RediStart TM Solid State Starter 2 Control RB2, RC2, RX2E Models User Manual 890034-01-02 August 2008 Software Version: 810023-01-08 Hardware Version: 300055-01-05 © 2008 Benshaw Inc. Benshaw retains the right to change specifications and illustrations in text without prior notification. The contents of this document may not be copied without the explicit permission of Benshaw. Important Reader Notice 2 Congratulations on the purchase of your new Benshaw RediStart MX Solid State Starter. This manual contains the information to install and 2 2 program the MX Solid State Starter. The MX is a standard version solid state starter. If you require additional features, please review the 3 expanded feature set of the MX Solid State Starter on page 5. 2 This manual may not cover all of the applications of the RediStart MX . Also, it may not provide information on every possible contingency 2 concerning installation, programming, operation, or maintenance specific to the RediStart MX Series Starters. The content of this manual will not modify any prior agreement, commitment or relationship between the customer and Benshaw. The sales contract contains the entire obligation of Benshaw. The warranty enclosed within the contract between the parties is the only warranty that Benshaw will recognize and any statements contained herein do not create new warranties or modify the existing warranty in any way. Any electrical or mechanical modifications to Benshaw products without prior written consent of Benshaw will void all warranties and may also void cUL listing or other safety certifications, unauthorized modifications may also result in product damage operation malfunctions or personal injury. 2 Incorrect handling of the starter may result with an unexpected fault or damage to the starter. For best results on operating the RediStart MX starter, carefully read this manual and all warning labels attached to the starter before installation and operation. Keep this manual on hand for reference. Do not attempt to install, operate, maintain or inspect the starter until you have thoroughly read this manual and related documents carefully and can use the equipment correctly. Do not use the starter until you have a full knowledge of the equipment, safety procedures and instructions. This instruction manual classifies safety instruction levels under "WARNING" and "CAUTION". Electrical Hazard that could result in injury or death. Caution that could result in damage to the starter. Highlight marking an important point in the documentation. Please follow the instructions of both safety levels as they are important to personal safety. DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Only qualified personnel familiar with low voltage equipment are to perform work described in this set of instructions. Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See NFPA 70E. Turn off all power before working on or inside equipment. Use a properly rated voltage sensing device to confirm that the power is off. Before performing visual inspections, tests, or maintenance on the equipment, disconnect all sources of electric power. Assume that circuits are live until they have been completely de-energized, tested, and tagged. Pay particular attention to the design of the power system. Consider all sources of power, including the possibility of backfeeding. Replace all devices, doors, and covers before turning on power to this equipment. Failure to follow these instructions will result in death or serious injury. TRADEMARK NOTICE Benshaw and are registered trademarks of Benshaw Incorporated. UL is a trademark of Underwriters Laboratories, Incorporated. SAFETY PRECAUTIONS Safety Precautions Electric Shock Prevention • While power is on or soft starter is running, do not open the front cover. You may get an electrical shock. • This soft starter contains high voltage which can cause electric shock resulting in personal injury or loss of life. • Be sure all AC power is removed from the soft starter before servicing. • Do not connect or disconnect the wires to or from soft starter when power is applied. • Make sure ground connection is in place. • Always install the soft starter before wiring. Otherwise, you may get an electrical shock or be injured. • Operate the switches with dry hands to prevent an electrical shock. • Risk of Electric Shock - More than one disconnect switch may be required to de-energize the equipment before servicing. Injury Prevention • Service only by qualified personnel. • Make sure power-up restart is off to prevent any unexpected operation of the motor. • Make certain proper shield installation is in place. • Apply only the voltage that is specified in this manual to the terminals to prevent damage. Transportation and Installation • Use proper lifting gear when carrying products, to prevent injury. • Make certain that the installation position and materials can withstand the weight of the soft starter. Refer to the installation information in this manual for correct installation. 2 • If parts are missing, or soft starter is damaged, do not operate the RediStart MX . • Do not stand or rest heavy objects on the soft starter, as damage to the soft starter may result. • Do not subject the soft starter to impact or dropping. • Make certain to prevent screws, wire fragments, conductive bodies, oil or other flammable substances from entering the soft starter. Trial Run • Check all parameters, and ensure that the application will not be damaged by a sudden start-up. Emergency Stop • To prevent the machine and equipment from hazardous conditions if the soft starter fails, provide a safety backup such as an emergency brake. Disposing of the RediStart MX2 • Never dispose of electrical components via incineration. Contact your state environmental agency for details on disposal of electrical components and packaging in your area. i TABLE OF CONTENTS Table of Contents 1 INTRODUCTION ............................................2 1.1 Additional MX3 Product Features....................................5 2 TECHNICAL SPECIFICATIONS ...................................10 2.1 General Information ...........................................10 2.2 Electrical Ratings .............................................10 2.2.1 Terminal Points and Functions........................................10 2.2.2 Measurements and Accuracies........................................11 2.2.3 List of Motor Protection Features ......................................11 2.2.4 Solid State Motor Overload..........................................12 2.2.5 CT Ratios ....................................................13 2.3 Starter Power Ratings ..........................................13 2.3.1 Standard Duty (350% for 30 sec) Ratings ..................................14 2.3.2 Heavy Duty (500% current for 30 sec) Ratings ...............................15 2.3.3 Severe Duty (600% current for 30 sec) Ratings ...............................16 2.3.4 Inside Delta Connected Standard Duty (350% for 30 sec) Ratings....................17 2.3.5 RB2 Power Stack Ratings and Protection Requirements .........................18 2.3.6 Power Stack Input Ratings with Protection Requirements for Separate Bypass ............19 2.3.7 Power Stack Input Ratings with Protection Requirements for RC No Bypass .............20 2.3.8 RB2 Starter Control Power Requirements .................................21 2.3.9 RC2 Starter Control Power Requirements .................................21 2.4 Dimensions ................................................22 2.4.1 RB2 Chassis with Integral Bypass ......................................22 2.4.2 RC2 Chassis with no Bypass .........................................24 2.5 Environmental Conditions........................................25 2.6 Altitude Derating .............................................25 2.7 Approvals .................................................26 2.8 Certificate of Compliance ........................................26 3 INSTALLATION .............................................28 3.1 Before You Start..............................................28 3.1.1 Inspection....................................................28 3.1.2 Installation Precautions ............................................28 3.1.3 Safety Precautions ...............................................28 3.2 Installation Considerations .......................................29 3.2.1 Site Preparation ................................................29 3.2.2 EMC Installation Guidelines .........................................29 3.2.3 Use of Power Factor Capacitors .......................................29 3.2.4 Use of Electro-Mechanical Brakes ......................................29 3.2.5 Reversing Contactor..............................................29 3.3 Mounting Considerations ........................................30 3.3.1 Bypassed Starters ...............................................30 3.3.2 Non-Bypassed Starters ............................................30 3.4 Wiring Considerations ..........................................31 3.4.1 Wiring Practices ................................................31 3.4.2 Considerations for Control and Power Wiring...............................31 3.4.3 Considerations for Signal Wiring ......................................31 3.4.4 Meggering a Motor ..............................................31 3.4.5 High Pot Testing ................................................31 3.5 Power and Control drawings for