User manual BENSHAW MVRSM18 SERIES

BENSHAW REDISTART MICRO II INSTRUCTION MANUAL MVRSM12/18 SERIES Solid State Motor Control Technology Publication #: 890015-01-08 The Leader In 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 . . . . . . . Voltage Inputs. . . . . . . . . . . . . . . . . . Metering . . . . . . . . . . . . . . . . . . . . . Real Time Clock. . . . . . . . . . . . . . . . . Output Relays . . . . . . . . . . . . . . . . . . Control Power. . . . . . . . . . . . . . . . . . Storage and Operating Conditions . . . . . . DeviceNet (Embedded) . . . . . . . . . . . . Modbus (Optional) . . . . . . . . . . . . . . . EU Declaration of Conformity . . . . . . . . Overload Curves . . . . . . . . . . . . . . . . Overload Curve Chart . . . . . . . . . . . . . RediStart Micro II Computer Card Jumpers . Computer Card JC11 Header Assignments . Old RediStart Micro II Power Card Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 8 8 8 8 9 9 9 9 10 11 12 13 13 13 3. INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3.1 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Site Preparation . . . . . . . . . . . . . . . . . EMC Installation guidelines . . . . . . . . . . Installation Procedures. . . . . . . . . . . . . Preventative Maintenance . . . . . . . . . . . Remote RTD Module . . . . . . . . . . . . . . CT Ratio Scaling . . . . . . . . . . . . . . . . RediStart Micro II Computer Card Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 16 17 21 21 21 22 i TABLE OF CONTENTS 4. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 4.1 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Main Display Messages . . . . . . . . . Meter Display Pages . . . . . . . . . . . Parameters. . . . . . . . . . . . . . . . . Starter Modes . . . . . . . . . . . . . . . Current Ramp Adjustment . . . . . . . Programming A Kick Current. . . . . . Tachometer Feedback . . . . . . . . . . Programming The Motor Deceleration. PORT (Power Outage Ride Through) . TruTorque Acceleration Ramp . . . . . TruTorque Deceleration Ramp . . . . . How Fault Classes Work. . . . . . . . . Use of Overcurrent and Undercurrent . Overload . . . . . . . . . . . . . . . . . . Performing an Emergency Restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 27 31 31 32 33 33 34 35 35 36 37 38 38 40 5. PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 5.1 PROGRAMMING: How To Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Menu Buttons . . . . . Menu Structure . . . . Viewing a Parameter . Changing a Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 43 44 44 45 45 45 45 46 46 46 47 47 5.2 PROGRAMMING: Quick Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Motor FLA. . . . . . . . . . . . . Serv. Fact (service factor) . . . . Start Mode . . . . . . . . . . . . . Stop Mode . . . . . . . . . . . . . Int. Curr. (initial current) . . . . Max. Curr. (maximum current) . Ramp Time . . . . . . . . . . . . Overload . . . . . . . . . . . . . . Phase Order . . . . . . . . . . . . 5.3 PROGRAMMING: Motor Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Motor FLA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Serv. Fact (service factor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Motor RPMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 5.4 PROGRAMMING: Starter Setup - Starter Modes . . . . . . . . . . . . . . . . . . . . . 49 Start Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Stop Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 5.5 PROGRAMMING: Starter Setup - Forward1 Profile . . . . . . . . . . . . . . . . . . . . 50 Int. Curr. (initial current) . . . . Max. Curr. (maximum current) . Ramp Time . . . . . . . . . . . . Kick Curr. (kick current) . . . . . Kick Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 50 50 51 51 ii TABLE OF CONTENTS 5.6 PROGRAMMING: Starter Setup - Forward2 Profile . . . . . . . . . . . . . . . . . . . . 52 Forward #2 Ramp Profile . . . . Int. Curr. (initial current) . . . . Max. Curr. (maximum current) . Ramp Time . . . . . . . . . . . . Kick Curr. (kick current) . . . . . Kick Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 52 52 52 53 53 54 54 54 54 55 55 56 56 56 57 57 5.7 PROGRAMMING: Starter Setup - Tachometer Setup . . . . . . . . . . . . . . . . . . . 54 FS Volts (Full Speed Volts) . . . . . . . . . . Stab Cnst (Stability Constant) . . . . . . . . . Ramp#1 Tim. . . . . . . . . . . . . . . . . . . Ramp#2 Tim. . . . . . . . . . . . . . . . . . . TLoss Dela (Tachometer Signal Loss Delay) . TLoss Mode (Tachometer Signal Loss Mode) V Level #1 . . . . . . . . . . . . . . . . . . . . V Level #2 . . . . . . . . . . . . . . . . . . . . V DCL Time (decel time). . . . . . . . . . . . TT DCL Tim (TruTorque deceleration time). TT DCL Tor (ending deceleration torque) . . 5.8 PROGRAMMING: Starter Setup - Decel Setup . . . . . . . . . . . . . . . . . . . . . . . 56 5.9 PROGRAMMING: Starter Setup - PORT CTL Setup. . . . . . . . . . . . . . . . . . . . 58 Fault Dly (Fault Delay) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Bypass Dly (Bypass Delay) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Sense Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 5.10 PROGRAMMING: Starter Setup - TruTorque Ramp . . . . . . . . . . . . . . . . . . . 59 Int Torque (initial torque) . . . . . . . . . . . . . Max Torque (maximum torque). . . . . . . . . . Ramp Time . . . . . . . . . . . . . . . . . . . . . TT Over Cu (TruTorque overcurrent trip) . . . . Ovr Cur Dl (TruTorque overcurrent trip delay). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 59 59 60 60 5.11 PROGRAMMING: Motor Protection - Overload . . . . . . . . . . . . . . . . . . . . . 61 Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 5.12 PROGRAMMING: Motor Protection - Line Current . . . . . . . . . . . . . . . . . . . 62 % Imbalanc (percent imbalance) . . . . . Imbal Dela (imbalance delay) . . . . . . . @ Stop Dly (current at stop delay) . . . . % No C@Run (percent no current at run) No C@R Dly (no current at run delay) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 62 62 63 63 5.13 PROGRAMMING: Motor Protection - Line Voltage . . . . . . . . . . . . . . . . . . . 64 H/L Volts (high/low voltage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Delay Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 PH Dect Dl (Phase detect delay) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 5.14 PROGRAMMING: Motor Protection - Line Frequency. . . . . . . . . . . . . . . . . . 65 High Freq. (high frequency) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Low Freq. (low frequency). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Freq Delay (frequency delay) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 5.15 PROGRAMMING: Motor Protection - Ground Fault . . . . . . . . . . . . . . . . . . . 66 GND Fault (ground fault) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 GND Delay (ground delay) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 iii TABLE OF CONTENTS 5.16 PROGRAMMING: Motor Protection - Shorted SCR . . . . . . . . . . . . . . . . . . . 67 @ Ramp DLY (shorted SCR at ramp delay) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 @ Stop DLY (shorted SCR at stop delay) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 5.17 PROGRAMMING: Motor Protection - Over Current . . . . . . . . . . . . . . . . . . . 68 Current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Detect Dly (detect delay). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Release Dl (release delay) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 5.18 PROGRAMMING: Motor Protection - Under Current . . . . . . . . . . . . . . . . . . 69 Current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Detect Dly (detect delay). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Release Dl (release delay) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 5.19 PROGRAMMING: Motor Protection - Start Lockouts . . . . . . . . . . . . . . . . . . 70 Starts/Hou (starts per hour). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Time Start (time between starts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 BKS Timer (backspin timer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 5.20 PROGRAMMING: Motor Protection - Starting Timers. . . . . . . . . . . . . . . . . . 71 UTS Timer (up-to-speed timer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Zero Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 5.21 PROGRAMMING: Motor Protection - Permissive Input. . . . . . . . . . . . . . . . . 72 Inline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Trip Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 5.22 PROGRAMMING: Motor Protection - Misc.. . . . . . . . . . . . . . . . . . . . . . . . 73 Phase Orde (phase order) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 # Auto RST (number of auto resets) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 No Main PW (no main power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 5.23 PROGRAMMING: Motor Protection - Fault Classes . . . . . . . . . . . . . . . . . . . 74 Fault Classes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 5.24 PROGRAMMING: Meters & Relays - Meter Setup . . . . . . . . . . . . . . . . . . . . 75 Meter #1 , Meter #2. . . . AutoRange. . . . . . . . . Meter Rsts (meter resets). Scroll Tim (scroll time) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 76 76 76 5.25 PROGRAMMING: Meters & Relays - Standard Relays . . . . . . . . . . . . . . . . . 77 Relay#1, K5 and Relay#2, K6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 5.26 PROGRAMMING: Meters & Relays - Extended Relays . . . . . . . . . . . . . . . . . 78 Opt. #?, K? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 5.27 PROGRAMMING: Event Recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Event Recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 5.28 PROGRAMMING: Control Config - System Clock . . . . . . . . . . . . . . . . . . . . 81 System Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 5.29 PROGRAMMING: Control Config - System Password . . . . . . . . . . . . . . . . . 82 Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 iv TABLE OF CONTENTS 5.30 PROGRAMMING: Control Config - Comm. Settings . . . . . . . . . . . . . . . . . . 83 COMM. Mode (communications mode) . . . . . . . . COM Addres (communications address) . . . . . . . COM Delay (communications delay). . . . . . . . . . MB:Baud (MODBUS baud rate) . . . . . . . . . . . . . MB:Com T/O (MODBUS communications timeout) . DN:MAC ID (DeviceNet MAC ID) . . . . . . . . . . . DN:Baud (DeviceNet baud rate) . . . . . . . . . . . . DN:InAssy (DeviceNet input assembly) . . . . . . . . DN:OutAssy (DeviceNet output assembly) . . . . . . DN:T/O Act (DeviceNet timeout action) . . . . . . . DN:Rev (DeviceNet interface revision) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 83 83 84 84 84 84 85 85 85 85 5.31 PROGRAMMING: Control Config - Options List. . . . . . . . . . . . . . . . . . . . . 86 Options List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 5.32 PROGRAMMING: Control Config - Software Part# . . . . . . . . . . . . . . . . . . . 87 Software Part# . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 5.33 PROGRAMMING: Factory Setup - Hardware Setup . . . . . . . . . . . . . . . . . . . 88 C.T. Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Relay Card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 5.34 Programming: Factory Setup - BIST Setup. . . . . . . . . . . . . . . . . . . . . . . . . 89 Start BIST . . . . . . . . Test Inlin (test in-line) . Test Bypas (test bypass) 100% Gates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 89 89 89 90 90 90 90 90 91 92 92 92 92 92 5.35 PROGRAMMING: Factory Setup - Factory Control . . . . . . . . . . . . . . . . . . . 90 FACT Pass. (factory password) . . . . . . . . Reset Def (reset to default parameters). . . . CLR Events (clear event log) . . . . . . . . . CLR Pass. (clear password) . . . . . . . . . . Cal Volt L1, L2, L3 (calibrate voltage meter). Cal Curr L1, L2, L3 (calibrate current meter) 5.36 PROGRAMMING: RTD Setup - RTD Module Setup . . . . . . . . . . . . . . . . . . . 92 Mod#1 Addr (module #1 address) . . . . . . . . Mod#2 Addr (module #2 address) . . . . . . . . #RTDs Mod1 (number of RTDs on module #1) . #RTDs Mod2 (number of RTDs on module #2) . Temp Scale (temperature scale) . . . . . . . . . . 5.37 PROGRAMMING: RTD Setup - RTD SetPnts 1-8 . . . . . . . . . . . . . . . . . . . . . 93 RTD#? Grp (RTD #? Group). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 RTD#? Warn (RTD #? warning level) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 RTD#? Alm (RTD #? alarm level). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 5.38 PROGRAMMING: RTD Setup - RTD SetPnts 9-16 . . . . . . . . . . . . . . . . . . . . 94 RTD#? Grp (RTD #? Group). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 RTD#? Warn (RTD #? warning level) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 RTD#? Alm (RTD #? alarm level). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 v TABLE OF CONTENTS 6. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 6.1 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 LED Diagnostics . . . . . . . . . Meter Tests . . . . . . . . . . . . Event Recorder . . . . . . . . . . Fault/Log Codes . . . . . . . . . General Troubleshooting Charts Spare Parts. . . . . . . . . . . . . SCR Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 97 97 98 102 104 105 6.2 MEDIUM VOLTAGE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 106 Built-In Self Test (BIST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 7. DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 7.1 DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 RediStart Micro II Computer Card Diagram . . . . . . . . . . RediStart Micro II Power Card Layout . . . . . . . . . . . . . . Old RediStart Micro Power Card Layout . . . . . . . . . . . . RediStart Micro II Four (4) Relay Card Layout . . . . . . . . . RediStart Micro II Seven (7) Relay Card Layout . . . . . . . . RediStart Micro II RS-232 Communications Card Layout . . . RediStart Micro II RS-485 Communications Card Layout . . . RediStart Micro II RS-232/485 Communications Card Layout Modbus Master Card (for Remote RTD Module) . . . . . . . . RediStart Micro II Display Cut-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 111 112 113 113 114 114 115 115 116 8. PARAMETER LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 8.1 Parameter List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 RediStart Micro II Parameter List . Quick Start. . . . . . . . . . . . . . Motor Nameplate . . . . . . . . . . Starter Setup. . . . . . . . . . . . . Motor Protection . . . . . . . . . . Meters & Relays. . . . . . . . . . . Event Recorder . . . . . . . . . . . Control Config . . . . . . . . . . . Factory Setup . . . . . . . . . . . . RTD Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 118 118 118 119 122 122 123 123 124 vi 1. INTRODUCTION 1.1 INTRODUCTION Using This manual Layout This manual is divided into eight sections. Each section contains topics related to the section. The sections are as follows; · Introduction - Basic RediStart Micro II information. · Technical Specifications - RediStart Micro II specifications. · Installation - Information on installing the RediStart Micro II. · Operation - Information on how the starter operates. · Programming - Programming the RediStart Micro II. · Troubleshooting - Diagnosing RediStart Micro II problems. · Drawings - RediStart Micro II layout drawings. · Parameter List - List allowing user to record programmed values. 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. There are two symbols used in this manual to highlight important information. The symbols appear as the following; Parameter List Symbols 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. Benshaw technical field support personnel are available to conduct on-site training on RediStart Micro II operations and troubleshooting. 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. 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 Replacement Parts All RediStart MicroII documentation is available on-line at www.benshaw.com. Spare and replacement parts can be purchased from Benshaw. On-Site Training Services Technical Support Documentation 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: (412) 487 8235 Fax: (412) 487 4201 Benshaw Canada Controls Inc. R.R. #1 (Wallace Industrial Park) Listowel, Ontario Canada N4W 3G6 Phone: (519) 291 5112 Fax: (519) 291 2595 Benshaw West 7820 E. Evans Drive, Suite 900 Scottsdale, AZ 85260 United States of America Phone: (480) 905 0601 Fax: (480) 905 0757 Technical support for the RediStart Micro II is available at no charge by contacting Benshaw's customer service department at one of the above telephone numbers. A service technician is available Monday through Friday from 8:00 a.m. to 5:00 p.m. EST. NOTE: An on-call technician is available after normal business hours and on weekends by calling Benshaw and following the recorded instructions. To help assure prompt and accurate service, please have the following information available when contacting Benshaw: · Name of company. · Telephone number where caller can be contacted. · Fax number of caller. · Benshaw product name. · Benshaw model number. · Benshaw serial number. · Name of product distributor. · Approximate date of purchase. · Voltage of motor attached to Benshaw product. · FLA of motor attached to Benshaw product. · A brief description of the application. 4 1.1 INTRODUCTION Features General · Chassis or NEMA 1, 4, 12, or 3R enclosure Protection (ANSI standard numbers given) · 51 - Electronic motor overload (class 1 to 40) · 86 - Overload lockout · 48 - Adjustable up-to-speed timer (off; 0 to 300 seconds) · 59/27 - Adjustable over/under voltage protection · 46 - Adjustable line to average current imbalance · 81 - Adjustable high and low frequency protection · Single phase protection · 66 - Adjustable starts per hour (off or 1 to 20 starts) · Adjustable time between starts (off or 1 to 600 minutes) · Backspin timer (off or 1 to 200 minutes) · 51 - Over current detection (Off or 50 to 800%) and time (0.1 to 90.0 sec. in 0.1 sec. intervals) · 37 - Undercurrent detection (Off or 10 to 100% and time (0.1 to 90.0 sec. in 0.1 sec. intervals) · 51G - Ground fault detection (Off or 1 to 100 amps) and time (0.1 to 90.0 sec. in 0.1 sec. intervals) · Over-current, undercurrent, and ground fault can each be set to trip or activate a relay · 50 - Instantaneous electronic over-current trip · Shorted SCR detection · 47 - Phase rotation selectable ABC, CBA, or Ins (insensitive) · 38/49 - Remote Mountable RTD protection package, 8 or 16 RTD inputs (optional) · PORT (power outage ride through) available with external 120VAC. Control · Two programmable current ramp profiles selectable at any time via 120 volt input · Initial current, maximum current, and ramp time adjustments for each ramp · Kick Current and time adjustments for each ramp · TruTorque acceleration and deceleration profiles · Adjustable deceleration profiles (to eliminate water hammer) · Adjustable brake profile · Local start/stop controls · Emergency reset capability · Tachometer ramp control (requires 0-5VDC tachometer feedback signal) Input/Output and Display · Plain English operation via back lit LCD display interface · LCD and LED status and diagnostics (full fault annunciation) · Programmable metering (amps, volts, frequency, overload, power factor, elapsed time, watts, VARs, watt-hours, VA, · · · · · · Current Imbalance, Ground Fault Current, RTD temperatures) Programmable relay outputs Latched fault relay output Real time clock Time stamped event recorder Password protection Battery backed-up starter parameters and lockout times 5 2. TECHNICAL SPECIFICATIONS 2.1 TECHNICAL SPECIFICATIONS CT (Current Transformer) Inputs Conversion Range Accuracy Frequency Current Withstand Calibrated RMS, 12 samples per cycle 0.01 to 1.5 × phase CT primary amps set point ±3.5% of phase CT primary amps set point 23 to 72 Hz - 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 Range Accuracy Calibrated RMS, 12 samples per cycle 1000VAC to 9999VAC ±3.5% of full range Metering Current Voltage Watts Volt-Amps Reactive Volt-Amps WH PF ±5%, 0 to 9999Amps ±5%, 0 to 9999Volts ±5%, 0 to 6553kW ±5%, 0 to 6553kVAR ±5%, 0 to 6553kVA ±5%, 0 to 6553MWH ±3%, -0.01 to +0.01 Real Time Clock Accuracy Range ±1 minute per month 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 - SPDT - Form C - 16A, 250VAC resistive - 8A, 250VAC 0.4 PF - 16A, 30VDC resistive - 2000VA inrush Output Relay #1 & #2 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 - SPDT - Form C - 8A, 250VAC resistive - 4A, 250VAC 0.4 PF - 8A, 30VDC resistive - 800VA inrush Seven Relay Card Control Power Voltage Frequency Power Consumption Fuse 120VAC, ±15% 240VAC, ±15% (Optional) 50 to 60hz Varies for required control. Time delay control circuit protection fuses. Storage and Operating Conditions Storage Operating -20ºC (-4°F) to +60°C (+140°F) 0% to 95% relative humidity, non-condensing 0°C (+32°F) to +50°C (+122°F) 0% to 95% relative humidity, non-condensing DeviceNet (Embedded) Manual EDS File Device Type I/O Slave Messaging Baud Rates Available at www.benshaw.com or from your Benshaw sales office. Available at www.benshaw.com or from your Benshaw sales office. Softstart Starter Polling - 125K - 250K - 500K Self tested with ODVA (open DeviceNet Vendor Association) software. Conformance Modbus (Optional) Manual Type Connections Baud Rates Available at www.benshaw.com or from your Benshaw sales office. Modbus RTU - RS-232 - RS-485 - 2400 - 4800 - 9600 9 2.1 TECHNICAL SPECIFICATIONS EU Declaration of Conformity According to the EMC ­ Directive 89/336/EEC as Amended by 92/31/EEC and 93/68/EEC Product Category: Product Type: Model Numbers: Manufactures Name: Manufacture's Address: 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 The before mentioned products comply with the following EU directives and Standards: Safety: UL 347 Standard for Industrial Control Equipment covering devices for starting, stopping, regulating, controlling, or protecting electric motors with ratings of 1500 volts or more. EN 50081-2 Emissions Radiated/Conducted EN 55011/05.98+A1:1999 EN 50082-2 Immunity/Susceptibility which includes: EN 61000-4-2 Electrostatic Discharge EN 61000-4-3 Radiated RF EN 61000-4-4 Electrical Fast Transient/Burst EN 61000-4-6 Injected Currents The 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. Neil Abrams Quality Control Manager Harry Hagerty Advanced Controls and Drives Manager Charles E. Cook Product Development Manager EMC: 10 2.1 TECHNICAL SPECIFICATIONS Overload Curves General The RediStart Micro II comes with forty (40) standard overload curves. The 100% (no trip) point is the motor FLA setting multiplied by the service factor. These curves are shown on the next page. NOTE: When the overload counter is at a number other than 0%, the time to trip will be lowered by this percentage. Curves Trip Time Accuracy Class 1 to 40 in steps of 1. ±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 40 Class 25 Class 20 Class 15 Class 10 Class 7 Class 5 Class 3 1000 100 Class 2 Class 1 Class 1 10 1 0 100 200 300 400 500 600 700 800 Current as Percent of FLA 12 2.1 TECHNICAL SPECIFICATIONS RediStart Micro II Computer Card Jumpers Jumper JPC5 JPC7 JPC8 JPC12 JPC13 JPC14 JPC15 JPC17 JPC18 JPC19 JPC25 JPC27 Description LCD Start Button O/L Reset Auto/Manual Display Format SCR Firing LCD Stop Button RAM Size PWM/ADDR16 Voltage Select Voltage Select Fault Reset Synchronous Application Micro Enable/ADDR17 Position 1-2 (In - 2-pos. jumper) Enable Automatic Standard Pulse Enable 8K RAM ADDR16 4160 or 3300 3300 or 4800 Automatic Yes ADDR17 Position 2-3 (Out - 2-pos. jumper) Disable Manual Local Bus Block Disable 2K RAM PWM 2400 or 4800 2400 or 4160 Manual No Enable Standard 1-2 2-3 1-2 In 1-2 1-2 1-2,3-4 2-3 Out 1-2,3-4 Computer Card JC11 Header Assignments Position 1-16 2-15 3-14 4-13 5-12 6-11 7-10 8-9 Assignment Starter equipped with voltage divider card. Not used. Starter Equipped with MODBUS master card (for RTD module). Not used. Not used. Enables emergency reset. Not used. Not used. Old RediStart Micro II Power Card Jumpers Jumper JPP2 JPP3 JPP4 Description Line Synching Line Synching Line Synching Position 1-2 Line to Line Line to Line Line to Line Position 2-3 Line to Neutral Line to Neutral Line to Neutral Standard 1-2 1-2 1-2 NOTE: Jumpers JPP2, JPP3, and JPP4 do not apply to the BIPC-300030-xx Power Card. 13 2.1 TECHNICAL SPECIFICATIONS 14 3. INSTALLATION 3.1 INSTALLATION Site Preparation General Before the installation of the RediStart Micro II, the site should be prepared. The customer is responsible for: · Providing the correct power source. · Selecting the control mechanism. · Providing the connection cables and associated hardware. · Ensuring the installation site meets all environmental specifications for the enclosure NEMA rating. 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. 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. Connection Cables Site Requirements 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 Grounding Install the product in a grounded metal enclosure. 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. 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). 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. Wiring Filtering 16 3.1 INSTALLATION Installation Procedures General Information Installation of some models may require halting production during installation. If applicable, ensure that the starter is installed when production can be halted long enough to accommodate the installation. Before installing the starter, ensure: · The wiring diagram (supplied separately with the starter) is correct for the required application. · The starter is the correct current rating for the motor being started. · All of the installation safety precautions are followed. · The correct power source is available. · The starter control method has been selected. · The necessary installation tools and supplies are obtained. · The installation site meets all environmental specifications for the starter NEMA/CEMA rating. · The motor being started has been installed and is ready to be started. · Any power factor correction capacitors (PFCC) are installed on the power source side of the starter and not on the motor side. NOTE: Failure to remove power factor correction or surge capacitors from the load side of the starter will result in serious damage to the starter which will not be covered by the starter's warranty. The capacitors must be powered from the line side of the starter. The up-to-speed contact can be used to energize the capacitors after the motor has reached full speed. Safety Precautions To ensure the safety of the individuals installing the starter, and the safe operation of the starter, observe the following guidelines: · Ensure that the installation site meets all of the required environmental conditions (Refer to Site Preparation, page 16). · LOCK OUT ALL SOURCES OF POWER. · Install circuit disconnecting devices (i.e., circuit breaker, fused disconnect or non-fused disconnect) if they were not previously installed by the factory as part of the package. · Install short circuit protection (i.e., circuit breaker or fuses) if not previously installed by the factory as part of the package. See page 13 for the fault rating table. · Follow all NEC (National Electrical Code) and/or C.S.A. (Canadian Standards Association) standards. · Remove any foreign objects from the interior of the enclosure. · Ensure that wiring is installed by an experienced electrician. · Ensure that the individuals installing the starter have protective eye wear and clothing. The opening of the branch circuit protective device may be an indication that a fault current has been interrupted. To reduce the risk of electrical shock, current carrying parts and other components of the starter should be inspected and replaced if damaged. 17 3.1 INSTALLATION Installation To begin installation: · Read and follow all of the installation safety precautions. · Procure the necessary installation tools and any supplies. · Ensure the site has sufficient lighting for safe installation. · Move the starter to the installation site. · Ensure that the starter is positioned so that the cabinet door has ample clearance, and all of the controls are accessible. · DO NOT install the starter in direct contact with any materials that cannot withstand the maximum heat sink temperature of 194 degrees Fahrenheit (90 degrees Centigrade). All models require airway passages around the heat sink for proper cooling. If the starter is to be wall mounted: · Mount the starter on the applicable surface using the appropriate hardware. NOTE: Moving some models may require more than one individual or lifting equipment (e.g., forklift, crane). Control Wiring The control wiring should be connected to suit the customers needs. The control terminals on the control cards are as follows: RediStart Micro II Power Card (refer to card layout on page 111): 24VDC common for relay and reversing card · TBP1-1 24VDC power for relay and reversing card · TBP1-2 · TBP2-1 · TBP2-2 · TBP2-5 · · · · · · · · · TBP3-1 TBP3-2 TBP3-3 TBP3-4 TBP3-5 TBP3-6 TBP3-7 TBP3-8 TBP3-9 Run relay neutral Run relay live Run relay holding contact General fault contact N.C. (not faulted) General fault contact common General fault contact N.O. (not faulted) Programmable relay #1 N.O. Programmable relay #1 common Programmable relay #1 N.C. Programmable relay #2 N.O. Programmable relay #2 common Programmable relay #2 N.C. RediStart Micro II computer card inputs (refer to card layout on page 110): · JC13-1 Heat sink thermal switch or external starter trip input. · JC13-2 AC neutral. · JC13-3 Run confirm. · JC13-4 In-line monitoring. · JC13-5 Disconnect monitoring. · JC13-6 Reverse/Forward Jog. · JC13-7 Bypass monitoring. · JC13-8 Jog mode. · JC13-9 Profile #2 select. · JC13-10 External motor thermal overload reset. · JC13-11 External computer reset. · JC13-12 AC neutral. 18 3.1 INSTALLATION RediStart Micro II Four (4) Relay Card (refer to card layout on page 113): Optional programmable relay #1 N.O. · TB2-1 Optional programmable relay #1 N.C. · TB2-2 Optional programmable relay #1 common · TB2-3 Optional programmable relay #1 N.O. · TB2-4 Optional programmable relay #1 N.C. · TB2-5 Optional programmable relay #1 common · TB2-6 Optional programmable relay #2 N.O. · TB2-7 Optional programmable relay #2 N.C. · TB2-8 Optional programmable relay #2 common · TB2-9 Optional programmable relay #2 N.O. · TB2-10 Optional programmable relay #2 N.C. · TB2-11 Optional programmable relay #2 common · TB2-12 Optional programmable relay #3 N.O. · TB2-13 Optional programmable relay #3 N.C. · TB2-14 Optional programmable relay #3 common · TB2-15 Optional programmable relay #3 N.O. · TB2-16 Optional programmable relay #3 N.C. · TB2-17 Optional programmable relay #3 common · TB2-18 Optional programmable relay #4 N.O. · TB2-19 Optional programmable relay #4 N.C. · TB2-20 Optional programmable relay #4 common · TB2-21 Optional programmable relay #4 N.O. · TB2-22 Optional programmable relay #4 N.C. · TB2-23 Optional programmable relay #4 common · TB2-24 RediStart Micro II seven (7) Relay Card (refer to card layout on page 113): Optional programmable relay #1 N.O. · TB2-1 Optional programmable relay #1 common · TB2-2 Optional programmable relay #1 N.C. · TB2-3 Optional programmable relay #2 N.O. · TB2-4 Optional programmable relay #2 common · TB2-5 Optional programmable relay #2 N.C. · TB2-6 · 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. 19 3.1 INSTALLATION Power Wiring Thread the power and motor cables through a connector into the enclosure. Strip away the motor cable insulation and apply anti-oxidation paste to the conductors. Attach the motor cables: · Use the T1, T2 and T3 lugs or terminals. · Attach the power source cables: · Use the L1, L2 and L3 lugs or terminals. NOTE: For larger starters, thread each incoming power cable through its applicable current transformer (CT); if not already supplied in the unit. The cables must be threaded through the CTs in the same direction to insure proper operation (Refer to the wiring diagram supplied with the starter). The following is a list of the recommended crimp-on wire connectors manufactured by Penn-union Corp. Wire Size 1/0 2/0 3/0 4/0 250 MCM 300 MCM 350 MCM 400 MCM 450 MCM Part # BLU-1/0S20 BLU-2/0S4 BLU-3/0S1 BLU-4/0S1 BLU-025S BLU-030S BLU-035S BLU-040S4 BLU-045S1 Wire Size 500 MCM 600 MCM 650 MCM 750 MCM 800 MCM 1000 MCM 1500 MCM 2000 MCM Part # BLU-050S2 BLU-060S1 BLU-065S5 BLU-075S BLU-080S BLU-100S BLU-150S BLU-200s Power Factor Capacitors Power factor correction capacitors and surge capacitors MUST NOT be connected between the RediStart Micro II and the motor. These devices can damage the SCR's in the package during ramping. These devices appear like a short circuit to the SCR when it turns on, which causes a di/dt level greater than the SCR can handle. If used, power factor correction capacitors or surge capacitors must be connected ahead of the RediStart Micro II. Programmable relay #2 (K6) can be set to an up-to-speed (UTS) contact (up-to-speed is the default setting) and then used to pull-in a contactor to connect the capacitors after the motor has reached full speed. NOTE: The motor manufacturer should be contacted before surge capacitors are removed from the motor terminal box. Finishing After all of the safety precautions and installation procedures have been completed, verify that the following settings are correct for the application: · Current transformer scaling switches. · Hardware deceleration/braking control (JPC3). · RediStart Micro II computer card jumpers. 20 3.1 INSTALLATION Preventative Maintenance General Information Preventive maintenance performed on a regular basis will help ensure that the starter continues to operate reliably and safely. The frequency of preventive maintenance depends upon the type of maintenance and the installation site's environment. NOTE: Preventive maintenance should always be performed by a trained technician. Preventive Maintenance During Commissioning; · Torque all power connections during commissioning. This includes pre-wired equipment. · Check all of the control wiring in the package for loose connections. For the first month after the starter has been put in operation; · Re-torque all power connections every two weeks. This includes pre-wired equipment. · Inspect the cooling fans after two weeks to ensure proper operation. After the first month of operation; · Re-torque all power connections every year. · Clean any accumulated dust from the starter using a clean source of compressed air. · Inspect the cooling fans every three months to ensure proper operation. · Clean or replace any air vent filters on the starter every three months. · NOTE: If mechanical vibrations are present at the installation site, inspect the connections more frequently. Remote RTD Module General The RediStart Micro II can have up to 2 RTD modules installed. The RTD modules can be installed in the cabinet with the RediStart Micro II or they can be installed remotely at the motor. Refer to the Remote RTD Module manual for details on this module. The MODBUS master card is installed on the RediStart Micro II CPU card to allow the starter to communicate with the RTD Module. MODBUS Master Card CT Ratio Scaling General Information The motor current signal scaling is set according to the motor current specified when the starter is ordered. To ensure accurate operation, the motor current signal must be correctly scaled for the motor current being controlled by the starter.Motor current signal scaling may have to be changed if the motor size has been changed from the original specification.Motor current signal scaling is accomplished by verifying the current transformer ratio as supplied with the starter and then selecting the correct DIP switch setting from the chart on the following page for the current transformer ratio. The DIP switches are: · ON in the right position · OFF in the left position NOTE: Adjust the DIP switches only when the motor is stopped, or the switches could be damaged. 21 3.1 INSTALLATION Confirm Switch Settings To verify or change the motor current signal scaling: · Compare the CT ratio stamped on each CT to the CT ratio listed on the wiring diagram supplied with the starter to ensure the correct CTs are installed. · Inspect the RediStart Micro II power card to ensure that the DIP switches are in the correct positions for the applicable CT ratio and the motor full-load current (FLA) rating. CT Ratio 288:1 288:1 288:1 864:1 864:1 864:1 2640:1 2640:1 2640:1 5760:1 5760:1 5760:1 Motor FLA 3A to 9A 9A to 24A 25A to 60A 20A to 24A 25A to 70A 71A to 180A 40A to 80A 81A to 200A 201A to 500A 70A to 160A 161A to 400A 401A to 1200A Switch 1 Off On On Off On On Off On On Off On On Switch 2 Off Off On Off Off On Off Off On Off Off On Switch Settings Changing FLA If the actual motor FLA has been changed from the motor FLA documented on the purchase order: · The DIP switch positions may need to be changed. · Different CTs may have to be installed in the starter and the current transformer ratio parameter may need to be changed (Refer to current transformer ratio parameter, page 88). RediStart Micro II Computer Card Jumpers General Information The RediStart Micro II computer card has a number of jumpers that affect the operation of the starter. In some cases, these jumpers will over-ride the programmed values. The LCD Start button can be enabled or disabled by this jumper. The LCD Start button is factory enabled unless the purchase order requests that the LCD Start button is disabled. The LCD Start button is controlled by jumper JPC5 on the RediStart Micro II computer card (Refer to RediStart Micro II computer card layout on page 110). Mode Enable Disable JPC7 - Overload Auto/Man. Position 1-2 2-3 JPC5 - LCD Start button The motor thermal overload can be set to require a manual reset or to automatically reset after a thermal trip. The motor thermal overload is set to the manual reset position unless the purchase order requests that the motor thermal overload is set to the automatic reset position. The motor thermal overload reset is controlled by jumper JPC7 on the RediStart Micro II computer card (Refer to RediStart Micro II computer card layout on page 110). Mode Automatic Reset Manual Reset Position 1-2 2-3 22 3.1 INSTALLATION JPC13 - LCD Stop Button The LCD Stop button can be enabled or disabled by this jumper. The LCD Stop button is factory enabled unless the purchase order requests that the LCD Stop button is disabled. The LCD Stop button is controlled by jumper JPC13 on the RediStart Micro II computer card (Refer to RediStart Micro II computer card layout on page 110). Mode Enable Disable JPC17 - Voltage Select Position 1-2 2-3 The RediStart Micro must be set for the line voltage that it is operating on. This is so that it will know the voltage to be able to implement the high/low voltage protection feature. The line voltage should be set to the voltage requested when the starter was ordered since the power poles and control power transformer must change for different line voltages.The line voltage is set by JPC17 on the RediStart Micro computer card, which works in conjunction with JPC18. (Refer to RediStart Micro computer card layout on page 110). Setting 3300VAC or 4160VAC 2400VAC or 4800VAC Position 1-2 2-3 JPC18 - Voltage Select The RediStart Micro must be set for the line voltage that it is operating on. This is so that it will know the voltage to be able to implement the high/low voltage protection feature. The line voltage should be set to the voltage requested when the starter was ordered since the power poles and control power transformer must change for different line voltages.The line voltage is set by JPC18 on the RediStart Micro computer card, which works in conjunction with JPC17. (Refer to RediStart Micro computer card layout on page 110). Setting 3300VAC or 4800VAC 2400VAC or 4160VAC Position 1-2 2-3 JPC19 - Fault Reset The RediStart Micro II can be set to either require a manual reset or automatically reset after a fault occurs. The RediStart Micro II is set for manual fault reset unless the purchase order requests that the fault reset jumper is set to automatic. The fault reset is controlled by jumper JPC19 on the RediStart Micro II computer card (Refer to RediStart Micro II computer card layout on page 110). Mode Automatic Fault Reset Manual Fault Reset Position 1-2 2-3 The automatic fault reset works in conjunction with the # auto resets parameter (see page 73) and the Fault Classes sub-menu (see page 74). The # auto resets parameter sets how many non-critical faults will be reset in one hour. Once this number has been reached, the starter will not automatically reset the next fault. When this occurs, the user should check the event recorder for the cause of the faults and correct the problem. The fault classes sub-menu allows the user to set faults as critical, non-critical, disabled, warning relay A, warning relay B or warning relay C. When JPC19 is set to automatic fault reset and a fault is set to non-critical, the RediStart Micro II will automatically reset the fault. 23 3.1 INSTALLATION 24 4. OPERATION 4.1 OPERATION Main Display Messages General During normal operation, the RediStart Micro II can show a number of different operating messages on the display. These messages give information on the present operating state of the starter and motor. There are three locations where messages are displayed as shown in the following diagram. Location 1 Location 2 Run UTS I= Running . V= 0A 0V Location 3 Messages The messages, display locations and descriptions are as follows: Message Stop Coast BKS hld TBS hld SPH hld BKS LOC TBS LOC SPH LOC JOG RUN Stopping RUN UTS RUN SYN XXX.Xmin PH Err Freq Err Volt Err OCT Trip UCT Trip GDF Trip Door In No Line OL Warn OL Trip OL Lock Ready Accel Accel 2 Running FWD Acc REV Acc Forward Reverse LS Acc HS Acc Low Sp High Sp Kicking Kicking 2 Decel Braking FWD Jog REV Jog ComLoss EN Save Heater RTD Alar RTD ComF RTD Open RTD Shor RTD Warn Location 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 Description Starter is in a stopped state. Starter coasting between direction changes. Backspin timer is active. Time between starts is active. Starts per hour is active. Backspin timer is locked. Time between starts counter has locked. Starts per hour counter has locked. Starter is operating in the jog at set speed mode. Starter is applying power to motor. Stop command was applied, motor is being stopped. Starter is running and motor is at full speed. Starter is running and motor is synchronized. Next start cannot be performed for xxx.x min. The phase order is incorrect. The line frequency is outside of the trip settings. The line voltage is outside of the trip settings. Motor current went above the over current trip setting. Motor current went below the under current trip setting. A ground fault was detected. The Disconnect switch is open. Line voltage is not present. Motor thermal overload is over 90% content. Motor thermal overload is tripped and reset is allowed. Motor thermal overload tripped and reset is not allowed. All conditions OK to run. Starter is ramping. Starter is ramping using 2nd ramp profile. Starter ramp profile is complete. The motor is being accelerated in the forward direction. The motor is being accelerated in the reverse direction. The motor is running in the forward direction. The motor is running in the reverse direction. The motor is being accelerated in low speed. The motor is being accelerating in high speed. The motor is running in low speed. The motor is running in high speed. Starter is applying kick start current. Starter is kicking using 2nd ramp profile. Motor is decelerating. The motor is being braked. Motor is jogging in the forward direction. Motor is jogging in the reverse direction. Modbus communications lockout. Energy saver is active. The motor heater is operating. A RTD went over its alarm setting. Communications with an RTD module was lost. A RTD is detected as being open. A RTD is detected as being shorted. A RTD went over its warning setting. 26 4.1 OPERATION If Lock If CTRL PF CTRL TachLoss PORT . (dot) 2 2 2 2 2 3 Starter is providing set maximum field current. Starter is in field current control mode. Starter is in power factor control mode. The tachometer feedback signal was lost. The starter is in Power Outage Ride-Through mode. Password protection is enabled. Meter Display Pages General Besides the main display, the RediStart Micro II has a number of other display pages that show various operational values. By pressing the Up or Down arrow buttons, it is possible for the user to view all operational information without having to enter the menu system. The display pages are described below in the order they appear when pressing the Up button. NOTE: Not every display page shown here may be present depending on the options provided with the starter. Current Page The current meter page displays the currents for all three phases. Current I2= I1= 0 I3= 0A 0A Phase 2 Current Phase 3 Current Phase 1 Current Voltage Page The voltage page displays the voltages for all three phases. Voltage V1= 0 V2= V3= 0V 0V Phase 2 Voltage Phase 3 Voltage Phase 1 Voltage Kilo-Watt Hour Page The Kilo-Watt Hour power page displays the true power measurements for the motor. KWatt Hour= 0.0H MWatt Hour= 0.0H Kilo-Watt Hours Mega-Watt Hours Power Page The power page displays the KW and kVA power measurements for the motor. KWatts = 0.0W KVA Usage = 0.0 Kilo-Watts KVA Tru Torque Page The tru torque page displays the Tru Torque % and Power Factor measurements for the motor. Tru Torq% = 0.0% Motor pf = 1.0 True Torque Power Factor 27 4.1 OPERATION Runtime Page The runtime page displays the runtime on the motor. RunTime Hr= 123h HoursX100 = 1.2 Operating Hours Hundreds of Hours User Counts Page The user counts page displays the user resettable runtime and number of starts. User RT Hr= 123h User Start= 45# User Resettable Run time User Resettable Starts Motor #1 Page The motor #1 page displays the motor current imbalance as a percentage and the number of motor starts. Curr. Imba= # Starts = 3% 45 Current Imbalance Number of Starts Motor #2 Page The motor #2 page displays overload content and ground fault current information. % Overload= Ground Fau= 3% 0A Overload Content Ground Fault Current Motor #3 Page The motor #3 page displays operating frequency and motor power factor information. Frequency= 60.0 Motor PF = 1.00 Line Frequency Power Factor Sync Page The sync page gives the synchronous motor field current and slip. Field Amps= 0.0A % Rotor Sl=99.9% Field Current Slip Percentage Communications Page The communications page displays the communications statistics. Com's Tx= Cr= 0 Rx= 0# 0# # of Transmits # of Receives Communication Rate RTD #1 & #2 Temp. The RTD #1 & #2 temperature page displays the temperatures those RTDs are measuring. RTD#1 RTD#2 = = 90C 80C RTD #1 Temperature RTD #2 Temperature 28 4.1 OPERATION RTD #3 & #4 Temp. The RTD #3 & #4 temperature page displays the temperatures those RTDs are measuring. RTD#3 RTD#4 = = 90C 80C RTD #3 Temperature RTD #4 Temperature RTD #5 & #6 Temp. The RTD #5 & #6 temperature page displays the temperatures those RTDs are measuring. RTD#5 RTD#6 = = 90C 80C RTD #5 Temperature RTD #6 Temperature RTD #7 & #8 Temp. The RTD #7 & #8 temperature page displays the temperatures those RTDs are measuring. RTD#7 RTD#8 = = 90C 80C RTD #7 Temperature RTD #8 Temperature RTD #9 & #10 Temp. The RTD #9 & #10 temperature page displays the temperatures those RTDs are measuring. RTD#9 RTD#10 = = 90C 80C RTD #9 Temperature RTD #10 Temperature RTD #11 & #12 Temp. The RTD #11 & #12 temperature page displays the temperatures those RTDs are measuring. RTD#11 RTD#12 = = 90C 80C RTD #11 Temperature RTD #12 Temperature RTD #13 & #14 Temp. The RTD #13 & #14 temperature page displays the temperatures those RTDs are measuring. RTD#13 RTD#14 = = 90C 80C RTD #13 Temperature RTD #14 Temperature RTD #15 & #16 Temp. The RTD #15 & #16 temperature page displays the temperatures those RTDs are measuring. RTD#15 RTD#16 = = 90C 80C RTD #15 Temperature RTD #16 Temperature 29 4.1 OPERATION Max. RTD Temp. The maximum RTD temperature page displays the temperature and RTD number from the highest measuring RTD. Max of All= M All RTD#= 90C 5# Max. RTD Temperature RTD Number Max. Bearing RTD Temp. The maximum bearing RTD temperature page displays the temperature and RTD number from the highest measuring RTD in the bearing group. Max Bearin= M Bea RTD#= 90C 5# Max. Bearing Temp. Bearing RTD Number Max. Stator RTD Temp. The maximum stator RTD temperature page displays the temperature and RTD number from the highest measuring RTD in the stator group. Max Stator= M Sta RTD#= 90C 5# Max. Stator Temp. Stator RTD Number Peak RTD Temp. The peak RTD temperature page displays the highest peak temperature reached and the number of the RTD that read the temperature. Peak of Al= P All RTD#= 90C 5# Peak RTD Temp. RTD Number Peak Bearing RTD Temp. The peak bearing RTD temperature page displays the highest bearing temperature reached and the number of the RTD that read the temperature. Peak Beari= P Bea RTD#= 90C 5# Peak Bearing Temp. Bearing RTD Number Peak Stator RTD Temp. The peak stator RTD temperature page displays the highest stator temperature reached and the number of the RTD that read the temperature. Peak Stato= 90C P Sta RTD#= 5# Peak Stator Temp. Stator RTD Number 30 4.1 OPERATION Parameters Parameter Usage The description and use of each parameter is described in the programming section of the manual. Most parameters are fairly straightforward and don't require any further explanation. The rest of this chapter gives a more detailed description of the use of the parameters that are more complicated to use. Starter Modes Description The Starter Mode sub menu (see page 49) contains parameters for selecting the type of start and stop to perform. By allowing the user to select the start and stop mode the system can be operated in the optimal start and stop fashion for the load. Below are the available modes along with some examples for typical applications. Curr (Current Ramp): The current ramp is ideal for most general-purpose motor control applications; Examples: crushers, ball mills, compressors, saws, and centrifuges). The Current Ramp applies to the following in the Starter Setup Main Menu: Forward1 Profile, Forward2 Profile, Reverse1 Profile, and Reverse2 Profile. TT (Tru Torque): The true torque ramp is suitable for applications that require a minimum of torque transients during starting or for consistenly loaded applications that require a reduction of torque surges during starting; Examples: pumps, fans, and belt driven equipment). The Tru Torque ramp applies to the following in the Starter Setup Main Menu: True Torque Ramp Tach (Tachometer Feedback): The tachometer feedback ramp is for applications where torque transients must be held to a minimum, and the starting load is unknown, vary, or change during the start cycle; Examples: Belts, and conveyors. The Tachometer ramp applies to the following in the Starter Setup Main Menu: Tachometer Setup Stop Modes Coas (Coast): A coast stop should be used when no special stopping requirements are necessary; Example: crushers, balls mills, centrifuges, belts, conveyor. There is no menu that applies in the Starter Setup Main Menu. VDCL (S Curve Voltage Deceleration): A standard open loop S-Curve voltage deceleration is best suited for applications such as pumps and compressors. The S Curve Voltage Deceleration applies to the following in the Starter Setup Main Menu: Decel Setup TT (Tru Torque): The true torque deceleration is best suited to pumping and compressor applications where pressure surges during a stop must be eliminated. This setup is easier than the S-Curve Voltage Deceleration and is less source voltage dependent. The Tru Torque deceleration applies to the following in the Starter Setup Main Menu: True Torque Ramp Start Modes 31 4.1 OPERATION Current Ramp Adjustment Current Ramp The current ramp sets how the motor accelerates. The current ramp is a linear increase in current from the initial setting to the maximum setting. The ramp time sets the speed of this linear current increase. The following figure shows the relationships of these different ramp settings. Current (% of FLA) Maximum Current Kick Current Initial Current Motor Running Stall Time 0 0 Kick Time Ramp Time Up To Speed Time (Seconds) Initial Current Setting The initial current should be set to the level that allows the motor to begin rotating within a couple of seconds of receiving a start command. To adjust the initial current setting give the starter a run command. Observe the motor to see how long it takes before it begins rotating and then stop the unit. For every second that the motor doesn't rotate, increase the initial current by 20%. Typical loads will require an initial current in the 50% to 175% range. Maximum Current Setting For most applications, the maximum current can be left at 600%. This will ensure that enough current is applied to the motor to accelerate it to full speed. The maximum current can also be set to a lower current limit. This is usually done to limit the voltage drop on the power system or to limit the torque the motor produces to help prevent damage to the driven load. NOTE: The motor may achieve full speed at any time during the current ramp. This means that the maximum current setting may not be reached. Therefore, the maximum current setting is the most current that could ever reach the motor, and not necessarily the maximum current that will reach the motor. NOTE: When setting a current limit, the motor must be monitored to ensure that the current is high enough to allow the motor to reach full speed under worst case load conditions. 32 4.1 OPERATION Ramp Time Setting The ramp time is the time it takes for the current to go from the initial current to the maximum current. To make the motor accelerate faster, decrease the ramp time. To make the motor accelerate slower, increase the ramp time. If the ramp time expires before the motor reaches full speed, the starter will maintain the set maximum current level until either the motor reaches full speed, the stall time expires, or the motor thermal overload trips. NOTE: Setting the ramp time to a specific value does not necessarily mean that the motor will take this time to accelerate to full speed. The motor and load may achieve full speed before the ramp time expires if the application does not require the set ramp time and maximum current to reach full speed. Alternatively, the motor and load may take longer than the set ramp time to achieve full speed. Programming A Kick Current General The kick current sets a current level that overrides the current ramp when a start is first commanded. The kick current is only useful on motor loads that are hard to get rotating but then are much easier to move once they are rotating. An example of a load which is hard to get rotating is a ball mill. The ball mill requires a high torque to get it to rotate the first quarter turn (90o). Once the ball mill is past 90o of rotation, the material inside will begin tumbling and it is easier to turn. The kick current parameter is usually set to a low value and then the kick time is adjusted to get the motor rotating. If the kick time is set to more than 2.0 seconds without the motor rotating, increase the kick current by 100% and re-adjust the kick time. The kick time adjustment should begin at 0.5 seconds and be adjusted by 0.1 or 0.2 second intervals until the motor begins rotating. If the kick time is adjusted above 2.0 seconds without the motor rotating, start over with a higher kick current setting. Kick Current Kick Time Tachometer Feedback Description The Tachometer control ramp profile (see page 54)provides a method to linearly ramp the speed of the system. When this control mode is selected, the starter uses a tachometer to provide speed feedback to the starter. This mode is commonly used on conveyor belt applications where a smooth controlled start is necessary under various load conditions to prevent belt breakage, lifting, or excessive stretching. The Tachometer controller consists of an inner PID current loop and an outer PI speed control loop. NOTE: The maximum current limit will override the speed control loop if necessary. If the Maximum Current level is not set high enough or the load is too great, the RediStart Micro II starter will limit the motor current to this maximum level. When current limiting occurs, the speed profile will no longer be linear and the motor(s) will take longer to accelerate to full speed. Therefore, if current limiting is undesirable, this parameter must be set higher than the peak starting current during a linear speed ramp start. Tachometer Requirements In addition to the basic motor and starter setup variables, the following needs to done to use the tachometer feedback control ramp: 1. Connect a tachometer with appropriate DC output voltage and correct polarity to the Redistart Micro II power card input (terminal TBP13). 2. The tachometer feedback Start Mode is selectable as "Tach" from the Starter Modes menu. 3. Program the appropriate variables in the Tachometer Setup menu. 4. Set the Initial Current level in either the Quick Start menu or the Forward1 Profile menu to the desired current limit. 33 4.1 OPERATION 5. Set the Maximum Current level in either the Quick Start menu or the Forward1 Profile menu to the desired maximum current limit. Programming The Motor Deceleration Deceleration Control The standard deceleration control on the RediStart Micro II uses an open loop voltage ramp. The RediStart Micro II will ramp the voltage down to decelerate the motor. The curve shows the motor voltage vs the decel setting. RediStart Micro Decel Curve 100 90 Motor Voltage (% of Line Voltage) 80 70 60 50 40 30 20 10 0 100 90 80 70 60 50 40 30 20 10 0 Programmed Decel Level (%) Decel Level 1 This sets the starting voltage of the deceleration ramp. Most motors require the voltage to drop to around 60% or lower before any significant deceleration is observed. Therefore, a good first setting for this parameter is 35%. To adjust this parameter, it is necessary to observe the motor operation as soon as a stop is commanded. If the motor hunts (speed oscillations) at the beginning of the deceleration, then lower the parameter by 5%. If the motor has a big drop in speed as soon as a stop is commanded, then raise the parameter by 5%. Some motors are very sensitive to the adjustment of this parameter. If a 5% adjustment changes the motor from hunting to dropping in speed, then a smaller change of 1% or 2% may be necessary. Decel Level 2 This sets the final voltage for the deceleration ramp. In most cases, this parameter can be set to 10% and the decel time can be used to adjust the deceleration rate. If the motor is coming to a stop too quickly or if the starter continues to apply current to the motor after the motor has stopped, this parameter can be increased in 5% increments to fix this. The decel time sets how quicky the motor decelerates. Usually a time of 30 seconds is a good starting point. To make the motor take longer to decelerate, increase this parameter or to make the motor decelerate quicker, decrease this parameter. Decel Time 34 4.1 OPERATION PORT (Power Outage Ride Through) Description The Power Outage Ride Through capability (see page 58)allows the starter to ride through short duration brown outs, single phase, and power loss conditions. When the system senses a voltage disturbance in a time frame greater than the Sense Time parameter, the power will be removed from the motor for a coast to stop, and the Fault Dly timer will begin to time; if it is not set to OFF. If the power disturbance ends before the programmed Fault Dly time, the motor will restart -- if a start command is still present -- from initial to maximum current in the specified ramp time. If the outage lasts longer than the programmed Fault Dly time, the starter will issue a Fault 98; "No Mains PWR." If Fault Dly is set to OFF, the starter will use the standard motor protection fault delay timers to sense power disturbances. NOTE: Starts/Hou (starters per hour), Time Start (time between starts), and BKS Timer (backspin timer) are not incremented for PORT. NOTE: If the system Start Mode parameter is programmed with a tachometer ramp, the system will restart using a tachometer ramp. Bypass Delay PORT can also hold a bypass contactor in for a programmed BYP Dly when the power disturbance is Sensed. NOTE: The BYP Dly is fixed at 0.0 seconds to protect systems that contain an integral bypass card. NOTE: Caution must be taken when the BYP Dly is set above 0.0 seconds. If the bypass contactor is energized when the power disturbance ends, the motor will start across the line. The resulting torque may damage the system. PORT Detection The starter can be detected in PORT operation by monitor of the PORT relay output; Selectable on any of the programmable relays. Once programmed, this relay can be used to feed 120VAC to input 9 of the JC13 terminal block on the computer card. This causes the system to use the Forward/Reverse2 Profile for starting the motor. TruTorque Acceleration Ramp TruTorque Ramp The TruTorque ramp sub-menu (see page 59) contains the parameters that that are used to activate and tune TruTorque Acceleration and Deceleration Control. The primary purpose of TruTorque Control is to reduce the torque surge that occurs as an AC induction motor comes up to full speed. This torque surge can be a problem in applications especially in pumps and belt driven applications. In pumping applications this torque surge results in a pressure peak as the motor comes up to speed. In most situations this small pressure peak is not a problem. However in selected cases, even a small pressure peak can be highly undesirable. In belt drive applications, TruTorque prevents the slipping of belts as the motor reaches full speed. Note: When TruTorque acceleration control is enabled the second ramp (Ramp #2) and Kick Current functions are disabled. TruTorque control can be very useful for a variety of applications. However it is best used for pump and other variable torque applications. TruTorque generally should not be used in applications where the starting load varies greatly from one start to another. 35 4.1 OPERATION Initial Torque This value sets the initial torque value for the motor. The initial torque level should be set to a level that allows the motor to begin rotating within a couple of seconds of receiving a start command. Typical loads will require values between 10% to 30% If the value is set too high a current surge may result. If the value is set too low a "No current at Run" fault may occur. Maximum Torque This value sets the final torque reference value at the end of the ramp time. Typical loads require a value around 100-110%. If the load is less than motor rating then the maximum torque value can be decreased. If the load is hard to start or the motor is a NEMA C or D type motor then this value may need to be increased. If the motor reaches full speed too quickly then decrease the Maximum Torque value by 5% and retest. If the motor does not achieve full speed, increase the Maximum Torque value by 10% and retest. If the motor can be started either by using default TruTorque values or current ramp control, the Maximum Torque value can be more precisely determined so that the motor comes up to speed in approximately the preset Ramp Time. In this case, while the motor is running at full load, display the TT% meter on the display (see Meter Setup for information on how to display the TT% meter). Record the value displayed when the motor is running with full load. The Maximum Torque value should then be set to the recorded running value of TT% plus an additional 10%. Retest with this value to verify correct operation. Note: When setting the Maximum Torque value the motor must be monitored to ensure that the torque is high enough to allow the motor to reach full speed under worst case load conditions. Ramp Time The Ramp Time setting is the time it takes for the torque to go from the Initial Torque Setting to the Maximum Torque Setting. To make the motor accelerate faster, decrease the ramp time. To make the motor accelerate slower, increase the ramp time. If the ramp time expires before the motor reaches full speed the starter will maintain the set Maximum Torque level until either the motor reaches full speed, the stall (UTS) timer expires, or the motor thermal overload trips. Note: Setting the ramp time to a specific value does not necessarily mean that the motor will take this time to accelerate to full speed. The motor and load may achieve full speed before the ramp time expires if the application does not require the set ramp time and maximum torque to reach full speed. Alternatively, the motor and load may take longer than the set ramp time to achieve full speed. TruTorque Deceleration Ramp General The TruTorque ramp sub-menu (see page 59) contains the parameters that activate TruTorque Acceleration and Deceleration Control. TruTorque deceleration is a closed-loop deceleration control. The RediStart MicroII will ramp down the torque to smoothly decelerate the motor. TruTorque deceleration is very simple to setup. TruTorque Decel Mode As a default deceleration control will be an open-loop voltage ramp. TruTorque Decel Mode needs to be turned on to utilize TruTorque deceleration control. When TruTorque deceleration is enabled the TruTorque deceleration settings listed below will be used for deceleration control. 36 4.1 OPERATION TT End Decel Torque The value sets the final torque level for the TruTorque deceleration ramp. In most cases, this parameter can be set to 10%. To adjust this parameter, it is necessary to observe the motor. If the motor is coming to a stop too quickly or if the starter continues to apply current to the motor after the motor has stopped this parameter can be increased in 5% increments. If the motor is still rotating when the desired deceleration time has expired, decrease this parameter by 5% and retest. TT Decel Ramp Time The TruTorque deceleration time sets how quickly the motor decelerates. Usually a time of 30 seconds is a good starting point. To make the motor decelerate at a slower rate increase this time or to make the motor stop quicker decrease this time. How Fault Classes Work General The Fault classes sub-menu (see page 74) allows the starter behavior for different faults to be altered. There are six different options that a fault can be set to. These options are described in the following paragraphs. See page 98 for a complete fault code and description listing. Non-critical fault. If this fault occurs, the starter will shut down and display the fault number and description on the display. A non-critical fault can be set to either require a manual reset or to automatically reset. The automatic resetting of a non-critical fault is dependant on the automatic computer reset jumper JPC19 (see page 23). WhenJPC19 is set to auto reset (position 1-2), the starter will automatically reset the fault. The number of automatic resets parameter (# Auto RST) on page 73 sets how many times the starter will perform this automatic reset sequence in one hour. Crit Critical fault. If this fault occurs, the starter will shut down and display the fault number and description on the display. To clear the fault, the computer reset button must be pressed or the control power to the starter cycled. Fault is Disabled. If this fault occurs, the starter will ignore the fault and continue to operate. Fault warning relay A. If this fault occurs, the starter will continue to operate. If a programmable relay is programmed to WrnA, that relay will be energized when the fault occurs. The WrnA relay can be assigned to as many different faults as the user requires. Fault warning relay B. If this fault occurs, the starter will continue to operate. If a programmable relay is programmed to WrnB, that relay will be energized when the fault occurs. The WrnB relay can be assigned to as many different faults as the user requires. Fault warning relay C. If this fault occurs, the starter will continue to operate. If a programmable relay is programmed to WrnC, that relay will be energized when the fault occurs. The WrnC relay can be assigned to as many different faults as the user requires. NonC Dis WrnA WrnB WrnC 37 4.1 OPERATION Use of Overcurrent and Undercurrent General For the over current and undercurrent trips, there are settings for the current level and the detect time. The motor current must go above or below the current level settings for the detect time before the overcurrent or undercurrent condition is detected. The overcurrent and undercurrent trips do not become active until the starter is up-to-speed (UTS is shown in top line of display). The overcurrent parameters are for the user to set a user defined high current trip. The overcurrent parameters are not used for the thermal overload. If the driven load can be damaged by the full motor torque being applied during a stall or jam of the driven load, the over-current should be used to prevent this. The undercurrent parameters are used to set a user defined low current trip. The undercurrent parameters are used to protect a driven load from running empty. A good example of the undercurrent trip usage is a water pump. If the pump can run dry, the undercurrent parameters can be set to detect the low current and shut the pump down. To use this, the current could be set to 50% and the detect delay to 5 seconds to shut the pump down 5 seconds after the current falls below 50% of the motor FLA parameter. To make the starter activate a relay when an overcorrect or undercurrent is detected, a programmable relay must be programmed to OCT or UCT respectively. As the default, the starter will trip when an over-current or undercurrent is detected. To keep the starter operating, the over-current fault (fault #78) or undercurrent fault (fault #79) must be set to dis (disabled) in the fault classes sub-menu (see page 74) to turn off the fault trip. Once the over-current or undercurrent fault is disabled, the starter will not trip when the over-current or undercurrent condition is detected, The relay programmed to OCT or UCT will still operate when the condition is detected. Once the condition clears, the relay will remain active for the programmed release delay time. The user must monitor the relay output and take appropriate action when the relay is energized. Overcurrent Undercurrent Activating a Relay Tripping vs Running Overload General The RediStart Micro II comes with a programmable overload that allows classes 1-40 to be programmed plus an overload disable and overload bypass during starting. The thermal overload is displayed as a percentage of overload used, with 0% representing a "cold" overload and 100% representing a "tripped" overload. The overload always operates on the highest phase current. The overload class sets the time it takes for the overload to trip when the motor current is six (6) times the motor FLA. The overload follows an exponential curve that gives a long trip time for slight overloads and a short trip time for large overloads. This models the heating of a typical squirrel cage induction motor. See page 11 for the motor thermal overload curves. Overload Classes 38 4.1 OPERATION Overload Operation There are two ways that the overload can operate. The operation is changed in the fault classes sub-menu by changing the overload lock fault (fault #90) from Crit to Dis. When fault #90 is set to Crit; · The overload warning relay will energize when the O/L content goes above 90% and de-energize when the O/L content goes back below 80%. · The starter will shut down if the overload content reaches 100%. · The overload lock relay will energize when the O/L content reaches 100% and de-energize when the O/L content goes back below 60%. · The starter will not allow an overload reset once the overload trips until the overload content goes back below 60%. · The overload relay will energize when the overload trips and will de-energize when the overload condition is cleared by an automatic or manual reset. When fault #90 is set to Dis; · The overload warning relay will energize if the overload content goes above 90% and will de-energize when the overload content goes back below 80%. · The starter will not shut if the overload content reaches 100%. · The overload lock relay will never energize. · The overload relay will energize when the overload content goes above 100% and will de-energize when the overload content goes back below 100%. Overload OK Starter Prohibited: No OLW Relay: Off OLL Relay: Off OL Relay: Off Overload Warning Starter Prohibited: No OLW Relay: On OLL Relay: Off OL Relay: Off OL > 100% & F90 = Crit OL > 100% & F90 = Dis OL < 100% Overload > 100% Starter Prohibited: No OLW Relay: On OLL Relay: Off OL Relay: On OL > 90% OL < 80% OL Reset (Manual or Automatic) Overload Tripped Starter Prohibited: Yes OLW Relay: Off OLL Relay: Off OL Relay: On OL < 60% Overload Warning & Lock Starter Prohibited: Yes OLW Relay: On OLL Relay: On OL Relay: On OL < 80% Overload Lock Starter Prohibited: Yes OLW Relay: Off OLL Relay: On OL Relay: On Running Overload When the RediStart Micro II is running the overload content will never discharge below 30%. The overload content will always hold at any value below 30% during the running period. As soon as the unit is stopped the overload will begin to discharge back to 0%. 39 4.1 OPERATION Resolving Overload Trips The National Electrical Code, article 430 Part C, allows for different overload multiplier factors depending on the motor and operating conditions. NEC section 430-32 outlines the allowable service factor (Serv. Fact) for different motors as follows: Motor Service factor 1.15 or more Motor temp. rise 40°C or less All others Overload Multiplier 1.25 1.25 1.15 NEC section 430-34 permits further modifications if the service factor (Serv. Fact) is not sufficient to start the motor: Motor Service factor 1.15 or more Motor temp. rise 40°C or less All others Overload Multiplier 1.40 1.40 1.30 Although the NEC doesn't address the effect of the ambient temperature of the motor location, guidance can be derived by examining NEC limits. If the motor is operating in an ambient temperature that is less than 40°C, then the overload multiplier can be increased while still protecting the motor from exceeding it maximum designed temperature. The following curve gives the ambient temperature vs the correction factor. Temperature vs Correction Factor 100 80 Temperature 60 40 20 0 0.50 1.00 Correction Factor 1.50 Example: If a motor operates at 0°C then a 1.36 correction factor could be applied to the overload multiplier. This could give a theoretical overload multiplier of 1.36 x 1.25 or 1.70. The highest legal value of overload multiplier is 1.40 so this could be used. Performing an Emergency Restart General The RediStart Micro II has an emergency restart feature which allows the user to override any lock-outs that are present. This feature should only be used in an emergency. Before an emergency reset is performed, the reason for the lock-out and the condition of the motor should be examined to ensure that the motor is capable of being re-started without causing any damage. Place a jumper between pins 6 and 11 of JC11 on the computer card. Hold the Enter button on the display and press the thermal overload reset pushbutton until a microprocessor reset occurs. Performing a Reset 40 5. PROGRAMMING 5.1 PROGRAMMING: How To Program Menu Buttons General The RediStart Micro II has a display/keypad that allows the user to set the starter parameters using a plain English interface. The functions of the display buttons are as follows. MENU · · · · · · · · · · · · · · · · · · Press to enter the menu system. Press to abandon changes made to a parameter (before pressing the Enter key). Press to exit a sub-menu. Press to exit the menu system. Press to enter a menu. Press to enter a sub-menu. Press to change the parameter displayed. Press to store the new value entered. Select the menu to enter. Select the sub-menu to enter. Scroll between parameters when in a specific menu or sub-menu. Increase a parameter value. Press to view the meter pages when the main display is shown. Select the menu to enter. Select the sub-menu to enter. Scroll between parameters when in a specific menu or sub-menu. Decrease a parameter value. Press to view the meters when the main display is shown. ENTER START · Press to start the motor when the starter is connected for local display control. · Press to activate the BIST (Built-In Self Test). · If 2-wire control is used or the Start button is disabled, this button is inoperative. STOP · Press to stop the motor when the starter is connected for local display control. · If 2-wire control is used or the Stop button is disabled, this button is inoperative. 42