BENSHAW RediStart MX 2 SEP User Manual

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Hardware Version: 300063-01

2015 Benshaw Inc.

890040-01-01

Solid State Starter

SEP Synchronous Control

RediStart

User Manual

MX SEP Models

Benshaw retains the right to change specifications and illustrations in text without prior notification. The contents of this document may not be copied without the explicit permission of Benshaw.

Software Version: 810027-01-08

ADVANCED CONTROLS & DRIVES

Important Reader Notice

Congratulations on the purchase of your new Benshaw MX2 SEP Controller. This manual contains the information to install and program the MX2 SEP Controller.

This manual may not cover all of the applications for the MX provide information on every possible contingency concerning installation, programming, operation, or maintenance specific to the MX

The content of this manual will not modify any prior agreement, commitment or relationship between the customer and Benshaw. The sales contract contains the entire obligation of Benshaw. The warranty enclosed within the contract between the parties is the only warranty that Benshaw will recognize and any statements contained herein do not create new warranties or modify the existing warranty in any way.

Any electrical or mechanical modifications to Benshaw products without prior written consent of Benshaw will void all warranties, and may also void UL listings or other safety certifications. Unauthorized modifications may result in product damage, operation malfunctions, or personal injury.

SEP. Also, it may not

SEP Controller.

Incorrect handling of the controller may result with an unexpected fault or damage to the controller. For best results on operating the MX

SEP, carefully read this manual, and all warning labels attached to the controller before installation and operation. Keep this manual on hand for reference.

Do not attempt to install, operate, maintain or inspect the controller until you have thoroughly read this manual and related documents carefully and can use the equipment correctly. Do not use the controller until you have a full knowledge of the equipment, safety procedures and instructions. This instruction manual classifies safety instruction levels under “WARNING” or “CAUTION”.

WARNING: Indicates situations in which a high voltage can cause physical injury, or death.

CAUTION: Indicates situations in which damage to equipment may occur.

NOTE: Marks an important point in the documentation.

Please follow the instructions of both safety levels as they are important to personal safety and equipment protection.

High Voltage Motor control equipment and electronic controllers are connected to hazardous line

voltages. When servicing starters and electronic controllers, there may be exposed components with housings or protrusions at or above line potential. Extreme care should be taken to protect against shock.

Stand on an insulating pad and make it a habit to use only one hand when checking components. Always work with another person in case an emergency occurs. Disconnect power before checking controllers or performing maintenance. Be sure equipment is properly grounded. Wear safety glasses whenever working on electronic controllers or rotating machinery.

Trademark Notice Benshaw and are registered trademarks of Benshaw Incorporated. UL

is a trademark of Underwriters Laboratories, Incorporated.

RediStart MX 2 - SEP Synchronous Controller User Manual

SAFETY PRECAUTIONS

Electric Shock Prevention

Injury Prevention

Transp ortat ion and Installation

• This controller contains high voltage which can cause electric shock resulting in personal injury or loss of life.

• Do not open the front cover while power is on or the controller is running.

• Be sure all AC power is removed from the controller before servicing.

• More than one disconnect switch may be required to de-energize the equipment before servicing.

• Do not connect or disconnect the wires to or from the controller when power is applied.

• Make sure ground connection is in place.

• Always install the controller before wiring.

• Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See NFPA 70E.

• Service must be performed by qualified personnel only.

• Ensure that the power-up restart feature is off to prevent any unexpected operation of the motor.

• Make certain proper shield installation is in place.

• Apply only the voltage specified in this manual to the terminals to prevent damage.

• To prevent injury, use proper lifting gear when carrying products.

• Ensure that the installation position and materials can withstand the weight of the controller. Refer to the installation information in this manual for correct installation.

• If parts are missing, or the synchronous controller is damaged, do not operate the MX

• Do not stand or rest heavy objects on the controller, as equipment damage may result.

• Do not subject the controller to impact or dropping.

• Make certain to prevent screws, wire fragments, conductive bodies, oil or other flammable substances from entering the synchronous controller.

SEP.

Trial Run • Check all parameters, and ensure that the application will not be damaged by a sudden start-up.

Emergency Stop • To prevent the machine and equipment from hazardous conditions if the controller fails, provide a safety

backup such as an emergency brake.

Disposal • Never dispose of electrical components via incineration. Contact your state environmental agency for details

on disposal of electrical components and packaging in your area.

Table of Contents

1 - INTRODUCTION

Using This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Benshaw Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

General Overview of a Synchronous Field Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2 - TECHNICALSPECIFICATIONS

2.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.2 Electrical Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.2.1 Terminal Points and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.2.2 Measurements and Accuracies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.2.3 List of Motor Protection Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.3 Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.4 Altitude Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.5 Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.6 Certificate of Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3 - INSTALLATION

3.1 Before You Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.1.1 Installation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.1.2 General Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.1.2 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.2 Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.2.1 Site Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.2.2 EMC Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.2.3 Application Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.3 Mounting Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.4 Wiring Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.4.1 Wiring Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.4.2 Considerations for Control and Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.4.3 Considerations for Signal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.4.4 Meggering a Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.4.5 High Pot Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.5 Power and Control Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.5.1

3.5.2

3.5.3

3.5.4

3.6 Power Wiring Input Line Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.6.1 Recommended Incoming Line Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.6.2 Recommended Wire Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.6.3 Power Wire Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.6.4 Compression Lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.6.5 Torque Requirements for Power Wiring Terminations . . . . . . . . . . . . . . . . . . . . . . 28

3.7 Control Card Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Control Card Layout (with Communication Card for Power Factor Control) . . . . . . . . . 30

3.8 Control Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.8.1 Control Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.8.2 Output Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.8.3 Digital Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.8.4 Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.8.5 SW1 DIP Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

MX2 ATL Synchronous Brushtype (Field Control) Solid State MX2 ATL Synchronous Brushtype with contactors MX2 ATL Synchronous Brushless

MX2 Synchronous with Power Factor Control . . . . . . . . . . . . . . . . . . . . . . . . . 26

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

. . . . . . . . . . . . . . . . . . . . . . . 24

. . . . . . . . . . . . . . 23

RediStart MX 2 - SEP Synchronous Controller User Manual

3.9 Remote LCD Keypad/Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

3.9.1 Remote Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.9.2 Display Cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.9.3 Installing Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4 - KEYPAD OPERATION

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

4.2 Standard Keypad and Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

4.3 Viewing Parameter Values for the Standard Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . .37

4.4 Changing Parameter Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

4.5 Messages Displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

4.5.1 Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4.5.2 Stopped. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4.5.3 Running. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4.5.4 Alarm Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

4.5.5 Lockout Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

4.5.6 Faulted Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

4.5.7 Quick Meters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

4.6 Jump Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

4.7 Restoring Factory Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

4.8 Resetting a Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

4.9 Remote LCD Keypad and Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

4.10 Description of the LEDs on the Keypad. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

4.11 Description of the Keys on the Remote LCD Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . .44

4.12 Alphanumeric Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

4.12.1 Power Up Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4.12.2 Operate Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4.12.3 Parameter Group Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

4.12.4 Meter Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

4.12.5 Fault Log Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

4.12.6 Fault Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

4.12.7 Lockout Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

4.12.8 Alarm Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

4.13 Procedure for Setting Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

5 - PARAMETER GROUPS

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

5.2 LED / LCD Parameter Cross-Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

5.3 Parameter Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

5.3.1 Quick Start Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

5.3.2 Control Function Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

5.3.3 Protection Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

5.3.4 I/O Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

5.3.5 Function Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

5.3.6 LCD / LED Fault Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

6 - PARAMETER DESCRIPTIONS

6.1 Parameter Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Quick Start Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Control Function Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Protection Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

I/O Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Function Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Table of Contents

7 - THEORY OF OPERATION

7.1 Control Modes of Synchronous Motor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

7.1.1 Brush Type (Field Control) Synchronous Motor Operation . . . . . . . . . . . . . . . . . . 89

7.1.2 Brushless Type Synchronous Motor Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

7.1.3 Current Follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

7.1.4 Closed Loop Power Factor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

7.2 Hall Effect Current Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

7.2.1 Analog Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

7.3 Simplified I/O Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

7.4 Remote Modbus Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

7.4.1 Supported Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

7.4.2 Modbus Register Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

7.4.3 Cable Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

7.4.4 Terminating Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

7.4.5 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

7.4.6 Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

7.4.7 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

7.5 Dynamic Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

8 - TROUBLESHOOTING & MAINTENANCE

8.1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

8.2 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

8.2.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

8.2.2 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

8.3 General Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

8.3.1 Motor does not start, no output to motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

8.3.2 During starting, motor rotates but does not reach full speed . . . . . . . . . . . . . . . . 100

8.3.3 Motor stops unexpectedly while running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

8.3.4 Metering incorrect (Hall Effect) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

8.3.5 Other Situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

8.4 Fault Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

8.5 SCR Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

8.5.1 Resistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

8.5.2 Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

8.6 Field Discharge Resistor Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

8.7 Built-In Self Test (BIST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

8.7.1 Powered BIST Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

8.7.2 BIST Programming / Test Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

8.8 SCR Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

8.8.1 Typical Stack Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

8.8.2 SCR Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

8.8.3 SCR Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

8.8.4 SCR Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

8.8.5 Tightening the Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

8.8.6 Testing the SCR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

APPENDIX A - ALARM CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

APPENDIX B - FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

APPENDIX C - REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

APPENDIX D - EU DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

APPENDIX E - MODBUS REGISTER MAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

RediStart MX 2 - SEP Synchronous Controller User Manual

1 - Introduction

Using This Manual

Layout This manual is divided into 9 sections. Each section contains topics related to the section. The sections are as

follows:

• Introduction

• Technical Specifications

• Installation

• Keypad Operation

• Parameter Groups

• Parameter Descriptions

• Theory of Operation

• Troubleshooting & Maintenance

• Appendices

Notations There are 3 notations used in this manual to highlight important information. These notations appear as the

following:

WARNING: Indicates situations in which high voltages can cause physical injury, or death.

CAUTION: Indicates situations in which damage to equipment may occur.

NOTE: Marks an important point in the documentation.

WARNING: HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH

• Only qualified personnel familiar with low or medium voltage equipment are to perform work described in this set of instructions.

• Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See NFPA 70E.

• Turn off all power before working on or inside equipment.

• Use a properly rated voltage sensing device to confirm that the power is off.

• Before performing visual inspections, tests, or maintenance on the equipment, disconnect all sources of electric power. Assume that circuits are live until they have been completely de-energized, tested, and tagged. Pay particular attention to the design of the power system. Consider all sources of power, including the possibility of backfeeding.

• Replace all devices, doors, and covers before turning on power to this equipment.

Failure to follow these instructions may result in death or serious injury

RediStart MX 2 - SEP Synchronous Controller User Manual

Benshaw Services

General Information

Start-Up Services

On-Site Training Services

Tech nical Support

Documentation Benshaw provides all customers with:

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 Page 11.

Benshaw technical field support personnel are available to customers with the initial start-up of the MX Controller. Information about start-up services and fees are available by contacting Benshaw.

Benshaw technical field support personnel are available to conduct on-site training on MX troubleshooting.

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 Page 11.

• Operations manual.

• Wiring diagrams.

SEP

SEP operations and

All drawings are produced in AutoCAD format. The drawings are available via e-mail by contacting Benshaw.

Replacement Parts

Software Number

Hardware Number

Publication History

Warranty Benshaw provides a 1 year standard warranty with its controllers. An extension to the 3 year warranty is

Spare and replacement parts can be purchased from Benshaw Technical Support.

This manual pertains to software version number 810027-01-08.

This manual pertains to the hardware version number 300063-01.

See inside back cover.

provided when a Benshaw or Benshaw authorized service technician completes the installation and initial start up. The warranty data sheet must also be signed and returned. The cost of this service is not included in the price of the Benshaw controller and will be quoted specifically to each customers needs. All recommended maintenance procedures must be followed throughout the warranty period to ensure validity.

1 - Introduction

Contacting Benshaw

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

Benshaw Corporate Headquarters Benshaw Canada

615 Alpha Drive 550 Bright Street East Pittsburgh, PA 15116 Listowel, Ontario N4W 3W3 Phone: 412-968-0100 Phone: 519-291-5112 Fax: 412-968-5415 Fax: 519-291-2595

Tech Support: 1-800-203-2416 Tech Support: 1-877-291-5112 E-mail: bpg-usatechnicalsupport@regalbeloit.com

Technical support for the MX 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

• Voltage of motor attached to Benshaw product

• FLA of motor attached to Benshaw product

• A brief description of the application

SEP Controller is available at no charge by contacting the Benshaw Customer

RediStart MX 2 - SEP Synchronous Controller User Manual

C = Open Chassis

3 = Three Phase Bridge

S = Solid State

Current Rating of Bridge

Interpreting Model Numbers

Figure 1: RediStart MX

MX2SEP-125VDC-50A-3-S-C

SEP Series Model Numbers

M = Mechanical (contactors)

1 = Single Phase Bridge

Voltage Rating of Field (125 or 250 VDC)

MX2 Control

1 - Introduction

General Overview of a Synchronous Field Controller

General Overview

Features Enhanced engineering features of the controller include:

The RediStart MX2 SEP synchronous field controller is a microprocessor based controller for single or threephase field supply. The synch controller can be custom designed for specific applications. A few of the features are:

• Solid state design

• Closed-loop motor current control

• Programmable operating parameters

• Programmable metering

Each MX frequency values 23 to 72Hz.

The field controller can be programmed for synchronous motor fields. The RediStart MX the motor and its load from damage that could be caused by incorrect phase order wiring.

The controller continually monitors the amount of current being delivered to the motor. This protects the motor from overheating or drawing excess current.

SEP can operate within applied line voltage of 100VAC to 600VAC (optional 1000VAC) and

• Multiple frame sizes

• Universal voltage operation

• Universal frequency operation

• Phase rotation protection

• Regulated current control

• Electronic over/under current protection

• Single phase protection

• Programmable metering

• Passcode protected

• Programmable Relays

• Analog output with digital offset and span adjustment

• Analog input with digital offset and span adjustment

• Voltage and Current Accuracy of 3%

SEP can also protect

RediStart MX 2 - SEP Synchronous Controller User Manual

2 - Technical Specifications

2.1 General Information

The physical specifications of the controller vary depending upon its configuration. The applicable motor current determines the configuration and its specific application requirements. Specifications are subject to change without notice.

This document covers the control electronics:

Control Card Set

• MX

2.2 Electrical Ratings

2 - Technical Specifications

2.2.1 Terminal Points and Functions

Function

Control Power TB1

Relay 1 (R1) TB2

Relay 2 (R2) TB2

Relay 3 (R3) TB2

Digital Inputs TB3

Serial Comm TB4

Terminal

Block

Table 1: Terminals

Terminal Number Description

G ground N 120VAC neutral N 120VAC neutral L 120VAC line L 120VAC line

NO1: Normally Open Contact RC1: Common NC1: Normally Closed Contact

NO2: Normally Open Contact RC2: Common Contact NC2: Normally Closed Contact

NO3: Normally Open Contact RC3: Common Contact NC3: Normally Closed Contact

1: Start 2: DI1 3: DI2 4: DI3 5: Common

1: B + 2: A – 3: COM

96 – 144 VAC input, 50/60 Hz 45VA required for Control Card

Relay Output, SPDT form C

NO Contact (resistive) NC Contact (resistive)

5A at 250VAC 3A at 250VAC 5A at 125VAC 3A at 125VAC 5A at 30VDC 3A at 30VDC 1250VA 750VA

Relay Output, SPDT form C NO Contact (resistive) NC Contact (resistive)

5A at 250VAC 3A at 250VAC 5A at 125VAC 3A at 125VAC 5A at 30VDC 3A at 30VDC 1250VA 750VA

10A at 250VAC 10A at 125VAC 10A at 30VDC 2500VA

120VAC digital input 2500V optical isolation 4mA current draw Off: 0 – 35VAC On: 60 – 120VAC

Modbus RTU serial communication port. RS-485 interface

19.2k baud maximum 2500V Isolation

RediStart MX 2 - SEP Synchronous Controller User Manual

Table 1: Terminals (Continued)

Function

Analog I/O

(Hall Effect

Input)

Display RJ45 — Door Mounted Display Connector

SCR J6 to J11

Terminal

Block

TB5

1: Ain Power 2: M 3: Common 4: Ground (Shield) 5: Aout 6: Common 7: Shield

1: Gate 2: Cathode

Wire Gauge: The terminals can support 1–14 AWG wire or 2–16 AWG wires or smaller.

Torq u e R a t ing: The terminals on the control cards have a torque rating of 5.0-inch lb. or 0.56Nm.

This MUST be followed or damage will occur to the terminals.

NOTE: Refer to Control Card Layouts on Pages 29 and 30.

2.2.2 Measurements and Accuracies

Terminal Number Description

Input: Voltage or Current Voltage: 0 Current: 0

Output:

Voltage or Current Voltage: 0 Current: 0

SCR Gate Connections

– 10VDC, 67KΩ impedance – 20mA, 500Ω impedance

– 10VDC, 120mA maximum – 20mA, 500Ω load maximum

Table 2: Measurements and Accuracies

Internal Measurements

Hall Effect Input

Line Voltage Inputs

Metering

Conversion: True RMS, Sampling @ 1.562kHz Range: 1 – 1000A

Conversion: True RMS, Sampling @ 1.562kHz Range: 100 – 1,250VAC, 23 to 72 Hz

Current: 0 – 40,000 Amps ± 3% Slip % 0.0 – 100% Voltage: 0 – 1,250 Volts ± 3% Line Frequency: 23 – 72 Hz ± 0.1 Hz Run Time: ± 3 seconds per 24 hour period Analog Input: Accuracy ± 3% of full scale (10 bit) Analog Output: Accuracy ±2% of full scale (12 bit)

NOTE: Percent accuracy is percent of full scale of the given ranges, Current = Motor FLA,

Voltage = 8,000V, Watts/Volts-Amps/Watt-Hours = Motor & Voltage range

2 - Technical Specifications

2.2.3 List of Motor Protection Features

• ANSI 27 / 59 - 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 37 - Undercurrent detection (Off or 5 to 100% and time 0.1 to 90.0 sec. in 0.1 sec. intervals)

• ANSI 47 - Phase rotation (selectable ABC, CBA, Insensitive, or Single Phase)

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

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

• ANSI 56 - Field Application

• ANSI 74 - Alarm relay output available

• ANSI 81 - Over / Under Frequency

• ANSI 95 - Reluctance torque sync

• ANSI 96 - Autoloading

• Single Phase Protection

• Shorted SCR Detection

RediStart MX 2 - SEP Synchronous Controller User Manual

2.3 Environmental Conditions

Table 3: Environmental Ratings

2.4 Altitude Derating

Benshaw controllers are capable of operating at altitudes up to 3,300 feet (1000 meters) without requiring altitude derating. Table 6 provides the derating percentage to be considered when using a controller above 3,300 feet (1000 meters).

Operating Temperatures

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

Humidity 0% to 95% non condensing

Altitude 1000m (3300ft) without derating

Maximum Vibration 5.9m/s

Cooling Natural convection (Fans optional)

–10°C to +40°C (14°F to 104°F) enclosed –10°C to +50°C (14°F to 122°F) open

(19.2ft/s2) [0.6G]

Table 4: Altitude Derating

Altitude

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%

Percent Derating

(Amps)

2.5 Approvals

The MX2 SEP Control Card is UL, cUL Recognized

2.6 Certificate of Compliance

CE Mark, see Appendix D on Page 117.

For derating above 10,000 feet consult Benshaw Inc.

3 - Installation

3.1 Before You Start:

3.1.1 Inspection

Before storing or installing the RediStart MX2 SEP Series sync controller, thoroughly inspect the device for possible shipping damage. Upon receipt:

• Remove the controller 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 controller 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 controller, and ensure that the correct cuurent and input voltage for the application has been purchased.

3 - Installation

3.1.2 Installation Precautions

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

• The wiring diagram (supplied separately with the controller) is correct for the required application.

• The controller is the correct current rating and voltage rating for the motor being started.

• All installation safety precautions are followed.

• The correct power source is available.

• The control method has been selected.

• The connection cables, and associated mounting hardware, have been obtained (lugs).

• The necessary installation tools and supplies are procured.

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

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

RediStart MX 2 - SEP Synchronous Controller User Manual

3.1.3 Safety Precautions

To ensure the safety of the individuals installing the sync controller, and the safe operation of the controller, observe the following guidelines:

• Ensure that the installation site meets all required environmental conditions (refer to Site Preparation, Section

3.2.1).

• Lock out all sources of power.

• Install circuit disconnecting devices (i.e., circuit breaker, fused disconnect or non-fused disconnect) if 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.

• 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 controller are wearing ALL protective eye wear and clothing.

• Ensure the controller is protected from debris, metal shavings and any other foreign objects.

NOTE: 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 controller should be inspected and replaced if damaged.

3.2 Installation Considerations

3.2.1 Site Preparation - General Information

Before the sync controller 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 controller 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 controller NEMA/CEMA rating. For optimal performance, the installation site must meet the appropriate environmental and altitude requirements.

3.2.2 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 22.

Filtering To comply with Conducted Emission Limits (CE requirement), a high voltage (1000V or greater)

0.1 uF capacitor should be connected from each input line to ground at the point where the line enters the cabinet.

3.2.3 Application Considerations

Although the MX SEP controls and provides protection for the motor field current, protection of the motor’s stator windings must be addressed separate from the MX SEP package. For example, if the motor is started using a Benshaw motor starter, the overcurrent protection on the starter can be set to provide overcurrent protection of the stator windings in cases such as the rotor puling out of synchronization. Additionally, a low Power Factor trip can be used to detect when the rotor is no longer synchronized.

3 - Installation

3.3 Mounting Considerations

Provisions should be made to ensure that the temperature inside the enclosure never rises above 122oF / 50oC. If the temperature inside the enclosure is too high, the controller can be damaged, and the operational life can be reduced.

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

The field supply produces 4 watts of heat per amp of current, and 26 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 controllers in sealed enclosures. Benshaw supplies controllers under 124 amps nonbypassed, 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 controller.

Table 5: Ventilation Requirements

RediStart MX 2 - SEP Synchronous Controller User Manual

3.4 Wiring Considerations

3.4.1 Wiring Practices

When making power and control signal connections, the following should be observed:

• 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 degree angle.

• Different wire groups should be run in separate conduits.

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

3.4.2 Considerations for Control and Power Wiring

Control wiring refers to wires connected to the control terminal strip that normally carries 24V to 115V. Power wiring refers to wires connected to the line and load terminals that normally carry 208VAC to 600VAC 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.

• Grounding must be in accordance with NEC, CEC, or local codes. If multiple controllers are installed near each other, each must be connected to ground. Take care to not form a ground loop. 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.

3.4.3 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.

3.4.4 Meggering a Motor

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

3.4.5 High Pot Testing

CAUTION: If the controller must be high pot tested, perform a DC high pot test. The maximum high pot

voltage must not exceed 2.0 times rated RMS voltage + 1000VAC (High pot to 75% of factory). Failure to comply will damage the control board, which will not be replaced under warranty. An example to find the maximum high pot voltage is (2.0 * rated RMS voltage + 1000) * 0.75.

3.5 Power and Control Drawings

3.5.1 MX2 ATL Synchronous Brushtype (Field Control) Solid State

3 - Installation

Figure 2: Sample Power Schematic for RB2 Low HP

RediStart MX 2 - SEP Synchronous Controller User Manual

3.5.2 MX2 ATL Synchronous Brushtype with contactors

Figure 3: Sample MX

Power Schematic ATL Synchronous Brushtype with contactors

3.5.3 MX2 ATL Synchronous Brushless

Figure 4: Sample MX

3 - Installation

Power Schematic ATL Synchronous Brushless

RediStart MX 2 - SEP Synchronous Controller User Manual

3.5.4 Synch Controller with Power Factor Control

Figure 4: Sample Power Schematic Synch Controller with Power Factor Control

3.6 Power Wiring Input Line Requirements

The input line source must be an adequate source to start the motor, generally 2 times the rating of the motor FLA. (This may not apply in some cases, such as being connected to a generator).

3.6.1 Recommended Incoming Line Protection

A semi-conductor fuse is needed. The fuse shall be 150% of the DC Field Amps from motor. An HCJ fuse is recommended.

Input Line Requirements

The input line source needs to be an adequate source, generally 2 times the rating of the motor rotor FLA. (This may not apply in some cases such as being connected to a generator).

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) or CEC Part 1 Table 5C is adhered to. In some areas, local codes may take precedence over the NEC. Refer to your local requirements.

3 - Installation

3.6.3 Power Wire Connections

Attach the motor cables:

• Use the F+ and F- 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).

3.6.4 Compression Lugs

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

Table 6: Single Hole Compression Lugs

Wire Size Part # Wire Size Part # Wire Size Part # Wire Size Part #

1/0 BLU-1/0S20 300 MCM BLU-030S 600 MCM BLU-060S1 1500 MCM BLU-150S

2/0 BLU-2/0S4 350 MCM BLU-035S 650 MCM BLU-065S5 2000 MCM BLU-200s

3/0 BLU-3/0S1 400 MCM BLU-040S4 750 MCM BLU-075S — —

4/0 BLU-4/0S1 450 MCM BLU-045S1 800 MCM BLU-080S — —

250 MCM BLU-025S 500 MCM BLU-050S2 1000 MCM BLU-100S — —

Table 7: Two Hole Compression Lugs

Wire Size Part # Wire Size Part # Wire Size Part # Wire Size Part #

1/0 BLU-1/0D20 300 MCM BLU-030D 600 MCM BLU-060D1 1500 MCM BLU-150D

2/0 BLU-2/0D4 350 MCM BLU-035D 650 MCM BLU-065D5 2000 MCM BLU-200D

3/0 BLU-3/0D1 400 MCM BLU-040D4 750 MCM BLU-075D — —

4/0 BLU-4/0D1 450 MCM BLU-045D1 800 MCM BLU-080D — —

250 MCM BLU-025D 500 MCM BLU-050D2 1000 MCM BLU-100D — —

RediStart MX 2 - SEP Synchronous Controller User Manual

3.6.5 Torque Requirements for Power Wiring Terminations

Table 8: Slotted Screws and Hex Bolts

Wire size installed in conductor

AWG or

kcmil

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)

(mm2)

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

Slot width-0.047 inch

(1.2mm) or less and

slot length ¼ inch

(6.4mm) or less

Tightening torque, pound-inches (N-m)

Slot width-over 0.047

inch (1.2mm) or slot

length – over ¼ inch

(6.4mm) or less

Split- bolt connectors Other connectors

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 9: Tightening Torque for 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) 275 (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.

3.7 Control Card Layout

Unfused 120 VAC Out

Control

Power

120 VAC

Auxiliary

Relays:

I/O 5-7

(P46-48)

Digital Inputs: I/O 1-3

(P42-44)

Modbus

Communications

(P66-69)

Keypad Port:

I/O 14 (P55)

I/O 09-11

(P50-52)

Selector Switch SW1

Part/Serial #

SCR 1

TB5

RJ45

Hall Effect

Transf ormer

RX LED

TX LED

CPU LED

3 - Installation

Figure 5: Control Card Layout

Jumper

120 VAC

Stack In

(Benshaw Only)

Stack

Control

Port: FUN 10-13

Analog Output:

Analog Voltage/Current

SCR 4

SCR 2

SCR 5

SCR 3

SCR 6

4x7 LED Display

Software Part #

RediStart MX 2 - SEP Synchronous Controller User Manual

Unfused 120 VAC Out

Control

Power

120 VAC

Auxiliary

Relays:

I/O 5-7

(P46-48)

Digital Inputs: I/O 1-3

(P42-44)

Modbus

Communications

Port: FUN 10-13

(P66-69)

Keypad Port:

I/O 14 (P55)

I/O 09-11 (P50-52)

Selector Switch SW1

Part/Serial #

SCR 1

RJ45

Hall Effect

Transformer

Fiber Optic

Connections

4x7 LED Display

RX LED

TX LED

CPU LED

Figure 6: Control Card Layout (with Communication Card for Power Factor Control)

Jumper

120 VAC

Stack In

(Benshaw Only)

Stack

Control

SCR 4

SCR 2

Analog Output:

Analog Voltage/Current

TB5

Software Part #

SCR 5

SCR 3

SCR 6

3.8 Control Wiring

120VAC LIVE

120VAC NEUTRAL

TRIP

TRIP PILOT LIGHT

(RELAY 1 SET TO FLFS - FAULT FAILSAFE)

120VAC LIVE

120VAC NEUTRAL

STOP

RUN & STOPPED PILOT LIGHT

(RELAY 2 SET TO RUN)

RUN

TB2 TB2

120VAC LIVE

120VAC NEUTRAL

TB1

3.8.1 Control Power

120VAC control power is supplied to TB1. The connections are as follows:

• 1 - Ground

• 2 - Neutral

• 3 - Neutral

• 4 - Line (120VAC)

• 5 - Line (120VAC)

3.8.2 Output Relays

TB2 is for output relays R1, R2 and R3. These relays connect as follows:

• 1 - NO1: Relay 1 normally open

• 2 - RC1: Relay 1 common

• 3 - NC1: Relay 1 normally closed

• 4 - NO2: Relay 2 normally open

• 5 - RC2: Relay 2 common

• 6 - NC2: Relay 2 normally closed

• 7 - NO3: Relay 3 normally open

• 8 - RC3: Relay 3 common

• 9 - NC3: Relay 3 normally closed

3 - Installation

Figure 7: Control Power Wiring Example

Figure 8: Relay Wiring Examples

See Also: Relay Output Configuration (I/O 05–07 / P44-46) on Page 76.

RediStart MX 2 - SEP Synchronous Controller User Manual

120VAC LIVE

120VAC NEUTRAL

120VAC LIVE

120VAC NEUTRAL

START

DI1

DI2

DI3

120VAC LIVE

120VAC NEUTRAL

120VAC LIVE

FAULTRESET

2-WIRE CONTACT CONTROL

FAULT RESET BUTTON

EXTERNAL TRIP INPUT

TRIP

(DI3 SET TO FL - FAULT LOW)

STOP

(DI1 SET TO STOP)

3.8.3 Digital Input

TB3 is for digital inputs Start, DI1, DI2 and DI3. These digital inputs use 120VAC. These digital inputs connect as follows:

• 1 - Start: Start Input

• 2 - DI1: Digital Input 1

• 3 - DI2: Digital Input 2

• 4 - DI3: Digital Input 3

• 5 - Com: 120VAC neutral

Figure 9: Digital Input Wiring Examples

DIGITAL INPUT WIRING

TB3 TB3

120VAC NEUTRAL

START

3-WIRE START / STOP BUTTONS

TB3 TB3

TB3

120VAC LIVE

120VAC NEUTRAL

(DI2 SET TO Fr - FAULT RESET)

See Also: Digital Input Configuration (I/O 01 – 03 / P40-42) on Page 75.

3.8.4 Analog Output

ANALOG OUTPUT SW1-2 ON = 0-10V OFF = 0-20mA

ANALOG INPUT

SW1-1

ON = 0-20mA

OFF = 0-10V

V/I

TO METER / ANALOG INPUT CARD

TB5

The analog output can be configured for Voltage or Current loop. The output is shipped in the Voltage loop configuration unless specified in a custom configuration. Below, TB5 is SW1-2. When the switch is in the off position, the output is current. When on, it is a Voltage loop output. The control is shipped with the Switch on.

NOTE: The analog output is a low voltage output, maximum of 15VDC. The output will be damaged if

control power (115VAC) or line power is applied to the analog output.

The terminals are as follows:

• 5) analog output

• 6) common

• 7) shield

3 - Installation

Figure 10: Analog Output Wiring Example

See Also: Analog Output Configurations (I/O 9 - 11 / P54 - 56) on Pages 77 and 78.

3.8.5 SW1 DIP Switch

The SW1 DIP switch on the card allows selecting the analog input and output values of 0–10V or 0–20mA. The picture below represents how to adjust the switch to select the desired signal.

Figure 11: SW1 DIP Switch Settings

RediStart MX 2 - SEP Synchronous Controller User Manual

50.50

[1.99"]

50.50

[1.99"]

31.50 [1.24"]

101.00 [3.98"]

63.00 [2.48"]

63.50

[2.50"]

63.50

[2.50"]

38.50

[1.52"]

38.50

[1.52"]

127.00 [5.00"]

77.00

[3.03"]

3.9 Remote LCD Keypad/Display

The display has a NEMA 3R / IP65 service rating when properly mounted to an enclosure door with the correct gasket. The display is available in 2 versions, a small display as P/N KPMX3SLCD, and large display as P/N KPMX3LLCD.

3.9.1 Remote Display

The LCD keypad is mounted remotely from the MX connects between the MX2 and remote display's RJ45 terminals.

3.9.2 Display Cutout

Figure 12: Small Display Keypad Mounting Dimensions

Control via a straight through display cable, which

Part # KPMX3SLCD

Figure 13: Large Display Keypad Mounting Dimensions

Part #: KPMX3LLCD

3.9.3 Installing Display

MX³ DISPLAY

GASKET

ENCLOSURE DOOR

MX³ DISPLAY CABLE

CLIP

The remote display is installed as follows:

• Install the gasket onto the display.

• Insert the display through the door cutout.

• Insert the mounting clips into the holes in each side of the display.

• Tighten the mounting clips until they hold the display securely in place. (Torque requirements are 0.7 NM or 6.195 in lbs.)

• Plug the cable into the display connector on the MX for the connector location.

• Route the cable through the enclosure to the display. Observe the wiring considerations as listed in Section 3.4 on Page 22.

• Plug the other end of the cable into the LCD display.

3 - Installation

card. See Figures 5 and 6 on Pages 29 and 30

Figure 14: Mounting Remote Keypads

RediStart MX 2 - SEP Synchronous Controller User Manual

4 - Keypad Operation

UPDOWNPARAMRESET

4.1 Introduction

The MX applications right out of the box, customization of parameter values to better suit your particular application is easily accomplished with the standard

The MX the MX additional keys including start and stop keys for operation of the controller from the keypad. When the remote LCD keypad is connected, the local display is disabled.

4.2 Standard Keypad and Display

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

SEP provides a comprehensive set of parameters. While the controller can meet the requirements of many

SEP has an optional 2x16 character, back-lit LCD display/keypad that may be mounted remotely from

SEP control card. The remote LCD keypad has the same keys as the standard display with several

4 - Keypad Operation

on-board, 4-digit, 7-segment LED display/keypad.

Figure 15: Standard Keypad and Display

8.8.8.8.

4.3 Viewing Parameter Values for the Standard Keypad

Parameter view mode can be entered by:

1. At the default meter display, press the [PARAM] key to enter parameter mode. “P1” is displayed to indicate Parameter 1.

2. Use the [UP] and [DOWN] keys to scroll through the available parameters.

3. Pressing the [UP] key from “P1” advances to parameter “P2”.

4. Pressing the [DOWN] key from “P1” wraps 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.

ENTER

To return to the default meter display, either:

1. Press the [PARAM] key while in the parameter number display mode, or

2. Wait 60 seconds and the display returns to the default meter display.

RediStart MX 2 - SEP Synchronous Controller User Manual

4.4 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 is saved and the display goes 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, or

2. Wait 60 seconds and the display returns to the default meter display.

4.5 Messages Displayed

In addition to being able to view and change parameters, various special messages may be displayed during different conditions. Here is a summary of the possible special messages.

The following sections provide more detail for some of the conditions that cause special messages to be displayed.

4 - Keypad Operation

LED Display

noL

rdY

run

Sync

inch

dynb

L CP

L Ot

LOC

AbC

CbA

SPH

b AL

b Fl

b -

dFLt

FLSH

ProG

rEAd

donE

No Line Voltage

Ready

Controller active

Motor running and synchronized

Motor running, synchronized, with field forcing being applied

Motor pullout / pole slip detected.

Inching field control mode active

Dynamic braking active.

Low Control Power – A start is not allowed because the control power is low.

Power Stack Over Temperature Lockout

Lockout State

Phase order meter showing ABC phasing

Phase order meter showing CBA phasing

Phase order meter showing single phase

XX = parameter code

XX = alarm code. If the condition persists, a fault will occur

XX = fault code

BIST mode, waiting for line voltage to be applied

BIST mode, field supply active

BIST mode, BIST complete

Default – Flashes when parameter defaults are loaded.

In Reflash mode, waiting for download

In Reflash mode, programming

In Reflash mode, verifying

In Reflash mode, complete

RediStart MX 2 - SEP Synchronous Controller User Manual

LCD Display

4.5.1 Power Up

The software version is displayed as a series of single digits once power has been applied to the MXSEP. If the parameters were being reset on power up, “ software version is displayed.

Stopped

Fault

Lockout

Wait

Syncing

Synced

Sync FF

Pullout

B Ctl

Cntr

Inching

Braking

Shtdwn

BIST

Controller stopped

Controller tripped on a Fault

Controller is locked out due to a unusual condition being present

Controller is monitoring start and waiting for command and/or timer to expire before applying field current.

Controller is attempting to apply field and synchronize motor

Motor running synchronized

Motor running synchronized with field forcing active

Motor pullout / pole slip detected.

Brushless motor control active

Current Control mode active

Inching field control mode active

Dynamic braking active

Controller shutting down

Controller in Built In Self Test mode.

dFLt” is flashed on the display for three seconds, and then the

4.5.2 Stopped

When the controller is not in the run mode, the display shows the status condition of the controller, such as

rdY” (ready) or “noL” (No Line).

“

4.5.3 Running

When running, the display shows the selected meter function. The following meters can be selected using the Meter display parameter (P17 / FUN 01–02).

Ave Current

Slip Percent Run Days Ave Volts Phase Order Run Hours L1-L2 Volts (Input) Line Freq Starts L2-L3 Volts (Input) Analog Input L3-L1 Volts (Input) Analog Out

4.5.4 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 no line alarm condition exists, “noL” is displayed.

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

4.5.5 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 power stack thermal overload lockout condition exists, “L Ot” is displayed.

• When a low control power lockout condition exists, “L CP” is displayed.

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

4.5.6 Faulted Condition

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

4 - Keypad Operation

• When the fault is Instantaneous Over Current, “ioc” is displayed.

4.5.7 Quick Meters

Although any meter may be viewed by changing the Meter parameter (P17 / FUN 01–02), there are 3 “Quick Meters” that are always available with a single key press. When the controller is in the normal display mode, the display may be toggled between the information currently displayed, and the following quick meters. Quick meters are only used with the LED keypad.

Status Meter

Toggle between the programmed meter display and the controller operational status display (rdY, run, dcL, etc) by pressing the [ENTER] key.

Phase Order Meter

Toggle between the programmed meter display and the phase order by pressing the [UP] key. The phase order is displayed as “AbC” or “CbA”.

DC Current

Toggle between the programmed meter display and the DC Current by pressing the [DOWN] key.

RediStart MX 2 - SEP Synchronous Controller User Manual

4.6 Jump Code

At the beginning of each parameter group, there is a Jump Code parameter. By changing the value of this parameter and pressing [ENTER], you can jump directly to any parameter within that group.

4.7 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 blinks “dFLt”. Parameters unique to the controller applications need to be set again to appropriate values before motor operation.

P23 / FUN06 - Rated RMS Voltage (set to specified equipment rating) I/O 01 / P40 - Digital Input #1 P41 / I/O 02 - Digital Input #2 P42 / I/O 03 - Digital Input #3 P44 / I/O 05- Relay #1 P45 / I/O 06 - Relay #2 P46 / I/O 07 - Relay #3

NOTE: Consult the wiring schematic for digital inputs and relay output configuration.

4.8 Resetting a Fault

To reset from a fault condition, press [RESET].

4.9 Remote LCD Keypad and Display

The MX2 Sync Controller can be equipped with an optional 2x16 character, back-lit LCD display/keypad that is mounted remotely from the control card. The remote keypad is NEMA 3R / IP65 when mounted directly on the door of an enclosure with the correct gasket.

Like the standard keypad, the remote LCD keypad has the same basic functions with enhancements that allow using plain text instead of codes and a menu structure instead of a straight line of parameters.

Additional keys have been added, such as [MENU], [STOP], and a [LEFT] arrow for moving the cursor around in the LCD display. Status indicators provide additional information for controller operation.

NOTE: The Start push button does not operate with a synchronous controller.

4 - Keypad Operation

Figure 16: Remote LCD Keypad

4.10 Description of the LEDs on the Keypad

The keypad provides three LED indicators in addition to the 2x16 character display. The LEDs provide controller status information.

Table 10: Remote Keypad LED Functions

LED State Indication

STOP

RUN

ALARM Flashing Alarm condition exists. If condition persists, a fault occurs.

NOTE: By default, the [STOP] key is always active, regardless of selected control source (Local Source

and Remote Source parameters). It may be disabled though using the Keypad Stop Disable (I/O

14) parameter. For more information refer to the Keypad Stop Disable (I/O 14) parameter on Page

80.

On Stopped

Flashing Faulted

On Running and up-to-speed

Flashing Running and not up-to-speed (ramping, decelerating, braking etc).

RediStart MX 2 - SEP Synchronous Controller User Manual

stop

4.11 Description of the Keys on the Remote LCD Keypad

The [UP] arrow, [DOWN] arrow, [ENTER] and [MENU] keys on the LCD keypad perform the same functions as the [UP], [DOWN], [ENTER] and [PARAM] keys on the standard keypad. Three keys have been added, with one key serving a dual function:

Table 11: LCD Keypad Key Functions

Key Function

• The [START] key triggers has no assigned function with a synchronous controller.

start

• Increases the value of a numeric parameter.

• Advances to the next value of an enumerated parameter.

• Scrolls forward through a list of parameters within a group (when the last parameter is displayed, it scrolls to the beginning of the list).

• When a list of faults is displayed, it moves from one fault to the next.

• When the controller is in the Operate Mode, pressing [UP] allows you to change which group of meter values is monitored.

• Decreases the value of a numeric parameter.

• Reverts to the previous value of an enumerated parameter.

• Scrolls backward through a list of parameters within a group (when the first parameter is displayed, it scrolls to the end of the list).

• When a list of faults is displayed, it moves from one fault to the previous fault.

• When the controller is in the Operate Mode, pressing [DOWN] allows you to change which group of meter values is monitored.

• When editing a numeric parameter, the [LEFT] arrow key moves the cursor one digit to the left. If cursor is already at the most significant digit, it returns to the least significant digit on the right.

• When in Menu mode, the [LEFT] arrow allows groups to be scrolled through in the opposite direction of the [MENU] Key.

• Stores the change of a value.

enter

reset

• When in Fault History, [ENTER] key scrolls through information logged when a fault occurred.

• When an alarm condition exists, [ENTER] scrolls through all active alarms.

• [MENU] scrolls between the operate screen and the available parameter groups.

• When viewing a parameter, pressing [MENU] jumps to the top of the menu.

• When a parameter is being edited and [MENU] is pressed, the change is aborted and the parameter’s old value is displayed.

• The [STOP/RESET] key halts the operation of the controller (Stop Key) and causes a fault 68 to occur.

• If a fault has occurred, the [STOP/RESET] key is used to clear the fault (Reset Key).

4.12 Alphanumeric Display

S T O P P E D V a = 0 V

n o L

The remote LCD keypad and display uses a 32-character alphanumeric LCD display. All controller functions can be accessed by the keypad. The keypad allows easy access to controller programming with parameter descriptions on the LCD display.

4.12.1 Power Up Screen

On power up, the software part numbers are displayed for a few seconds. Pressing any key immediately changes the display to the operate screen.

Software PN 810027-01-08

4.12.2 Operate Screen

The Operate Screen is the Main Screen. The Operate Screen is used to indicate the status of the controller: if it is running, what state it is in, and display the values of Meter 1 and Meter 2, which are selectable.

The Operate Screen is divided into five sections:

4 - Keypad Operation

• Sections A and B display status information

• Sections C and D display the meters selected by the Meter 1 and 2 parameters, see FUN 01–02

• Section S displays the source for the start command

Figure 17: Operate Screen

Section A Section CSection S

a = 0.0 A

Section B Section D

Table 12: Operate Screen Section A

Display Description

noL

Ready

Alarm

Run

L1, L2, L3 not present

Controller ready to run

A fault condition is present. If it continues, a fault occurs

Controller is running

Display Description

Controller is stopped and no Faults

Controller tripped on a Fault

Controller is Locked Out due to an unusual condition being present

Stopped

Fault

Lockout

Table 13: Operate Screen Section B

RediStart MX 2 - SEP Synchronous Controller User Manual

Table 13: Operate Screen Section B

Display Description

Syncing

Synced

Sync FF

Pullout

B Ctl

Cntr

Inching

Braking

Shtdown

BIST

Display Description

Controller is attempting to apply field and synchronize motor

Motor running synchronized

Motor running synchronized with field forcing active

Motor pullout / pole slip detected

Brushless motor control active

Current Control mode active

Inching field control mode active

Dynamic braking active

Controller shutting down

Controller in Built In Self Test mode

Table 14: Operate Screen Section S

Terminal Block Wiring Control

Serial Communication Connection Control

4.12.3 Parameter Group Screens

From the Operate Screen, the parameter groups are accessed by pressing either the Menu or the [LEFT] arrow keys. The parameter group screens display the parameter groups: QST (Quick Start), CFN (Control Functions),

PFN (Protection Functions), I/O (Input/Output Functions), FUN (Function) and FL1 (Faults).

MMM: PPPPPPPPPP MI VVVVVVVVVV

• MMM: = Parameter Group

• MI: = Menu Index

• PPP: = Parameter Name

• VVV: = Parameter Value and Units

Refer to Section 5 for a listing of the parameters and ranges.

4.12.4 Meter Pages

Although any meter may be viewed by changing the two meter parameters (FUN 01, FUN 02), there are 6 “Meter Pages” that are easily accessed to view all of the meter information. These meter pages are scrolled through by pressing the [UP] or [DOWN] arrows from the operate screen.

Current = 0.0A Slip Perce = 0.0A

Voltage V2= 0V V1= 0 V3= 0V

Frequency = 0.0H Phase = noL

Run Days = xxxx Run Hours = xx:xx

Analog In = 0.1% Analog Out = 0.0%

4 - Keypad Operation

Starts = xxxx

NOTE: Run Hours 00:00 - 23:59

Run Days 0 – 2730 days or 7.5 years Starts 0 – 65535

RediStart MX 2 - SEP Synchronous Controller User Manual

4.12.5 Fault Log Screen

Information regarding each fault is available through the remote MX

FL#: Fault ## NNNNNNNNNNNNN

• FL#: = Fault Log Number. FL1 is the most recent fault and FL9 is the oldest fault.

• Fault ## = Fault Code

• NNN... = Fault Name, or the condition when the fault occurred.

Press [MENU] until you can view the FL1 parameter.

Pressing the [UP] and [DOWN] keys navigates through older and newer faults in the log.

Once the fault is displayed on the screen, begin pressing the [ENTER] key to cycle through the steps shown below, which detail the controller conditions when the fault occurred.

Enter Step

1 Fault Number and Description.

2 Status when the fault occurred, Run, Stopped, etc.

3 The current at the time of the fault.

4 L1-2 voltage at the time of the fault.

5 L2-3 voltage at the time of the fault.

6 L3-1 voltage at the time of the fault.

7 Frequency at the time of the fault.

8 Run time since last run time reset.

SEP LCD display.

4.12.6 Fault Screen

When a Fault occurs, the Main Screen is replaced with a Fault Screen. The screen shows the fault number and the name of the fault. The Main Screen is not shown until the fault is reset.

When a fault occurs, the STOP LED flashes.

Fault ## Fault Name

NOTE: For a list of the Faults, refer to Appendix B - Fault Codes on Page 113.

4.12.7 Lockout Screens

When a lockout is present, one of the following screens will be displayed. The Main Screen is not shown until the lockout is cleared.

The stack over temperature lockout will be displayed if a stack over temperature is detected.

The control power lockout will be displayed if control power is not within specifications.

4.12.8 Alarm Screen

When an alarm is present, the word “Alarm” is displayed on the operate screen (and the Alarm LED indicators on the Control Board are illuminated). Pressing the [ENTER] key displays more information about the alarm.

4 - Keypad Operation

Stack Overload Lockout

Control Power Lockout

Alarm ## Alarm Name

RediStart MX 2 - SEP Synchronous Controller User Manual

4.13 Procedure for Setting Data

Select a parameter that is to be changed. To change the Current Setpoint from 10 Amps to 30 Amps:

From the main screen:

T Ready Ia = 0.0A Stopped Va = 480V

Press [MENU] key, the display shows QST (Quick Start) screen.

QST: Jump Code 00 1

Press [UP] key once to access Motor FLA (QST 01).

QST: Cur Setpoint 01 10 Amp

Press [ENTER] key once, the cursor starts to flash in the “ones” place.

QST: Cur Setpoint 01 1

0 Amp

Press [LEFT] key once, the cursor flashes in the “tens” place.

QST: Cur Setpoint 01

Press [UP] arrow to increase the value, for a value of 30, press twice.

10 Amp

QST: Cur Setpoint 01

Press [ENTER] to store the value.

30 Amp

QST: Cur Setpoint 01 30 Amp

Press [UP] arrow to change another parameter in QST.

Press [MENU] to change another parameter in another group.

Press [LEFT] arrow to go back to the main screen.

4 - Keypad Operation

Starts = 0

CFN:Inch UTS Dl y

11 Off

PFN:Resync Tries

18 1

I/O: Auto Start

15 Disabled

FUN: Passcode

16 Off

T Ready Ia= 0.0A

Stopped Va= 0V

PFN:O ver Cur Tim

03 1.0 sec

PFN: Over Cur Lvl

02 125 %

PFN:Open Field T

01 1.0 sec

PFN: Jump Code

I/O: DI 3 Config

03 Off

I/O: DI 2 Config

02 Off

I/O: DI 1 Config

01 Off

I/O: Jum

FUN: HE Ratio

03 2000:1

Operate Screen QST Group CFN Group PFN Group I/O Group FUN Group Fault History

CFN:Slip Percent

01 5.0%

CFN:F Force Lvl

03 120 %

QST: Jump Code

QST:F Apply D ly

02 Off

QST:Inc Seq Time

03 30 sec

Current = x.xA

V1= 0 V3= 0V

Frequency = 0.0H

Phase =noL

QST: Remote Src

05 Terminal

In any of the parameter groups, the user can jum

steps:

Select a parameter group that requires a chang

At the beginning of each program group the me

Enter the code number of the parameter neede

There is no jump code for [Operate Screen].

!!!

N: Meter 2

02 Ave Volts

FUN: Meter 1

FUN: Jump Code

p Code

p to a specific parameter code by following these

nu will read [Jump Code]. Press the [ENTER] key.

d to be changed then press [ENTER].

01 Ave Current

RediStart MX 2 - SEP Synchronous Controller User Manual

5 - Parameter Groups

5.1 Introduction

The MX2 SEP incorporates a number of parameters that allow you to configure the controller to meet the special requirements of your particular application. The parameters are organized two ways, depending on the

display being used:

• When the remote LCD display is used, the parameters are divided into groups of related functionality, and

within the groups the parameters are identified by a short, descriptive name. The parameters are subdivided into six groups. The groups are QST (Quick Start), CFN (Control Functions), PFN (Protection Functions), I/O (Input/Output Functions), FUN (Function) and FL1 (Faults).

• When the standard, on-board LED display is used, the parameters are in a single group and numbered P1,

P2, P3… etc.

LCD parameters are divided into groups of related functionality, and within the groups the parameters are identified by a short, descriptive name. They are numbered by the group name, followed by an index within the group.

5 - Parameter Groups

The Quick Start group provides a collection of parameters most commonly changed when commissioning a controller. Many of the parameters in the Quick Start group are duplicates of parameters in other groups.

This section lists all of the parameters and possible values, and the tables provide a convenient place to record the parameter settings for your system.

RediStart MX 2 - SEP Synchronous Controller User Manual

5.2 LED / LCD Parameter Cross-Reference

Table 15: LED / LCD Cross-Reference

Parameter

Number

P1 QST 01 B, BL, CF Current Setpoint 60 P40 I/O 01 B, BL, CF DI 1 Function 75

P3 QST 02 B, BL Field Application Delay Time 60 P41 I/O 02 B, BL, CF DI 2 Function 75

P6 QST 03 B Incomplete Sequence Time 61 P42 I/O 03 B, BL, CF DI 3 Function 75

P36 QST 04 B, BL, CF Local Control Source 61 P43 I/O 04 B, BL, CF DI Trip Time 76

P37 QST 05 B, BL, CF Remote Control Source 61 P44 I/O 05 B, BL, CF Relay 1 Function 76

P2 CFN 01 B Slip Percentage 63 P45 I/O 06 B, BL, CF Relay 2 Function 76

P3 CFN 02 B, BL Field Application Delay Time 63 P46 I/O 07 B, BL, CF Relay 3 Function 76

P4 CFN 03 B Field Force Level 64 P47 I/O 08 B, BL FCA Delay 77

P5 CFN 04 B Field Force Time 64 P54 I/O 09 B, BL, CF Analog Output Function 77

P10 CFN 05 B Stop Mode 64 P55 I/O 10 B, BL, CF Analog Output Span 78

P11 CFN 06 B Dynamic Brake Level 65 P56 I/O 11 B, BL, CF Analog Output Offset 78

P12 CFN 07 B Dynamic Brake Time 65 P49 I/O 12 B, BL, CF Inline Configuration 79

P13 CFN 08 B Dynamic Brake Delay 65 P48 I/O 13 B, BL

P14 CFN 09 B Inch Field Level 66 P58 I/O 14 B, BL, CF Keypad Stop Enabled 80

P15 CFN 10 B Inch Field Application Time 66 P57 I/O 15 B, BL, CF Auto Start 80

P16 CFN 11 B Inch UTS Relay Delay Time 66 P17 FUN 01 B, BL, CF LCD Meter 1 81

P18 PFN 01 B Open Field Trip Time 67 N/A FUN 02 B, BL, CF LCD Meter 2 81

P19 PFN 02 B, BL, CF Over Current Level 68 P35 FUN 03 B, BL, CF HE Sensor Ratio (x:1) 82

P20 PFN 03 B, BL, CF Over Current Time 68 P36 FUN 04 B, BL, CF HE Sensor Turns 82

P21 PFN 04 B, BL, CF Under Current Level 69 P34 FUN 05 B, BL, CF Input Phase Sensitivity 83

P22 PFN 05 B, BL, CF Under Current Time 69 P23 FUN 06 B, BL, CF Rated RMS Voltage 83

P24 PFN 06 B, BL, CF Over Voltage Level 70 P60 FUN 07 B, BL, CF Rated Power Factor 84

P25 PFN 07 B, BL, CF Under Voltage Level 70 P61 FUN 08 B, BL, CF Min PF Control Current 84

P26 PFN 08 B, BL, C F

P27 PFN 09 B, BL, CF Phase Loss Trip Time 71 P52 FUN 10 B, BL, CF COM Address (Drop #) 85

P28 PFN 10 B, BL, CF High Line Frequency Trip 71 P51 FUN 11 B, BL, CF COM Baud Rate 85

P29 PFN 11 B, BL, CF Low Line Frequency Trip 71 P50 FUN 12 B, BL, CF COM Timeout 85

P30 PFN 12 B, BL, CF Frequency Trip Time 72 P53 FUN 13 B, BL, CF COM Parity 86

P31 PFN 13 B, BL, CF Auto Fault Reset Time 72 P62 FUN 14 B, BL, CF Software Number 86

P32 PFN 14 B, BL, CF

P33 PFN 15 B Controlled Fault Shutdown 73 P63 FUN 16 B, BL, CF Passcode 88

P7 PFN 16 B Pullout Mode 73 P64 FL 1-9 B, BL, CF Fault Log —

P8 PFN 17 B Resynchronization Time 74 — — — — —

P9 PFN 18 B Resynchronization Attempts 74 — — — — —

Group

Control

Mode

Parameter Name

Over/Under Voltage Trip Time

Auto Fault Reset Maximum Count

Page #Parameter

Number

70 P39 FUN 09 B, BL, CF Control Type 84

72 P59 FUN 15 B, BL, CF

Group

Control

Mode

Parameter Name

Field Contactor(s) Feedback Time

Miscellaneous Commands

Page

NOTE: The Control Mode column shows which parameters apply to the three different types of control.

B = Brush type control (Field control) BL = Brushless type control CF = Current Follower control

See "Control Type" (FUN 09 / P39) on Page 84.

5 - Parameter Groups

5.3 Parameter Tables

LCD Parameters are subdivided into six groups: QST (Quick Start), CFN (Control Functions), PFN (Protection Functions), I/O (Input/Output Functions), FUN (Function), and FL1 (Fault Log).

The Quick Start Group provides a collection of the parameters that are most commonly changed when commissioning a controller. Many of the parameters in the Quick Start group are duplicates of the same parameters in other groups.

The following tables show the menu structure for the LCD display, the corresponding LED code, as well as the text displayed and pertinent information for each parameter.

If the LCD is not connected, parameters will only be shown on the MX

5.3.1 Quick Start Group

Table 16: Quick Start Parameter Group

Group LED Display Parameter Setting Range Units Default

QST 00 — Jump Code Jump to Parameter 1 – 5 — 1

QST 01 P1 Current Setpoint Current Setpoint 1 – 1000 Amps 10 Y 60

QST 02 P3 Field Application Time Field Application Time OFF, 0.1 – 20.0 sec OFF Y 60

QST 03 P6 Incomplete Sequence Time Incomplete Sequence Time 1 – 200 sec 30 Y 61

QST 04 P37 Local Control Source Local Control Source

QST 05 P38 Remote Control Source Remote Control Source

TEr:Terminal SEr:Serial

Control Card LED display.

Adjust

During

Run?

– 60

— Terminal Y 61

— Terminal N 61

Page Setting

5.3.2 Control Function Group

Table 17: Control Function Group

Group LED Display Parameter Setting Range Units Default

CFN 00 — Jump Code Jump to Parameter 1 – 11 — 1 — 63

CFN 01 P2 Slip Percent Slip Percentage 0.5 – 10.0 % 5.0 Y 63

CFN 02 P3 F Apply Dly Field Application Delay Time OFF, 0.1 – 20.0 sec OFF Y 63

CFN 03 P4 F Force Lvl Field Forcing Level 50 – 125 % 120 Y 64

CFN 04 P5 F Force Time Field Forcing Time OFF, 0.1 – 90.0 sec 0.1 Y 64

CFN 05 P10 St op Mode Stop Mode

CFN 06 P11 Brake Level Dynamic Braking Level 10 – 125 % 25 Y 65

CFN 07 P12 Brake Time Dynamic Braking Time 1 – 180 sec 5 Y 65

CFN 08 P13 Brake Delay Dynamic Brake Delay 0.1 – 5.0 sec 0.5 Y 65

CFN 09 P14 Inch Field Inch Field Level 75 – 125 % 100 Y 66

CFN 10 P15 Inch F App T Inch Field Application Time 0.1 – 90.0 sec 2.0 Y 66

CFN 11 P16 Inch UTS Dly Inch UTS Relay Delay Time OFF, 0.1 – 90.0 sec OFF Y 66

CoS:Coast DCB:Dynamic Brake

— Coast N 64

Adjust During

Run?

Page Setting

RediStart MX 2 - SEP Synchronous Controller User Manual

5.3.3 Protection Group

Table 18: Protection Group

Group LED Display Parameter Setting Range Units Default

PFN 00

PFN 01 P18 Open Field T Open Field Trip Time OFF, 0.1 – 90.0 sec 1.0 Y 67

PFN 02 P19 Over Cur Lvl Over Current Level OFF, 50 – 200 % 125 Y 68

PFN 03 P20 Over Cur Tim Over Current Time OFF, 0.1 – 90.0 sec 1.0 Y 68

PFN 04 P21 Undr Cur Lvl Under Current Level OFF, 5 – 99 % OFF Y 69

PFN 05 P22 Undr Cur Tim Under Current Time OFF, 0.1 – 90.0 sec 1.0 Y 69

PFN 06 P24 Over Vlt Lvl Over Voltage Level OFF, 1 – 40 % OFF Y 70

PFN 07 P25 Undr Vlt Lvl Under Voltage Level OFF, 1 – 40 % OFF Y 70

PFN 08 P26 Vlt Trip Tim

PFN 09 P27 Ph Loss Time Phase Loss Trip Time 0.1 – 5.0 sec 0.2 Y 71

PFN 10 P28 Over Frq Lvl High Line Frequency Trip 24 – 72 Hz 72 Y 71

PFN 11 P29 Undr Frq Lvl Low Line Frequency Trip 23 – 71 Hz 23 Y 71

PFN 12 P30 Frq Trip Tim Frequency Trip Time 0.1 – 90.0 sec 0.1 Y 72

PFN 13 P31 Auto Reset Auto Fault Reset Time OFF, 1 – 900 sec OFF Y 72

PFN 14 P32 Auto Rst Lim Auto Fault Reset Max Count OFF, 1 – 10 — OFF Y 72

PFN 15 P33 Ctrl Flt En

PFN 16 P7 Pullout Mode Pullout Mode Response

PFN 17 P8 Resync Time

PFN 18 P9 Resync Tries Resynchronization Retries 1 – 10 — 1 Y 74

— Jump Code Jump to Parameter 1 – 18 — 1 – 67

Over/Under Voltage Trip Time

Controlled Fault Stop Enable

Resynchronization Delay Timer

0.1 – 90.0 sec 0.1 Y 70

OFF, ON — ON Y 73

trip: Fault Immediate rtry: Retry after delay

—

rt: Ride Through

1 – 30 sec 5 Y 74

Fault

Immed

Adjust

During

Run?

Page Setting

Y73

5.3.4 I/O Group

5 - Parameter Groups

Table 19: I/O Group

Adjust

Number LED Display Parameter Setting Range Units Default

I/O 00

I/O 01 P40 DI 1 Config DI 1 Configuration OFF: Off

I/O 02 P41 DI 2 Config DI 2 Configuration

I/O 03 P42 DI 3 Config DI 3 Configuration

— Jump Code Jump to Parameter 1 – 15 — 1 – 75

StOP: Stop inch: Inching FH: Fault High FL: Fault Low Fr: Fault Reset FS1: FS1 Confirm FS2: FS2 Confirm FF: Field Force FldA: Field Apply bdIS: Brake Disabl bEn: Brake Enable

— OFF N 75

During

Run?

InLn: Inline Cnfrm L-r: Local/Remote

I/O 04 P43 Din Trp Time Digital Fault Input Trip Time 0.1 to 90.0 sec 0.1 Y 76

I/O 05 P44 R1 Config R1 Configuration (Relay #1) OFF: Off

I/O 06 P45 R2 Config R2 Configuration (Relay #2) FS1

I/O 07 P46 R3 Config R3 Configuration (Relay #3) Running

I/O 08 P47 FCA Delay FCA Time Delay OFF, 0.1 – 90.0 sec OFF Y 77

I/O 09 P54 Aout Fctn Analog Output Function

I/O 10 P55 Aout Span Analog Output #1 Span 1 – 125 % 100 Y 78

I/O 11 P56 Aout Offset Analog Output #1 Offset 0 – 99 % 0 Y 78

I/O 12 P49 Inline Confg Inline Delay OFF, 1.0 – 10.0 sec 3.0 Y 79

I/O 13 P48 Cont Fbk Tim Field Contactor Feedback Time 0.1 – 5.0 sec 1.0 Y 79

I/O 14 P58 Keypad Stop Keypad Stop Enabled

FLFS: Fault FS (Fail Safe) FLnF: Fault NFS (Non Fail

Safe)

SIFS: Interlock FS SInF: Interlock NFS run: Running SYnc: Synced inch: Inching iutS: Inching UTS AL: Alarm rdYr: Ready LOC: Locked Out OC: Overcurrent UC: Undercurrent ShFS: Shunt Trip FS SHnF: Shunt Trip NFS FS1: Field supply contactor FS2: Field discharge resistor

contactor

FcA: Field Contactor Aux. dYnb: Dyn. Braking FAn: Cool Fan Ctl

0: OFF (no output) 1: DC Current (0 – 200%) 2: Ave. Voltage (0 – 150%) 3: Motor Slip % 4: Analog Input 5: Output Voltage (based on

firing angle)

6: Calibrate (full 100% output)

On: Enabled Off:Disabled

—

— 0 Y 77

—

SIFS

N 76

Enabled N 80

0: Disabled

I/O 15 P57 Auto Start Auto Start

1:Power 2:Fault

— Disabled Y 80

3: Power & Fault

Page

Setting

RediStart MX 2 - SEP Synchronous Controller User Manual

5.3.5 Function Group

Table 20: Function Group

Number LED Display Parameter Setting Range Units Default

FUN 00 — Jump Code Jump to Parameter 1 – 16 — 1 — 81

FUN 01 P17 Meter 1 LCD Meter 1

0:Status

Ave Current Y 81

Adjust

During

Run?

Page Setting

1:Ave Current 2:Ave Volts 3:L1-L2 Volts 4:L2-L3 Volts 5:L3-L1 Volts 6:Slip Percent

FUN 02 — Meter 2 LCD Meter 2 Ave Volts Y 81

7: Phase Order 8: Line Freq

—

9: Analog Input 10: Analog Output 11: Run Days 12: Run Hours 13:Starts

FUN 03 P35 HE Ratio Current Sensor Ratio 1000, 2000, 5000 — 2000:1 N 82

FUN 04 P36 HE Turns Current Sensor Turns 1 – 10 — 1 N 82

FUN 05 P34 Phase Order Phase Order ABC, CBA, INS, SPH — INS N 83

100, 110, 120, 200, 208, 220,

FUN 06 P23 Rated Volts

FUN 07 P60 Rated PF

FUN 08 P61 Min PF Curr

FUN 09 P39 Control Type Controller Type

FUN 10 P52 Com Drop # Modbus Address 1 – 247 — 1 N 85

FUN 11 P51 Com Baudrate Modbus Baud Rate 1.2, 2.4, 4.8, 9.6, 19.2 Kbps 19.2 N 85

FUN 12 P50 Com Timeout Modbus Timeout OFF, 1 – 120 sec OFF Y 85

FUN 13 P53 Com Parity Modbus Framing

FUN 14 P62 Software 1

FUN 15 P59 Misc Command

FUN 16 P63 Passcode Passcode

Rated Input Voltage

Rated Power Factor

Minimum PF Control Current

Software Part Number

Miscellaneous Command

230, 240, 320, 350, 380, 400, 415, 440, 460, 480, 500, 525, 575, 600, 660, 690, 800, 1000, 114 0

-0.10 – +0.10

40 – 100 % 60 Y 84

Fld: Field Control BruS: Brushless Control Cur: Current Control PF: Power Factor Control PFbL: PF Control Brushless Motor

0: Even Parity, 1 Stop Bit 1: Odd Parity, 1 Stop Bit 2: No Parity, 1 Stop Bit 3: No Parity, 2 Stop Bits

Displays SW part number — — — 86

0: No command 1: Powered BIST 2: Reset Run Time 3: Reflash Mode 4: Store Parameters 5: Load Parameters 6: Factory Reset

—

Vrms 120 N 83

—

— 0N86

— 0N87

— — — 88

1.0 Y 84

Field Ctrl N 84

5.3.6 LCD / LED Fault Groups

The LCD and LED Fault Groups contain a rotating list of the last 9 fault conditions recorded by the controller. Record any values displayed for troubleshooting purposes. Refer to Appendix B.

6 - Parameter Descriptions

6.1 Parameter Descriptions

The detailed parameter descriptions in this section are organized in the same order as they appear on the LCD display. Each parameter has a detailed description, displayed in the following format:

MMM__ / P__ Parameter Name

LCD / LED Displays

Range Parameter Value Range

Description The description of the function.

See Also Cross references to related parameters or other sections.

MMM: Parameter MI Value

In the above format, the top of each parameter listing contains the parameter group number (as it appears in the menu on the LCD display), the P number (as it appears in the menu on the LED display), and the parameter name.

The LCD / LED Displays portion shows an example of what actually appears on the remote mounted LCD keypad and the built in display, respectively. On the LCD, the parameter group (represented above by “MMM”) and the (possibly abbreviated) parameter name are shown on the first line. The parameter group number (represented above by “MI” for “menu index”), and the parameter’s value (and units) are shown on the second line.

Some parameters appear in two different menus of the LCD display. This is normally the case for those parameters in the Quick Start Group.

For some parameters, the Range section is enough to describe the parameter. For others, there may be an additional

Options section to describe each of the options that can be selected for a parameter. The form that the options take may be

different for the LED and LCD displays, so this section shows how the options appear on both displays.

8.8.8.8.

The

See Also portion lists cross-references to other related parameters, as well as references to further detail in other

chapters.

RediStart MX 2 - SEP Synchronous Controller User Manual

QST 00 Jump to Parameter

LCD Display

QST: Jump Code 00 1

Description By changing the value of this parameter and pressing [ENTER], you can jump directly to any parameter within

that group.

QST 01 / P1 Current Setpoint

LCD / LED Displays

Range 1 1000 Amps DC (Default: 10)

Description The Current Setpoint sets the field current supplied to the motor.

QST: Cur Setpoint 01 10 Amp

QST 02 / P3 Field Apply Delay

LCD / LED Displays

Range Off, 0.1 – 20.0 (Default: Off)

Description The following is when (FUN 09 / P39) is set to “Brush Type”:

See Also • Controller Type (FUN 09 / P39) on Page 84.

QST: F Apply Dly 02 Off

The field apply delay timer will delay the application of the field after the motor has reached the slip speed (CFN 01 / P2).

The following is when (FUN 09 / P39) is set to “Brushless Control”:

The field apply delay timer will delay the application of the field when a start command is received. In most cases, this should be set to a long enough time to allow the motor to reach it's operating speed before applying the field.

NOTE: See Theory of Operation for complete descriptions of Control Modes on Page 89.

NOTE: Not used in Current Controller mode.

• Digital Inputs (I/O 01–03 / P40–42) on Page 75.

• Theory of Operation, Control Modes of Synchronous Motor Controls on Page 89.

OFF

6 - Parameter Descriptions

QST 03 / P3 Inc Seq Time

LCD / LED Displays

Range Off, 1  200 (Default: 30)

Description The Incomplete sequence timer sets how long the motor has to reach synchronization before the controller

QST: Inc Seq Time 03 30 sec

trips on an incomplete sequence fault. The motor has to be synchronized for 3 seconds before the synchronizing sequence is considered complete.

NOTE: The Incomplete seq timer starts when the start command is given.

NOTE: Not used in Current Control mode.

QST 04 / P36 Local Source

LCD / LCD Displays

Range LCD LED Description

QST: Local Src 04 Terminal

Terminal tEr The start/stop control is from the terminal strip inputs. (Default) Serial SEr The start/stop control is from the network.

tEr

Description The MX

Source (QST 04 / P37), and Remote Source (QST 05 / P38), select the source of the start and stop control.

If a digital input is programmed as Local / Remote, then that input selects the control source. When the input is low, the local source is used. When the input is high, the remote source is used. If no digital input is programmed as Local / Remote, then the local/remote bit in the controller control Modbus register selects the control source. The default value of the bit is Local (0).

See Also • Local Source (QST 05 / P37) parameter on Page 61.

SEP can have two sources of start and stop control: Terminal and Serial. Two parameters, Local

NOTE: By default, the [STOP] key is always enabled, regardless of selected control source. It may be

disabled though using the Keypad Stop Disable (I/O 14) parameter.

• Digital Input Configuration (I/O 01–03 / P40–42) parameters on Page 75.

QST 05 / P37 Remote Source

LCD / LED Displays

Range LCD LED Description

QST: Remote Src 05 Terminal

Terminal tEr The start/stop control is from the terminal strip inputs. (Default) Serial SEr The start/stop control is from the network.

tEr

RediStart MX 2 - SEP Synchronous Controller User Manual

Local Source

“Local/Remote”

configured by parameter

input, DI1-DI3,

Description The MX2 SEP can have two sources of start and stop control: Terminal and Serial. Two parameters, Local

Source (QST 04 / P37), and Remote Source (QST 05 / P38), select the source of the start and stop control.

Figure 16: Local / Remote Source

See Also • Local Source (QST 04 / P36) parameter on Page 61.

• Digital Input Configuration (I/O 01–03 / P40–42) parameters on Page 75.

• Keypad Stop Disable (I/O 14 / P58) parameter on Page 80.

• Modbus Register Map - Appendix E

Modbus Starter Control Register Local/Remote Bit

6 - Parameter Descriptions

CFN 00 Jump to Parameter

LCD Display

CFN: Jump Code 00 1

Description By changing the value of this parameter and pressing [ENTER], you can jump directly to any parameter within

that group.

CFN 01 / P2 Slip Percent

LCD / LED Displays

Range 0.5 – 10.0% (Default: 5.0)

Description The slip percentage sets how close to synchronous speed the motor must be before synchronization is

CFN: Slip Percent 01 5.0%

attempted. The motor speed is calculated by subtracting the slip from 100%. For example, 5% slip equals 95% motor speed.

NOTE: Setting this parameter too low can cause the speed to never be reached, and synchronization to

never be attempted.

NOTE: Brush type motor only. (FUN 09 / P39) set to “Field Type”.

5.0

CFN 02 / P3 Field Apply Dly

LCD / LED Displays

Range

Description The following is when (FUN 09 / P39) is set to “Brush Type”

See Also • Controller Type (FUN 09 / P39) on Page 84.

CFN: F Apply Dly 02 Off

Off, 0.1 – 20.0 (Default: Off)

The field apply delay timer will delay the application of the field after the motor has reached the slip speed (CFN 01 / P2).

The following is when (FUN 09 / P39) is set to “Brushless Control”

NOTE: Not used in Current control mode.

• Digital Inputs (I/O 01–03 / P40–42) on Page 75.

• Theory of Operation, Control Modes of Synchronous Motor Controls on Page 89.

OFF

RediStart MX 2 - SEP Synchronous Controller User Manual

CFN 03 / P4 Field Force Level

LCD / LED Displays

Range 50 – 125% (Default: 120)

Description The Field Force Level allows a user to over drive the field at synchronization for a programmed time. This is

LCD / LED Displays

Range Off, 0.1 – 90.0 (Default: 0.1)

Description The Field Force Time sets how long the system will apply the field forcing current before dropping to the

CFN: F Force Lvl 03 120%

most commonly used where the load takes more time to stabilize or the application requires a higher magnitude of torque to synchronize.

NOTE: May require a higher voltage field supply transformer to produce the desired current.

NOTE: Not used in Current control mode.

CFN 04 / P5 Field Force Time

CFN: F Force Time 04 0.1

programmed current.

120

0.1

NOTE: Not used in Current Control mode (FUN 09 / P39).

CFN 05 / P10 Stop Mode

LCD / LED Displays

Range Coast, Dyn Brake (Default: Coast)

Description One of two Stop Modes can be chosen.

CFN: Stop Mode 05 Coast

Coast:

When Coast mode is selected the controller will immediately remove the DC field when a stop command is received. The controller will perform a sequenced stop to ensure the motor field is properly removed.

Dynamic Braking:

When Dynamic brake mode is selected the controller will perform a dynamic braking sequence. The controller will maintain the motor field current and sequence a braking resistor to quickly stop the motor.

NOTE: The motor controller must have a contactor and dynamic braking resistor installed to use dynamic

braking.

CoS

NOTE: Brush type motor only. (FUN 09 / P39) set to “Field Type”.

6 - Parameter Descriptions

See Also • Dynamic Brake Level (CFN 06 / P11) on Page 65.

• Dynamic Brake Time (CFN 07 / P12) on Page 65.

• Dynamic Brake Delay (CFN 08 / P13) on Page 65.

CFN 06 / P11 Dynamic Brake Level

LCD / LED Displays

Range 10 – 125% (Default: 25)

Description The Dynamic Brake Level sets the level of DC field current when in Dynamic Braking mode.

LCD / LED Displays

Range 1 – 180 seconds (Default: 5)

Description The dynamic brake time sets the amount of time that the brake relay is energized. The brake relay is used to

CFN: Brake Level 06 25%

NOTE: See Dynamic Braking in Theory of Operation on Page 97.

NOTE: Brush type motor only: (FUN 09 / P39) set to "Field Type".

CFN 07 / P12 Dynamic Brake Time

CFN: Brake Time 07 5 sec

connect the dynamic braking resistor.

NOTE: See Dynamic Braking in Theory of Operation on Page 97.

CFN 08 / P13 Dynamic Brake Delay

LCD / LED Displays

Range 0.1 – 5.0 seconds (Default: 0.5)

Description The dynamic brake delay parameter sets the delay time between the stop command being received and the

CFN: Brake Delay 08 0.5 sec

brake relay being energized. This parameter sets a coasting time for the motor.

NOTE: See Dynamic Braking in Theory of Operation on Page 97.

0.5

RediStart MX 2 - SEP Synchronous Controller User Manual

CFN 09 / P14 Inch Field Level

LCD / LED Displays

Range 75 – 125% (Default: 100%)

Description The inching field level parameter sets the field current level that will be applied when the controller is in inching

See Also • Inch Field Application Time (CFN 10 / P15) on Page 66.

CFN: Inch Field 09 100%

mode. This current will be applied when a digital input programmed to “inch” is energized and the inch field application delay time (CFN 10 / P15) has expired.

The inching is used to sequence the application of the field when the motor is being inched. The actual motor inching is performed by the stator controller.

• Inch UTS Delay (CFN 11 / P16) on Page 66.

• Digital Inputs (I/O 01–03 / P40–42) on Page 75.

100

Inching operating sequence

CFN 10 / P15 Inch Field Application Delay Time

LCD / LED Displays

Range 0.1 – 90.0 seconds (Default: 2.0)

Description The Delay before Inching Field Application time delay sets the delay time between the “inching” digital input

LCD / LED Displays

Range Off, 0.1 – 90.0 seconds (Default: Off)

Description The Inch UTS delay starts timing after the inching field has been applied and delays the energizing of any relay

CFN: Inch F App T 10 2.0

being energized and the inching field current being applied to the motor.

NOTE: See (CFN 09 / P14) for inching operating sequence.

CFN 11 / P16 Inch UTS Delay

CFN: Inch UTS Dly 11 Off

that is programmed as Inching UTS.

2.0

OFF

NOTE: See (CFN 09 / P14) for inching operating sequence.

6 - Parameter Descriptions

PFN 00 Jump to Parameter

LCD / LED Displays

Description By changing the value of this parameter and pressing [ENTER], you can jump directly to any parameter within

PFN: Jump Code 00 1

that group.

PFN 01 / P18 Open Field Trip Time

LCD / LED Displays

Range Off, 0.1 – 90.0 seconds (Default: 1.0)

Description The Open field trip time parameter sets how long before the controller will trip if an open field is detected during

PFN: Open Field T 01 1.0 sec

starting.

NOTE: If the motor is still spinning and a start is attempted, the unit may trip on open field.

NOTE: Brush type motor only, (FUN 09 / P39) set to "Field Type".

1.0

RediStart MX 2 - SEP Synchronous Controller User Manual

Over Cur Level

PFN 01

Current Setpoint

QST 01

% Current

Condition

Trip

Delay Time

Time

PFN 02 / P19 Over Current Level

LCD / LED Displays

Range Off, 50 – 200% (Default: 125)

Description The Over Current Trip Level sets the high field current trip level. This parameter should be set to the highest

See Also • Over Current Level (PFN 02 / P19) parameter on Page 68.

PFN: Over Cur Lvl 02 125%

continuously allowable field current. Usually this value is 125% of rated field current. Consult the motor manufacturer if necessary.

A relay can be programmed to change state when an over current alarm condition is detected.

• Relay Output Configuration (I/O 05–07 / P44–46) parameters on Page 76.

125

Alar

Fault

PFN 02

LCD / LED Displays

Range Off, 0.1 – 90.0 seconds (Default: 1.0)

Description The Over Current Trip Time parameter sets the period of time that the motor field current must be greater than

See Also

•

Relay Output Configuration (I/O 05–07 / P44–46) on Page 76.

I/O 9 / P54 Analog Output Function

LCD / LED Displays

Range LCD LED Description

Description The Analog Output Function parameter selects the function of the analog output. The available analog output

I/O: Ain Trp Lvl 17 Off

Off 0-200% Curr 0-150% Volt 0-100% Slip 0-100% Ain 0-100% Firing Calibration

function selections and output scaling are shown below. The analog output is updated every 25 msec.

0 Disabled (Default) 1 Based on per cycle RMS values 2 Based on per cycle RMS values 3 Motor speed, 100% = stopped, 0% = full speed 4 The output value takes into account the inputs span and offset settings 5 Output Voltage to Motor, based on SCR firing angle 6 Calibration, full (100%) output

OFF

See Also • Analog Output Span (I/O 10 / P55) parameter on Page 78.

• Analog Output Offset (I/O 11 / P56) parameter on Page 78.

RediStart MX 2 - SEP Synchronous Controller User Manual

Analog Output

Selected Output

value = 100%

Aout Offset

= 20%

10V /

20mA

Selected Output

value = 0%

0 V / 0mA

Aout Span =

80%

2V / 4mA

I/O 10 / P55 Analog Output Span

LCD / LED Displays

Range 1 – 125% (Default: 100%)

Description The analog output signal can be scaled using the Analog Output Span parameter. For a 0-10V output or 0-

I/O: Aout Span 10 100%

20mA output, a 100% scaling outputs the maximum voltage (10V) or current (20mA) when the selected output function requests 100% output. A scale of 50% outputs 50% voltage/current when the analog output function requests a 100% output.

NOTE: For a 4-20mA output, set the Analog Output Span to 80% and the Analog Output Offset (I/O 11 /

P56) parameter to 20%.

NOTE: The output does not exceed 100% (10V or 20mA).

Example: 0% output => 4mA, 100% output => 20ma

100

See Also • Analog Output Offset (I/O 11 / P56) parameter on Page 78.

I/O 11 / P56 Analog Output Offset

LCD / LED Displays

Range 0 – 99% (Default: 0%)

Description The analog output signal can be offset using the Analog Output Offset parameter. A 50% offset outputs a 50%

See Also • Analog Output Span (I/O 10 / P55) parameter on Page 78.

I/O: Aout Offset 11 0%

output (5V in the 10V case) when 0% is commanded. If the selected variable requests 100% output, the span should be reduced to (100 minus offset) so that a 100% output request causes a 100% output voltage (x% offset + (100-x)%span) =100%.

NOTE: For a 4-20mA output, set the Analog Output Span (I/O 10) to 80% and the Analog Output Offset

to 20%.

6 - Parameter Descriptions

I/O 12 / P49 Inline Configuration

LCD / LED Displays

Range Off, 0 – 10.0 seconds (Default: 3.0)

Description The Inline Configuration parameter controls the behavior of the No Line warning, No Line fault, and the Ready

See Also • Relay Output Configuration (I/O 05–07 / P44–46) parameters on Page 76.

I/O: Inline Confg 12 3.0 sec

relay function.

If the Inline Configuration parameter is set to “Off”, then the MX and that line voltage should be present while stopped. If no line is detected, then a No Line alarm condition exists and the ready condition does not exist. If a start is commanded, then a No Line fault is declared.

If the Inline Configuration parameter is set to a time delay, then the MX contactor and that line voltage need not be present while stopped. If no line is detected, then the No Line alarm condition does not exist and the ready condition does exist. If a start is commanded and there is no detected line voltage for the time period defined by this parameter, then a “noL” (No Line) fault is declared.

In order to control an inline contactor, program a relay as a “Running” relay.

NOTE: This fault is different than over/under voltage trip delay time (PFN 08 / P26) since it detects the

presence of NO line.

3.0

SEP assumes that there is no Inline contactor

SEP assumes that there is an Inline

I/O 13 / P48 Contactor Feedback Time

LCD / LED Displays

Range 0.1 – 5.0 seconds (Default: 1.0 sec)

Description FS1 and FS2. This is the delay to allow the contactor to operate, and the feedback to appear once the MX

See Also • Digital Input Configuration (I/O 01–03 / P40–42) on Page 75.

I/O: Cont Fbk Tim 13 1.0 sec

changed its output relay, which is operating the contactor.

1.0

RediStart MX 2 - SEP Synchronous Controller User Manual

I/O 14 / P58 Keypad Stop Disable

LCD / LED Displays

Range LCD LED Description

Description If “Disabled”

See Also • Local Source (QST 04 / P37) parameter on Page 61.

I/O: Keypad Stop 14 Enabled

Disabled Enabled

When this parameter is set to “Disabled”, the keypad [STOP] button is de-activated; this should be done with caution, as the [STOP] button will not stop the controller.

If “Enabled”

When this parameter is set to “Enabled”, the keypad [STOP] button is enabled and trips the controller on a keypad stop fault regardless of the selected control source (QST 04 / P37 or QST 05 / P38) selected as (terminal or serial).

• Remote Source (QST 05 / P38) parameter on Page 61.

OFF Keypad Stop does not stop the controller On Keypad Stop does stop the controller (Default)

I/O 15 / P57 Auto Start Selection

LCD / LED Displays

Range LCD LED Description

Description The Auto Start parameter determines whether or not a transition from low to high is required on the Start input

I/O: Auto Start 15 Disabled

Disabled

Power

Fault Power, Fault

for a start to occur after either a power up or a fault reset.

0 When disabled, the Start input must always transition from low to high for a

start to occur. (Default)

1 When set to Power, a start will occur if the Start input is high while control power

is applied.

2 When set to Fault, a start will occur if the Start input is high when a fault is reset. 3 When set to Power and Fualt, a start will occur if the Start input is high while

control power is applied, and a start will occur if the Start input is high when a fault is reset.

6 - Parameter Descriptions

FUN 00 Jump to Parameter

LCD Display

FUN: Jump Code 00 1

Description By changing the value of this parameter and pressing [ENTER], you can jump directly to any parameter within

that group.

FUN 01- 02 / P17 Meter 1 - Meter 2

LCD / LED Displays

FUN: Meter 1 01 Ave Current

FUN: Meter 2 02 Ave Volts

Range LCD LED Description

Status Ave Current Ave Volts L1-L2 Volts

L2-L3 Volts L3-L1 Volts Slip Percent Phase Order Line Freq Analog Input Analog Out Run Days Run Hours Star ts

0 Running State. (LED Meter only, Default LED meter) 1 DC field current. (Default LCD Meter 1) 2 Average Voltage L-L RMS. (Default LCD Meter 2) 3 Voltage in, L1 to L2 RMS.

4 Voltage in, L2 to L3 RMS. 5 Voltage in, L3 to L1 RMS. 6 The percentage of rotor slip. 7 Phase rotation. 8 Line Frequency.

9 Analog Input %. 10 Analog Output % 11 Running time in days, wraps at 2,750 days. 12 Running time in Hours and Minutes, wraps at 24:00. 13 Number of Starts, wraps at 65,536.

Description For the LED display, this parameter configures which single meter is displayed on the main screen. For the

LCD display, parameters FUN 01 and FUN 02 configure which meters are displayed on the two lines of the main display screen.

RediStart MX 2 - SEP Synchronous Controller User Manual

FUN 03 / P35 Hall Effect Ratio

LCD / LED Displays

FUN: HE Ratio 03 2000:1

Range 1000:1, 2000:1, 5000:1 (Default: 2000:1)

Description

Hall Effect Ratio

1000:1

2000:1

5000:1

Number of Turns

(FUN04 / P36)

2000

Burden Resistance

(Ohms)

100 ohm, 0.5W, 1% 1 8

100 ohm, 0.5W, 1%

100 ohm, 0.5W, 1% 13 25

100 ohm, 0.5W, 1% 26 50

56.2 ohm, 1W, 1% 5 35

56.2 ohm, 1W, 1% 36 50

56.2 ohm, 1W, 1% 51 100

56.2 ohm, 1W, 1% 101 200

56.2 ohm, 1W, 1% 201 400

15 ohm, 0.5W, 1% 401 600

10 ohm, 0.5W, 1% 600 900

Current Low Current High

NOTE: The 5000:1 hall effect sensor requires +/- 24VDC.

FUN 04 / P36 Hall Effect Turns

LCD / LED Displays

Range 1 – 10 Turns (Default: 1)

Description See above parameter (FUN 03 / P35) for Number of Turns.

FUN: HE Turns 04 1

The Hall Effect turns parameter sets the number of times the field power wire passes through the window of the Hall Effect current sensor.

6 - Parameter Descriptions

FUN 05 / P34 Input Phase Sensitivity

LCD / LED Displays

Range LCD LED Description

Description The Input Phase Sensitivity parameter sets the phase sensitivity of the controller. This can be used to protect

FUN: Phase Order 05 Insensitive

Insensitive ABC CBA Single Phase

the motor from a possible change in the incoming phase sequence. If the incoming phase sequence does not match the set phase rotation, the controller displays an Alarm while stopped and faults if a start is attempted.

InS Runs with any three phase sequence. (Default) AbC Only runs with ABC phase sequence. CbA Only runs with CBA phase sequence. SPH Single Phase.

1nS

FUN 06 Rated RMS Voltage

LCD / LED Displays

Range 100, 110, 120, 200, 208, 220, 230, 240, 340, 350, 380, 400, 415, 440, 460, 480, 500, 525, 575, 600, 660, 690,

FUN: Rated Volts 05 120 Vlt

800, 1000, 1140 (Default: 120)

120

Description The Rated Voltage parameter sets the line voltage that is used when the controller performs Over and Under

line voltage calculations. This value is the supply voltage, NOT the motor utilization voltage.

NOTE: Rated Voltage must be set properly for the controller to operate properly.

See Also • Meter (FUN 01 / P17) parameter on Page 81.

• Under Voltage Level (PFN 07 / P25) parameter on Page 70.

• Voltage Trip Time (PFN 08 / P26) parameter on Page 70.

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FUN 07 / P60 Rated Power Factor

LCD / LED Displays

Range -0.10 – +0.10 (Default: 1.0)

Description The Rated Power Factor parameter sets the reference point for the PF controller algorithm. The PF will adjust

See Also • Min PF Control Current (FUN 08 / P61) parameter on Page 84.

LCD / LED Displays

Range 40% – 100% (Default: 60%)

Description The Minimum Power Factor Control Current parameter sets the minimum field current that will be allowed when

FUN: Rated PF 07 1.0

the field current to achieve this motor power factor

FUN 08 / P61 Min PF Control Current

FUN: Min PF Curr 08 60%

operating in Power Factor Control Mode.

1.0

See Also • Rated Power Factor (FUN 07 / P60) parameter on Page 84.

FUN 09 / P39 Control Type

LCD / LED Displays

Range LCD LED Description

FUN: Control Type 09 Field Ctl

Field Ctl

Brushless

Curr Follow cFoL DC current controller

PF Control

PF Control BL

NOTE: Control Types are described in the Theory of Operation section beginning on Page 89.

FcT1 Brush type motor field controller.

See Brushtype control in Section 7.1.1 on Page 89.

bruS Brushless type field controller.

See Brushless control in Section 7.1.2 on Page 90.

See Current Follower in Section 7.1.3 on Page 90.

PF Power Factor Control

See Power Factor Control in Section 7.1.4 on Page 91.

PFbL Power Factor Control - Brushless Motor

See Power Factor Control in Section 7.1.4 on Page 91.

Fct1

6 - Parameter Descriptions

FUN 10 / P52 Com Address (Drop #)

LCD / LED Displays

Range 1 – 247 (Default: 1)

Description The Communication Address parameter sets the controller’s address for Modbus communications.

See Also • Local Source (QST 04 / P37) parameter on Page 61.

LCD / LED Displays

Range 1200, 2400, 4800, 9600, 19200 bps (Default: 19200)

Description The Communication Baud Rate parameter sets the baud rate for Modbus communications.

See Also • Local Source (QST 04 / P36) parameter on Page 61.

FUN: Com Drop # 10 1

• Remote Source (QST 05 / P38) parameter on Page 61.

FUN 11 / P51 Communication Baudrate

FUN: Com Baudrate 11 19200

• Remote Source (QST 05 / P37) parameter on Page 61.

19.2

FUN 12 / P50 Communication Timeout

LCD / LED Displays

Range Off, 1 – 120 (Default: Off)

Description The Communication Timeout parameter sets the time that the controller continues to run without receiving a

See Also • Local Source (QST 04 / P37) parameter on Page 61.

FUN: Com Timeout 12 Off

valid Modbus request. If a valid Modbus request is not received for the time that is set, the controller declares a F82 (Modbus Timeout Fault). The controller performs a controlled stop.

• Remote Source (QST 05 / P38) parameter on Page 61.

• Stop Mode (CFN 05 / P10) parameter on Page 64.

• Controlled Fault Stop Enable (PFN 15 / P33) parameter on Page 73.

• Communication parameters (FUN 10–13 / P50–53) on Pages 85–86.

OFF

RediStart MX 2 - SEP Synchronous Controller User Manual

FUN 13 / P53 Communication Parity

LCD / LED Displays

Range LCD LED

Description The Communication Parity parameter sets both the parity and number of stop bits.

See Also • Communication parameters (FUN 10–13 / P50–53) on Pages 85–86.

FUN: Com Parity 13 Even, 1 Stop

Even, 1 Stop (Default) Odd, 1 Stop 1 None, 1 Stop 2 None, 2 Stop 3

FUN 14 / P62 Software 1

LCD / LED Displays

Description The Software Part Number parameter displays the MX2 SEP software version, for hardware BIPC-300063-01.

FUN: Software 1 14 810027-01-08

When calling Benshaw for service, this number should be recorded so it can be provided to the service technician.

In addition to viewing the software version with this parameter, the software version is also displayed on power up. On the LED display, the software version is flashed one character at a time on power up. On the LCD display, the software PN is fully displayed on power up.

NOTE: The seven segment LED in position one will flash the current software version currently in use

when first powered on. The full software part number will flash consecutively (one digit per second).

For Example: 8...1...0...0...2...7...-...0...1...-...0...8

6 - Parameter Descriptions

FUN 15 / P59 Miscellaneous Commands

LCD / LED Displays

Range LCD LED Description

Description The Miscellaneous Commands parameter is used to issue various commands to the MX

FUN: Misc Command 15 None

None Powered BIST Reset RT 2 Reset Run Time Meter

Reflash Mode Store Params 4 The current parameter values are stored in non-volatile memory Load Params Factory Rst

The powered BIST command will put the controller into a powered BIST test. See section 8.7.1 on Page 107.

The Reset Run Time command resets the user run time meters back to zero (0).

The Reflash Mode command puts the MX only be entered if the MX2 SEP controller is idle. When the reflash mode is entered, the MX2 SEP waits to be programmed. The onboard LED display shows “FLSH”. The remote display is disabled after entering reflash mode. The MX cycling control power.

0 No commands (Default) 1 Built In Self Test with line voltage applied to the controller

3 Activate Reflash Mode

5 All parameter are retrieved from non-volatile memory 6 All parameters are restored to the factory defaults

SEP into a reflash program memory mode. The reflash mode can

SEP does not operate normally until reflash mode is exited. Reflash mode may be exited by

SEP controller.

The Store Parameters command allows the user to copy the parameters into non-volatile memory as a backup. If changes are being made, store the old set of parameters before any changes are made. If the new settings do not work, the old parameter values can be loaded back into memory.

The Load Parameters command loads the stored parameters into active memory.

The Factory Reset command restores all parameters to the factory defaults. These can be found in chapter 5.

RediStart MX 2 - SEP Synchronous Controller User Manual

FUN 16 / P63 Passcode

LCD / LED Displays

Description The MX2 SEP supports a 4-digit passcode. When the passcode is set, parameters may not be changed.

FUN: Passcode 16 Off

The MX the parameters values may be viewed on the display, but any attempt to change their values by pressing the [UP] or [DOWN] key is ignored.

Viewing the Passcode parameter indicates whether or not the parameters are locked. If they are locked, the Passcode parameter displays "On". If they are not locked, the Passcode parameter displays “Off”.

To lock the parameters, press the [ENTER] key while viewing the Passcode parameter. This allows entry of a 4digit number. Press the [UP] or [DOWN] keys and [ENTER] for each of the four digits. After entering the fourth digit, the number is stored as the passcode and the parameters are locked.

Once parameters are locked, the same 4-digit number must be re-entered into the Passcode parameter in order to unlock them. Any other 4-digit number entered will be ignored.

When a passcode is set and an attempt is made to change a parameter through the display/keypad, the [UP] and [DOWN] keys simply have no effect. When a passcode is set and an attempt is made to change a parameter through Modbus, the MX to indicate that the register can not be changed.

LED Display

SEP provides a means of locking parameter values so that they may not be changed. Once locked,

SEP returns an error response with an exception code of 03 (Illegal Data)

OFF

The following steps must be performed to set a passcode using the LED Display:

1. At the default meter display, press the [PARAM] key to enter the parameter mode.

2. Press the [UP] or [DOWN] keys to get to the Passcode parameter (FUN 16).

3. Press the [ENTER] key. “Off” is displayed to indicate that no passcode is currently set.

4. Press the [UP] or [DOWN] keys and [ENTER] for each digit to be defined, select a value from 0000 to 9999 starting at the most significant digit.

5. Press the [ENTER] key to set the passcode.

The following steps must be performed to clear a passcode:

1. At the default meter display, press the [PARAM] key to enter the parameter mode.

2. Press the [UP] or [DOWN] keys to get the Passcode parameter (FUN16).

3. Press the [ENTER] key. “On” is displayed to indicate that a passcode is presently set.

4. Press the [UP] or [DOWN] keys and [ENTER] after each digit to select the previously set passcode value.

5. Press the [ENTER] key. The passcode is then cleared.

7 - Theory of Operation

7.1 Control Modes of Synchronous Motor Operation

7.1.1 Brush Type (Field Control) Synchronous Motor Operation

The brush type (field control) synchronous motor will start as an induction motor. The field winding will generate an AC voltage during starting, and a resistor must be connected to the winding to control the voltage levels generated. The size of the resistor is also partly responsible for the torque the motor generated during starting. Once the motor has reached synchronizing speed, the field is applied and the motor synchronizes.

Figure 18: Brush Type Synchronous Motor Operation Curve

Synchronizing Conditions:

The following conditions must be true before the controller will apply the DC field to a brush type motor:

• A start command must be given.

• Motor slip must be less than the slip percentage (CFN 01 / P2) or the motor speed must be greater than

100% - slip parameter (CFN 01 / P2).

• The Field Application delay Timer (QST 02 / P3) must expire.

• The digital input(s) (I/O 01–03 / P40–42) programmed as “Field Apply”.

See Also • Slip Percentage (CFN 01 / P2) on Page 63.

• Field Application Delay Timer (QST 02 / P3) on Page 60.

• Digital Inputs (I/O 01–03 / P40–42) on Page 75.

Stator Protection must be set up for:

• Lagging Power Factor to trip, in the case of loss of synchronization.

• Stator IOC (Over Current) must be set for a level approximately 1.5 to 3 times the motor stator FLA that will indicate if the rotor has pulled out, and is slipping poles. Contact the motor manufacturer or Benshaw for more information.

RediStart MX 2 - SEP Synchronous Controller User Manual

Start

Sync Speed

Reached

DC applied

DC applied (if Field Apply Digital Input)

Slip<Set-point

(CFN01 / P2)

Field Apply Delay

(QST02 / P3)

Field Apply Input

(Digital Input)

Timeline

Command

ACTIONS PARAMETER S

7.1.2 Brushless Type Synchronous Motor Operation

The brushless type synchronous motor will start as an induction motor. All of the field controls are installed on the rotor of the motor. The external motor controller just has to provide the DC field current for the auxiliary generator at the appropriate time.

Synchronizing Conditions:

The following conditions must be true before the controller will apply the DC field to a brush type motor:

• A start command must be given.

• The Field Application Delay Timer (QST 02 / P3) must expire.

• The digital input(s) programmed as “Field Apply” must be energized.

• If the Field Application Delay Timer is turned “OFF” and there is a digital input programmed for “Field

Apply” then the field will be applied when the input is energized.

• If the Field Application Delay Timer is turned “OFF” and there is no digital input programmed then the

field will be applied as soon as the run command is received.

See Also • Slip Percentage (CFN 01 / P2) on Page 63.

• Field Application Delay Timer (QST 02 / P3) on Page 60.

• Digital Inputs (I/O 01–03 / P40–42) on Page 75.

Timeline

(if no digital input)

7.1.3 Current Follower

The Current Follower is used to provide a regulated DC current. This controller can be used any place that a regulated DC current is required.

When the controller is used in Current Follower mode it will provide the DC current when a start is provided. There are no other conditions that have to be met before the DC is provided.

7 - Theory of Operation

Lagging PF

Leading PF

Rated P

P=50%

P=0



7.1.4 Closed Loop Power Factor Control

The MX will be started as described in Sections 7.1.1 and 7.1.2 for the brush type or brushless type motor. After motor synchronization has been completed, active PF control will be enabled. As the load and stator voltage of a synchronous motor changes, the motor’s operating power factor will change. Typically a motor manufacturer will provide what is called the “V” curves of a motor (see example below) that describe the motor power factor and stator current, relative to the motor load and the field excitation current level.

SEP controller optionally provides closed loop motor power factor (PF) control. In this mode the motor

Amps

Stator - A

Field Excitation - DC Amps

Unity

Power Factor

In this example, the load curves are drawn at 0% load, 50% load, and 100% load. The dotted unity PF line is drawn through the curves. When the motor is operating to the left of the unity PF line the motor’s PF will be lagging (reactive) and when operating right of the unity PF line the motor’s PF will be leading (capacitive). What can be seen from these curves is that the motor PF varies depending on motor load and DC field current level. For example, if a motor is operating at unity PF at 50% load, and the load is increased to 100%, the motor PF will become lagging. When MX

SEP PF control is used, the field current will be automatically increased so

that the motor continues to operate at its defined PF level.

Closed loop PF control has multiple benefits:

1. As the mechanical load changes on the motor, the motor PF will change. PF control will actively raise or

lower the field excitation current so that the motor operates at the desired PF set point. Also by operating at the optimal PF, the stator current magnitude can be minimized, which minimizes losses. By raising the field current as load increases, in order to keep a constant PF, the pull out torque capability of the motor will also be increased as the field current is raised.

2. As input voltage levels vary, the PF control can stabilize the PF of the motor to prevent swings in motor

power factor that can occur.

3. A synchronous motor can be used to drive a mechanical load, as well as provide leading (capacitive)

Vars to a plant power system. These leading Vars can be used to improve the overall PF of the facility. Closed loop PF control allows the user to set a given PF set point; then the PF control will adjust the motor field excitation current to operate the motor at the desired set point.

RediStart MX 2 - SEP Synchronous Controller User Manual

ANALOG OUTPUT SW1-2 ON = 0-10V OFF = 0-20mA

ANALOG INPUT

SW1-1

ON = 0-20mA

OFF = 0-10V

To L E M

To MX2 Card (COM)

7.2 Hall Effect Current Sensor

The Hall Effect Current sensor is connected to the analog input of the MXSEP card along with a burden resistor. The analog input must be set to be a 0-10V voltage input for correct operation. The sensor scaling and burden resistance are factory selected. Please consult factory if changes to either the sensor scaling or burden resistance is required.

7.2.1 Analog Input

The analog input is used for Hall Effect input. The SW1 switch must be set to the voltage loop configuration.

Figure 19: SW1 DIP Switch Settings

The terminals for the Analog input on the MX2 card (TB5) are as follows:

2) + input (white)

3) - input (black)

4) Common (black)

NOTE: The analog input (Hall Effect) 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.

The terminals for the synchronous controller card (LEM) are as follows:

To LEM To MX2 card

1) + (to LEM, red) 5) M (white)

2) M (to LEM, white) 6) Com (black)

3) - (to LEM, black) 7) GND (shield)

4) GND (shield)

Figure 20: LEM Connections

COMMON

(MX² CARD)

TB5

300044-02-01

(SYNC CARD)

LEM

GO TO LEM

+M-

Red

White

Black

White

Black

BURDEN RESISTOR (SEE P 35)FUN03 /

7 - Theory of Operation

Figure 21: Hall Effect Connections (0 - 700 Amps)

300063-01-xx

RediStart MX 2 - SEP Synchronous Controller User Manual

7.3 Simplified I/O Schematics

Figure 22: Digital Input Simplified Schematic

Figure 23: Analog Input Simplified Schematic

Figure 24: Analog Output Simplified Schematic

7 - Theory of Operation

7.4 Remote Modbus Communications

The MX2 SEP controller provides a Modbus RTU to support remote communication.

The communication interface is RS-485, and allows up to 247 slaves to be connected to one master (with repeaters when the number of drops exceeds 31). Please refer to Figures 24 and 25 for connection diagrams.

7.4.1 Supported Commands

The MX

Up to 64 registers may be read or written with a single command.

7.4.2 Modbus Register Addresses

The Modbus specification defines holding registers to begin at 40001 and input registers to begin at 30001. Holding registers may be read and written. Input registers may only be read.

SEP supports the following Modbus commands:

• Read Holding Registers (03 hex)

• Read Input Registers (04 hex)

• Preset Single Register (06 hex)

• Preset Multiple Registers (10 hex)

In the MX example, the Motor FLA parameter is available both in holding register 40101 and in input register 30101. This is why the register addresses in the Modbus Register Map are listed with both numbers (e.g. 30101/40101).

7.4.3 Cable Specifications

Good quality twisted, shielded communications cable should be used when connecting to the Modbus port on the MX conductors for the A(-) and B(+) signals. Use the other pair of conductors for the Common signal. The cable should adhere to the following specifications:

Examples of cables that meet these specifications:

7.4.4 Terminating Resistors

The MX2 SEP does not have a terminating resistor for the end of the trunk line. If a terminating resistor is required, the resistor must be wired to the terminal block.

SEP, the register maps are identical for both the holding registers and the input registers. For

SEP. The cable should contain two twisted pairs and have an overall shield. Use one pair of

• Conductors: 2 twisted pair

• Impedance: 100 Ohm to 120 Ohm

• Capacitance: 16 pF/ft or less

• Shield: Overall shield or individual pair shields

• Belden part number 9842

• Alpha Wire part number 6412.

The purpose of terminating resistors is to eliminate signal reflections that can occur at the end of a network trunk line. In general, terminating resistors are not needed unless the bit rate is very high, or the network is very long. In fact, terminating resistors place a large load on the network and may reduce the number of drops that may be placed on the network.

The maximum baudrate of 19,200 supported by the MX2 SEP is not high enough to warrant a terminating resistor unless the network is extremely long (3,000 feet or more). A terminating resistor should only be installed on the MX2 SEP if signal reflection is known to be a problem and only if the MX2 SEP is at the end of the network. Terminating resistors should never be installed on nodes that are not at the end of the network.

RediStart MX 2 - SEP Synchronous Controller User Manual

B+

A-

COM

TB4

IMPORTANT

CABLE MUST GO TO

EACH STARTER

Right

Wrong

7.4.5 Grounding

RS-485 buses with isolated nodes are most immune to noise when the bus is not connected to earth ground at any point. If electrical codes require that the bus be connected to earth ground, then the Common signal should be connected to earth ground at one point and one point only. If the Common signal is connected to earth ground at more than one point, then significant currents can flow through the Common signal when earth ground potentials are different at those points. This can cause damage to devices attached to the bus.

7.4.6 Shielding

The shield should be continuous from one end of the trunk to the other. The shield must be tied to the RS-485 Common signal at one point and one point only. If the shield is not tied to Common at any point or is tied to Common at more than one point, then its effectiveness at eliminating noise is greatly reduced.

7.4.7 Wiring

Figure 22 shows the wiring of TB4 to a Modbus-485 Network. If the controller is the end device in the network, a 120, 1/4W terminating resistor may be required. Please refer to Figure 24 for wire and termination.

Figure 25: TB4 Connector

Figure 26: Modbus Network Wiring Example

DO NOT CREATE STUBS.

7.5 Dynamic Braking

The dynamic braking can be used to quickly stop the motor. The motor is used as a generator and the energy from the motor is dissipated into resistors. Dynamic Braking only works on Brush type motors.

7 - Theory of Operation

Braking Operation Sequence

Figure 27: MX2 ATL Synchronous Brushtype with DB Braking Resistor.

The dynamic braking resistor is sized to 3X the motor FLA at rated motor voltage. For example, motor with stator rated 600VAC, 380A, rated 2 starts/hour hot.

Resistor is sized to draw 1140A when 600VAC is applied:

• 600 / (sqrt3 x 1140) = 0.304 ohms/phase Y connected

• 600 / (1140/sqrt3) = 0.912 ohms / phase delta connected

The resistor must be capable of dissipating the energy in the rotating assembly. The energy is calculated as:

E = 0.0002311 x I x rpm

, where: I = total inertia in lb.ft

E = energy in J = w.s

RediStart MX 2 - SEP Synchronous Controller User Manual

8 - Troubleshooting & Maintenance

8.1 Safety Precautions

For the safety of maintenance personal, as well as others who might be exposed to electrical hazards associated with maintenance activities, the safety related work practices of NFPA 70E, Part II, should always be followed when working on electrical equipment. Maintenance personnel must be trained in the safety practices, procedures, and requirements that pertain to their respective job assignments.

WARNIN G: To avoid shock hazard, disconnect main before working on controller, motor, or control devices such as start/stop pushbuttons. Procedures which require parts of the equipment to be energized during troubleshooting, testing, etc, must be performed by properly qualified personnel, using appropriate work practices and precautionary measures as specified in NFPA70, Part II.

CAUTION: Disconnect the controller from the motor before measuring insulation resistance (IR) or the motor windings. Voltages used for insulation resistance testing can cause failure of SCRs. Do not make any measurements on the controller with an IR tester (megger).

8.2 Preventive Maintenance

8.2.1 General Information

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

NOTE: Preventive maintenance should always be performed by a trained technician.

8.2.2 Preventive Maintenance

During Commissioning:

• Torque all power connections during commissioning, including factory wired equipment.

• Check all of the control wiring in the package for loose connections.

• If fans are installed, ensure proper operation.

After the controller has been put in operation:

• Re-torque all power connections, including factory wired equipment.

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

After the first month of operation:

• Clean any accumulated dust from the controller using a clean source of compressed air or a vacuum cleaner.

• Re-torque all power connections, then repeat annually.

• Inspect the cooling fans every three months to ensure proper operation.

• Clean or replace any air vent filters on the controller every three months.

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

frequently.

RediStart MX 2 - SEP Synchronous Controller User Manual

8.3 General Troubleshooting Charts

The following troubleshooting charts can be used to help solve many of the common issues that may occur.

8.3.1 Motor does not start, no output to motor

Condition Cause Solution

Display Blank, CPU Heartbeat LED on MX2 board not blinking.

Fault Displayed. Fault Occurred.

Start command given but nothing happens.

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

Control voltage absent.

SEP control board problem. Consult factory.

Start/Stop control input problems.

Control Source parameters (QST 04–05 / P4–5) not set correctly.

No line voltage has been detected by the MX2 SEP when a start command is given.

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

See fault code troubleshooting table for more details.

Verify that the start/stop wiring and start input voltage levels are correct.

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 MX2 SEP control board.

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

See fault code troubleshooting table for more details.

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

Condition Cause Solution

Fault Displayed. Fault Occurred.

See fault code troubleshooting table for more details.

8.3.3 Motor stops unexpectedly while running

Condition Cause Solution

Fault Displayed. Fault Occurred.

Ready Displayed. Start command lost.

Display Blank, Heartbeat LED on MX not blinking.

card

Control voltage absent.

MX2 control card problem. Consult factory.

See fault code troubleshooting table for more details.

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

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

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

100

BENSHAW RediStart MX 2 SEP User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual