Benshaw MVRSM12, MVRSM18 Manual

BENSHAW

REDISTART MICRO II

INSTRUCTION MANUAL

MVRSM12/18 SERIES

The Leader In

Solid State Motor Control

Technology

Publication #: 890015-01-08

TABLE OF CONTENTS

Table of Contents

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

1.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Using This manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Benshaw Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2. TECHNICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.1 TECHNICAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

CT (Current Transformer) Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8
Voltage Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8
Metering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8
Real Time Clock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8
Output Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8
Control Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9
Storage and Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9
DeviceNet (Embedded) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9
Modbus (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9
EU Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	10
Overload Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11
Overload Curve Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	12
RediStart Micro II Computer Card Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . .	13
Computer Card JC11 Header Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . .	13
Old RediStart Micro II Power Card Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . .	13

3. INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.1 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Site Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 EMC Installation guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Installation Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Remote RTD Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 CT Ratio Scaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 RediStart Micro II Computer Card Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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4. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.1 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Main Display Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	26
Meter Display Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	27
Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	31
Starter Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	31
Current Ramp Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	32
Programming A Kick Current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	33
Tachometer Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	33
Programming The Motor Deceleration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	34
PORT (Power Outage Ride Through) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	35
TruTorque Acceleration Ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	35
TruTorque Deceleration Ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	36
How Fault Classes Work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	37
Use of Overcurrent and Undercurrent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	38
Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	38
Performing an Emergency Restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	40

5. PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

5.1 PROGRAMMING: How To Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Menu Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Viewing a Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Changing a Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

5.2 PROGRAMMING: Quick Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Motor FLA. . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 45
Serv. Fact (service factor) . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 45
Start Mode . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 45
Stop Mode . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 45
Int. Curr. (initial current) . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 46
Max. Curr. (maximum current) . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 46
Ramp Time . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 46
Overload . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 47
Phase Order . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 47
5.3 PROGRAMMING: Motor Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Motor FLA. . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 48
Serv. Fact (service factor) . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 48
Motor RPMs . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 48
5.4 PROGRAMMING: Starter Setup - Starter Modes	. . . . . . . . . . . . . . . . . . . . . 49
Start Mode . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 49
Stop Mode . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 49
5.5 PROGRAMMING: Starter Setup - Forward1 Profile . . . . . . . . . . . . . . . . . . . . 50
Int. Curr. (initial current) . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 50
Max. Curr. (maximum current) . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 50
Ramp Time . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 50
Kick Curr. (kick current) . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 51
Kick Time . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 51

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5.6 PROGRAMMING: Starter Setup - Forward2 Profile . . . . . . . . . . . . . . . . . . . . 52

Forward #2 Ramp Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	52
Int. Curr. (initial current) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	52
Max. Curr. (maximum current) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	52
Ramp Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	52
Kick Curr. (kick current) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	53
Kick Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	53

5.7 PROGRAMMING: Starter Setup - Tachometer Setup . . . . . . . . . . . . . . . . . . . 54

FS Volts (Full Speed Volts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	54
Stab Cnst (Stability Constant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	54
Ramp#1 Tim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	54
Ramp#2 Tim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	54
TLoss Dela (Tachometer Signal Loss Delay) . . . . . . . . . . . . . . . . . . . . . . . . . . . .	55
TLoss Mode (Tachometer Signal Loss Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . .	55

5.8 PROGRAMMING: Starter Setup - Decel Setup . . . . . . . . . . . . . . . . . . . . . . . 56

V Level #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 V Level #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 V DCL Time (decel time). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 TT DCL Tim (TruTorque deceleration time). . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 TT DCL Tor (ending deceleration torque) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

5.9 PROGRAMMING: Starter Setup - PORT CTL Setup. . . . . . . . . . . . . . . . . . . . 58

Fault Dly (Fault Delay) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Bypass Dly (Bypass Delay) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Sense Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

5.10 PROGRAMMING: Starter Setup - TruTorque Ramp . . . . . . . . . . . . . . . . . . . 59

Int Torque (initial torque) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Max Torque (maximum torque). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Ramp Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 TT Over Cu (TruTorque overcurrent trip) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Ovr Cur Dl (TruTorque overcurrent trip delay). . . . . . . . . . . . . . . . . . . . . . . . . . 60

5.11 PROGRAMMING: Motor Protection - Overload . . . . . . . . . . . . . . . . . . . . . 61

Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

5.12 PROGRAMMING: Motor Protection - Line Current . . . . . . . . . . . . . . . . . . . 62

% Imbalanc (percent imbalance) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Imbal Dela (imbalance delay) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 @ Stop Dly (current at stop delay) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 % No C@Run (percent no current at run) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 No C@R Dly (no current at run delay) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

5.13 PROGRAMMING: Motor Protection - Line Voltage . . . . . . . . . . . . . . . . . . . 64

H/L Volts (high/low voltage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	64
Delay Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	64
PH Dect Dl (Phase detect delay) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	64

5.14 PROGRAMMING: Motor Protection - Line Frequency. . . . . . . . . . . . . . . . . . 65

High Freq. (high frequency) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Low Freq. (low frequency). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Freq Delay (frequency delay) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

5.15 PROGRAMMING: Motor Protection - Ground Fault . . . . . . . . . . . . . . . . . . . 66

GND Fault (ground fault) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 GND Delay (ground delay) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

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5.16 PROGRAMMING: Motor Protection - Shorted SCR . . . . . . . . . . . . . . . . . . . 67

@ Ramp DLY (shorted SCR at ramp delay) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 @ Stop DLY (shorted SCR at stop delay) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

5.17 PROGRAMMING: Motor Protection - Over Current . . . . . . . . . . . . . . . . . . . 68

Current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Detect Dly (detect delay). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Release Dl (release delay) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

5.18 PROGRAMMING: Motor Protection - Under Current . . . . . . . . . . . . . . . . . . 69

Current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Detect Dly (detect delay). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Release Dl (release delay) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

5.19 PROGRAMMING: Motor Protection - Start Lockouts . . . . . . . . . . . . . . . . . . 70

Starts/Hou (starts per hour). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Time Start (time between starts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 BKS Timer (backspin timer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

5.20 PROGRAMMING: Motor Protection - Starting Timers. . . . . . . . . . . . . . . . . . 71

UTS Timer (up-to-speed timer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Zero Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

5.21 PROGRAMMING: Motor Protection - Permissive Input. . . . . . . . . . . . . . . . . 72

Inline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Trip Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

5.22 PROGRAMMING: Motor Protection - Misc.. . . . . . . . . . . . . . . . . . . . . . . . 73

Phase Orde (phase order) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

# Auto RST (number of auto resets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 No Main PW (no main power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

5.23 PROGRAMMING: Motor Protection - Fault Classes . . . . . . . . . . . . . . . . . . . 74

Fault Classes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

5.24 PROGRAMMING: Meters & Relays - Meter Setup . . . . . . . . . . . . . . . . . . . . 75

Meter #1 , Meter #2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 AutoRange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Meter Rsts (meter resets). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Scroll Tim (scroll time) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

5.25 PROGRAMMING: Meters & Relays - Standard Relays . . . . . . . . . . . . . . . . . 77

Relay#1, K5 and Relay#2, K6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

5.26 PROGRAMMING: Meters & Relays - Extended Relays . . . . . . . . . . . . . . . . . 78

Opt. #?, K? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

5.27 PROGRAMMING: Event Recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Event Recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

5.28 PROGRAMMING: Control Config - System Clock . . . . . . . . . . . . . . . . . . . . 81

System Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

5.29 PROGRAMMING: Control Config - System Password	. . . . . . . . . . . . . . . . . 82
Password . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . 82

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5.30 PROGRAMMING: Control Config - Comm. Settings . . . . . . . . . . . . . . . . . .	83
COMM. Mode (communications mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	83
COM Addres (communications address) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	83
COM Delay (communications delay). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	83
MB:Baud (MODBUS baud rate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	84
MB:Com T/O (MODBUS communications timeout) . . . . . . . . . . . . . . . . . . . . . . .	84
DN:MAC ID (DeviceNet MAC ID) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	84
DN:Baud (DeviceNet baud rate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	84
DN:InAssy (DeviceNet input assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	85
DN:OutAssy (DeviceNet output assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . .	85
DN:T/O Act (DeviceNet timeout action) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	85
DN:Rev (DeviceNet interface revision) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	85
5.31 PROGRAMMING: Control Config - Options List. . . . . . . . . . . . . . . . . . . . .	86
Options List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	86
5.32 PROGRAMMING: Control Config - Software Part# . . . . . . . . . . . . . . . . . . .	87
Software Part# . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	87
5.33 PROGRAMMING: Factory Setup - Hardware Setup . . . . . . . . . . . . . . . . . . .	88
C.T. Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	88
Relay Card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	88
5.34 Programming: Factory Setup - BIST Setup . . . . . . . . . . . . . . . . . . . . . . . . .	89
Start BIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	89
Test Inlin (test in-line) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	89
Test Bypas (test bypass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	89
100% Gates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	89
5.35 PROGRAMMING: Factory Setup - Factory Control . . . . . . . . . . . . . . . . . . .	90
FACT Pass. (factory password) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	90
Reset Def (reset to default parameters). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	90
CLR Events (clear event log) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	90
CLR Pass. (clear password) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	90
Cal Volt L1, L2, L3 (calibrate voltage meter). . . . . . . . . . . . . . . . . . . . . . . . . . . .	90
Cal Curr L1, L2, L3 (calibrate current meter) . . . . . . . . . . . . . . . . . . . . . . . . . . .	91
5.36 PROGRAMMING: RTD Setup - RTD Module Setup . . . . . . . . . . . . . . . . . . .	92
Mod#1 Addr (module #1 address) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	92
Mod#2 Addr (module #2 address) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	92
#RTDs Mod1 (number of RTDs on module #1) . . . . . . . . . . . . . . . . . . . . . . . . . .	92
#RTDs Mod2 (number of RTDs on module #2) . . . . . . . . . . . . . . . . . . . . . . . . . .	92
Temp Scale (temperature scale) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	92
5.37 PROGRAMMING: RTD Setup - RTD SetPnts 1-8 . . . . . . . . . . . . . . . . . . . . .	93
RTD#? Grp (RTD #? Group). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	93
RTD#? Warn (RTD #? warning level) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	93
RTD#? Alm (RTD #? alarm level). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	93
5.38 PROGRAMMING: RTD Setup - RTD SetPnts 9-16 . . . . . . . . . . . . . . . . . . . .	94
RTD#? Grp (RTD #? Group). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	94
RTD#? Warn (RTD #? warning level) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	94
RTD#? Alm (RTD #? alarm level). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	94

v

TABLE OF CONTENTS

6. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
6.1 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
LED Diagnostics . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . . . 96
Meter Tests . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . . . 97
Event Recorder . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . . . 97
Fault/Log Codes . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . . . 98
General Troubleshooting Charts . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . . . 102
Spare Parts. . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . . . 104
SCR Replacement . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . . . 105
6.2 MEDIUM VOLTAGE TROUBLESHOOTING	. . . . . . . . . . . . . . . . . . . . . . . 106
Built-In Self Test (BIST) . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . . . 106
Maintenance. . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . . . 108

7. DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

7.1 DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . 110
RediStart Micro II Computer Card Diagram . . . . . . . . . . .	. . . . . . . . . . . . . . . . 110
RediStart Micro II Power Card Layout . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . 111
Old RediStart Micro Power Card Layout . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . 112
RediStart Micro II Four (4) Relay Card Layout . . . . . . . . . .	. . . . . . . . . . . . . . . . 113
RediStart Micro II Seven (7) Relay Card Layout . . . . . . . . .	. . . . . . . . . . . . . . . . 113
RediStart Micro II RS-232 Communications Card Layout . . . .	. . . . . . . . . . . . . . . . 114
RediStart Micro II RS-485 Communications Card Layout . . . .	. . . . . . . . . . . . . . . . 114
RediStart Micro II RS-232/485 Communications Card Layout .	. . . . . . . . . . . . . . . . 115
Modbus Master Card (for Remote RTD Module) . . . . . . . . .	. . . . . . . . . . . . . . . . 115
RediStart Micro II Display Cut-out . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . 116

8. PARAMETER LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

8.1 Parameter List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

RediStart Micro II Parameter List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Quick Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Motor Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Starter Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Motor Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Meters & Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Event Recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Control Config . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Factory Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 RTD Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

vi

1. INTRODUCTION

1.1 INTRODUCTION

	Using This manual
Layout	This manual is divided into eight sections. Each section contains topics related to the
	section. The sections are as follows;
	• Introduction - Basic RediStart Micro II information.
	• Technical Specifications - RediStart Micro II specifications.
	• Installation - Information on installing the RediStart Micro II.
	• Operation - Information on how the starter operates.
	• Programming - Programming the RediStart Micro II.
	• Troubleshooting - Diagnosing RediStart Micro II problems.
	• Drawings - RediStart Micro II layout drawings.
	• Parameter List - List allowing user to record programmed values.
Parameter List	The last chapter of the manual is a parameter list. This list gives the user a place to
	enter the programmed value for each parameter and also gives the page number
	where the description of the parameter can be found. This list can be used as a quick
	reference to find the information on a parameter.
Symbols	There are two symbols used in this manual to highlight important information. The
	symbols appear as the following;

Electrical hazard that could result in injury or death.

Caution that could result in damage to the starter or motor.

Highlight marking an important point in the documentation.

2

			1.1 INTRODUCTION
			Benshaw Services
	General Information	Benshaw offers its customers the following services:
		• Start-up services.
		• On-site training services.
		•	Technical support.
		•	Detailed documentation.
		•	Replacement parts.
		NOTE: Information about products and services is available by contacting Benshaw.
	Start-Up Services	Benshaw technical field support personnel are available to assist customers with the
		initial start-up of the RediStart Micro II. Information about start-up services and fees
		are available by contacting Benshaw.
	On-Site Training Services	Benshaw technical field support personnel are available to conduct on-site training on
		RediStart Micro II 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 information about
		contacting technical support personnel, refer to Contacting Benshaw on page 4.
	Documentation	Benshaw provides all customers with:
		•	Operations manual.
		•	Wiring diagram.
		All drawings are produced in AutoCAD© format. The drawings are available on
		standard 3.5” diskettes or via e-mail by contacting Benshaw.
	On-Line Documentation	All RediStart MicroII documentation is available on-line at www.benshaw.com.
	Replacement Parts	Spare and replacement parts can be purchased from Benshaw.

3

1.1 INTRODUCTION

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:	[phone]
	Fax:	[phone]
	Benshaw Canada Controls Inc.
	R.R. #1 (Wallace Industrial Park)
	Listowel, Ontario
	Canada
	N4W 3G6
	Phone:	[phone]
	Fax:	[phone]
	Benshaw West
	7820 E. Evans Drive, Suite 900
	Scottsdale, AZ 85260
	United States of America
	Phone:	[phone]
	Fax:	[phone]

Technical support for the RediStart Micro II 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 caller can be contacted.

•Fax number of caller.

•Benshaw product name.

•Benshaw model number.

•Benshaw serial number.

•Name of product distributor.

•Approximate date of purchase.

•Voltage of motor attached to Benshaw product.

•FLA of motor attached to Benshaw product.

•A brief description of the application.

4

1.1 INTRODUCTION

Features

General

• Chassis or NEMA 1, 4, 12, or 3R enclosure

Protection (ANSI standard numbers given)

•51 - Electronic motor overload (class 1 to 40)

•86 - Overload lockout

•48 - Adjustable up-to-speed timer (off; 0 to 300 seconds)

•59/27 - Adjustable over/under voltage protection

•46 - Adjustable line to average current imbalance

•81 - Adjustable high and low frequency protection

•Single phase protection

•66 - Adjustable starts per hour (off or 1 to 20 starts)

•Adjustable time between starts (off or 1 to 600 minutes)

•Backspin timer (off or 1 to 200 minutes)

•51 - Over current detection (Off or 50 to 800%) and time (0.1 to 90.0 sec. in 0.1 sec. intervals)

•37 - Undercurrent detection (Off or 10 to 100% and time (0.1 to 90.0 sec. in 0.1 sec. intervals)

•51G - Ground fault detection (Off or 1 to 100 amps) and time (0.1 to 90.0 sec. in 0.1 sec. intervals)

•Over-current, undercurrent, and ground fault can each be set to trip or activate a relay

•50 - Instantaneous electronic over-current trip

•Shorted SCR detection

•47 - Phase rotation selectable ABC, CBA, or Ins (insensitive)

•38/49 - Remote Mountable RTD protection package, 8 or 16 RTD inputs (optional)

•PORT (power outage ride through) available with external 120VAC.

Control

•Two programmable current ramp profiles selectable at any time via 120 volt input

•Initial current, maximum current, and ramp time adjustments for each ramp

•Kick Current and time adjustments for each ramp

•TruTorque acceleration and deceleration profiles

•Adjustable deceleration profiles (to eliminate water hammer)

•Adjustable brake profile

•Local start/stop controls

•Emergency reset capability

•Tachometer ramp control (requires 0-5VDC tachometer feedback signal)

Input/Output and Display

•Plain English operation via back lit LCD display interface

•LCD and LED status and diagnostics (full fault annunciation)

•Programmable metering (amps, volts, frequency, overload, power factor, elapsed time, watts, VARs, watt-hours, VA, Current Imbalance, Ground Fault Current, RTD temperatures)

•Programmable relay outputs

•Latched fault relay output

•Real time clock

•Time stamped event recorder

•Password protection

•Battery backed-up starter parameters and lockout times

5

2. TECHNICAL SPECIFICATIONS

2.1 TECHNICAL SPECIFICATIONS

		CT (Current Transformer) Inputs
Conversion	Calibrated RMS, 12 samples per cycle
Range	0.01 to 1.5 × phase CT primary amps set point
Accuracy	±3.5% of phase CT primary amps set point
Frequency	23 to 72 Hz
Current Withstand	- 2.0 × CT primary amps set point (CT ratio parameter) - continuous
	- 10	× CT primary amps set point (CT ratio parameter) - 30 seconds
	- 55	× CT primary amps set point (CT ratio parameter) - 1 seconds

Voltage Inputs

Conversion	Calibrated RMS, 12 samples per cycle
Range	1000VAC to 9999VAC
Accuracy	±3.5% of full range

Metering

Current	±5%, 0 to 9999Amps
Voltage	±5%, 0 to 9999Volts
Watts	±5%, 0 to 6553kW
Volt-Amps Reactive	±5%, 0 to 6553kVAR
Volt-Amps	±5%, 0 to 6553kVA
WH	±5%, 0 to 6553MWH
PF	±3%, -0.01 to +0.01

Real Time Clock

Accuracy	±1 minute per month
Range	1/1/1970 to 1/1/2069

Output Relays

Fault Relay	- SPDT - Form C
	- 2A, 125VAC, resistive
	- 1A, 125VAC, 0.4 PF
	- 2A, 30VDC resistive
	- 100VA inrush
Output Relay #1 & #2	- SPDT - Form C
	- 16A, 250VAC resistive
	- 8A, 250VAC 0.4 PF
	- 16A, 30VDC resistive
	- 2000VA inrush

8

2.1 TECHNICAL SPECIFICATIONS

Four Relay Card	- DPDT - Dual Form C
	- 5A, 250VAC, resistive
	- 2A, 250VAC, 0.4 PF
	- 5A, 30VDC, resistive
	- 500VA inrush
Seven Relay Card	- SPDT - Form C
	- 8A, 250VAC resistive
	- 4A, 250VAC 0.4 PF
	- 8A, 30VDC resistive
	- 800VA inrush

Control Power

Voltage	120VAC, ±15%
	240VAC, ±15% (Optional)
Frequency	50 to 60hz
Power Consumption	Varies for required control.
Fuse	Time delay control circuit protection fuses.

Storage and Operating Conditions

Storage	-20ºC (-4°F) to +60°C (+140°F)
	0% to 95% relative humidity, non-condensing
Operating	0°C (+32°F) to +50°C (+122°F)
	0% to 95% relative humidity, non-condensing

	DeviceNet (Embedded)
Manual	Available at www.benshaw.com or from your Benshaw sales office.
EDS File	Available at www.benshaw.com or from your Benshaw sales office.
Device Type	Softstart Starter
I/O Slave Messaging	Polling
Baud Rates	- 125K
	- 250K
	- 500K
Conformance	Self tested with ODVA (open DeviceNet Vendor Association) software.

	Modbus (Optional)
Manual	Available at www.benshaw.com or from your Benshaw sales office.
Type	Modbus RTU
Connections	- RS-232
	- RS-485
Baud Rates	- 2400
	- 4800
	- 9600

9

Neil Abrams

Quality Control Manager

10

Harry Hagerty

Advanced Controls and Drives Manager

EMC:

EN 50081-2 Emissions Radiated/Conducted

EN 55011/05.98+A1:1999

Product Category: Product Type: Model Numbers: Manufactures Name:

Manufacture’s Address:

Motor Controller

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 technical files and other documentation are on file at Benshaw, Inc. and controlled by the Product Engineering Group. Benshaw, Inc. has internal production control systems that ensures compliance between the manufactured products and the technical documentation.

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

Safety: UL 347 Standard for Industrial Control Equipment covering devices for starting, stopping, regulating, controlling, or protecting electric motors with ratings of 1500 volts or more.

Reduced Voltage Solid State Motor Controller RSM6, RSM7, RSM10, RSM11, RMB6, MVRSM12/18 Benshaw, Inc.

1659 East Sutter Road Glenshaw, PA USA 15116

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

2.1 TECHNICAL SPECIFICATIONS

EU Declaration of Conformity

Charles E. Cook

Product Development Manager

		2.1 TECHNICAL SPECIFICATIONS
		Overload Curves
	General	The RediStart Micro II comes with forty (40) standard overload curves. The 100% (no
		trip) point is the motor FLA setting multiplied by the service factor. These curves are
		shown on the next page.
		NOTE: When the overload counter is at a number other than 0%, the time to trip will
		be lowered by this percentage.
	Curves	Class 1 to 40 in steps of 1.
	Trip Time Accuracy	±2 seconds up to 30 seconds

11

2.1 TECHNICAL SPECIFICATIONS

Overload Curve Chart

RediStart Micro II Overload Curves

10000
	Class 40
	Class 35
	Class 30
	Class 25
	Class 40
	Class 20
1000	Class 15
	Class 10
	Class 7
	Class 5
	Class 3
100	Class 2
	Class 1

Class 1

10

1

0

100

200

300

400

500

600

700

800

Current as Percent of FLA

12

2.1 TECHNICAL SPECIFICATIONS

RediStart Micro II Computer Card Jumpers

Jumper	Description	Position 1-2	Position 2-3	Standard
		(In - 2-pos. jumper)	(Out - 2-pos. jumper)
JPC5	LCD Start Button	Enable	Disable	1-2
JPC7	O/L Reset Auto/Manual	Automatic	Manual	2-3
JPC8	Display Format	Standard	Local Bus	1-2
JPC12	SCR Firing	Pulse	Block	In
JPC13	LCD Stop Button	Enable	Disable	1-2
JPC14	RAM Size	8K RAM	2K RAM	1-2
JPC15	PWM/ADDR16	ADDR16	PWM	1-2,3-4
JPC17	Voltage Select	4160 or 3300	2400 or 4800
JPC18	Voltage Select	3300 or 4800	2400 or 4160
JPC19	Fault Reset	Automatic	Manual	2-3
JPC25	Synchronous Application	Yes	No	Out
JPC27	Micro Enable/ADDR17	ADDR17	Enable	1-2,3-4

	Computer Card JC11 Header Assignments
Position	Assignment
1-16	Starter equipped with voltage divider card.
2-15	Not used.
3-14	Starter Equipped with MODBUS master card (for RTD module).
4-13	Not used.
5-12	Not used.
6-11	Enables emergency reset.
7-10	Not used.
8-9	Not used.

Old RediStart Micro II Power Card Jumpers

Jumper	Description	Position 1-2	Position 2-3	Standard
JPP2	Line Synching	Line to Line	Line to Neutral	1-2
JPP3	Line Synching	Line to Line	Line to Neutral	1-2
JPP4	Line Synching	Line to Line	Line to Neutral	1-2

NOTE: Jumpers JPP2, JPP3, and JPP4 do not apply to the BIPC-300030-xx Power Card.

13

2.1 TECHNICAL SPECIFICATIONS

14

3. INSTALLATION

3.1 INSTALLATION

	Site Preparation
General	Before the installation of the RediStart Micro II, the site should be prepared. The
	customer is responsible for:
	• Providing the correct power source.
	• Selecting the control mechanism.
	• Providing the connection cables and associated hardware.
	• Ensuring the installation site meets all environmental specifications for the
	enclosure NEMA rating.
Connection Cables	The connection cables for the starter must have the correct NEC/C.S.A. current rating
	for the unit being installed. Depending upon the model, the connection cables can
	range from a single #14 AWG conductor to four 750 MCM cables.
Site Requirements	The installation site must adhere to the applicable starter NEMA rating. For optimal
	performance, the installation site must meet the following specifications, unless
	equipment (such as a heater or air conditioner) was added to the unit for operation
	outside of these ranges:
	• Temperature: 0°C (+32F) to 40°C (+104°F).
	• Humidity: 20% to 95% non-condensing.
	• Airways: Clearances are provided around all heat sinks.
	• Altitude: Less than 3300 feet (1000 meters) above sea level.
	NOTE: The starter rating must be derated 1% for every 330 feet (100 meters) above
	3300 feet (1000 meters).
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.
	EMC Installation guidelines
General	In order to help our customers comply with European electromagnetic compatability
	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	Wire in an industrial application can be divided into three groups: power control and
	signal. The following recommendations for physical separation between these groups
	are provided to reduce the coupling effect;
	• Different wire groups should cross at 90 degrees inside an enclosure.
	• Minimum spacing between different wiring groups in the same tray should be
	six inches.
	• Wire runs outside an enclosure should be run in conduit or have shielding/armor
	with equivalent attenuation.
	• Different wire groups should be run in separate conduits.
	• Minimum spacing between conduits containing different wire groups should be
	three inches (8cm).
Filtering	To comply with Conducted Voltage Limits a 0.33 uF capacitor should be connected
	between each incoming power line and ground at a point nearest to where the
	incoming power enters the enclosure.

16

		3.1 INSTALLATION
		Installation Procedures
	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 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 necessary installation tools and supplies are obtained.

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

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

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

NOTE: Failure to remove power factor correction or surge capacitors from the load side of the starter will result in serious damage to the starter which will not be covered by the starter’s warranty. The capacitors must be powered from the line side of the starter. The up-to-speed contact can be used to energize the capacitors after the motor has reached full speed.

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 16).
	• 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. See page 13 for the fault rating
	table.
	• Follow all NEC (National Electrical Code) and/or C.S.A. (Canadian Standards
	Association) standards.
	• Remove any foreign objects from the interior of the enclosure.
	• Ensure that wiring is installed by an experienced electrician.
	• Ensure that the individuals installing the starter have protective eye wear and
	clothing.
	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.

17

3.1 INSTALLATION

Installation	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.
	• DO NOT install the starter in direct contact with any materials that cannot
		withstand the maximum heat sink temperature of 194 degrees Fahrenheit (90
		degrees Centigrade). All models require airway passages around the heat sink
		for proper cooling.
	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, crane).
Control Wiring	The control wiring should be connected to suit the customers needs. The control
	terminals on the control cards are as follows:
	RediStart Micro II Power Card (refer to card layout on page 111):
	•	TBP1-1	24VDC common for relay and reversing card
	•	TBP1-2	24VDC power for relay and reversing card
	•	TBP2-1	Run relay neutral
	•	TBP2-2	Run relay live
	•	TBP2-5	Run relay holding contact
	•	TBP3-1	General fault contact N.C. (not faulted)
	•	TBP3-2	General fault contact common
	•	TBP3-3	General fault contact N.O. (not faulted)
	•	TBP3-4	Programmable relay #1 N.O.
	•	TBP3-5	Programmable relay #1 common
	•	TBP3-6	Programmable relay #1 N.C.
	•	TBP3-7	Programmable relay #2 N.O.
	•	TBP3-8	Programmable relay #2 common
	•	TBP3-9	Programmable relay #2 N.C.

RediStart Micro II computer card inputs (refer to card layout on page 110):

•JC13-1 Heat sink thermal switch or external starter trip input.

•JC13-2 AC neutral.

•JC13-3 Run confirm.

•JC13-4 In-line monitoring.

•JC13-5 Disconnect monitoring.

•JC13-6 Reverse/Forward Jog.

•JC13-7 Bypass monitoring.

• JC13-8

Jog mode.

•JC13-9 Profile #2 select.

•JC13-10 External motor thermal overload reset.

•JC13-11 External computer reset.

•JC13-12 AC neutral.

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3.1 INSTALLATION

RediStart Micro II Four (4) Relay Card (refer to card layout on page 113):

•TB2-1 Optional programmable relay #1 N.O.

•TB2-2 Optional programmable relay #1 N.C.

•TB2-3 Optional programmable relay #1 common

•TB2-4 Optional programmable relay #1 N.O.

•TB2-5 Optional programmable relay #1 N.C.

•TB2-6 Optional programmable relay #1 common

•TB2-7 Optional programmable relay #2 N.O.

•TB2-8 Optional programmable relay #2 N.C.

•TB2-9 Optional programmable relay #2 common

•TB2-10 Optional programmable relay #2 N.O.

•TB2-11 Optional programmable relay #2 N.C.

•TB2-12 Optional programmable relay #2 common

•TB2-13 Optional programmable relay #3 N.O.

•TB2-14 Optional programmable relay #3 N.C.

•TB2-15 Optional programmable relay #3 common

•TB2-16 Optional programmable relay #3 N.O.

•TB2-17 Optional programmable relay #3 N.C.

•TB2-18 Optional programmable relay #3 common

•TB2-19 Optional programmable relay #4 N.O.

•TB2-20 Optional programmable relay #4 N.C.

•TB2-21 Optional programmable relay #4 common

•TB2-22 Optional programmable relay #4 N.O.

•TB2-23 Optional programmable relay #4 N.C.

•TB2-24 Optional programmable relay #4 common

RediStart Micro II seven (7) Relay Card (refer to card layout on page 113):

•TB2-1 Optional programmable relay #1 N.O.

•TB2-2 Optional programmable relay #1 common

•TB2-3 Optional programmable relay #1 N.C.

•TB2-4 Optional programmable relay #2 N.O.

•TB2-5 Optional programmable relay #2 common

•TB2-6 Optional programmable relay #2 N.C.

•TB2-7 Optional programmable relay #3 N.O.

•TB2-8 Optional programmable relay #3 common

•TB2-9 Optional programmable relay #3 N.C.

•TB2-10 Optional programmable relay #4 N.O.

•TB2-11 Optional programmable relay #4 common

•TB2-12 Optional programmable relay #4 N.C.

•TB2-13 Optional programmable relay #5 N.O.

•TB2-14 Optional programmable relay #5 common

•TB2-15 Optional programmable relay #5 N.C.

•TB2-16 Optional programmable relay #6 N.O.

•TB2-17 Optional programmable relay #6 common

•TB2-18 Optional programmable relay #6 N.C.

•TB2-19 Optional programmable relay #7 N.O.

•TB2-20 Optional programmable relay #7 common

•TB2-21 Optional programmable relay #7 N.C.

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3.1 INSTALLATION

Power Wiring	Thread the power and motor cables through a connector into the enclosure. Strip
	away the motor cable insulation and apply anti-oxidation paste to the conductors.

Attach the motor cables:

•Use the T1, T2 and T3 lugs or terminals.

•Attach the power source cables:

•Use the L1, L2 and L3 lugs or terminals.

NOTE: For larger starters, thread each incoming power cable through its applicable current transformer (CT); if not already supplied in the unit. The cables must be threaded through the CTs in the same direction to insure proper operation (Refer to the wiring diagram supplied with the starter).

The following is a list of the recommended crimp-on wire connectors manufactured by

Penn-union Corp.

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

Power Factor Capacitors	Power factor correction capacitors and surge capacitors MUST NOT be connected
	between the RediStart Micro II and the motor. These devices can damage the SCR’s in
	the package 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
	RediStart Micro II. Programmable relay #2 (K6) can be set to an up-to-speed (UTS)
	contact (up-to-speed is the default setting) and then used to pull-in a contactor to
	connect the capacitors after the motor has reached full speed.
	NOTE: The motor manufacturer should be contacted before surge capacitors are
	removed from the motor terminal box.
Finishing	After all of the safety precautions and installation procedures have been completed,
	verify that the following settings are correct for the application:

• Current transformer scaling switches.

• Hardware deceleration/braking control (JPC3).

• RediStart Micro II computer card jumpers.

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		3.1 INSTALLATION
		Preventative Maintenance
	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: Preventive maintenance should always be performed by a trained technician.
	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.

For the first month after the starter has been put in operation;

•Re-torque all power connections every two weeks. This includes pre-wired equipment.

•Inspect the cooling fans after two weeks to ensure proper operation.

After the first month of operation;

•Re-torque all power connections every year.

•Clean any accumulated dust from the starter using a clean source of compressed air.

•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 connections more frequently.

	Remote RTD Module
General	The RediStart Micro II can have up to 2 RTD modules installed. The RTD modules
	can be installed in the cabinet with the RediStart Micro II or they can be installed
	remotely at the motor. Refer to the Remote RTD Module manual for details on this
	module.
MODBUS Master Card	The MODBUS master card is installed on the RediStart Micro II CPU card to allow
	the starter to communicate with the RTD Module.

	CT Ratio Scaling
General Information	The motor current signal scaling is set according to the motor current specified when
	the starter is ordered. To ensure accurate operation, the motor current signal must be
	correctly scaled for the motor current being controlled by the starter.Motor current
	signal scaling may have to be changed if the motor size has been changed from the
	original specification.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:

•ON in the right position

•OFF in the left position

NOTE: Adjust the DIP switches only when the motor is stopped, or the switches could be damaged.

21

3.1 INSTALLATION

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 RediStart Micro II power card to ensure that the DIP switches are in the correct positions for the applicable CT ratio and the motor full-load current (FLA) rating.

Switch Settings	CT Ratio	Motor FLA	Switch 1	Switch 2
	288:1	3A to 9A	Off	Off
	288:1	9A to 24A	On	Off
	288:1	25A to 60A	On	On
	864:1	20A to 24A	Off	Off
	864:1	25A to 70A	On	Off
	864:1	71A to 180A	On	On
	2640:1	40A to 80A	Off	Off
	2640:1	81A to 200A	On	Off
	2640:1	201A to 500A	On	On
	5760:1	70A to 160A	Off	Off
	5760:1	161A to 400A	On	Off
	5760:1	401A to 1200A	On	On
Changing FLA	If the actual motor FLA has been changed from the motor FLA documented on the
	purchase order:

•The DIP switch positions may need to be changed.

•Different CTs may have to be installed in the starter and the current transformer ratio parameter may need to be changed (Refer to current transformer ratio parameter, page 88).

		RediStart Micro II Computer Card Jumpers
General Information	The RediStart Micro II computer card has a number of jumpers that affect the
	operation of the starter. In some cases, these jumpers will over-ride the programmed
	values.
JPC5 - LCD Start button	The LCD Start button can be enabled or disabled by this jumper. The LCD Start
	button is factory enabled unless the purchase order requests that the LCD Start
	button is disabled. The LCD Start button is controlled by jumper JPC5 on the
	RediStart Micro II computer card (Refer to RediStart Micro II computer card layout
	on page 110).
	Mode	Position
	Enable	1-2
	Disable	2-3
JPC7 - Overload Auto/Man.	The motor thermal overload can be set to require a manual reset or to automatically
	reset after a thermal trip. The motor thermal overload is set to the manual reset
	position unless the purchase order requests that the motor thermal overload is set to
	the automatic reset position. The motor thermal overload reset is controlled by jumper
	JPC7 on the RediStart Micro II computer card (Refer to RediStart Micro II computer
	card layout on page 110).
	Mode	Position
	Automatic Reset	1-2
	Manual Reset	2-3

22