drawings

32


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)

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)

MX

Ca

rd


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 permanently mounted 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


Mechanical Drawings

34

Figure 16 - Keypad Bezel Mounting Dimensions Bezel

35

3 Installation

3 – INSTALLATION

Control Board Layout

36

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

Site Requirements

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

Mounting

The starter must be mounted so the heat sink fins are vertically oriented in an area that does not experience excessive shock or vibration. 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 these temperatures.

3.2 Installation Precautions

General Information

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

• The wiring diagram (supplied separately with the starter) is correct for the required application. • The starter is the correct current rating and voltage rating for the motor being started. • All of the installation safety precautions are followed. • The correct power source is available. • The starter control method has been selected. • The connection cables have been obtained. (LUGS and associated mounting hardware) • The necessary installation tools and supplies are procured. • The installation site meets all environmental specifications for the starter NEMA/CEMA rating. • The motor being started has been installed and is ready to be started. • Any power factor correction capacitors (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 serious damage to the starter that will not be covered by the starter warranty. The capacitors must be connected to the line side of the starter. The up-to-speed (UTS) contact can be used to energize the capacitors after the motor has reached full speed.

3 – INSTALLATION

Control & Power Schematics

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. To reduce the risk of electrical shock, current carrying parts and other components of the starter should be inspected and replaced 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, and

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

• Minimum spacing between different wiring groups in the same tray should be six inches. • Wire runs outside an enclosure should be run in metallic conduit or have shielding/armor with equivalent attenuation. • Whenever power and control wiring cross it should be at a 90 degrees angle. • Different wire groups should be run in separate conduits.

3 – INSTALLATION


38

• 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 in the 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 the line 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 60/75°C 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 environments may cause radio interference, in which case the installer may need to use additional mitigation methods.

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 to Wiring Practices on page 37.

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

3 – INSTALLATION

Control Board Basic Wiring

39

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/stop control by programming DI1 as a stop input. 2-wire start/stop control can be implemented by just using the start input. Refer to sections 5 & 6 for configuring the Digital and Analog input and output in software.

Figure 17 – Basic Wiring Diagram

3 – INSTALLATION


40

3.3.4 Control Board Layout

Figure 18 – Control Board Layout

START DI 1 S/DI COM DI2 DI3 DI2/D3 COM

NO1 RC1

NC1 NO2 RC2

NC2

NC3 RC3 NO3

BIPC 300050-00-01 SN

Gnd

120V Control

Relay OutputR1, R2, R3

Digital InputsStart, DI1, DI2, DI3

Modbus Serial Port

SCR 6

CT Input

LED Display & Keypad

Analog Output & Config Jumper

CT Burden Selector Switch

Analog Input

& Config Jumper

SCR 3

SCR 5

SCR 1

SCR 4

SCR 2

Serial Number

120V Control

CPU Heart Beat LED Serial Com LEDs

Shield Ground

Terminating Resistor

Reset Button

Conn 3 Conn 2

3 – INSTALLATION


41

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

3 – INSTALLATION


42

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

3 – INSTALLATION


43

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

3 – INSTALLATION


44


3 – INSTALLATION


45


3 – INSTALLATION


46

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

3 – INSTALLATION


47

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

3 – INSTALLATION


48


3 – INSTALLATION


49


3 – INSTALLATION


50

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

3 – INSTALLATION


51

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

3 – INSTALLATION


52

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

3 – INSTALLATION


53

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

3 – INSTALLATION


54

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

3 – INSTALLATION


55

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

3 – INSTALLATION


56

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

3 – INSTALLATION


57

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

3 – INSTALLATION

Installation Procedures

58

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 ensure accurate operation, the motor current signal must be correctly scaled for the motor (and its application) being controlled by the starter. Motor current signal scaling may have to be changed if:

• Motor size has been changed from the original specification.

• 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 selecting the 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 for actual 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 the motor, 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 and TruTorque motor control functions to operate properly.

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

The CT can be placed either before or after the starter. In specific applications, like Inside Delta and a starter with a DC brake, the CT’s 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 Minimum FLA (A rms)

Maximum FLA (A rms)

Switch 6 Position 1

Switch 6 Position 2

2 3 Off Off 3 4 Off On 4 9 On Off

72 (4 wraps 288:1)

9 16 On On 3 4 Off Off 4 5 Off On 5 12 On Off

96 (3 wraps 288:1)


144 (2 wraps 288:1)

18 32 On On 8 14 Off Off

14 16 Off On 16 32 On Off

288


864


1320 (2 wraps

2640) 165 290 On On 73 128 Off Off 128 151 Off On 151 330 On Off

2640


2880


3900


5760


8000


14400 Mult.

CT-CT Combinations 1800 3200 On On

800 1400 Off Off 1400 1680 Off On 1680 3600 On Off

28800 Mult.

CT-CT Combinations 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 unless specified in a custom configuration. Next to the analog input terminal block is JP3. When the jumper is installed, the input is current loop. 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 line power 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 specified in a custom configuration. Next to the analog output terminal block is JP1. When the jumper is installed, the output is Voltage. When removed, 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 used in the RBX product line. The first is the use of an isolated heatsink with dual flat pack SCR modules mounted on the heatsink. This style is used up to 96A. The second style uses hockey puck SCR devices, which are sandwiched between two pieces of heatsink. In this 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 delta connected 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 by a 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 the reduction 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 shown in Figure 38.

By observation of Figure 38, access to all six stator-winding terminals is required for an inside delta application. In the line connected soft starter of Figure 37, access to only three leads of the stator windings of the motor is required. For a 12-lead motor, all 12 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 trip circuit breaker is recommended to protect the motor. A programmable relay can be configured as a shunt trip relay and can be used to trip 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 the inside delta soft starter is always electrically live when the circuit breaker is closed. This requires caution to ensure these leads of the motor 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 sized to 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 state starter. The bypass contactor is used to reduce the heat that would be generated if the SCR’s were not bypassed. While bypassed, the SCR’s 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 some reason the solid state starter cannot start the motor.

Benshaw Inc. offers bypass contactor ratings from AC1/definite purpose for bypassing the SCR’s to NEMA rating used for full voltage 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 not apply 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 when this 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 devices can damage the SCRs during ramping. These devices appear like a short circuit to the SCR when it turns on, which causes a di/dt level greater than the SCR can handle. If used, power factor correction capacitors or surge capacitors must be connected ahead of the starter and sequenced into the power circuit after the start is completed. A programmable relay can be configured as an up-to-speed (UTS) relay and then used to pull-in a contactor to connect the capacitors after the motor has reached full speed.

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 is applied 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 a contactor 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 300 MCM BLU-030S 1000 MCM BLU-100S 350 MCM BLU-035S 1500 MCM BLU-150S 400 MCM BLU-040S4 2000 MCM BLU-200s 450 MCM BLU-045S1

Table 16 – Two Hole Compression Lugs

Wire Size Part # Wire Size Part # 1/0 BLU-1/0D20 500 MCM BLU-050D2 2/0 BLU-2/0D4 600 MCM BLU-060D1 3/0 BLU-3/0D1 650 MCM BLU-065D5 4/0 BLU-4/0D1 750 MCM BLU-075D 250 MCM BLU-025D 800 MCM BLU-080D 300 MCM BLU-030D 1000 MCM BLU-100D 350 MCM BLU-035D 1500 MCM BLU-150D 400 MCM BLU-040D4 2000 MCM BLU-200D 450 MCM BLU-045D1

3.6.2 Recommended Wire Gauges

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

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3.6.3 CT Mounting

For starters larger than 124 amps, the CTs are shipped loose from the power stack and need to be mounted on the power wiring. Thread the motor or incoming lead through the CT with the polarity mark towards the line side. (The polarity marks may be a white dot, an “X” on the side of the CT, or the white wire.) Each phase has its own CT. The CT must then be attached to the power wiring, at least three inches from the power wire lugs, using two tie-wraps.

3.6.3.1 Line Connected Soft Start

For line connected starters, the CT is on the output of the starter. Refer to Figure 39 – Typical CT Mounting, Output of Starter

Figure 39 – Typical CT Mounting, Output of Starter

FRONT VIEW DETAILSIDE VIEW DETAIL

MUST BE A 3" (MIN.)

SPACE BETWEEN CT

AND BOTTOM OFLUG

CUSTOMER MUST FASTEN CTTO POWER WIRE WITH TWO 1/4"

NYLON WRAPS TO PREVENTMOVEMENT DURING RUNNING

3.6.3.2 Inside Delta Connection

For inside delta connected starters, the CTs are on the incoming line. Refer to Figure 40 – Typical CT Mounting, Input of Starter.

Figure 40 – Typical CT Mounting, Input of Starter

FRONT VIEW SIDE VIEW DETAIL

MUST BE A 3" (MIN.)SPACE BETWEEN CTAND TOP OF LUG

CUSTOMER MUST FASTEN CTTO POWER WIRE WITH TWO 1/4"

NYLON WRAPS TO PREVENTMOVEMENT DURING RUNNING Dot, or X,

White Wire

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3.6.4 Torque Requirements for Power Wiring Terminations

Table 17 – Slotted Screws and Hex Bolts

Tightening torque, pound-inches (N-m) Wire size installed in

conductor

Slotted head NO. 10 and larger Hexagonal head-external drive socket

wrench AWG or

kcmil

(mm2) Slot width-0.047 inch

(1.2mm) or less and slot length ¼ inch (6.4mm) or

less

Slot width-over 0.047 inch (1.2mm) or slot length – over ¼ inch

(6.4mm) or less

Split- bolt connectors

Other connectors

18 – 10 (0.82 – 5.3) 20 (2.3) 35 (4.0) 80 (9.0) 75 (8.5) 8 (8.4) 25 (2.8) 40 (4.5) 80 (9.0) 75 (8.5) 6 – 4 (13.3 – 21.2) 35 (4.0) 45 (5.1) 165 (18.6) 110 (12.4) 3 (26.7) 35 (4.0) 50 (5.6) 275 (31.1) 150 (16.9) 2 (33.6) 40 (4.5) 50 (5.6) 275 (31.1) 150 (16.9) 1 (42.4) -- -- 50 (5.6) 275 (31.1) 150 (16.9) 1/0 – 2/0 (53.5 – 64.4) -- -- 50 (5.6) 385 (43.5) 180 (20.3) 3/0 – 4/0 (85.0 – 107.2) -- -- 50 (5.6) 500 (56.5) 250 (28.2) 250 – 350 (127 – 177) -- -- 50 (5.6) 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 (124.3) 600 (67.8)

NOTE – For a value of slot width or length not corresponding to those specified above, the largest torque value associated with the conductor size shall be marked. Slot width is the nominal design value. Slot length is measured at the bottom of the slot.

Table 18 – Tightening Torque for Inside Hex Screws

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

1/8 (3.2) 45 (5.1) 5/32 (4.0) 100 (11.3) 3/16 (4.8) 120 (13.6) 7/32 (5.6) 150 (16.9) 1/4 (6.4) 200 (22.6) 5/16 (7.9) 275 (31.1) 3/8 (9.5) 375 (42.4) 1/2 (12.7) 500 (56.5) 9/16 (14.3) 600 (67.8)

NOTE – For screws with multiple tightening means, the largest torque value associated with the conductor size shall be marked. Slot length shall be measured at the bottom of the slot.

3.6.5 Meggering a Motor

If the motor needs to be meggered, remove the motor leads from the starter before conducting the test. Failure to comply may damage the SCRs and WILL damage the control board, which will not be replaced under warranty.

3.6.6 High Pot Testing

If the starter needs to be high pot tested, remove the SCR gate leads from the control board before conducting the test. Failure to comply WILL damage the control board WHICH will not be replaced under warranty.

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3.7 Mounting Considerations

3.7.1 Bypassed Starters

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

3.7.2 Non-Bypassed Starters (with out bypass)

Provisions should be made to ensure that the temperature inside the enclosure never rises above 50°C. If the temperature inside the enclosure is too high, the starter can be damaged or the operational life can be reduced. As a general rule of thumb, the following ventilation guidelines can be followed.

Table 19 – Ventilation Requirements

Current Range Bottom of Enclosure Top of Enclosure < 200 amps Fans or grills depending on enclosure size 200 to 300 amps 2 x 4” grills (12 sq. in.) 2 x 4” grills (12 sq.in.) 301 to 400 amps 1 x 4” fan (115 cfm) 2 x 4” grills (12 sq.in.) 401 to 600 amps 2 x 4” fan (230 cfm) 2 x 6” grills (28 sq.in.) 601 to 700 amps 2 x 6” fan (470 cfm) 2 x 6” grills (28 sq.in.) > 700 amps Consult factory Consult Factory

3.8 Enclosed Product

3.8.1 Packaged by Benshaw Inc.

Benshaw supplies starters under 124 amps non-bypassed, with the heat sink protruding from the back of the enclosure. This allows a small enclosure size while still maintaining the cooling capability of the starter. The starter produces 4 watts of heat per amp of current and 14 square inches of enclosure surface is required per watt of heat generation. Contact Benshaw and ask for the enclosure sizing technical note for more information concerning starters in sealed enclosures.

3.9 Preventive Maintenance

3.9.1 General Information

Preventive maintenance performed on a regular basis will help ensure that the starter continues to operate reliably and safely. The frequency of preventive maintenance depends upon the type of maintenance and the installation site’s environment.

NOTE: a trained technician should always perform preventive maintenance.

3.9.2 Preventive Maintenance

During Commissioning:

• Torque all power connections during commissioning. This includes pre-wired equipment. • Check all of the control wiring in the package for loose connections. • If fans are installed, ensure proper operation

One month after the starter has been put in operation:

• Re-torque all power connections during the month. This includes pre-wired equipment. • Inspect the cooling fans after two weeks to ensure proper operation.

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After the first month of operation:

• Re-torque all power connections every year. • Clean any accumulated dust from the starter using a clean source of compressed air. • Inspect the cooling fans every three months to ensure proper operation. • Clean or replace any air vent filters on the starter every three months.

NOTE: If mechanical vibrations are present at the installation site, inspect the electrical connections more frequently.

3.10 Options

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

The LCD display is remotely mounted from the MX control. 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 high enclosure rating. The display and bezel have a NEMA 4 service rating.

3.10.1.1 Installing Driver Board, BIPC-3000049-01

When a remote keypad is used, a driver board is added to the MX control. The driver board connects to connector conn 3 on the MX control board via a header connector. The driver circuit board is held in place by double-sided tape between the backside of the driver board and the control card terminal strip. When installing the driver board, first remove the cover over the tape, install the header connector to the bottom side of the board into the driver board conn J2, and then install the header into Conn 3 on the MX board. The double-sided tape will adhere to the terminal strip, securing the driver board to the MX control board.

Figure 41 – Driver Board for Remote Keypads

3.10.1.2 Installing Remote Cable

The remote interconnect cable is connected between J1 of the driver board and J1 of the remote display. The cable has a 12 pin connector on each end with one end having a ground wire. The ground wire end is to be connected to J1 of the driver board. Connect the cable to J1 of the MX control and connect the ground wire to the terminal marked G in the upper left hand corner of the control terminal strip. The red wire of the connector is on the pin 1 side of the connector for both the driver board and the display.

Red Wire

Ground Wire

Remote Cable

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3.10.1.3 Mounting The Keypad

Figure 42 –Mounting Remote Keypads

KPMXLCDSKP

Part of GKT-100008-00

MD-100001-00

GKT-100008-00

Note: See Figure 16 for mounting dimensions and hole locations

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3.10.2 Single Phase Soft Starter

There are times a single phase motor may need to be started using a soft starter. This can be accomplished with any 3 phase starter with the following modifications to the starter.

• Ground L2 Input • Line power to L1 and L3 • Remove gate leads from TB6 and TB7 and tie off so the leads will not touch anything. • Remove gate leads from TB8 (SCR 3) and reinstall to TB6, from TB9 (SCR 6) and reinstall to TB7, • Change Input Phase Sensitivity, P66/FUN04 to “SPH” Single Phase • Connect motor to terminal T1 and T3

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Figure 43 – Power Schematic for RBX integral Bypass Power Stack for Single Phase Operation

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4 Keypad Operation

4 – KEYPAD OPERATION

Standard LED Keypad and Display

74

4.1 Introduction

The MX Control provides a comprehensive set of parameters to allow the use of the reduced voltage solid state starter in nearly any industrial application. While the starter can meet the requirements of many applications right out of the box, customization of parameter values to better suit your particular application is easily accomplished with the standard, on-board, 4-digit, 7-segment LED display/keypad, a remote display/keypad, or via remote serial communication.

The MX control has two remote keypads and displays that are optional equipment; a remote 4-digit, 7-segment LED display and a 2x16-backlit LCD display. Both keypads have the same keys as the standard display with several additional keys including start and stop keys for operation of the starter from the keypad. When the remote keypad is connected, the local keypad and display are disabled.

4.2 Standard Keypad and Display

The LED display provides information on starter operation and programming. The 4-digit, 7-segment display shows starter meter outputs and programming data. Special symbols provide further information about the starter operation (see the following section).

Figure 44 – Standard Keypad and Display

PARAM DOWN UP ENTER

RESET

4.2.1 Special Messages Displayed

The keypad's display may show special information under certain conditions.

Table 20 – LED Special Characters Displayed No Line Ready Accelerating or Kicking Accelerating or Kicking with ramp 2 Up to Speed Run – Done with Accel ramp but not yet Up to

Speed. Decelerating Motor Overload Alarm – The motor overload level is

between 90% and 100%. Overload Fault – The motor overload level has

reached 100%. Overload Lockout – A start is not allowed until the

motor overload level cools below 60%. Control Power Lockout – A start is not allowed

because the control power is too low. Lock out State

Phase order meter showing ABC Phase order meter showing CBA Phase order meter showing Single Phase

xxx xxx = overload content. xx xx = Parameter code. xx xx = Alarm code. If the condition persists,

a fault will occur. xx xx = Fault code.

Instantaneous Overcurrent Default – Flashes when parameter defaults

are loaded. Heater/Anti-windmill Mode Energy Saver In reflash mode In reflash mode, programming In reflash mode, verifying In reflash mode, complete



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4.2.2 Viewing and Changing Parameters for the Standard Keypad

4.2.2.1 Viewing Parameter Values

Parameter view mode can be entered by:

1. At the default meter display, press the PARAM key to enter parameter mode. “P 1” will be displayed to indicate Parameter 1. 2. Use the UP and DOWN keys to scroll through the available parameters. 3. Pressing the UP key from “P 1” will advance to parameter “P 2”. 4. Pressing the DOWN key from “P 1” will wrap around to the highest parameter. 5. The value of the parameter can be viewed by pressing the ENTER key. 6. To view another parameter without changing/saving the parameter, press the PARAM key to return to the parameter number

display.

To return to the default meter display either:

1. Press the PARAM key while in the parameter number display mode. 2. Wait 60 seconds and the display will return to the default meter display.

4.2.2.2 Changing Parameter Values

Parameter change mode can be entered by:

1. At the default meter display, press the PARAM key to enter parameter mode. 2. Use the UP and DOWN keys to scroll through the available parameters. 3. The value of the parameter can be viewed by pressing the ENTER key. 4. When viewing the parameter value, the parameter can be changed by using the UP and DOWN keys. 5. To store the new value, press the ENTER key. When the ENTER key is pressed the value will be saved and the display will go

back to parameter # “P_”.

To exit parameter change mode without saving the new parameter value either:

1. Press the PARAM key to return to the parameter number display. 2. Wait 60 seconds and the display will return to the default meter display.

4.2.3 Display Output for the Standard Keypad

The display will output different information depending on the operation of the starter Table 20 – LED Special Characters Displayed.

4.2.3.1 Power Up

The software version will be displayed as a series of blinking digits once power has been applied to the MX control. If the parameters were being reset on power up, “dFLt” will be flashed on the display for three seconds, then the software version will be displayed.

4.2.3.2 Stopped

When the starter is not in the run mode, the display will show the status condition of the starter, such as “rdY” (ready), “L OL” (Overload Lockout), “noL” (No Line).



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4.2.3.3 Running

When running, the display will show the user selected meter function. The following meters can be selected using the “Meter” display parameter P68.

Avg. RMS current GF Current (% FLA) Overload % MWh Running Time Days Phase 1 RMS current Avg. Voltage (RMS) Power Factor Phase Rotation Running Time Hours Phase 2 RMS current L1-L2 Voltage (RMS) KW Line Frequency Starts Phase 3 RMS current L2-L3 Voltage (RMS) KVA Analog Input % TruTorque % Current Imbalance % L3-L1 Voltage (RMS) KWh Analog Output % Power %

4.2.3.4 Alarm Condition

When an alarm condition exists, the display alternates between displaying the selected meter and the alarm code. The alarm code is displayed as “A XX”, where XX is the alarm code.

• When a thermal overload alarm condition exists, “A OL” will be displayed. • When a no line alarm condition exists, “noL” will be displayed.

When the starter is stopped, the selected meter is not displayed.

4.2.3.5 Lockout Condition

When a lockout condition exists, the display shows the lockout code. The lockout code is displayed as “L XX: where XX is the lockout code. Following are the defined lockout conditions and their codes:

• When a motor thermal overload lockout condition exists, “L OL” will be displayed. • When a power stack thermal overload lockout condition exists, “L Ot” will be displayed. • When a low control power lockout condition exists, “L CP” will be displayed.

When there are multiple lockout codes, each will be displayed at 2 second intervals.

4.2.3.6 Faulted Condition

When a fault condition exists, the display shows the fault code. The exceptions to this are as follows:

• When the fault is thermal overload trip, “F OL” will be displayed. • When the fault is Instantaneous over current, ioc will be displayed.

4.2.4 Quick Meters

Although any meter may be viewed by changing the meter parameter, there are 3 “Quick Meters” that are always available with a single key press. When the starter is in the normal display mode, the display may be toggled between the information currently displayed and the following quick meters.

Status Meter Toggle between the programmed meter display and the starter operational status display (rdY, run, utS, dcL, etc) by pressing the ENTER key.

Overload Meter Toggle between the programmed meter display and the overload content by pressing the DOWN key. The overload will be displayed as “oXXX” where XXX is the overload content. For example if the overload content is 76 percent, it will be displayed as “o 76”.

Phase Order Meter Toggle between the programmed meter display and the phase order by pressing the UP key. The phase order will be displayed as “AbC” or “CbA”.



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4.2.5 Restoring Factory Parameter Settings

To restore ALL parameters to the factory default settings, press and hold the PARAM and ENTER pushbutton switch on power up. The display will blink “dFLt”. Parameters unique to the motor starter applications will need to be set again to appropriate values before motor operation

4.2.6 Resetting a Fault

To reset from a fault condition, press RESET.

4.2.7 Emergency Thermal Reset

To perform an emergency thermal reset, press RESET and DOWN. This will set the motor thermal overload content to 0.



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5 Troubleshooting

5–TROUBLESHOOTING

80

5.1 The troubleshooting section is divided into 3 sections.

• 5.2 MX Control; General Troubleshooting when MX controlled is installed

• 5.4 SCR Testing

• 5.5 SCR Replacement

5.2 MX Control; General Troubleshooting

The following troubleshooting charts can be used to help solve many of the more common problems that may occur when the MX control is installed.

5.2.1 Motor does not start, no output to motor

Condition Cause Solution

Control voltage absent. Check for proper control voltage input. Verify fuses and wiring.

Display Blank, CPU Heartbeat LED on MX board not blinking.

MX control board problem. Consult factory.

Fault Displayed. Fault Occurred. See fault code troubleshooting table for more details.

Start/Stop control input problems. Verify that the start/stop wiring and start input voltage levels are correct.

Start command given but nothing happens.

Control Source parameters (QST 04-05, P4-5) not set correctly.

Verify that the parameters are set correctly.

Check input supply for inline contactor, open disconnects, open fuses, open circuit breakers, or disconnected wiring.

Verify that the SCR gate wires are properly connected to the MX control board.

On medium voltage systems, verify wiring of the voltage feedback measurement circuit.

NOL or No Line is displayed and a start command is given, it will fault in F28.

No line voltage has been detected by the MX when a start command is given..

See fault code troubleshooting table for more details.

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



Maximum Motor Current setting (QST 07, P7) set too low.

Review acceleration ramp settings.

Motor loading too high and/or current not dropping below 175% FLA indicating that the motor has not come up to speed.

Reduce load on motor during starting.

Motor FLA (QST 01, P1) or CT ratio (FUN 03, P68) parameter set incorrectly.

Verify that Motor FLA and CT ratio parameters are set correctly.

Abnormally low line voltage. Fix cause of low line voltage.

Display shows Accel or Run.

A mechanical or supplemental brake is still engaged.

Verify that any external brakes are disengaged.

Motor Hums before turning Initial current to low Increase initial current

FLA or CT incorrect Verify FLA or CT’s

5.2.3 Acceleration not operating as desired


Ramp time (QST 08, P8) too short. Increase ramp time.

Initial current (QST 06, P6) set too high.

Decrease Initial current.

Maximum current (QST07, P7) set too high.

Decrease Maximum current.

Kick start current (CFN10, P13) too high.

Decrease or turn off Kick current.

Kick start time (CFN11, P14) too long.

Decrease Kick time.



Motor accelerates too quickly.

Starter Type parameter (FUN 07, P64) set incorrectly.

Verify that Starter Type parameter is set correctly.

Maximum Motor Current setting (QST 07, P7) set too low.

Review acceleration ramp settings. Increase max current

Motor loading too high. Reduce load on motor during starting.



Abnormally low line voltage. Fix cause of low line voltage.

Motor accelerates too slowly

Ramp time to long Decrease ramp time

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5.2.4 Deceleration not operating as desired


Decel Time (CFN17, P18) set to short.

Increase Decel Time. Motor stops too quickly.

Decel Begin and End Levels CFN 15-16, P16-17) set improperly.

Increase Decel Begin and/or Decel End levels.

Decel time seems correct but motor surges (oscillates) at beginning of deceleration cycle.

Decel Begin Level (CFN15, P16) set too high.

Decrease Decel Begin Level until surging is eliminated.

Decel time seems correct but motor stops before end of deceleration cycle.

Decel End Level (CFN16, P17) set too low.

Increase Decel End Level until motor just stops at the end of the deceleration cycle.

Decel End Level (CFN16, P17) set too high.

Decrease Decel End Level until water hammer is eliminated.

Water hammer still occurs at end of cycle.

Decel Time (CFN17, P18) too short. If possible, increase Decel Time to decelerate system more gently.

Motor speed drops sharply before decel

Decel begin level to low. Increase the Decel Begin Level until drop in speed is eleminated.

5.2.5 Motor stops unexpectedly while running



Verify start command input signal is present or serial communications start command is present.

Ready Displayed. Start command lost.

Check any permissives that may be wired into the run command (Start/Stop)

Control voltage absent. Check for proper control voltage input. Verify wiring and fuses.

Display Blank, Heartbeat LED on MX board not blinking.

MX control board problem. Consult factory.


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5.2.6 Metering incorrect


CTs installed or wired incorrectly. Verify correct CT wiring and verify that the CTs are installed with all the White dots towards the input line side.

CT ratio parameter (FUN 03, P68) set incorrectly.

Verify that the CT ratio parameter is set correctly.

Power Metering not reading correctly.

Burden switches set incorrectly. Verify that the burden switches are set correctly.

PF Meter not reading correctly. CTs installed or wired incorrectly. Verify correct CT wiring and verify that the CTs are installed with all the White dots towards the input line side.

Energy Saver active. Turn off Energy Saver if not desired.

Loose connections. Shut off all power and check all connections.

SCR fault. Verify that the SCRs gate leads are connected properly and the SCRs are ok.

Load actually not steady. Verify that the load is actually steady and that there are not mechanical issues.

Motor Current or Voltage meters fluctuating with steady load.

Other equipment on same power feed causing power fluctuations and/or distortion.

Fix cause of power fluctuations and/or distortion.

Voltage Metering not reading correctly.

Rated Voltage parameter (FUN 05, P66) set incorrectly.

Verify that Rated Voltage parameter is set correctly.




Current Metering not reading correctly.





Ground Fault Current Metering not reading correctly.


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5.2.7 Other Situations


If input phasing correct, exchange any two output wires.

Motor Rotates in Wrong Direction Phasing incorrect

If input phasing incorrect, exchange any two input wires.

Erratic Operation Loose connections Shut off all power and check all connections.

Motor overloaded Reduce motor load.

Too many starts per hour Allow for adequate motor cooling between starts. Set Hot/Cold ratio higher or lengthen cooling time.

High ambient temperature Reduce ambient temperature or provide for better cooling. Set OL class lower to compensate for ambient temperature.

Acceleration time too long Reduce starting load and/or review acceleration ramp settings.

Incorrect motor OL settings Review and correct if necessary motor OL settings.

Motor Overheats

Motor cooling obstructed/damaged Remove cooling air obstructions. Check motor cooling fan.

Fan power supply lost Verify fan power supply, check fuses.

Fan wiring problem Check fan wiring.

Starter cooling fans do not operate (When Present)

Fan failure Replace fan

Voltage/Current output jumper (JP1) not set correctly.

Set jumper to give correct output.

Wiring problem Verify output wiring.

Analog Output Function parameter (I/O 12, P50) set incorrectly.

Verify that the Analog Output Function parameter is set correctly.

Analog Output Offset and/or Span parameters (I/O 13-14, P51-52) set incorrectly.

Verify that the Analog Output Span and Offset parameters are set correctly.

Load on analog output too high. Verify that load on analog output meets MX control analog output specifications.

Analog Output not functioning properly

Ground loop or noise problems. Verify correct grounding of analog output connection to prevent noise and/or ground loops from affecting output.

Keypad cable not plugged in properly or cable damaged.

Verify that the remote keypad cable has not been damaged and that it is properly seated at both the keypad and the MX Control board.

Display interface board (when present) not firmly plugged in.

Verify that the display interface board (if present) is firmly attached to MX control card.

Remote Keypad does not operate correctly.

Remote display damaged. Replace remote display.


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5.3 Fault Code Troubleshooting Table

The following is a list of possible faults that can be generated by the MX starter control.

Fault Code Description Detailed Description of Fault / Possible Solutions

Motor did not achieve full speed before the UTS timer (QST 09, P9) expired.

Check motor for jammed or overloaded condition.

Verify that the combined kick time (CFN11, P14) and acceleration ramp time (QST 08, P8) is shorter than the UTS timer setting.

Evaluate acceleration ramp settings. The acceleration ramp settings may be too low to permit the motor to start and achieve full speed. If so, revise acceleration ramp settings to provide more motor torque during starting.

F01 UTS Time Limit Expired

Evaluate UTS timer setting and, if acceptable, increase UTS timer setting (QST 09, P9).

The MX motor thermal overload protection has tripped.

Check motor for mechanical failure, jammed, or overloaded condition.

Verify the motor thermal overload parameter settings (QST 03, P3 and PFN 12-16, P35-38) and motor service factor setting (QST 02, P2).

Verify that the motor FLA (QST 01, P1), CT ratio (FUN 03, P68), and burden switch settings are correct.

If motor OL trip occurs during starting, review acceleration ramp profile settings.

Verify that there is not an input line power quality problem or excessive line distortion present.

Verify that PF caps, if installed, are ahead of CT’s and starter.

F02 (F OL) Motor Thermal Overload Trip

Reset overload when content falls below 15%.

Input phase rotation is not ABC and Input Phase Sensitivity parameter (FUN 04, P67) is set to ABC only.

Verify correct phase rotation of input power. Correct wiring if necessary.

F10 Phase Rotation Error, not ABC

Verify correct setting of Input Phase Sensitivity parameter (FUN 04, P67).

Input phase rotation is not CBA and Input Phase Sensitivity parameter (FUN 04, P67) is set to CBA only.

Verify correct phase rotation of input power. Correct wiring if necessary.

F11 Phase Rotation Error, not CBA

Verify correct setting of Input Phase Sensitivity parameter (FUN 04, P67).

Line frequency below 23 Hz was detected.

Verify input line frequency.

If operating on a generator, check generator speed governor for malfunctions.

Check input supply for open fuses or open connections

F12 Low Line Frequency

Line power quality problem / excessive line distortion.

Line frequency above 72 Hz was detected.

Verify input line frequency.

If operating on a generator, check generator speed governor for malfunctions.

F13 High Line Frequency

Line power quality problem / excessive line distortion.

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Three-phase power has been detected when the starter is expecting single-phase power.

Verify that input power is single phase.

Verify that single-phase power is connected to the L1 and L3 inputs. Correct wiring if necessary.

F14 Input power not single phase


Single-phase power has been detected when the starter is expecting three-phase power.

Verify that input power is three phase. Correct wiring if necessary.


F15 Input power not three phase


Low voltage below the Undervoltage Trip Level parameter setting (PFN 08, P31) was detected for longer than the Over/Under Voltage Trip delay time (PFN 09, P32).

Verify that the actual input voltage level is correct.

Verify that the Rated Voltage parameter (FUN 05, P66) is set correctly.

Check input supply for open fuses or open connections.

F21 Low Line L1-L2

On medium voltage systems, verify wiring of the voltage measurement circuit.





F22 Low Line L2-L3






F23 Low Line L3-L1


High voltage above the Over voltage Trip Level parameter setting (PFN 07, P30) was detected for longer than the Over/Under Voltage Trip delay time (PFN 09, P32).


F24 High Line L1-L2


Line power quality problems/ excessive line distortions.


87




F25 High Line L2-L3





F26 High Line L3-L1



The MX control has detected the loss of one or more input or output phases when the starter was running. Can also be caused by line power dropouts.

Check input supply for open fuses.

Check power supply wiring for open or intermittent connections.

Check motor wiring for open or intermittent connections.


F27 Phase Loss

Check Gate and Cathode connections to MX board

No input voltage was detected for longer than the Inline Configuration time delay parameter setting (I/O 15, P53) when a start command was given to the starter.

If an inline contactor is being used, verify that the setting of the Inline Configuration time delay parameter (I/O 15, P53) allows enough time for the inline contactor to completely close before the No Line fault occurs.

Check input supply for open disconnects, open fuses, open circuit breakers, or disconnected wiring.


F28 No Line


During operation, the MX controller detected a very high level of current in one or more phases.

Check motor wiring for short circuits or ground faults.

Check motor for short circuits or ground faults.

Check if power factor or surge capacitors are installed on the motor side of the starter.

F30 I.O.C.

(Instantaneous Overcurrent Current)


Motor current exceeded the Over Current Trip Level setting (PFN 01, P24) for longer than the Over Current Trip Delay Time setting (PFN 02, P25).

F31 Overcurrent

Check motor for a jammed or an overload condition.

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Motor current dropped under the Under Current Trip Level setting (PFN 03, P26) for longer than the Under Current Trip Delay time setting (PFN 04, P27).

F34 Undercurrent

Check system for cause of under current condition.

A current imbalance larger than the Current Imbalance Trip Level parameter setting (PFN 05, P28) was present for longer than ten (10) seconds.

Check motor wiring for cause of imbalance. (Verify dual voltage and 6 lead motors for correct wiring configuration).

Check for large input voltage imbalances that can result in large current imbalances.

F37 Current Imbalance

Check motor for internal problems.

Ground current above the Ground Fault Trip level setting (PFN 06, P29) has been detected for longer than 3 seconds.

Check motor wiring for ground faults.

Check motor for ground faults.

Megger motor and cabling (disconnect from starter before testing).


Verify that the CTs are installed with all the White dots towards the input line.

F38 Ground Fault

In Single phase applications, verify that only two CTs are being used; that they are installed with all the White dots or Xs in the correct direction; and that the CTs are connected to the L1 and L3 CT inputs on the MX control card.

Motor current went below 10% of FLA while the starter was running.

Verify Motor Connections.

Verify the CT wiring to the MX control board.


Check if load is still connected to starter

Check if motor may have been driven by the load (a regeneration condition)

Check Gate and Cathode connections to MX for loose connections.

F39 No Current at Run

Check for inline contactor or disconnect.

A shorted or open SCR condition has been detected.

Verify that all SCR gate leads wires are properly connected at the SCR devices and the MX control board.

Check all SCRs with ohmmeter for shorts.

Verify that the Input Phase Sensitivity parameter setting (FUN 04, P67) is correct.

Verify that the Starter Type parameter setting (FUN 07, P64) is correct.

F40 Shorted / Open SCR

Verify the motor wiring. (Verify dual voltage motors for correct wiring configuration).


89

Motor current was detected while the starter was not running.

Examine starter for shorted SCRs.

Examine bypass contactor (if present) to verify that it is open when starter is stopped.

F41 Current at Stop


The MX electronic power stack OL protection has detected an overload condition.

Check motor for jammed or overloaded condition.

Verify Starter Model Number parameter setting (FUN 13, P70) is correct (if available).

Verify that the CT ratio (FUN 03, P68) and burden switch settings are correct.

F47 Stack Protection Fault (stack thermal overload)

Motor load exceeds power stack rating. Consult factory

A digital input has been programmed as a Bypass/2M Contactor Feedback input and an incorrect bypass feedback has been detected for longer than the Bypass Confirm time parameter setting (I/O 16, P54).

Verify that the bypass/2M contactor coil and feedback wiring is correct.

Verify that the relay output that is connected to the bypass/2M contactor(s) is programmed to the UTS function.

Verify that the bypass/2M contactor power supply is present.

Verify that the appropriate Digital Input Configuration parameter has been programmed correctly.

F48 Bypass /2M Contactor Fault

Verify that the bypass contactor(s) are actually not damaged or faulty.

Low control power (below 90V) has been detected while running, by the MX controller.

Verify that the control power input level is correct especially during starting when there may be significant line voltage drop.

Check control power transformer tap setting (if available).

Check control power transformer fuses (if present).

F50 Control Power Low

Check wiring between control power source and starter.

Indicates that the MX control board self-diagnostics have detected a problem with one or more of the current sensor inputs.


Verify that no actual current is flowing through any of the starter’s CTs when the starter is not running.

F51 Current Sensor Offset Error

Consult factory if fault persists.

F52 Burden Switch Error The burden switch settings were changed when starter was running. Only change burden switches when starter is not running.

DI#1 has been programmed as a fault type digital input and the input indicates a fault condition is present.


F60 External Fault on DI#1 Input

Verify wiring and level of input.

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DI#2 has been programmed as a fault type digital input and input indicates a fault condition is present.


F61 External Fault on DI#2 Input


DI#3 input has been programmed as a fault type digital input and input indicates a fault condition is present.


F62 External Fault on DI#3 input


Based on the Analog Input parameter settings, the analog input level has either exceeded or dropped below the Analog Input Trip Level setting (I/O 08, P46) for longer than the Analog Input Trip Delay time (I/O 09, P47).

Measure value of analog input to verify correct reading.

Verify settings of all Analog Input parameters (I/O 07-11, P45-49).

Verify correct positioning of input jumper JP3 (Voltage or Current) on the MX control card.

F71 Analog Input Level Fault Trip.

Verify correct grounding of analog input connection to prevent noise or ground loops from affecting input.

Indicates that communication has been lost with a remote device such as a remote keypad.

(This fault will normally occur if the remote keypad is disconnected while the MX control board is powered up. Only connect and disconnect a remote keypad when the control power is off.)

Verify that the remote keypad cable has not been damaged and that its connectors are firmly seated at both the keypad and the MX Control board.

Verify that the display interface board (when present) is firmly attached to MX control card.

F81 SPI Communication Fault

Route keypad cables away from high power and/or high noise areas to reduce possible electrical noise pickup.

Indicates that the starter has lost serial communications. Fault occurs when the starter has not received a valid serial communications within the Communication Timeout parameter (FUN 12, P59) defined time.

Verify communication parameter settings (FUN 10-12, P59-P61).

Check wiring between the remote network and the MX control card.

F82 Modbus Timeout Fault

Examine remote system for cause of communication loss.

Typically occurs when attempting to run a version of control software that is incompatible with the MX control board hardware being used. Verify that the software is a correct version for the MX control board being used. Consult factory for more details.

F94 CPU Error – SW fault

Fault can also occur if the MX control has detected an internal software problem. Consult factory.


91

The non-volatile user parameter values have been found to be corrupted. Typically occurs when the MX control is re-flashed with new software.

Perform a Factory Parameter reset and then properly set all user parameters before resuming normal operation.

F95 CPU Error – Parameter EEPROM Checksum Fault

If fault persists after performing a Factory Parameter reset, consult factory.

F96 CPU Error The MX control has detected an internal CPU problem. Consult factory.

F97 CPU Error – SW Watchdog Fault

The MX control has detected an internal software problem. Consult factory.

F98 CPU Error The MX control has detected an internal CPU problem. Consult factory.

The non-volatile program memory has been corrupted. F99 CPU Error – Program EPROM Checksum Fault

Consult factory. Control software will need to be reloaded in to the MX control card before normal operation can resume.

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5.4 SCR Testing

Resistance The SCR in the starter can be checked with a standard ohmmeter to determine their condition.

Remove power from the starter before performing these checks

Check from L to T on each phase. The resistance should be over 50k ohms.

Check between the gate leads for each SCR (red and white twisted pair). The resistance should be from 8 to 50 ohms.

NOTE: The resistance measurements may not be within these values and the SCR may still be good. The checks are to determine if an SCR is shorted “L” to “T” of if the gate in an SCR is shorted or open. An SCR could also still be damaged even though the measurements are within the above specifications.

Voltage When the starter is running, the operation of SCR can be confirmed with a voltmeter.

Extreme caution must be observed while performing these checks since the starter has lethal voltages applied while operating

While the starter is running and up to speed, use an AC voltmeter, check the voltage from “L” to “T” of each phase. The voltage should be less that 1.5 Volts. If the starter has a bypass contactor, the voltage drop should be less that 0.3 volts.

Using a DC voltmeter, check between the gate leads for each SCR (red and white twisted pair). The voltage should between 0.5 and 2.0 volts.

Integral Bypass A voltage check from “L” to “T” of each phase of the RediStart starter should be preformed every 6 months to confirm the bypass contactors are operating correctly.

Extreme caution must be observed while performing these checks since the starter has lethal voltages applied while operating

While the starter is running and Up to Speed, use an AC voltmeter; check the voltage from “L” to “T” of each phase. The voltage drop across the contactor contacts should be less than 300mV. If greater that 300mV the integral bypass should be disassembled. It may be necessary to clean the contact tips or replace the contactor.


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5.5 SCR Replacement

This section is to help with SCR replacements on stack assemblies. Please read prior to installation.

5.5.1 Typical Stack Assembly

5.5.2 SCR CLAMP PARTS

Item # Quantity Description

1 1 Loader Bar 2 2 Insulator cup 3 2 Bolt 4 2 Washer 5 2 Serrated nut (larger style clamp has 1 support bar) 6 1 or 2 Indicator Washer – Quantity dependant on style of

clamp

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5.5.3 SCR Clamp

Below is an exploded view of a typical SCR clamp. Refer to the Clamp Parts List for names of the parts being used.

5.5.4 SCR Removal

To remove the SCR from the heatsink, loosen the two bolts (3) on the loader bar side of the clamp. Do not turn on the nuts (5). The nuts have a locking ridge that sink into the aluminum heatsink. Do ¼ turns until the SCR comes loose. Remove the SCRs from the heatsink. Note: Do not loosen nut on indicator washer (6). This will change the clamping pressure of the clamp and the clamp will be defective.

5.5.5 SCR INSTALLATION

• Coat the faces of the SCRs to be installed with a thin layer of EJC. • Place the SCRs onto the dowel pins. The top SCR will have the cathode to the left and the bottom SCR will have

the cathode to the right. The SCR symbol has a triangle that points to the cathode. • Finger tighten nuts on the bolts.

5.5.6 Tightening Clamp

Finger tighten the clamp. Ensure both bolts are tightened an equal amount so that the loader bar (item 1) is square in the heatsink. Tighten the bolts equally in 1/8 turn increments until the indicator washer(s) (item 6), which are under the nut(s) in the center of the loader bar, becomes loose indicating the clamp is tight. On the loader bars with two indicator washers, it may be necessary to tighten or loosen one side of the clamp to get both indicator washers free.

5.5.7 Testing SCR

After the SCRs have been replaced, conduct the resistance test as defined in section 5.4

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6 Appendices

96

List of Tables Table 1 – Environmental Ratings................................................................................................................................................................ 8 Table 2 – Altitude Derating........................................................................................................................................................................ 8 Table 3 – Terminals ................................................................................................................................................................................... 9 Table 4 - Connectors .................................................................................................................................................................................10 Table 5 – Accuracy ...................................................................................................................................................................................10 Table 6 – CT Ratios ..................................................................................................................................................................................11 Table 7 – Class 10 (Standard Duty) Horsepower Ratings............................................................................................................................13 Table 8 – Class 20 (Heavy Duty) Horsepower Ratings ...............................................................................................................................14 Table 9 – Class 30 (Severe Duty) Horsepower Ratings...............................................................................................................................15 Table 10 – Inside Delta Class 10 (Standard Duty) Horsepower Ratings.......................................................................................................16 Table 11 – Power Ratings with Integral Bypass..........................................................................................................................................17 Table 12 – Power Ratings with Separate Bypass ........................................................................................................................................18 Table 13 – Power Ratings with No Bypass.................................................................................................................................................19 Table 14 – CT Ratios and Burden Switch Settings......................................................................................................................................59 Table 15 – Single Hole Compression Lugs.................................................................................................................................................64 Table 16 – Two Hole Compression Lugs ...................................................................................................................................................64 Table 17 – Slotted Screws and Hex Bolts...................................................................................................................................................66 Table 18 – Tightening Torque for Inside Hex Screws .................................................................................................................................66 Table 19 – Ventilation Requirements.........................................................................................................................................................67 Table 20 – LED Special Characters Displayed ...........................................................................................................................................74

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List of Figures Figure 1 – Common Motor Overload Curves .............................................................................................................................................12 Figure 2 - Dimensions for 2 to 65 Amp RB_1 Starter .................................................................................................................................20 Figure 3 - Dimensions for 66 to 96 Amp RB_1 Starter ...............................................................................................................................21 Figure 4 - Dimensions for 97 to 361 Amp RB_1 Starter............................................................................................................................22 Figure 5 - Dimensions for 362 to 720 Amp RB_1 Starter............................................................................................................................23 Figure 6 - Dimensions for 838 Amp RB_1 Starter......................................................................................................................................24 Figure 7 - 2 to 65 Amp Dimensions with ATL Bypass (AC3 or AC4/NEMA rating) ..................................................................................25 Figure 8 - 66 to 77 Amp Dimensions with ATL Bypass (AC3 rating).........................................................................................................26 Figure 9 - 78 to 96 Amp Chassis Dimensions for use with separate ATL Bypass........................................................................................27 Figure 10 - 97 to 361 Amp Chassis Dimensions for use with Separate Bypass (ATL) ..................................................................................28 Figure 11 - 362 to 840 Chassis Dimensions for use with Separate Bypass (ATL) ........................................................................................29 Figure 12 - 2 to 124 Amp Dimensions for Continuous Operation Chassis...................................................................................................30 Figure 13 - 125 to 477 Amp Dimensions for Continuous Operation Chassis..............................................................................................31 Figure 14 - 478 to 840 Amp Dimensions for Continuous Operation Chassis..............................................................................................32 Figure 15 - Keypad Mounting Dimensions without Bezel...........................................................................................................................33 Figure 16 - Keypad Bezel Mounting Dimensions Bezel..............................................................................................................................34 Figure 17 – Basic Wiring Diagram ............................................................................................................................................................39 Figure 18 – Control Board Layout .............................................................................................................................................................40 Figure 19 – Power Schematic for RBX Integral Bypass Power Stack, 3 Amps to 96 Amps ..........................................................................42 Figure 20 – Control Schematic for RBX Integral Bypass Power Stack, 3 Amps to 96 Amps ........................................................................43 Figure 21 – Power Schematic for RBX Integral Bypass Power Stack, 97 Amps to 361 Amps ......................................................................44 Figure 22 – Control Schematic for RBX Integral Bypass Power Stack, 97 Amps to 361 Amps ....................................................................45 Figure 23 – Power Schematic for RBX Integral Bypass Power Stack, 362 Amps to 720 amps .....................................................................46 Figure 24 – Control Schematic for RBX Integral Bypass Power Stack, 362 Amps to 720 amps....................................................................47 Figure 25 – Power Schematic for RBX Integral Bypass Power Stack, 721 Amps to 840 Amp......................................................................48 Figure 26 – Control Schematic for RBX Integral Bypass Power Stack, 721 Amps to 840 Amp....................................................................49 Figure 27 – Power Schematic for RBX with ATL Separate Bypass 3 – 96 Amp ........................................................................................50 Figure 28 – Control Schematic for RBX with ATL Separate Bypass 3 to 96 Amp .....................................................................................51 Figure 29 – Power Schematic for RBX with ATL Separate Bypass 97 Amps and up .................................................................................52 Figure 30 – Control Schematic for RBX with ATL Separate Bypass 97 Amp and up.................................................................................53 Figure 31 – Power Schematic for RCX No Bypass 3 to 124 Amp ..............................................................................................................54 Figure 32 – Control Schematic for RCX with No Bypass 3 to 124 Amp ....................................................................................................55 Figure 33 – Power Schematic for RCX with No Bypass 125 to 840 Amp ..................................................................................................56 Figure 34 – Power Schematic for RCX with No Bypass 125 to 840 Amp ..................................................................................................57 Figure 35 – CT Inputs and CT switches .....................................................................................................................................................58 Figure 36 – MX Control Board Analog Jumper Placement .........................................................................................................................60 Figure 37 – Typical Motor Connection ......................................................................................................................................................61 Figure 38 – Typical Inside Delta Motor Connection ...................................................................................................................................62 Figure 39 – Typical CT Mounting, Output of Starter ..................................................................................................................................65 Figure 40 – Typical CT Mounting, Input of Starter.....................................................................................................................................65 Figure 41 – Driver Board for Remote Keypads ..........................................................................................................................................68 Figure 42 –Mounting Remote Keypads......................................................................................................................................................69 Figure 43 – Power Schematic for RBX integral Bypass Power Stack for Single Phase Operation.................................................................71 Figure 44 – Standard Keypad and Display .................................................................................................................................................74

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Appendix A – CE Mark

According to the EMC – Directive 89/336/EEC as Amended by 92/31/EEC and 93/68/EEC

Product Category: Motor Controller

Product Type: Reduced Voltage Solid State Motor Controller

Model Numbers:

RBX-1-S-027A-11C RBX-1-S-096A-13C RBX-1-S-240A-15C RBX-1-S-515A-17C RBX-1-S-040A-11C RBX-1-S-125A-14C RBX-1-S-302A-15C RBX-1-S-590A-18C RBX-1-S-052A-12C RBX-1-S-156A-14C RBX-1-S-361A-16C RBX-1-S-720A-19C RBX-1-S-065A-12C RBX-1-S-180A-14C RBX-1-S-414A-17C RBX-1-S-838A-20C RBX-1-S-077A-13C RBX-1-S-180A-15C RBX-1-S-477A-17C RCX-1-S-096A-13C RCX-1-S-240A-15C RCX-1-S-515A-17C RCX-1-S-125A-14C RCX-1-S-302A-15C RCX-1-S-590A-18C RCX-1-S-156A-14C RCX-1-S-361A-16C RCX-1-S-720A-19C RCX-1-S-180A-14C RCX-1-S-414A-17C RCX-1-S-838A-20C RCX-1-S-180A-15C RCX-1-S-477A-17C

Manufacturer’s Name: Benshaw, Inc.

Manufacturer’s Address: 1659 East Sutter Road Glenshaw, PA USA 15116

The before mentioned products comply with the following EU directives and Standards:

Safety: UL 508 Standard for Industrial Control Equipment covering devices for starting, stopping, regulating, controlling, or protecting electric motors with ratings of 1500 volts or less.

EMC: EN 50081-2 Emissions Radiated/Conducted EN 55011/05.98+A1:1999 EN 50082-2 Immunity/Susceptibility which includes: EN 61000-4-2 Electrostatic Discharge EN 61000-4-3 Radiated RF EN 61000-4-4 Electrical Fast Transient/Burst EN 61000-4-6 Injected Currents

The products referenced above are for the use of control of AC motors.

For application information, consult the following document from Benshaw:

The use in residential and commercial premises (Class B) requires an optional EMC series filter.

Via internal mechanisms and Quality Control, it is verified that these products conform to the requirements of the Directive and applicable standards.

Glenshaw, PA USA - 1 October 2003

Neil Abrams Durand Miller Quality Control VP General Manager Manager

99

Appendix B – Fault Codes

See Section 7 for Troubleshooting Solutions

Fault Code

Description Controlled Fault Stop

Shunt Trip Fault

Auto-Reset Allowed

F00 No fault - - - F01 UTS Time Limit Expired Y N Y F02 Motor Thermal Overload Trip Y N Y F03 Jog Time Limit Expired N N N F04 Reserved F10 Phase Rotation Error, not ABC N N Y F11 Phase Rotation Error, not CBA N N Y F12 Low Line Frequency N N Y F13 High Line Frequency N N Y F14 Input power not single phase N N Y F15 Input power not three phase N N Y F21 Low Line L1-L2 Y N Y F22 Low Line L2-L3 Y N Y F23 Low Line 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 Reserved F30 I.O.C. N Y N F31 Overcurrent Y N Y F34 Undercurrent Y N Y F35 Reserved F36 Reserved F37 Current Imbalance Y N Y F38 Ground Fault N Y Y F39 No Current at Run N N Y F40 Shorted / Open SCR N Y N F41 Current at Stop N Y N F47 Stack Protection Fault (stack thermal overload) N N Y F48 Bypass Contactor Fault Y N N F50 Control Power Low N N Y F51 Current Sensor Offset Error - Y N F52 Burden Switch Error N N N F53 Reserved F60 External Fault on DI 1 Input N N Y F61 External Fault on DI 2 Input N N Y F62 External Fault on DI 3 Input N N Y F63 Reserved F64 Reserved F71 Analog Input #1 Level Fault Trip (local) Y N Y F72 Reserved F73 Reserved F81 SPI Communication Fault Y N N F82 Modbus Timeout Fault Y N Y F94 CPU Error – SW fault N N N F95 CPU Error – Parameter EEPROM Checksum Fault N N F96 CPU Error N Y N F97 CPU Error - SW Watchdog N Y N F98 CPU Error N N N F99 CPU Error – Program EPROM Checksum Fault N N N

100

Appendix C – Alarm Codes

The following is a list of all MX alarm codes. The alarm codes correspond to associated fault codes. In general, an alarm indicates a condition that if continued, will result in the associated fault.

Alarm Code

Description Notes

A02 Motor Overload Alarm This occurs when the motor thermal content reaches the 90%. The MX will trip when it reaches 100%. The alarm will continue until the overload trip lockout is reset.

A10 Phase Rotation not ABC This alarm exists while the MX is stopped and line voltage is detected and phase sensitivity parameter is set to ABC. If a start is commanded, a Fault 10 will occur.

A11 Phase Rotation not CBA This alarm exists while the MX is stopped and line voltage is detected and phase sensitivity parameter is set to CBA. If a start is commanded, a Fault 11 will occur.

A12 Low Line Frequency This alarm exists when the MX has detected a line frequency below the user defined low line frequency level. The alarm will continue until either the line frequency changes to be in range or the fault delay timer has expired.

A13 High Line Frequency This alarm exists when the MX has detected a line frequency above the user defined high line frequency level. The alarm will continue until either the line frequency changes to a valid frequency or the fault delay timer has expired.

A14 Input power not single phase This alarm exists while the MX is stopped, set to single phase mode, and line voltage is detected. If a start is commanded, a Fault 14 will occur.

A15 Input power not three phase This alarm exists while the MX is stopped, set to a three-phase mode, and single-phase line voltage is detected. If a start is commanded, a Fault 15 will occur.

A21 Low Line L1-L2 This alarm exists while the MX is stopped and low line voltage is detected. If a start is commanded, a Fault 21 may occur.



A24 High Line L1-L2 This alarm exists while the MX is stopped and high line voltage is detected. If a start is commanded, a Fault 24 may occur.



A27 Phase Loss This alarm exists while the MX is running and a phase loss condition is detected, but the delay for the fault has not yet expired. When the delay expires, a Fault 27 will occur.

A28 No Line This alarm exists while the MX needs to be synced or is trying to sync to the line and no line is detected.

A31 Overcurrent This alarm exists while the MX is running and the average current is above the defined threshold, but the delay for the fault has not yet expired. When the delay expires, a Fault 31 will occur.

A34 Undercurrent This alarm exists while the MX is running and the average current is below the defined threshold, but the delay for the fault has not yet expired. When the delay expires, a Fault 34 will occur.

A35 Reserved

101

Alarm Code

Description Notes

A36 Reserved A37 Current Imbalance This alarm exists while the MX is running and a current

imbalance above the defined threshold is detected, but the delay for the fault has not yet expired. When the delay expires, a Fault 37 will occur.

A38 Ground Fault This alarm exists while the MX is running and a ground current above the defined threshold is detected, but the delay for the fault has not yet expired. When the delay expires, a Fault 38 will occur.

A47 Stack Overload Alarm This occurs when the stack thermal rises above 105%. A53 Reserved A71 Analog Input #1 Trip This alarm will exist if analog input #1 exceeds the defined

threshold, but the delay for the fault has not yet expired. When the delay expires, a Fault 71 will occur.

102

Appendix D – Spare Parts

Consult Factory

103

Revision History

Revision Date Changes ECO# 00 26 June 2004 Initial Release 01 30 June 2004 Corrected figures 27, 28, 29, 30, 31, 32 E0833 02 29 July 2005 Corrected keypad grounding E1041

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