Benshaw RSM6, RSM6B, RSM7, RSM7B Manual

BENSHAW

REDISTART MICRO II

INSTRUCTION MANUAL

RSM6/6B/7/7B SERIES

RCM / RBM SERIES

The Leader In

Solid State Motor Control

Technology

Publication #: 890015-02-08

TABLE OF CONTENTS

Table of Contents

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

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

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

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

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

CT (Current Transformer) Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8
Voltage Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8
Metering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8
Real Time Clock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8
Output Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8
Control Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9
Storage and Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9
DeviceNet (Embedded) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9
Modbus (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9
EU Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	10
Overload Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11
Overload Curve Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	12
Low Voltage UL/CUL Fault Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	13
Low Voltage UL/CUL Fault Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	14
RediStart Micro II CPU Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	15
Computer Card JC11 Header Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . .	15
RediStart Micro II Power Card Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	15

3. INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.1 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Site Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 EMC Installation guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Installation Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Ventilation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Remote RTD Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 CT Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 CT Ratio Scaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 RediStart Micro II Computer Card Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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4. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4.1 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Main Display Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	28
Meter Display Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	29
Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	33
Starter Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	33
Current Ramp Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	34
Programming A Kick Current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	35
Jog at Set Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	35
Tachometer Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	36
Programming The Motor Deceleration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	37
PORT (Power Outage Ride Through) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	38
TruTorque Acceleration Ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	38
TruTorque Deceleration Ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	39
How Fault Classes Work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	40
Use of Overcurrent and Undercurrent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	41
Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	41
Performing an Emergency Restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	43

5. PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

5.1 PROGRAMMING: How To Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Menu Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Viewing a Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Changing a Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

5.2 PROGRAMMING: Quick Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Motor FLA. . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 49
Serv. Fact (service factor) . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 49
Start Mode . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 49
Stop Mode . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 49
Int. Curr. (initial current) . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 50
Max. Curr. (maximum current) . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 50
Ramp Time . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 50
Overload . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 51
Phase Orde (Phase Order) . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 51
5.3 PROGRAMMING: Motor Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Motor FLA. . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 52
Serv. Fact (service factor) . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 52
Motor RPMs . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 52
Energy Sav (energy saver) . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 52
Source Volt (source voltage). . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 53
5.4 PROGRAMMING: Starter Setup - Starter Modes	. . . . . . . . . . . . . . . . . . . . . 54
Start Mode . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 54
Stop Mode . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 54
5.5 PROGRAMMING: Starter Setup - Forward1 Profile . . . . . . . . . . . . . . . . . . . . 55
Int. Curr. (initial current) . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 55
Max. Curr. (maximum current) . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 55
Ramp Time . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 55
Kick Curr. (kick current) . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 56
Kick Time . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . 56

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5.6 PROGRAMMING: Starter Setup - Forward2 Profile . . . . . . . . . . . . . . . . . . . . 57

Forward #2 Ramp Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	57
Int. Curr. (initial current) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	57
Max. Curr. (maximum current) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	57
Ramp Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	57
Kick Curr. (kick current) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	58
Kick Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	58

5.7 PROGRAMMING: Starter Setup - Jog Cntrl Setup . . . . . . . . . . . . . . . . . . . . . 59

Jog Curr. (jog current) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Max. Time (maximum time) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Kick Curr (kick current) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Kick Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

FWD Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

5.8 PROGRAMMING: Starter Setup - Tachometer Setup . . . . . . . . . . . . . . . . . . . 61

FS Volts (Full Speed Volts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	61
Stab Cnst (Stability Constant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	61
Ramp#1 Tim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	61
Ramp#2 Tim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	61
TLoss Dela (Tachometer Signal Loss Delay) . . . . . . . . . . . . . . . . . . . . . . . . . . . .	62
TLoss Mode (Tachometer Signal Loss Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . .	62

5.9 PROGRAMMING: Starter Setup - Brake Ctl Setup. . . . . . . . . . . . . . . . . . . . . 63

D.C. Injection Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Current #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Time #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Current #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Time #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

5.10 PROGRAMMING: Starter Setup - Decel Setup . . . . . . . . . . . . . . . . . . . . . . 65

V Level #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 V Level #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 V DCL Time (decel time). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 TT DCL Tim (TruTorque deceleration time). . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 TT DCL Tor (ending deceleration torque) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

5.11 PROGRAMMING: Starter Setup - PORT CTL Setup . . . . . . . . . . . . . . . . . . . 67

Fault Dly (Fault Delay). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Bypass Dly (Bypass Delay) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Sense Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

5.12 PROGRAMMING: Starter Setup - TruTorque Ramp . . . . . . . . . . . . . . . . . . . 68

Int Torque (initial torque) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Max Torque (maximum torque). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Ramp Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 TT Over Cu (TruTorque overcurrent trip) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Ovr Cur Dl (TruTorque overcurrent trip delay). . . . . . . . . . . . . . . . . . . . . . . . . . 69

5.13 PROGRAMMING: Starter Setup - Heat/Anti-wind . . . . . . . . . . . . . . . . . . . 70

Heat Curr. (heater current) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70

5.14 PROGRAMMING: Motor Protection - Overload . . . . . . . . . . . . . . . . . . . . . 71

Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

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5.15 PROGRAMMING: Motor Protection - Line Current . . . . . . . . . . . . . . . . . . . 72

% Imbalanc (percent imbalance) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Imbal Dela (imbalance delay) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 @ Stop Dly (current at stop delay) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 % No C@Run (percent no current at run) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 No C@R Dly (no current at run delay) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

5.16 PROGRAMMING: Motor Protection - Line Voltage . . . . . . . . . . . . . . . . . . . 74

H/L Volts (high/low voltage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	74
Delay Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	74
PH Dect Dl (Phase detect delay) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	74

5.17 PROGRAMMING: Motor Protection - Line Frequency. . . . . . . . . . . . . . . . . . 75

High Freq. (high frequency) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Low Freq. (low frequency). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Freq Delay (frequency delay) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

5.18 PROGRAMMING: Motor Protection - Ground Fault. . . . . . . . . . . . . . . . . . . 76

GND Fault (ground fault) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 GND Delay (ground delay) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

5.19 PROGRAMMING: Motor Protection - Shorted SCR . . . . . . . . . . . . . . . . . . . 77

@ Ramp DLY (shorted SCR at ramp delay) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 @ Stop DLY (shorted SCR at stop delay) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

5.20 PROGRAMMING: Motor Protection - Over Current . . . . . . . . . . . . . . . . . . . 78

Current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Detect Dly (detect delay). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Release Dl (release delay) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

5.21 PROGRAMMING: Motor Protection - Under Current . . . . . . . . . . . . . . . . . . 79

Current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Detect Dly (detect delay). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Release Dl (release delay) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

5.22 PROGRAMMING: Motor Protection - Start Lockouts . . . . . . . . . . . . . . . . . . 80

Starts/Hou (starts per hour). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Time Start (time between starts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 BKS Timer (backspin timer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

5.23 PROGRAMMING: Motor Protection - Starting Timers. . . . . . . . . . . . . . . . . . 81

UTS Timer (up-to-speed timer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Zero Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

5.24 PROGRAMMING: Motor Protection - Permissive Input. . . . . . . . . . . . . . . . . 82

Therm. In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82

5.25 PROGRAMMING: Motor Protection - Misc.. . . . . . . . . . . . . . . . . . . . . . . . 83

Phase Orde (phase order) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

# Auto RST (number of auto resets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 No Main PW (no main power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

5.26 PROGRAMMING: Motor Protection - Fault Classes . . . . . . . . . . . . . . . . . . . 84

Fault Classes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

5.27 PROGRAMMING: Meters & Relays - Meter Setup . . . . . . . . . . . . . . . . . . . . 85

Meter #1 , Meter #2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 AutoRange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Meter Rsts (meter resets). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Scroll Tim (scroll time) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

iv

TABLE OF CONTENTS

5.28	PROGRAMMING: Meters & Relays - Standard Relays . . . . . . . . . . . . . . . . .	87
	Relay#1, K5 and Relay#2, K6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	87
5.29	PROGRAMMING: Meters & Relays - Extended Relays . . . . . . . . . . . . . . . . .	88
	Opt. #?, K? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	88
5.30	PROGRAMMING: Event Recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	89
	Event Recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	89
5.31	PROGRAMMING: Control Config - System Clock . . . . . . . . . . . . . . . . . . . .	91
	System Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	91
5.32	PROGRAMMING: Control Config - System Password . . . . . . . . . . . . . . . . .	92
	Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	92
5.33	PROGRAMMING: Control Config - Comm. Settings . . . . . . . . . . . . . . . . . .	93
	COMM. Mode (communications mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	93
	COM Addres (communications address) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	93
	COM Delay (communications delay). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	93
	MB:Baud (MODBUS baud rate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	94
	MB:Com T/O (MODBUS communications timeout) . . . . . . . . . . . . . . . . . . . . . . .	94
	DN:MAC ID (DeviceNet MAC ID) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	94
	DN:Baud (DeviceNet baud rate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	94
	DN:InAssy (DeviceNet input assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	95
	DN:OutAssy (DeviceNet output assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . .	95
	DN:T/O Act (DeviceNet timeout action) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	95
	DN:Rev (DeviceNet interface revision) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	95
5.34	PROGRAMMING: Control Config - Options List. . . . . . . . . . . . . . . . . . . . .	96
	Options List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	96
5.35	PROGRAMMING: Control Config - Software Part# . . . . . . . . . . . . . . . . . . .	97
	Software Part# . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	97
5.36	PROGRAMMING: Factory Setup - Hardware Setup . . . . . . . . . . . . . . . . . . .	98
	C.T. Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	98
	Relay Card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	98
5.37	PROGRAMMING: Factory Setup - Factory Control . . . . . . . . . . . . . . . . . . .	99
	FACT Pass. (factory password) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	99
	Reset Def (reset to default parameters). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	99
	CLR Events (clear event log) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	99
	CLR Pass. (clear password) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	99
	Cal Volt L1, L2, L3 (calibrate voltage meter). . . . . . . . . . . . . . . . . . . . . . . . . . . .	99
	Cal Curr L1, L2, L3 (calibrate current meter) . . . . . . . . . . . . . . . . . . . . . . . . . . .	100
5.38	PROGRAMMING: RTD Setup - RTD Module Setup . . . . . . . . . . . . . . . . . . .	101
	Mod#1 Addr (module #1 address) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	101
	Mod#2 Addr (module #2 address) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	101
	#RTDs Mod1 (number of RTDs on module #1) . . . . . . . . . . . . . . . . . . . . . . . . . .	101
	#RTDs Mod2 (number of RTDs on module #2) . . . . . . . . . . . . . . . . . . . . . . . . . .	101
	Temp Scale (temperature scale) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	101
5.39	PROGRAMMING: RTD Setup - RTD SetPnts 1-8 . . . . . . . . . . . . . . . . . . . . .	102
	RTD#? Grp (RTD #? Group). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	102
	RTD#? Warn (RTD #? warning level) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	102
	RTD#? Alm (RTD #? alarm level). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	102

v

TABLE OF CONTENTS

5.40 PROGRAMMING: RTD Setup - RTD SetPnts 9-16 . . . . . . . . . . . . . . . . . . . . 103

RTD#? Grp (RTD #? Group). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 RTD#? Warn (RTD #? warning level) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 RTD#? Alm (RTD #? alarm level). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

6. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
6.1 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
LED Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	106
Meter Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	107
Event Recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	107
Fault/Log Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	108
General Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	112
Spare Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	114
SCR Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	115

7. DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

7.1 DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . 118
RediStart Micro II Computer Card Diagram . . . . . . . . . . .	. . . . . . . . . . . . . . . . 118
RediStart Micro II Power Card Layout . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . 119
Old RediStart Micro Power Card Layout . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . 120
RediStart Micro II Four (4) Relay Card Layout . . . . . . . . . .	. . . . . . . . . . . . . . . . 121
RediStart Micro II Seven (7) Relay Card Layout . . . . . . . . .	. . . . . . . . . . . . . . . . 121
RediStart Micro II RS-232 Communications Card Layout . . . .	. . . . . . . . . . . . . . . . 122
RediStart Micro II RS-485 Communications Card Layout . . . .	. . . . . . . . . . . . . . . . 122
RediStart Micro II RS-232/485 Communications Card Layout .	. . . . . . . . . . . . . . . . 123
RediStart Micro II Reversing/Braking Card Layout . . . . . . .	. . . . . . . . . . . . . . . . 123
Modbus Master Card (for Remote RTD Module) . . . . . . . . .	. . . . . . . . . . . . . . . . 124
RediStart Micro II Display Cut-out . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . 125

8. PARAMETER LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

8.1 Parameter List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

RediStart Micro II Parameter List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Quick Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Motor Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Starter Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Motor Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Meters & Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Event Recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Control Config . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Factory Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

RTD Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

vi

1. INTRODUCTION

1.1 INTRODUCTION

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

Electrical hazard that could result in injury or death.

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

Highlight marking an important point in the documentation.

2

			1.1 INTRODUCTION
			Benshaw Services
	General Information	Benshaw offers its customers the following services:
		• Start-up services.
		• On-site training services.
		•	Technical support.
		•	Detailed documentation.
		•	Replacement parts.
		NOTE: Information about products and services is available by contacting Benshaw.
	Start-Up Services	Benshaw technical field support personnel are available to assist customers with the
		initial start-up of the RediStart Micro II. Information about start-up services and fees
		are available by contacting Benshaw.
	On-Site Training Services	Benshaw technical field support personnel are available to conduct on-site training on
		RediStart Micro II operations and troubleshooting.
	Technical Support	Benshaw technical support personnel are available (at no charge) to answer customer
		questions and provide technical support over the telephone. For information about
		contacting technical support personnel, refer to Contacting Benshaw on page 4.
	Documentation	Benshaw provides all customers with:
		•	Operations manual.
		•	Wiring diagram.
		All drawings are produced in AutoCAD© format. The drawings are available on
		standard 3.5” diskettes or via e-mail by contacting Benshaw.
	On-Line Documentation	All RediStart MicroII documentation is available on-line at www.benshaw.com.
	Replacement Parts	Spare and replacement parts can be purchased from Benshaw.

3

1.1 INTRODUCTION

Contacting Benshaw	Information about Benshaw products and services is available by contacting Benshaw
	at one of the following offices:
	Benshaw Inc. Corporate Headquarters
	1659 E. Sutter Road
	Glenshaw, PA 15116
	United States of America
	Phone:	[phone]
	Fax:	[phone]
	Benshaw Canada Controls Inc.
	550 Bright Street East,
	Listowel, Ontario
	Canada
	N4W 3W3
	Phone:	[phone]
	Fax:	[phone]
	Benshaw West		600
	14715 North 78th Way, Suite
	Scottsdale, AZ 85260
	United States of America
	Phone:	[phone]
	Fax:	[phone]

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

EST.

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

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

•Name of company.

•Telephone number where caller can be contacted.

•Fax number of caller.

•Benshaw product name.

•Benshaw model number.

•Benshaw serial number.

•Name of product distributor.

•Approximate date of purchase.

•Voltage of motor attached to Benshaw product.

•FLA of motor attached to Benshaw product.

•A brief description of the application.

4

1.1 INTRODUCTION

Features

General

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

Protection (ANSI standard numbers given)

•51 - Electronic motor overload (Off, class 1 to 40, or bypass during start)

•86 - Overload lockout

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

•59/27 - Adjustable over/under voltage protection

•46 - Adjustable line to average current imbalance

•81 - Adjustable high and low frequency protection

•Single phase protection

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

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

•Backspin timer (off or 1 to 200 minutes)

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

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

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

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

•50 - Instantaneous electronic over-current trip

•Shorted SCR detection

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

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

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

Control

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

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

•Kick Current and time adjustments for each ramp

•TruTorque acceleration and deceleration profiles

•Adjustable deceleration profiles (to eliminate water hammer)

•Adjustable brake profile

•Energy saver (on or off)

•Local start/stop controls

•Emergency reset capability

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

Input/Output and Display

•Plain English operation via back lit LCD display interface

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

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

•Programmable relay outputs

•Latched fault relay output

•Real time clock

•Time stamped event recorder

•Password protection

•Battery backed-up starter parameters and lockout times

5

2. TECHNICAL SPECIFICATIONS

2.1 TECHNICAL SPECIFICATIONS

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

Voltage Inputs

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

Metering

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

Real Time Clock

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

Output Relays

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

8

2.1 TECHNICAL SPECIFICATIONS

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

Control Power

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

Storage and Operating Conditions

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

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

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

9

Neil Abrams

Quality Control Manager

10

Harry Hagerty

Advanced Controls and Drives Manager

EN 50081-2 Emissions Radiated/Conducted

EN 55011/05.98+A1:1999

EMC:

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

Manufacture’s Address:

EN 50082-2 Immunity/Susceptibility which includes: EN 61000-4-2 Electrostatic Discharge

EN 61000-4-3 Radiated RF

EN 61000-4-4 Electrical Fast Transient/Burst EN 61000-4-6 Injected Currents

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

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

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

Motor Controller

Reduced Voltage Solid State Motor Controller

RSM6, RSM7, RSM10, RSM11, RMB6, MVRSM12/18 Benshaw, Inc.

1659 East Sutter Road Glenshaw, PA USA 15116

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

2.1 TECHNICAL SPECIFICATIONS

EU Declaration of Conformity

Charles E. Cook

Product Development Manager

		2.1 TECHNICAL SPECIFICATIONS
		Overload Curves
	General	The RediStart Micro II comes with forty (40) standard overload curves. The 100% (no
		trip) point is the motor FLA setting multiplied by the service factor. These curves are
		shown on the next page.
		NOTE: The user can display the overload by setting the overload to Off. The overload
		can also be set to BYP (Bypass), which limits the charging current during ramping to
		90%. One the unit has reached UTS (up-to-speed), the overload can charge the
		remaining 10%. This is useful on extremely large centrifugal loads such as
		centrifuges.
		NOTE: When the overload counter is at a number other than 0%, the time to trip will
		be lowered by this percentage.
		NOTE: In heavy duty DC braking application, the overload settings may be limited to
		protect the starter and motor from potential damage.

Caution must be taken when using the Bypass mode. The starter does not overload protect the unit during the start.

Curves	The overload can be set to;
	•	OFF	- no thermal overload
	•	1-40	- class 1 through 40 overload in steps of 1.
	•	BYP	- overload bypassed during starting, class 10 once up-to-speed
Trip Time Accuracy	±2 seconds up to 30 seconds

11

2.1 TECHNICAL SPECIFICATIONS

Overload Curve Chart

RediStart Micro II Overload Curves

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

Class 1

10

1

0

100

200

300

400

500

600

700

800

Current as Percent of FLA

12

125%

Unit

Fuse Protected Rating

Current Limiting Circuit Breaker Protected Rating

Current

FLA (amps)

Withstand

Max. Fuse

Short Circuit

Short Circuit

Rating

Fuse Class

Catalog Number

Trip Plug

Rating

(amps)

Current Rating

Rating

Rating

1200

1440

85kA

L

1600A

100kA

HPD63F160

1200-1600A

85kA

2000A

50kA

960

1200

85kA

L

1600A

100kA

HPD63F160

1200-1600A

85kA

2000A

50kA

840

1050

85kA

L

1600A

100kA

CND63B

1200A

85kA

CND63B

800A

720

900

42kA

L

1600A

100kA

CND63B

1200A

85kA

CND63B

800A

590

737

42kA

L

1400A

100kA

CND63B

1200A

85kA

CND63B

800A

477

596

42kA

J, 600VAC T,

800A

100kA

CLD63B

600A

65kA

RK-1

CJD63B

400A

361

421

42kA

J, 600VAC T,

800A

100kA

CLD63B

600A

65kA

RK-1

CJD63B

400A

302

377

42kA

J, 600VAC T,

800A

100kA

CFD63B

400A

65kA

RK-1

240

300

42kA

J, 600VAC T,

600A

100kA

CFD63B

400A

65kA

RK-1

.2

J, 600VAC T,

180

225

42kA

400A

100kA

CFD63B

250A

65kA

1

RK-1

13

RatingsFaultUL/CULVoltageLow

SPECIFICATIONSTECHNICAL

156

195

42kA

J, 600VAC T,

400A

100kA

CFD63B

225A

65kA

RK-1

124

155

42kA

J, 600VAC T,

350A

100kA

CFD63B

225A

42KA

RK-1

96

120

42kA

J, 600VAC T,

225A

100kA

CFD63B

225A

42KA

RK-1

77

96

42kA

J, 600VAC T,

225A

100kA

CED63B

125A

42KA

RK-1

65

81

42kA

J, 600VAC T,

225A

100kA

CED63B

100A

42KA

RK-1

52

65

42kA

RK-1

60A

100kA

CED63B

100A

42KA

100A

50KA

40

50

42kA

RK-1

60A

100kA

CED63B

60A

42KA

100A

50KA

27

33.75

42KA

J, 600VAC T,

40A

100KA

CED63B

60A

42KA

RK-1, G, CD

60A

50KA

TABLE CONTINUED NEXT PAGE

14
				TABLE CONTINUED PREVIOUS PAGE
		125%	Unit		Fuse Protected Rating				Current Limiting Circuit Breaker Protected Rating
		Current
	FLA (amps)		Withstand			Max. Fuse		Short Circuit			Short Circuit
		Rating		Fuse Class					Catalog Number	Trip Plug
			Rating
		(amps)				Current Rating		Rating			Rating
	21	26.25	42	J, 600VAC T,		35A		100KA	CED63B	80A	65KA
				RK-1		45A		50KA
	14	17.5	42	J, 600VAC T,		20A		100KA	CED63B	50A	65KA
				RK-1		30A		50KA
	11	13.75	42	J, 600VAC T,		15A		100KA	CED63B	40A	65KA
				RK-1		20A		50KA
	7.6	9.5	42	J, 600VAC T,		12A		100KA	CED63B	30A	65KA
				RK-1		15A		50KA
	4.8	6	42	J, 600VAC T,		8A		100KA	CED63B	20A	65KA
				RK-1		10A		50KA
	3.4	4.25	42	J, 600VAC T,		5A		100KA	CED63B	15A	65KA
				RK-1		7A		50KA

Ratings Fault UL/CUL Voltage Low

SPECIFICATIONS TECHNICAL 1.2

2.1 TECHNICAL SPECIFICATIONS

RediStart Micro II CPU Jumpers

Jumper	Description	Position 1-2	Position 2-3	Standard
		(In - 2-pos. jumper)	(Out - 2-pos. jumper)
JPC5	LCD Start Button	Enable	Disable	1-2
JPC7	O/L Reset Auto/Manual	Automatic	Manual	2-3
JPC8	Display Format	Standard	Local Bus	1-2
JPC12	SCR Firing	Pulse	Block	In
JPC13	LCD Stop Button	Enable	Disable	1-2
JPC14	RAM Size	8K RAM	2K RAM	1-2
JPC15	PWM/ADDR16	ADDR16	PWM	1-2,3-4
JPC16	RS-232 Communications	Enable	Disable	Out
JPC17	Equip Forward Bypass	Yes	No	2-3
JPC18	Equip Reverse Bypass	Yes	No	2-3
JPC19	Fault Reset	Automatic	Manual	2-3
JPC25	Synchronous Application	Yes	No	Out
JPC27	Micro Enable/ADDR17	ADDR17	Enable	1-2,3-4

	Computer Card JC11 Header Assignments
Position	Assignment
1-16	Not used.
2-15	Enables D.C. Braking.
3-14	Starter Equipped with MODBUS master card (for RTD module).
4-13	Enables Motor Winding Heater/Anti-windmilling Brake.
5-12	Not used.
6-11	Enables emergency reset.
7-10	Enables light duty braking (2-15 must also be installed for this option).
8-9	Not used.

RediStart Micro II Power Card Jumpers

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

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

15

2.1 TECHNICAL SPECIFICATIONS

16

3. INSTALLATION

3.1 INSTALLATION

	Site Preparation
General	Before the installation of the RediStart Micro II, the site should be prepared. The
	customer is responsible for:
	• Providing the correct power source.
	• Selecting the control mechanism.
	• Providing the connection cables and associated hardware.
	• Ensuring the installation site meets all environmental specifications for the
	enclosure NEMA rating.
Connection Cables	The connection cables for the starter must have the correct NEC/C.S.A. current rating
	for the unit being installed. Depending upon the model, the connection cables can
	range from a single #14 AWG conductor to four 750 MCM cables.
Site Requirements	The installation site must adhere to the applicable starter NEMA rating. For optimal
	performance, the installation site must meet the following specifications, unless
	equipment (such as a heater or air conditioner) was added to the unit for operation
	outside of these ranges:
	• Temperature: 0°C (+32F) to 40°C (+104°F).
	• Humidity: 20% to 95% non-condensing.
	• Airways: Clearances are provided around all heat sinks.
	• Altitude: Less than 3300 feet (1000 meters) above sea level.
	NOTE: The starter rating must be derated 1% for every 330 feet (100 meters) above
	3300 feet (1000 meters).
Mounting	The starter must be mounted so the heat sink fins are vertically oriented in an area
	that does not experience excessive shock or vibration. All models require airway
	passages around the heat sink. During normal operation the heat sink may reach 194
	degrees Fahrenheit (90 degrees Centigrade). Do not install the starter in direct
	contact with any materials that cannot withstand these temperatures.
	EMC Installation guidelines
General	In order to help our customers comply with European electromagnetic compatability
	standards, Benshaw Inc. has developed the following guidelines.
	Attention: This product has been designed for Class A equipment. Use of the product
	in domestic environments may cause radio interference, in which case the installer
	may need to use additional mitigation methods.
Enclosure	Install the product in a grounded metal enclosure.
Grounding	Connect a grounding conductor to the screw or terminal provided as standard on each
	controller. Refer to layout/power wiring schematic for grounding provision location.
Wiring	Wire in an industrial application can be divided into three groups: power control and
	signal. The following recommendations for physical separation between these groups
	are provided to reduce the coupling effect;
	• Different wire groups should cross at 90 degrees inside an enclosure.
	• Minimum spacing between different wiring groups in the same tray should be
	six inches.
	• Wire runs outside an enclosure should be run in conduit or have shielding/armor
	with equivalent attenuation.
	• Different wire groups should be run in separate conduits.
	• Minimum spacing between conduits containing different wire groups should be
	three inches (8cm).
Filtering	To comply with Conducted Voltage Limits a 0.33 uF capacitor should be connected
	between each incoming power line and ground at a point nearest to where the
	incoming power enters the enclosure.

18

		3.1 INSTALLATION
		Installation Procedures
	General Information	Installation of some models may require halting production during installation. If
		applicable, ensure that the starter is installed when production can be halted long
		enough to accommodate the installation.

Before installing the starter, ensure:

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

•The starter is the correct current rating for the motor being started.

•All of the installation safety precautions are followed.

•The correct power source is available.

•The starter control method has been selected.

•The necessary installation tools and supplies are obtained.

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

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

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

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

Safety Precautions	To ensure the safety of the individuals installing the starter, and the safe operation of
	the starter, observe the following guidelines:
	• Ensure that the installation site meets all of the required environmental
	conditions (Refer to Site Preparation, page 18).
	• LOCK OUT ALL SOURCES OF POWER.
	• Install circuit disconnecting devices (i.e., circuit breaker, fused disconnect or
	non-fused disconnect) if they were not previously installed by the factory as part
	of the package.
	• Install short circuit protection (i.e., circuit breaker or fuses) if not previously
	installed by the factory as part of the package. See page 14 for the fault rating
	table.
	• Follow all NEC (National Electrical Code) and/or C.S.A. (Canadian Standards
	Association) standards.
	• Remove any foreign objects from the interior of the enclosure.
	• Ensure that wiring is installed by an experienced electrician.
	• Ensure that the individuals installing the starter have protective eye wear and
	clothing.
	The opening of the branch circuit protective device may be an indication that a fault
	current has been interrupted. To reduce the risk of electrical shock, current carrying
	parts and other components of the starter should be inspected and replaced if
	damaged.

19

3.1 INSTALLATION

Installation	To begin installation:
	• Read and follow all of the installation safety precautions.
	• Procure the necessary installation tools and any supplies.
	• Ensure the site has sufficient lighting for safe installation.
	• Move the starter to the installation site.
	• Ensure that the starter is positioned so that the cabinet door has ample
		clearance, and all of the controls are accessible.
	• DO NOT install the starter in direct contact with any materials that cannot
		withstand the maximum heat sink temperature of 194 degrees Fahrenheit (90
		degrees Centigrade). All models require airway passages around the heat sink
		for proper cooling.
	If the starter is to be wall mounted:
	• Mount the starter on the applicable surface using the appropriate hardware.
	NOTE: Moving some models may require more than one individual or lifting
	equipment (e.g., forklift, crane).
Control Wiring	The control wiring should be connected to suit the customers needs. The control
	terminals on the control cards are as follows:
	RediStart Micro II Power Card (refer to card layout on page 119):
	•	TBP1-1	24VDC common for relay and reversing card
	•	TBP1-2	24VDC power for relay and reversing card
	•	TBP2-1	Run relay neutral
	•	TBP2-2	Run relay live
	•	TBP2-5	Run relay holding contact
	•	TBP3-1	General fault contact N.C. (not faulted)
	•	TBP3-2	General fault contact common
	•	TBP3-3	General fault contact N.O. (not faulted)
	•	TBP3-4	Programmable relay #1 N.O.
	•	TBP3-5	Programmable relay #1 common
	•	TBP3-6	Programmable relay #1 N.C.
	•	TBP3-7	Programmable relay #2 N.O.
	•	TBP3-8	Programmable relay #2 common
	•	TBP3-9	Programmable relay #2 N.C.

RediStart Micro II computer card inputs (refer to card layout on page 118):

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

•JC13-2 AC neutral.

•JC13-3 Run confirm.

•JC13-4 Jog operation select.

• JC13-5

Not Used.

•JC13-6 Reverse operation select (for Jog and Reversing).

•JC13-7 Brake disable.

•JC13-8 Zero Speed input or motor winding heater/anti-windmilling brake select.

•JC13-9 Ramp #2 operation select.

•JC13-10 External motor thermal overload reset.

•JC13-11 External computer reset.

•JC13-12 AC neutral.

20

3.1 INSTALLATION

RediStart Micro II Four (4) Relay Card (refer to card layout on page 121):

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

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

•TB2-3 Optional programmable relay #1 common

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

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

•TB2-6 Optional programmable relay #1 common

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

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

•TB2-9 Optional programmable relay #2 common

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

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

•TB2-12 Optional programmable relay #2 common

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

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

•TB2-15 Optional programmable relay #3 common

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

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

•TB2-18 Optional programmable relay #3 common

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

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

•TB2-21 Optional programmable relay #4 common

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

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

•TB2-24 Optional programmable relay #4 common

RediStart Micro II seven (7) Relay Card (refer to card layout on page 121):

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

•TB2-2 Optional programmable relay #1 common

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

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

•TB2-5 Optional programmable relay #2 common

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

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

•TB2-8 Optional programmable relay #3 common

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

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

•TB2-11 Optional programmable relay #4 common

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

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

•TB2-14 Optional programmable relay #5 common

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

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

•TB2-17 Optional programmable relay #6 common

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

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

•TB2-20 Optional programmable relay #7 common

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

21

3.1 INSTALLATION

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

Attach the motor cables:

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

•Attach the power source cables:

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

NOTE: For larger starters, thread each incoming power cable through its applicable current transformer (CT). The cables must be threaded through the CTs in the same direction to insure proper operation (Refer to the wiring diagram supplied with the starter).

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

Penn-union Corp.

Wire Size	Part #		Wire Size	Part #
1/0	BLU-1/0S20		500 MCM	BLU-050S2
2/0	BLU-2/0S4		600 MCM	BLU-060S1
3/0	BLU-3/0S1		650 MCM	BLU-065S5
4/0	BLU-4/0S1		750 MCM	BLU-075S
250 MCM	BLU-025S		800 MCM	BLU-080S
300 MCM	BLU-030S		1000 MCM	BLU-100S
350 MCM	BLU-035S		1500 MCM	BLU-150S
400 MCM	BLU-040S4		2000 MCM	BLU-200s
450 MCM	BLU-045S1

Power Factor Capacitors	Power factor correction capacitors and surge capacitors MUST NOT be connected
	between the RediStart Micro II and the motor. These devices can damage the SCR’s in
	the package during ramping. These devices appear like a short circuit to the SCR
	when it turns on, which causes a di/dt level greater than the SCR can handle. If used,
	power factor correction capacitors or surge capacitors must be connected ahead of the
	RediStart Micro II. Programmable relay #2 (K6) can be set to an up-to-speed (UTS)
	contact (up-to-speed is the default setting) and then used to pull-in a contactor to
	connect the capacitors after the motor has reached full speed.
	NOTE: The motor manufacturer should be contacted before surge capacitors are
	removed from the motor terminal box.
Electro-Mechanical Brakes	If an electro-mechanical brake is used with the RediStart Micro II, it must be powered
	from the line side of the starter to ensure full voltage is applied to the brake during a
	start so it will properly release. Programmable relay #1 (K5) can be set to a run
	contact (run is the default setting) and then used to pull-in a contactor to power the
	brake whenever the starter is providing power to the motor.
Finishing	After all of the safety precautions and installation procedures have been completed,
	verify that the following settings are correct for the application:

• Current transformer scaling switches.

• Hardware deceleration/braking control (JPC3).

• RediStart Micro II computer card jumpers.

22