PUBLICATION #890023-03-00

28 JUNE 2004

RediStart
Solid State Starter
Quick Start Guide
for

Control
with LED Display

USA Headquarters: (412) 487 - 8235

USA West: (480) 905 0601
Canada: (519) 291 5112
Web Site: hppt:\\www.benshaw.com
E-Mail: [email protected]
[email protected]

2004 Benshaw Inc. All Rights Reserved

1
 MX Control Board Layout

BIPC 300050-00-01 Serial

SN
Number

120V
Control
SCR 1
Gnd

120V
Control
SCR 4

NO1

RC1

NC1
SCR 2
NO2

Relay Output RC2

R1, R2, R3
NC2

NO3
SCR 5
RC3

NC3

START

DI 1
SCR 3
S/DI
Digital Inputs COM
Start, DI1, Terminating Conn 3
DI2
DI2, DI3 Resistor Conn 2
DI3
CPU Heart Beat
DI2/D3
COM Serial Com LEDs SCR 6

Modbus
Serial Port

Reset
Button
Analog
Input
& Config
Jumper

CT Input

Shield Shield
Grounding Grounding

CT Burden
Selector Switch LED Display & Analog Output
Keypad & Config Jumper

Terminal 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
2 wire control Parameter Setting

2 wire control

If stop is not configured, the

starter is in 2 wire control

P39 (I/O DI1), P40 (DI2)

or P 41 (DI3)
not programmed to STOP.

3 Wire Control 3 Wire Control

If stop is configured, the

starter is in 3 wire control.

Normally DI1 is defaulted to

be the STOP input

P39 (I/O DI1), P40 (DI2)

or P 41 (DI3)
programmed to STOP.

3
Power Schematic for RBX Integral Bypass Power Stack, 97 Amps to 361 Amp

4
CT Switch Settings
When the starter is shipped from the factory the CT setting are set to match the CT ratios supplied with the
starter. If the MX control is changed the CT settings must be changed to match the CT ratios for that given current
rating.

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 current (FLA)

CT Ratio Minimum Maximum Switch 6 Switch 6 CT Ratio Minimum Maximum Switch 6 Switch 6
FLA FLA Position 1 Position 2 FLA (A rms) FLA (A rms) Position 1 Position 2
(A rms) (A rms)
72 2 3 Off Off 2880 73 140 Off Off
(4 wraps 3 4 Off On 140 165 Off On
288:1) 4 9 On Off 165 361 On Off
9 16 On On 361 640 On On
96 3 4 Off Off 3900 105 190 Off Off
(3 wraps 4 5 Off On 190 225 Off On
288:1) 5 12 On Off 225 490 On Off
12 21 On On 490 870 On On
144 4 7 Off Off 5760 160 280 Off Off
(2 wraps 7 8 Off On 280 330 Off On
288:1) 8 18 On Off 330 720 On Off
18 32 On On 720 1280 On On
288 8 14 Off Off 8000 223 390 Off Off
14 16 Off On 390 465 Off On
16 32 On Off 465 1000 On Off
36 64 On On 1000 1800 On On
864 24 42 Off Off 14400 400 700 Off Off
42 50 Off On Mult. 700 840 Off On
50 108 On Off CT-CT 840 1800 On Off
108 190 On On Combinations 1800 3200 On On
1320 37 64 Off Off 28800 800 1400 Off Off
(2 wraps 64 76 Off On Mult. 1400 1680 Off On
2640) 76 165 On Off CT-CT 1680 3600 On Off
165 290 On On Combinations 3600 6400 On On
2640 73 128 Off Off
128 151 Off On
151 330 On Off
330 590 On On

CT Mounting
For starters larger than 124 amps, the CT are mounted 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 mark maybe 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.

MUST BE A 3" (MIN.)

SPACE BETWEEN CT
AND TOP OF LUG

CUSTOMER MUST FASTEN CT

TO POWER WIRE WITH TWO 1/4"
NYLON WRAPS TO PREVENT
MOVEMENT DURING RUNNING

SIDE VIEW DETAIL BOTTOM VIEW DETAIL

5
Configuring the Analog Input
The analog input can be configured for Voltage or Current loop. The control 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 voltage input. The control is shipped with the
jumper 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.

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.
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.

Analog Input

Analog Output

6
 RESET

PARAM DOWN UP ENTER

Operation
LED Display Fault Log
1. View parameters, messages and faults. 10. Select P32 and press ENTER. The most recent fault will be
2. Shows software revision on power up. displayed as xFyy where x will be 1 to indicate the most
recent fault is being displayed and yy is the fault code.
Programming 11. Press DOWN to view older faults. Up to 9 faults may be
3. Press PARAM to enter the menu and then UP or DOWN to reach stored in the log.
the desired parameter.
4. Press ENTER to show the present value of the parameter. Resetting a Fault
5. Press UP or DOWN to change the parameter value. 12. Press RESET to reset from a fault.
6. Press ENTER to store the new value or PARAM to abandon the
change. Resetting Parameters
13. Press and hold PARAM and ENTER on power up to reset
Quick Meters parameters to default values.
7. Press DOWN to display the motor thermal overload content.
8. Press UP to display the incoming line phase order. Emergency Thermal Reset
9. Press ENTER to display the status meter. 14. Press RESET and DOWN to perform an emergency thermal
reset.

Messaging
No Line Phase order meter showing ABC
Ready Phase order meter showing CBA
Accelerating or Kicking Phase order meter showing Single Phase
Accelerating or Kicking with ramp 2 xxx xxx = overload content.
Up to Speed xx xx = Parameter code.
Run Done with Accel ramp but not yet Up to xx xx = Alarm code. If the condition persists,
Speed. a fault will occur.
Decelerating Motor xx xx = Fault code.
Overload Alarm The motor overload level is Instantaneous Overcurrent
between 90% and 100%. Default Flashes when parameter defaults
Overload Fault The motor overload level has are loaded.
reached 100%. Heater/Anti-windmill Mode
Overload Lockout A start is not allowed until the Energy Saver
motor overload level cools below 60%. In reflash mode
Control Power Lockout A start is not allowed In reflash mode, programming
because the control power is too low. In reflash mode, verifying
Lock out State In reflash mode, complete

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.

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 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

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.

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.
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).

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

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.
q When a thermal overload alarm condition exists, A OL will be displayed.
q When a no line alarm condition exists, noL will be displayed.
When the starter is stopped, the selected meter is not included.
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 wil be displayed.
When there are multiple lockout codes, each will be displayed for 2 seconds.
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 I.O.C. (Instantaneous over current), will be displayed.

8
Quick Start, Initial Parameters that must be set
In order for the starter to operate properly, there are 7 parameters that need to be validated before the starter can correctly
start a motor. For the range of parameters, refer to the parameter table

P1 Motor FLA
This parameter configures the motor full load amps, and is obtained from the nameplate on the attached motor.
NOTE: Incorrectly setting this parameter will affect proper operation of the motor overload protection, motor over current
protection, motor undercurrent protection, ground fault protection and acceleration control.

P2 Motor Service Factor

The service factor parameter should be set to the service factor of the motor. The service factor is used for the overload
calculations. If the service factor of the motor is not known then the service factor should be set to 1.00.
NOTE: The NEC (National Electrical Code) does not allow the service factor to be set above 1.40. Check with other local
electrical codes for their requirements.

P3 Motor Over Load Class while Running

The running overload parameter sets the class of the electronic overload when up to speed and stopping. The starter
stores the thermal overload value as a percentage value between 0 and 100%, with 0% representing a cold overload
and 100% representing a tripped overload. When the running overload is set to OFF, the electronic overload is disabled
when up to speed and a separate motor overload protection device must be supplied.
If separate starting verses running OL class are desired, see P35 and P36.
For more information about overload class, see manual section 8, Theory of Operation, Motor Overload
NOTE: Care must be taken not to damage the motor when turning the running OL off or setting a high value.
NOTE: Consult motor manufacturer data to determine the correct motor OL settings.

P6 Initial Motor Current

The initial current parameter is set as a percentage of the motor FLA parameter setting. The initial current parameter sets
the current that will initially be supplied to the motor when a start is commanded. The initial current should be set to the
level that allows the motor to begin rotating within a couple of seconds of receiving a start command.
To adjust the initial current setting, give the starter a run command. Observe the motor to see how long it takes before it
begins rotating and then stop the unit. For every second that the motor doesnt rotate, increase the initial current by 20%.
Typical loads will require an initial current in the range of 50% to 175%.
If the motor does not rotate within a few seconds after a start command, the initial current should be increased. If the
motor takes off too quickly after a start command, the initial current should be decreased.
The initial current must be set to a value that is lower than the maximum current parameter setting

P7 Maximum Motor Current

The maximum current parameter is set as a percentage of the motor FLA parameter setting. The maximum current
parameter performs two functions. It sets the current for the end of the ramp profile. It also sets the maximum current that
is allowed to reach the motor after the ramp is completed.
If the ramp time expires before the motor has reached full speed, the starter will hold the current at the maximum current
level until the UTS timer expires, the motor reaches full speed, or the overload trips.
Typically, the maximum current is set to 600% unless the power system or load dictates the setting of a lower maximum
current.

P8 Ramp Time
The ramp time is the time it takes for the current to go from the initial current to the maximum current. To make the motor
accelerate faster, decrease the ramp time. To make the motor accelerate slower, increase the ramp time.
A typical ramp time setting is from 15 to 30 seconds.
If the ramp time expires before the motor reaches full speed, the starter will maintain the set maximum current level until
either the motor reaches full speed, the stall time expires, or the motor thermal overload trips.
NOTE: Setting the ramp time to a specific value does not necessarily mean that the motor will take this time to accelerate
to full speed. The motor and load may achieve full speed before the ramp time expires if the application does not require
the set ramp time and maximum current to reach full speed. Alternatively, the motor and load may take longer than the set
ramp time to achieve full speed.

P9 Up to Speed Time (UTS)

The up-to-speed timer parameter sets the maximum acceleration time to full speed that the motor can take. A stalled
motor condition will be detected if the motor does not get up-to-speed before the up-to-speed timer expires. This allows
the programming of a maximum acceleration time for the motor. The motor is considered up-to-speed once the current
stabilizes below 175 percent of the FLA value and the ramp time expires.

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Parameter Description Setting Range Units Default
P1 Motor FLA 1 6400 RMS 10
Amps
P2 Motor Service Factor 1.00 1.99 1.15
P3 Motor Overload Class Running OFF, 1 40 10
P4 Local Source PAd: Keypad tEr
P5 Remote Source tEr Terminal
SEr: Serial
P6 Initial Motor Current 1 50 600 %FLA 100
P7 Maximum Motor Current 1 100 800 %FLA 600
P8 Ramp Time 1 0 300 Seconds 15
P9 UTS Time / Transition Time 1 900 Seconds 20
P10 Start Mode oLrP: Voltage Ramp curr
curr: Current Ramp
tt: TT Ramp
Pr: Power Ramp
P11 Initial Voltage/Torque/Power 1 100 % 25
P12 Maximum Torque/Power 10 325 % 105
P13 Kick Level 1 OFF, 100 800 %FLA OFF
P14 Kick Time 1 0.1 10.0 Seconds 1.0
P15 Stop Mode CoS Coast CoS
SdcL Volt Decel
tdcL TT Decel
P16 Decel Begin Level 100 1 % 40
P17 Decel End Level 99 1 % 20
P18 Decel Time 1 180 Seconds 15
P19 Initial Motor Current 2 50 600 %FLA 100
P20 Maximum Motor Current 2 100 800 %FLA 600
P21 Ramp Time 2 0 300 Seconds 15
P22 Kick Level 2 OFF, 100 800 %FLA OFF
P23 Kick Time 2 0.1 10.0 Seconds 1.0
P24 Over Current Trip Level OFF, 50 800 % FLA OFF
P25 Over Current Trip Delay Time OFF, 0.1 90.0 Seconds 0.1
P26 Under Current Trip Level OFF, 5 100 % FLA OFF
P27 Under Current Trip Delay Time OFF, 0.1 90.0 Seconds 0.1
P28 Current Imbalance Trip Level OFF, 5 40 % 15
P29 Ground Fault Trip Level OFF, 5 100 % FLA OFF
P30 Over Voltage Trip Level OFF, 1 40 % OFF
P31 Under Voltage Trip Level OFF, 1 40 % OFF
P32 Over/Under Voltage Trip Delay 0.1 90.0 Seconds 0.1
Time
P33 Auto Fault Reset Time OFF, 1 900 Seconds OFF
P34 Controlled Fault Stop OFF, On On
P35 Independent Starting/Running OFF, On OFF
Overload
P36 Motor Overload Class Starting OFF, 1 40 10
P37 Motor Overload Hot/Cold Ratio 0 99 % 60
P38 Motor Overload Cooling Time 1.0 999.9 Minutes 30.0
P39 DI 1 Configuration OFF: Off EoLr: E OL Reset StOP
(Digital Input #1) StOP: Stop L-r: Local/Remote
P40 DI 2 Configuration FH: Fault High hdIS: Heat Disable byP
(Digital Input #2) FL: Fault Low hEn: Heat Enable
P41 DI 3 Configuration Fr: Fault Reset rSEL Ramp Select FL
(Digital Input #3) byP: Bypass Cnfrm
P42 R1 Configuration OFF: Off OC: Over Current FLFS
(Relay #1) FLFS: Fault (fail safe) UC: Under Current
P43 R2 Configuration (Relay #2) FLnF: Fault (non fail OLA: OL Alarm run
P44 R3 Configuration (Relay #3) safe) ShFS: Shunt Trip (fail utS
run: Running safe)
utS: UTS ShnF: Shunt Trip (non
AL: Alarm fail safe)
rdyr: Ready GfLt: Ground Fault
LOC: Locked Out ES: Energy Saver
HEAt: Heating
P45 Analog Input Trip Type OFF: Disabled OFF
Lo: Low Level
Hi: High Level

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Parameter Description Setting Range Units Default
P46 Analog Input Trip Level 0 100 % 50
P47 Analog Input Trip Delay Time 0.1 90.0 Seconds 0.1
P48 Analog Input Span 1 100 % 100
P49 Analog Input Offset 0 99 % 0
P50 Analog Output Function 0: OFF (no output) 6: 0 100 kW 0
1: 0 200% Curr 7: 0 1 MW
2: 0 800% Curr 8: 0 10 MW
3: 0 150% Volt 9: 0 100% Ain
4: 0 150% OL 10: 0 100% Firing
5: 0 10 kW 11: Calibration
P51 Analog Output Span 1 125 % 100
P52 Analog Output Offset 0 99 % 0
P53 In Line Configuration OFF, 1.0 10.0 Seconds 3.0
P54 Bypass / 2M Confirm 0.1 5.0 Seconds 2.0
P55 Keypad Stop Disable Enabled, Disabled Enabled
P56 Reserved
P57 Reserved
P58 Miscellaneous Commands 0: None 4: Store Parameters 0
1: Reset Run Time 5: Load Parameters
2: Reset 6 Factory Reset
KWh/MWh
3: Enter Reflash
mode
P59 Communication Timeout OFF, 1 120 Seconds OFF
P60 Communication Baud Rate 1.2, 2.4, 4.8, 9.6, 19.2 Kbps 9.6
P61 Communication Address 1 247 1
P62 Energy Saver OFF, On OFF
P63 Heater Level OFF, 1 25 %FLA OFF
P64 Starter Type nor: Normal nor
Id: Inside Delta
y-d: Wye-Delta
PctL: Phase Control
cFol: Current Follow
AtL: ATL
P65 Motor Rated Power Factor -0.01 (Lag)1.00 (Unity) -0.92
P66 Rated RMS Voltage 100, 110, 120, 200, 208, 220, 230, 240, 350, 380, 400, RMS 480
415, 440, 460, 480, 500, 525, 575, 600, 660, 690, 1000, Voltage
1140, 2200, 2300, 2400, 3300, 4160, 4600, 4800, 6000,
6600, 6900, 10.00 (10000), 11.00 (11000), 11.50
(11500), 12.00 (12000), 12.47 (12470), 13.20 (13200),
13.80 (13800)
P67 Input Phase Sensitivity InS Insensitive InS
AbC ABC
CbA CBA
SPH Single Phase
P68 CT Ratio 72, 96, 144, 288, 864,1320, 2640, 2880, 3900, 288
5760, 8000, 14.4 (14400), 28.8 (28800)
P69 Meter 0: Status 14: VA 1
1: Ave Current 15: vars
2: L1 Current 16: kW hours
3: L2 Current 17: MW hours
4: L3 Current 18: Phase Order
5: Curr Imbal 19: Line Freq
6: Ground Fault 20: Analog Input
7: Ave Volts 21: AnalogOutput
8: L1-L2 Volts 22: Run Days
9: L2-L3 Volts 23: Run Hours
10: L3-L1 Volts 24: Starts
11: Overload 25: TruTorque %
12: Power Factor 26: Power %
13: Watts
P70 Starter Model Number Model Dependent
P71 Software Part Number Display Only
P72 Passcode Off
P73 Fault Log

11
Fault Code Description Alarm Description
Code
F00 No fault A02 Motor Overload Alarm
F01 UTS Time Limit Expired A10 Phase Rotation not ABC
F02 Motor Thermal Overload Trip A11 Phase Rotation not CBA
F03 Jog Time Limit Expired A12 Low Line Frequency

F04 Speed Switch Time Limit Expired A13 High Line Frequency

F10 Phase Rotation Error, not ABC A14 Input power not single phase
F11 Phase Rotation Error, not CBA A15 Input power not three phase
F12 Low Line Frequency A21 Low Line L1-L2
F13 High Line Frequency A22 Low Line L2-L3
F14 Input power not single phase A23 Low Line L3-L1
F15 Input power not three phase A24 High Line L1-L2
F21 Low Line L1-L2 A25 High Line L2-L3
F22 Low Line L2-L3 A26 High Line L3-L1
F23 Low Line L3-L1 A27 Phase Loss
F24 High Line L1-L2 A28 No Line
F25 High Line L2-L3 A31 Overcurrent
F26 High Line L3-L1 A34 Undercurrent
F27 Phase Loss A35 PF too Leading
F28 No Line A36 PF too Lagging
F29 Reserved A37 Current Imbalance
F30 I.O.C. A38 Ground Fault
F31 Overcurrent A47 Stack Overload Alarm
F34 Undercurrent A53 Tachometer Signal Loss Error
F35 Reserved A71 Analog Input #1 Trip
F36 Reserved
F37 Current Imbalance
F38 Ground Fault
F39 No Current at Run
F40 Shorted / Open SCR
F41 Current at Stop
F47 Stack Protection Fault (stack thermal
overload)
F48 Bypass Contactor Fault
F50 Control Power Low
F51 Current Sensor Offset Error
F52 Burden Switch Error
F53 Reserved
F60 External Fault on DI 1 Input
F61 External Fault on DI 2 Input
F62 External Fault on DI 3 Input
F63 Reserved
F64 Reserved
F71 Analog Input #1 Level Fault Trip (local)
F72 Reserved
F73 Reserved
F81 SPI Communication Fault
F82 Modbus Timeout Fault
F94 CPU Error SW fault
F95 CPU Error Parameter EEPROM
Checksum Fault
F96 CPU Error
F97 CPU Error - SW Watchdog
F98 CPU Error
F99 CPU Error Program EPROM Checksum
Fault

12